Sensor Connector Assembly for Circuit Breaker-Contactor Retrofit
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Solution Overview
Problem
Existing branch circuits for loads such as motors are not universally integrated into the digital world, face challenges with footprint, accessibility, temperature conditions, communication expansion, and compatibility, leading to high design costs and limited retrofitting feasibility.
Innovation Solution
A one-piece connector for circuit breakers and downstream contactors that integrates existing components and allows for future-proof adaptation, featuring sensors, evaluation units, and a unified mounting arrangement with same-direction contacts for easy integration and use of existing accessories.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different designs are used for feeders with electronics, then specific temperature conditions and functional requirements can be met, but the footprint increases and manufacturing costs rise due to high investment in feeder design
Solution Approach 1:
The patent applies universality by creating a standardized connector design that can be used across multiple feeder configurations. The connector housing serves multiple functions: it provides mechanical support, electrical connection, and temperature management for electronics. This single universal design replaces multiple specialized designs, reducing footprint while maintaining reliability for different electronic components and temperature conditions.
2Adaptability or versatility
If different designs are used for feeders with electronics, then specific functional requirements can be met, but manufacturing costs increase due to high investment in feeder design
Solution Approach 1:
The patent applies segmentation by separating the connector into distinct modular components: a standardized housing, removable electronic components, and interchangeable terminals. This allows the base connector design to remain unchanged while adapting to different functional requirements through component substitution. The segmentation enables low manufacturing investment in the base design while maintaining high adaptability through modular configurations.
Solution Approach 2:
The universal connector housing design can accommodate various electronic components and configurations without requiring redesign. The same basic structure supports different functional requirements through component variation, eliminating the need for multiple specialized feeder designs and reducing manufacturing investment while maintaining versatility.
3Adaptability or versatility
If existing accessories are not compatible with new connector designs, then new functional requirements can be met, but retrofitability to existing systems decreases
Solution Approach 1:
The connector design maintains universality by ensuring compatibility with existing accessories such as mounting plates, feed-in systems, and reversible wiring modules. The standardized interface and footprint allow the same connector to work with both existing and new accessories, enabling retrofitability while meeting new functional requirements through the integrated electronic components.
4Adaptability or versatility
If variation is achieved through base device design, then different applications can be created, but manufacturing costs increase and tooling options become expensive
Solution Approach 1:
The patent applies segmentation by separating variation into the removable electronic components and PCB assemblies rather than the base connector housing. The standardized housing is mass-produced with low tooling costs, while application-specific variations are achieved through interchangeable electronic components and PCB configurations. This reduces manufacturing effort and tooling costs for the base device while maintaining adaptability for different applications.
Solution Approach 2:
The patent uses parameter changes in the electronic components and PCB assemblies to achieve application variation without changing the base connector design. By varying electronic parameters (components, circuits, firmware) rather than mechanical parameters (housing shape, size), the same base device can serve multiple applications with minimal manufacturing effort and no additional tooling investment.
Data Source
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AI summary
The invention relates to a connector for a circuit breaker and a downstream contactor, wherein the connector is formed in one piece, wherein the connector enables the electrical connection between the circuit breaker and the downstream contactor and comprises at least one sensor, wherein the connector comprises an evaluation unit for the measured values of the sensor, and wherein the connector comprises first contacts to the circuit breaker and second contacts to the downstream contactor in the same plug-in direction.