Angled Contact Switch Assembly for High Current Repulsion
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Solution Overview
Problem
High current electromagnetic switches face challenges under extreme conditions, such as short-circuit scenarios, where repulsion forces can cause contact separation, leading to potential damage and requiring complex, costly, and large designs.
Innovation Solution
A switch assembly with a housing for high voltage current, featuring a motor-driven armature that moves angled contacts, utilizing a magnetic latching mechanism with AC or DC signals for efficient operation, and a non-magnetic coupler, allowing for linear motion and effective contact engagement even in adverse environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional electromagnetic switch is used to operate under high current conditions, then the switching device can handle high current, but repulsion force causes contact separation leading to device damage
Solution Approach 1:
A spring mechanism is introduced to apply a constant closing force on the armature, counteracting the repulsion force generated by high current. The spring acts as a counterbalancing element that maintains contact pressure between contacts even under extreme electromagnetic repulsion conditions.
2Reliability
If a complex pivot arm with compression spring is added to resist contact separation, then contact stability under high current is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The spring mechanism is integrated directly into the housing structure rather than being a separate component. The housing itself serves dual purposes: structural support and spring mounting, eliminating the need for complex pivot arms and reducing overall device complexity while maintaining contact stability.
3Reliability
If a complex pivot arm structure is used to maintain contact engagement, then contact stability is improved, but overall device size increases
Solution Approach 1:
The spring mechanism is nested within the housing structure, utilizing the existing internal space of the housing for spring placement. This nested arrangement allows the spring to be accommodated without increasing the external dimensions of the switching device, maintaining compactness while providing contact stability.
4Reliability
If multiple components are added to resist repulsion force, then contact stability under high current is improved, but manufacturing cost increases
Solution Approach 1:
The housing is designed to serve multiple functions: structural support, mounting for the spring mechanism, and integration of the armature. This multi-functional design eliminates the need for separate pivot arms and reduces the number of discrete components, thereby lowering manufacturing complexity and cost while maintaining reliability under high current conditions.
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 solution provides a low-cost, compact, and reliable high voltage switch assembly capable of maintaining positive electrical connections under high current conditions, minimizing contact separation risks and ensuring reliable operation in small spaces.
Implementation Method 1
The coil electromagnet is energized by passing current through the multi-turn coil to magnetize the core
Implementation Method 2
The magnetized coil attracts an armature to a first position
Implementation Method 3
the flow of the same current in opposite directions in the parallel paths, which respectively comprise the inlet bus-bar and the moving switch blade, generates an electrodynamic force between them
Data Source
AI summary
The invention is directed to a switch assembly which can be used in situation in which the switch accommodates the flow of high voltage current. An actuator assembly with moveable contacts is moved by a motor driven armature. The moveable contacts are in electrical engagement with the stationary contacts when the armature is in the first position, and the moveable contacts are spaced from the stationary contacts when the armature is in the second position. By angling the stationary contacts and moveable contacts, the linear motion of the armature causes the moveable contacts to move across the surface of the stationary contacts as the armature approaches the first position. As all of the movements of the assembly are in a direction parallel to the axis of the armature, the assembly can be manufactured and operated reliably in a relatively small space. In addition, the linear movement on the angled contact provides for a positive electrical connection even in adverse environments.