Self-Locking Power Connector for Circuit Breaker Bus Bars
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Solution Overview
Problem
Existing solutions for securing clusters onto pivots in large circuit breakers require additional installation time and labor due to the need for multiple parts and complex installation steps, which can lead to loose connections and safety hazards.
Innovation Solution
The development of self-locking power connectors featuring spring clips, sliding frames, and tapered fingers that create a bias force to securely hold clusters onto pivots, allowing for easy installation and removal without external fasteners, reducing complexity and labor costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If U-shaped retainer pin and retainer clip are used to secure clusters to pivots, then the clusters are securely held, but additional installation time and labor are required
Solution Approach 1:
The connector is designed to self-lock onto the pivot through its own structural features (tapered fingers, spring elements, and cage geometry) without requiring separate retainer pins or clips. The installation process is self-contained, where the connector's inherent mechanics automatically secure it to the pivot, eliminating the need for additional fastening components and reducing installation time.
Solution Approach 2:
The retention function previously performed by separate retainer pins and clips is merged into the connector's own structure. The cage, fingers, and spring elements work together as an integrated self-retaining mechanism, combining multiple functions (connection, retention, and locking) into a single unified component that secures itself to the pivot.
2Reliability
If cage is used to secure clusters onto pivots, then the clusters are anchored, but additional parts and installation steps are required
Solution Approach 1:
The cage structure is designed to self-anchor to the pivot through its geometric configuration and interaction with the tapered fingers. The cage does not require separate anchoring mechanisms or additional installation steps beyond the basic connection process, as its structure inherently provides the anchoring function through the self-locking mechanism.
Solution Approach 2:
The anchoring function is merged with the connection function. The cage, fingers, and spring elements work together as an integrated system where the same components that provide electrical connection also provide mechanical anchoring, eliminating the need for separate anchoring parts and simplifying the overall installation process.
3Reliability
If multiple parts are used to secure clusters, then reliable connection is achieved, but labor costs increase
Solution Approach 1:
The connector uses its own structural features (tapered fingers, spring elements, cage geometry) to achieve secure connection without requiring additional fastening parts. This self-service approach reduces the number of components that need to be manufactured, inventoried, and installed, thereby reducing labor costs while maintaining connection reliability.
Solution Approach 2:
Multiple functions (connection, retention, locking, and anchoring) are merged into a single integrated connector assembly. This consolidation reduces the total number of parts that need to be manufactured and assembled, simplifying the manufacturing process and reducing labor costs associated with assembling multiple separate components.
4Reliability
If spring elements are used to bias fingers, then fingers stay on pivots, but fingers may be urged apart under force
Solution Approach 1:
The connector uses a composite mechanical system combining spring elements (for elastic retention) with tapered rigid fingers and a cage structure (for mechanical locking). This composite approach allows the spring to provide continuous biasing force for retention while the tapered geometry and cage provide additional mechanical strength to resist separating forces that would otherwise overcome the spring bias.
Solution Approach 2:
The tapered finger geometry and cage structure are designed to preemptively counteract separating forces before they can overcome the spring bias. The self-locking mechanism engages automatically when the connector is installed, creating a preliminary mechanical lock that prevents the fingers from being urged apart, while the spring maintains continuous contact pressure for reliable retention.
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 self-locking mechanism provides reliable and secure connections, reducing the risk of cross-phase connections and short circuits, while minimizing installation time and labor, and preventing accidental dislodgment during operation.
Implementation Method 1
The spring clips have a leaf spring that provides a bias force that holds the spring clips on the pivot
Implementation Method 2
Each of the sliding frames can include a spring element, such as a leaf spring, that creates a bias force to retain the cage in the locked position
Implementation Method 3
The tapered surfaces on the fingers create a bias force on the cage to push it back down toward the locked position, thus creating a self-locking mechanism
Implementation Method 4
First and second spring members bias the lower end portions of the fingers toward one another
Data Source
AI summary
Self-locking power connectors and circuit breaker assemblies with self-locking power connecters are presented herein. A self-locking power connector is disclosed for connecting a circuit breaker to an electrically conductive bus bar. The connector includes a cage and a cluster of electrically conductive fingers pivotably mounted to the cage. A lower end portion of each finger is configured to straddle the cluster support of the circuit breaker. Spring members bias the lower end portions of the fingers onto the cluster support. A retaining member is operatively engaged with the cage and one or more of the fingers. The retaining member is designed to inhibit a compressive force applied to the upper end portions of the fingers from overcoming the bias of the spring members and thereby separating the lower end portions of the fingers from the cluster support of the circuit breaker.