Reactor Electrical Shock Protection Cover Design
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Solution Overview
Problem
Existing reactors do not effectively prevent electrical shocks from current-carrying portions when cables with small cross-sectional areas are connected, as they allow finger contact with the current-carrying parts, whereas cables with larger cross-sectional areas provide adequate protection.
Innovation Solution
A reactor design featuring a core body with magnetically connectable iron cores and a terminal base with an electrical shock protection cover that includes a main portion for covering current-carrying parts and a cable covering portion extending to form passages conforming to the cable shape, preventing finger contact regardless of cable thickness, using contractable members to fill any clearance for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables with small cross-sectional area are connected to the terminal base, then the reactor structure remains compact and installation is easier, but finger contact with current-carrying portions is allowed causing electrical shock hazard
Solution Approach 1:
The protection cover extends in the cable drawing direction (adding a dimensional element) to form a cable covering portion that provides protection along the cable path, transforming the protection from a simple top-cover approach to a multi-dimensional protective structure that addresses gaps between the cover and cable
Solution Approach 2:
The cable covering portion acts as an intermediary protective element between the current-carrying portion and the external environment (fingers), providing an additional layer of protection that fills the protective gap left by the main cover when small cables are used
2Object-affected harmful factors
If cables with large cross-sectional area are connected to the terminal base, then protection against finger contact is improved, but the reactor structure becomes more complex and installation becomes more difficult
Solution Approach 1:
The protection cover is segmented into functionally distinct portions: a main portion for covering the current-carrying portion and a cable covering portion for protecting the cable. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural efficiency
Solution Approach 2:
Different portions of the protection cover have different structural characteristics tailored to their specific functions - the main portion provides broad coverage while the cable covering portion extends specifically in the cable drawing direction. This local differentiation optimizes protection without requiring uniform structural complexity throughout
3Ease of manufacture
If a simple top-cover protection structure is used, then the reactor structure remains simple and manufacturing is easier, but protection effectiveness varies with cable thickness
Solution Approach 1:
The protection cover structure serves multiple functions: the main portion covers the current-carrying portion while the cable covering portion protects the cable and fills protective gaps. This multi-functionality ensures consistent protection effectiveness across different cable thicknesses without requiring fundamentally different structures
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents contact with current-carrying portions of the terminal base, ensuring compliance with IP code standards for protection against solid objects, regardless of cable thickness, thereby safeguarding against electrical shocks.
Implementation Method 1
a gap is formed between one of the iron cores and another of the iron cores adjacent to the one of the iron cores, so as to be magnetically connectable through the gap
Data Source
AI summary
A reactor includes a core body having an outer peripheral iron core, at least three iron cores contacting or coupled to an internal surface of the outer peripheral iron core, and coils wound on the iron cores. The reactor has a terminal base including terminals connected to the coils and connected to cables through current-carrying portions, and an electrical shock protection cover for covering the terminal base. The electrical shock protection cover includes a main portion for covering the current-carrying portions, and cable covering portions extending from the main portion to cable drawing directions so as to cover a part of each cable. The terminal base includes a main portion for supporting the current-carrying portions, and cable receiving portions in which passages are formed to pass the cables therethrough between the cable receiving portion and the cable covering portion.