DIN Rail Terminal Sensor Array for Overheating Mitigation
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Solution Overview
Problem
Existing terminal blocks in power devices often fail to effectively monitor and mitigate overheating, leading to potential damage and inefficiencies due to the lack of real-time temperature and resistance monitoring capabilities.
Innovation Solution
The integration of thermal conductors with temperature sensors into DIN rail terminal blocks, coupled with a controller circuit that converts sensed electrical properties into digital values, allowing for real-time monitoring and mitigating actions such as current reduction or notifications when abnormal temperatures or resistances are detected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If terminal blocks are equipped with real-time temperature and resistance monitoring capabilities, then reliability is improved, but device complexity increases
Solution Approach 1:
The temperature sensor is nested within the terminal block structure itself, with the sensor body positioned to contact the internal conductor through a recess. This integration eliminates the need for separate external monitoring devices and reduces overall system complexity while maintaining reliable temperature monitoring capability.
Solution Approach 2:
The monitoring function is merged with the terminal block structure by incorporating the temperature sensor directly into the terminal block housing. The sensor, thermal conductor, and controller are integrated as a unified assembly, combining the functions of electrical connection and temperature monitoring into a single device.
2Measurement precision
If thermal conductors and temperature sensors are integrated into terminal blocks, then temperature monitoring precision is improved, but manufacturing complexity increases
Solution Approach 1:
The terminal block is segmented into functional modules: the main terminal block body, the temperature sensor assembly, and the controller. This segmentation allows each component to be manufactured and tested separately before final assembly, simplifying the manufacturing process despite the increased functional complexity.
Solution Approach 2:
A thermal conductor acts as an intermediary between the internal conductor and the temperature sensor. This thermal conductor facilitates accurate temperature transfer from the conductor to the sensor while allowing the sensor to remain positioned in the recess, enabling precise temperature monitoring without direct sensor contact with the high-current conductor.
3Productivity
If multiple sensors are integrated into terminal blocks, then productivity is improved through real-time monitoring, but device complexity increases
Solution Approach 1:
The controller is designed with multi-functionality to handle temperature monitoring, resistance monitoring, and corrective actions. This universal controller can manage multiple sensors and perform various monitoring functions, reducing the need for separate dedicated circuits for each function and offsetting the complexity increase from multiple sensors.
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
This solution enables proactive prevention of overheating by monitoring internal conductors' temperatures and resistances, reducing heat generation and preventing damage by initiating corrective actions, thereby enhancing the reliability and efficiency of power devices.
Implementation Method 1
one or more thermal conductors configured in size and shape to fit into one or more recesses of a DIN rail terminal block, and couple thermally with internal conductors of the terminal blocks
Implementation Method 2
Temperature sensors are in thermal contact with the thermal conductors, and convert the sensed temperatures to electrical properties, such as a voltage, a current, a resistance, and/or an impedance
Data Source
AI summary
An apparatus having a conducting probe configured to couple with an electrical conductor of an electrical terminal. The apparatus has a sensor in contact with the conducting probe. The apparatus has a controller electrically coupled to the sensor, where the controller is configured to monitor the sensor values, and when the sensor values comply with a monitoring rule associated with a hazardous condition, the controller is configured to initiate an action to mitigate the hazardous condition.