Resistor Terminal Insulation Cap for Load Testing
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Solution Overview
Problem
In dry load testing apparatuses, resistors' terminals projecting from the frame body can cause short circuits due to exposure, necessitating protection without compromising insulation.
Innovation Solution
A load testing apparatus with a conductive cover and insulation cap for resistor terminals, preventing short circuits by maintaining insulation even during displacement, using materials like aluminum or iron for durability and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cover is used to protect the projecting terminal portion, then protection is improved, but short circuit risk increases due to contact with the terminal
Solution Approach 1:
An insulating cap is introduced as an intermediary component between the conductive cover and the resistor terminal. The cap made of insulating material (such as plastic or resin) prevents direct contact between the conductive cover and the terminal, thereby eliminating the short circuit risk while maintaining the protective function of the cover.
Solution Approach 2:
The protective structure is divided into two separate components: a conductive cover for mechanical protection and an insulating cap for electrical isolation. This segmentation allows each component to perform its specific function without interfering with the other, solving the contradiction between protection and short circuit prevention.
2Object-affected harmful factors
If a non-conductive material is used for the cover to prevent short circuit, then insulation is improved, but durability decreases due to cracks and damages
Solution Approach 1:
The insulating cap serves as a mediator that provides electrical isolation without requiring the cover itself to be non-conductive. This allows the use of durable conductive materials for the cover while maintaining short circuit prevention through the intermediate insulating cap.
Solution Approach 2:
The protective structure combines two different materials with complementary properties: a conductive material (aluminum, iron, or stainless steel) for the cover providing mechanical strength and durability, and an insulating material (plastic or resin) for the cap providing electrical isolation. This composite approach resolves the contradiction between durability and insulation.
3Ease of manufacture
If the terminal is exposed without a cap, then ease of manufacture is improved, but insulation reliability decreases when displacement occurs
Solution Approach 1:
The insulating cap is pre-installed on the terminal before the cover is attached. This preliminary action ensures that insulation is already in place before the terminal might come into contact with the cover due to displacement, vibration, or thermal expansion, thereby maintaining insulation reliability without complicating the overall manufacturing process.
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 short circuits and ensures safe load testing by maintaining insulation between the resistor terminals and the cover, allowing the use of conductive materials for the cover without risking damage from displacement or vibration.
Implementation Method 1
a cap having an insulation property and attached to the portion included in the terminal of the resistor and projecting from the wall
Data Source
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AI summary
Provided is a load testing apparatus or the like capable of protecting a portion projecting from a frame body of a resistor while preventing short circuit. The load testing apparatus includes a resistance unit including: a plurality of resistors R adapted to receive power supply from a test target power source; and a wall (casing 21) adapted to hold both ends of each of the plurality of resistors R. Included is a cover 11 attached to a frame holding the resistance unit, and adapted to protect the wall (casing 21) and a portion included in a terminal 63 of the resistor R and projecting from the wall. Included is a cap 70 having an insulation property and attached to the portion included in the terminal 63 of the resistor R and projecting from the wall. The cover 11 is made of a conductive material, and the cap 70 is arranged between the cover 11 and the portion included in the terminal 63 of the resistor R and projecting and exposed from the wall.