Residual Current Measurement Cable with Segmented Protective Conductor
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Solution Overview
Problem
Existing electrical device connection lines for residual current measurement are not reliable when currents flow through the protective conductor due to device damage, requiring device disconnection and reconnection, and are not space-saving or cost-effective for use in cramped conditions.
Innovation Solution
An electrical device connection line with a cable sheath where the protective conductor is separated from the neutral and phase conductors at a specific point, with an overmolding and ring integration for easy measurement and protection, allowing for reliable residual current testing without disconnecting devices and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the protective conductor is separated from the neutral and phase conductors with an overmolding and opening for measuring devices, then measurement precision and reliability are improved, but device complexity increases
Solution Approach 1:
The cable sheath is separated at a specific point to create distinct regions, and the overmolding segments the conductors by providing individual openings for the protective conductor versus the current-carrying conductors. This segmentation enables selective measurement of the protective conductor while maintaining structural organization.
Solution Approach 2:
The protective conductor is extracted from the common cable sheath at the separation point and routed through a dedicated opening in the overmolding, allowing it to be physically separated and individually accessed for measurement purposes without interfering with the other conductors.
2Measurement precision
If a conventional plug connector with separate protective conductor routing is used, then measurement capability is improved, but the connector size becomes too large for cramped conditions and production costs increase
Solution Approach 1:
The overmolding merges multiple functions into a single integrated component: it provides structural support, creates the separation point, forms the opening for the protective conductor, and maintains insulation. This consolidation eliminates the need for separate connector housings and complex assembly structures.
Solution Approach 2:
The overmolding serves multiple purposes simultaneously: it acts as a structural element, an insulating component, a routing guide for the protective conductor, and a mounting feature for measuring devices. This multi-functionality reduces the overall complexity and size compared to dedicated measurement connectors.
3Reliability
If the protective conductor is separated with individual overmolding, then measurement reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The cable sheath material parameters are modified at the separation point to create the overmolding with different properties (hardness, insulation characteristics). This parameter change enables the overmolding to provide both structural support and electrical insulation in a single component, simplifying manufacturing compared to assembling multiple parts.
Data Source
Figure 1~3
AI summary
The invention relates to an electrical appliance connection cable with a cable sheath (1) in which at least one protective conductor (2), a neutral conductor (3) and a phase conductor (4) are arranged and a coupling piece (5, 6) can be attached to each of its two ends, wherein the cable sheath (1) is separated at at least one point and the protective conductor (2) runs separately from the neutral conductor (3) and the phase conductor (4) in the separation point (7).