Vertical Busbar Wiring Layout for Compact Circuit Breakers
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Solution Overview
Problem
Existing power connection mechanisms for circuit breakers are lengthened, fail to meet miniaturization needs, and suffer from increased temperature rise and high production costs.
Innovation Solution
A miniaturized wiring device for circuit breakers featuring vertically arranged first busbar parts, L-shaped wiring busbars, and a simplified structure with staggered first connecting plates, which reduces length, minimizes copper usage, and lowers costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a copper bar or busbar is used for connection, then the connection is established, but the temperature rise increases and the cost increases
Solution Approach 1:
The patent transitions from traditional horizontal copper bar connections to a vertical busbar structure, utilizing the vertical dimension to reduce horizontal space occupation and improve heat dissipation. The busbar is positioned vertically within the circuit breaker, allowing better thermal management while maintaining electrical connection reliability.
Solution Approach 2:
The patent changes the material parameters and geometric parameters of the connection structure. By using a busbar with specific cross-sectional dimensions and vertical orientation, the current density is optimized, reducing resistive heating while maintaining connection reliability. The busbar dimensions are carefully selected to balance electrical performance and thermal management.
2Reliability
If a copper bar is used for connection, then the connection is established, but the length of the power connection mechanism is increased
Solution Approach 1:
The patent reconfigures the connection mechanism from a horizontal layout to a vertical layout. The busbar extends vertically, allowing the connection to be established within a compact horizontal footprint. This dimensional change reduces the overall length of the power connection mechanism while maintaining reliable electrical connection.
3Reliability
If a busbar is used for connection, then the connection is established, but the cost is high due to customization
Solution Approach 1:
The patent designs a universal busbar structure that can be applied to different circuit breaker models and configurations. The standardized vertical busbar design eliminates the need for custom fabrication, allowing mass production and reducing manufacturing costs while maintaining reliable electrical connection across various applications.
4Reliability
If the conductive assemblies are made longer to clamp the wiring copper bar, then the clamping function is achieved, but the length of the power connection mechanism is increased and temperature rise is increased
Solution Approach 1:
The patent repositions the clamping mechanism to utilize vertical space rather than extending horizontally. The clamping structure is integrated into the vertical busbar assembly, achieving reliable copper bar clamping while minimizing the horizontal length of the power connection mechanism and reducing temperature rise through improved heat dissipation geometry.
Data Source
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AI summary
Disclosed are a wiring device for a circuit breaker and a circuit breaker having same. The wiring device comprises: a wire holder (1) having a plurality of busbar slots (11) distributed in the height direction; a plurality of wiring busbars (2) correspondingly inserted into the plurality of busbar slots (11), the wiring busbars (2) being provided with first busbar parts (21) which are vertically arranged; a plurality of first conductive elements (3) arranged on the wire holder (1) at intervals in the width direction, the first conductive elements (3) being provided with first connecting plates (31) which are arranged in the vertical direction; and a first fastening structure (5) which is used for fixedly connecting the first busbar parts (21) and the first connecting plates (31). Since the plurality of first connecting plates (31) are vertically arranged in the width direction in a staggered manner, the plurality of first busbar parts (21) arranged in the height direction can be directly connected to the corresponding first connecting plates (31), such that the structure is simpler; the first busbar part (21) and the first connecting plate (31) of each layer are vertically arranged, such that the length of the wiring device for a circuit breaker is greatly reduced, and compared with the prior art, the wiring device for a circuit breaker is more miniaturized; and in addition, due to a small amount of copper materials being used, the temperature rise of the wiring device for a circuit breaker is not only lower, but the cost is also lower.