Compact Modular Surge Protection Device for Field Devices
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Solution Overview
Problem
Existing surge protection devices for field devices are not compact enough to fit within the limited space of explosion-proof field devices and are not easily replaceable when damaged by surge voltage, complicating wiring and maintenance.
Innovation Solution
A modular surge protection device with a compact design that includes terminal fittings connected to power supply terminals, a circuit board with a surge protection element, and an earth wiring cable, allowing easy installation and replacement, with the terminal fittings and earth wiring cable protruding from the main body to facilitate connection to power supply and earth terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a surge protection device is mounted on a circuit board or installed as a surge protection module, then the field device is protected from surge voltage, but the device occupies significant space and is difficult to replace when damaged
Solution Approach 1:
The surge protection device is designed as a separable component that can be independently replaced. The terminal fittings are detachably connected to the circuit board, allowing the surge protection device to be segmented from the main field device body. This enables easy replacement of the surge protection element without replacing the entire field device or complex wiring infrastructure.
Solution Approach 2:
The surge protection device is extracted as a distinct, removable module from the field device. The terminal fittings serve as the extraction interface, allowing the surge protection device to be taken out and replaced independently. This extraction approach simplifies maintenance by isolating the replaceable surge protection component from the permanent field device structure.
2Reliability
If a surge protection device is installed in the field device, then surge voltage protection is provided, but the device size is too large to fit within the limited space of explosion-proof field devices
Solution Approach 1:
The terminal fittings are designed to nest within or attach to the existing terminal block structure of the field device. The surge protection device utilizes the existing space and mounting infrastructure, nesting its components within the available volume rather than requiring separate external mounting space. This nesting approach allows the surge protection function to be integrated into the limited space of explosion-proof field devices.
3Reliability
If terminal fittings are connected to power supply terminals with power supply cable, then electrical power is supplied to the field device, but wiring complexity increases when surge protection device is installed
Solution Approach 1:
The terminal fittings serve a dual function: they provide power supply connection to the field device and simultaneously serve as the connection interface for the surge protection device. By merging these two functions into a single component, the wiring complexity is reduced. The power supply cable connects to the terminal fittings, which then distribute power to both the field device and the surge protection device, eliminating the need for separate wiring paths.
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 compact and modular design allows for efficient protection of field devices from surge voltage while enabling easy replacement of the surge protection device, reducing the complexity of wiring and maintenance, and ensuring reliable operation.
Implementation Method 1
a surge protection element mounted on the circuit board, the surge protection element including two electrodes connected to the pair of terminal fittings and a ground electrode configured to cause a surge current to flow
Data Source
Figure 1
Figure 2A~2D
Figure 3~4
AI summary
A surge protection device includes: a pair of terminal fittings to be connected to a pair of power supply terminals of a field device together with a power supply cable; a circuit board on which a surge protection element is mounted, the surge protection element including two electrodes connected to the pair of terminal fittings and a ground electrode configured to cause a surge current to flow to a ground when a surge voltage is applied between the two electrodes; an earth wiring cable connected to the ground electrode; and a main body that houses the circuit board, the main body being configured such that the pair of terminal fittings and the earth wiring cable protrude from an inside of the main body to an outside.