Universal Rigid Busbar Layout for Mixed Breaker Footprints
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Solution Overview
Problem
Power distribution panels in computer equipment cabinets face challenges due to breakers from different manufacturers having varying dimensions, leading to inconsistent footprints and connection terminal heights, which are often accommodated with flexible wiring that increases size and causes cooling issues and overheating.
Innovation Solution
A universal set of rigid busbars and interchangeable mounting brackets are used to accommodate breakers with different dimensions, allowing for standardized connection distances and positions, thereby enabling a universal power distribution panel that can be used with various breaker types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible wiring is used to accommodate breakers with different dimensions, then adaptability to different breaker types is improved, but the physical size of the wiring increases and cooling efficiency deteriorates
Solution Approach 1:
The patent changes the physical parameters of the wiring from flexible to rigid, and establishes standardized dimensions for busbars and mounting positions. This allows the use of rigid busbars with fixed dimensions that can be precisely positioned to accommodate different breaker types without increasing overall size, thereby resolving the contradiction between adaptability and compact size.
Solution Approach 2:
The patent creates a universal mounting system with standardized busbar dimensions and multiple configurable mounting positions that can accommodate breakers from different manufacturers. The rigid busbar system with adjustable positioning provides multi-functionality, allowing the same panel design to work with various breaker types while maintaining a compact form factor.
2Reliability
If flexible wiring with electrical insulation is used, then electrical insulation is provided, but the wiring size increases and air flow is restricted
Solution Approach 1:
The patent changes the wiring from flexible insulated cables to rigid busbars with standardized dimensions. The rigid busbars can be designed with optimized cross-sections and surface areas that provide adequate electrical insulation while minimizing the volume occupied, thereby allowing better air flow and reduced overheating risk.
Solution Approach 2:
The patent uses rigid busbars that can be precisely manufactured to standard dimensions, replacing the need for flexible insulated wiring. The standardized busbar designs incorporate insulation considerations directly into the manufacturing process, providing reliable electrical insulation without the bulk of flexible insulated cables.
3Adaptability or versatility
If flexible wiring is used to accommodate different breaker dimensions, then compatibility with different manufacturers is improved, but inventory complexity increases
Solution Approach 1:
The patent establishes a universal panel design with standardized rigid busbar dimensions and configurable mounting positions that can accommodate breakers from different manufacturers. This standardization reduces inventory complexity by allowing the same panel design and busbar set to work with multiple breaker types, eliminating the need for manufacturer-specific components.
Solution Approach 2:
The patent segments the mounting system into standardized busbars with fixed dimensions and configurable mounting positions. This segmentation allows the rigid busbar system to be universally applied across different breaker types while maintaining precise positioning capabilities, thereby reducing inventory requirements compared to flexible wiring solutions.
4Manufacturing precision
If rigid busbars with standardized dimensions are used, then manufacturing precision is improved, but adaptability to different breaker configurations decreases
Solution Approach 1:
The patent achieves universality by combining rigid busbars with standardized dimensions with configurable mounting positions. The standardized busbar dimensions provide manufacturing precision, while the configurable mounting positions allow the same busbar design to accommodate breakers with different dimensions, thereby resolving the contradiction between precision and adaptability.
Solution Approach 2:
The patent resolves the contradiction by adding the dimension of configurable mounting positions to the standardized busbar design. While the busbar dimensions themselves are fixed and precise, the mounting positions can be adjusted along the busbar length, providing adaptability to different breaker configurations without compromising manufacturing precision.
Data Source
AI summary
A power distribution panel can include a main line rigid busbar, a first breaker having a first base and a first line input terminal at a first input connection height from the first base, a first mounting bracket configured to dispose the first breaker in a compartment with the first line input terminal at a connection depth within the compartment, and an input line rigid busbar electrically coupled between the first line input terminal and the main line rigid busbar. The input line rigid busbar can be configured to be selectively coupled between a second line input terminal of a second breaker and the main line rigid busbar, and the second breaker can have a second base and the second line input terminal can be at a second input connection height from the second base, the second input connection height being different from the first input connection height.