Integrated Terminal Block with Recessed Current Transformers
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Solution Overview
Problem
The increasing complexity and congestion within power devices, such as rack powered distribution units, due to thick and unbendable wires make it difficult to route and assemble power cords with integrated current transformers, leading to laborious installation and component fitting challenges.
Innovation Solution
A terminal block design that integrates current transformers within its body, featuring recesses to house the transformers and lugs to secure wires, allowing for secure connection and measurement of current, with a two-piece construction and dielectric material for ease of assembly and flexibility in accommodating various power configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If current transformers are integrated within the terminal block body, then device complexity is reduced and assembly is simplified, but manufacturing precision requirements increase
Solution Approach 1:
The patent combines the terminal block and current transformers into a single integrated unit. The current transformers are embedded within recesses formed in the terminal block body, eliminating the need for separate mounting and reducing overall device complexity while maintaining functional independence of each component.
Solution Approach 2:
The terminal block body is segmented into multiple recesses, each designed to accommodate a specific current transformer. This segmentation allows for modular assembly and precise positioning of each transformer within its designated recess, managing manufacturing precision requirements through standardized recess geometries.
2Measurement precision
If thick and unbendable wires are used in congested power devices, then current measurement accuracy is maintained, but routing difficulty increases
Solution Approach 1:
The patent utilizes the three-dimensional space within the terminal block by forming recesses that accommodate current transformers in a compact arrangement. This spatial optimization allows thick wires to be routed through the device without excessive bending, as the integrated design provides dedicated pathways and sufficient clearance within the recess structures.
3Volume of stationary object
If multiple current transformers are integrated in a compact terminal block, then space utilization improves, but heat dissipation becomes more challenging
Solution Approach 1:
Each recess within the terminal block is designed with specific dimensional characteristics to accommodate individual current transformers. The recesses are positioned and sized to allow adequate thermal management for each transformer while maintaining compact overall dimensions. This localized design approach enables heat dissipation pathways to be optimized for each component's thermal requirements.
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 integrated terminal block simplifies the assembly of power devices by embedding current transformers within the terminal block, reducing installation complexity and improving the routing of power cords, while maintaining accurate current measurement and secure wire connections.
Implementation Method 1
at least one current transformer sized to fit within the at least one recess of the body
Data Source
AI summary
A terminal block for a power device includes a casing and a power cord. The terminal block is configured to be secured within the casing and to secure the power cord. The terminal block includes a body configured to fit within the casing of the power device. The body has at least one recess formed therein. The terminal block further includes at least one current transformer sized to fit within the at least one recess of the body.