Infrared Sensor Mounting Bracket for Switchgear Busbars
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Solution Overview
Problem
The installation of infrared sensors on low-voltage switchgear is complex due to specific requirements such as the need for a black coating and precise distance maintenance, leading to increased product updates and design complexity across various design offerings.
Innovation Solution
A non-conductive 'Z' shaped bracket with a high emissivity coating on a busbar section, allowing for easy mounting of an infrared sensor without altering existing designs, ensuring accurate spacing and emissivity for efficient heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a black coating is applied to the measuring surface to achieve maximum emissivity, then the measurement accuracy is improved, but the manufacturing complexity and process steps increase
Solution Approach 1:
The busbar section integrates multiple functions: it serves as the electrical conductor, the mounting structure for the sensor bracket, and the surface requiring high emissivity coating. By combining these functions into a single component, the patent eliminates the need for separate painting processes and multiple mounting locations, thereby reducing manufacturing complexity while maintaining measurement accuracy through the high emissivity coating on the busbar surface.
2Adaptability or versatility
If multiple locations for sensor bracket installation are provided to accommodate various design offerings, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The busbar section is designed as a universal mounting structure that can accommodate infrared sensors across different low-voltage switchgear design offerings. The standardized busbar with integrated bracket attachment capabilities serves multiple purposes: electrical conduction, structural support, and sensor mounting. This universal design eliminates the need for multiple specialized mounting locations for different switchgear variants, thereby reducing overall device complexity while maintaining broad adaptability.
3Measurement precision
If an additional painting process is introduced to provide the black coating, then the emissivity is improved, but the manufacturing time and process complexity increase
Solution Approach 1:
The high emissivity coating is applied directly to the busbar section during its manufacturing process, integrating the emissivity enhancement into the base component fabrication. This approach combines the electrical conductor manufacturing with the emissivity surface preparation, eliminating the need for a separate post-manufacturing painting process. The busbar is delivered ready-to-use with both electrical and thermal radiation properties optimized, thereby improving manufacturing efficiency while maintaining high emissivity for accurate sensor measurements.
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 simplifies the installation process, maintains accuracy, and meets UL1558 clearance and creepage requirements, providing a robust and cost-effective mounting system for multiple low-voltage switchgear variants.
Implementation Method 1
the busbar section having a high emissivity coating on a surface thereof
Data Source
AI summary
A sensor mounting system is provided including a non-conductive bracket having a first end portion and a second end portion; a busbar section connected to the first end portion of the non-conductive bracket and having a high emissivity coating on a surface thereof; and an infrared sensor connected to the second end portion the non-conductive bracket, such that the infrared sensor faces the surface of the bus bar having the high emissivity coating and is spaced apart from the busbar section a predetermined distance.