Arcing Horn Attachment via Deformed Orifices in Switchgear
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Solution Overview
Problem
Existing methods for fixing an arcing horn on a U-shaped fixed contact support in electrical switching devices face challenges due to limited access for crimping tools and additional volume issues, especially in compact differential switches, where traditional methods like screws, rivets, or welds are difficult to implement.
Innovation Solution
A method involving two semi-circular openings on the arcing horn and corresponding smaller orifices on the contact support, allowing the arcing horn to be mounted around a disc-shaped stud with a groove, using punches to secure the arcing horn by hooking and friction without adding volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fixing methods (screws, rivets, welds) are used to attach the arcing horn to the contact support, then the assembly is secure, but the device complexity increases and additional parts are required which are difficult to implement in compact differential switches
Solution Approach 1:
The fixing elements (orifices and deformation zones) are integrated directly into the contact support structure itself, eliminating the need for separate screws, rivets, or clips. The contact support combines both structural support and fixing functions in a single component, reducing device complexity while maintaining assembly reliability.
Solution Approach 2:
The contact support performs its own fixing function through its U-shaped structure with integrated orifices and deformation zones. The material deformation creates self-locking fixing elements that secure the arcing horn without requiring external fastening components, making the system self-sufficient.
2Ease of manufacture
If the contact support is made U-shaped to integrate the arcing horn, then the fixing is simplified, but there is no access to put a crimping tool between the two wings of the U
Solution Approach 1:
The U-shaped contact support is segmented with through-orifices that provide access channels for crimping tools. These orifices allow the tool to reach the deformation zones from the external side, dividing the fixing structure into accessible segments while maintaining the overall U-shape for structural integrity.
Solution Approach 2:
The orifices act as intermediaries that transmit the crimping force from the externally applied tool to the internal deformation zones. The orifices enable the crimping operation to be performed from outside the U-shape by serving as passage ways for the tool's action.
3Volume of moving object
If the arcing horn is made separable from the fixed contact support, then size problems are avoided, but the assembly becomes less reliable and requires additional fixing elements
Solution Approach 1:
The arcing horn features a semi-circular opening that conforms to the curved profile of the contact support's deformation zones. This curved geometry enables the arcing horn to be inserted through the orifices and deformed into a friction-fit configuration, creating a reliable connection without requiring additional volume or complex fixing mechanisms.
Solution Approach 2:
The fixing mechanism utilizes changes in material parameters through plastic deformation. The orifices and deformation zones are designed to undergo permanent shape change during assembly, transforming the arcing horn from a loose fit to a securely locked position through controlled material deformation, maintaining reliability without increasing volume.
4Reliability
If additional fixing elements are added to secure the arcing horn, then the assembly reliability improves, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The contact support structure itself provides the fixing function through its integrated orifices and deformation zones. The material of the contact support serves dual purposes: structural support and creating the fixing mechanism through its own deformation, eliminating the need for separate fixing elements and simplifying manufacturing.
Solution Approach 2:
The fixing mechanism utilizes the composite functionality of the contact support, which combines structural support, electrical connection, and mechanical fixing roles in a single component. The U-shaped structure with integrated orifices creates a multi-functional element that reduces the need for additional specialized parts.
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 method securely fixes the arcing horn to the contact support without increasing the device's size, ensuring reliable assembly and preventing contact carrier entanglement during operation.
Implementation Method 1
the material being pressed against the inner surface of said first orifices without the material emerging opposite said first orifices
Implementation Method 2
two punches (22, 23) being used in order to press the material (21) of the arcing horn (8) into the orifices (17, 18) of the fixed contact support (4)
Data Source
AI summary
The method involves realizing a set of openings (17,18) in a support (4) of a fixed contact, and providing an arcing horn (8) above the support so that the horn is mounted on a disk shaped stud (12) of a contact plug. A material of the horn is pushed within the former set of openings while creating another set of openings (19, 20) in the horn. The material is introduced by one of ends of the latter set of openings and flattened against an inner face of one of the former set of openings. The support is fixed on the horn by adhering, rubbing and/or arc dozing of the material on the inner face. An independent claim is also included for an electrical breaking apparatus comprising a fixed contact and a movable contact.