Auxiliary Switch Arc Gap Adjustment for Contactor Assembly

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Solution Overview

Problem

The assembly of auxiliary switches on electrical contactors is complex, time-consuming, and inconsistent due to the need for shims and contact bending to set arc gaps, leading to inefficient and costly disassembly and reassembly.

Innovation Solution

An electrical contactor auxiliary switch assembly featuring an auxiliary switch actuator with an upper, middle, and lower portion, and an adjustment nut that allows for precise setting of arc gaps during assembly without shims or contact bending.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If shims and contact bending are used to set arc gaps during assembly, then arc gap adjustment is possible, but the assembly process becomes complex and time-consuming

Engineering Contradiction:

Improvearc gap setting precisionVSAvoidassembly process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The adjustment nut is pre-installed on the auxiliary switch actuator during manufacturing, allowing arc gap adjustment to be performed as a simple rotational operation rather than requiring complex shim installation or contact bending procedures during assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The adjustment nut changes the arc gap parameter through rotational movement, which directly modifies the gap distance between switch contacts without requiring mechanical deformation or addition of shim components

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If shims and contact bending are used to set arc gaps, then arc gap adjustment is possible, but the assembly time increases significantly

Engineering Contradiction:

Improvearc gap setting precisionVSAvoidassembly time

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The complex mechanical procedures of shim installation and contact bending are replaced by a simple rotational adjustment mechanism, significantly reducing the time and skill required for arc gap setting

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If manual assembly and measurement procedures are used, then arc gap measurements can be taken, but inconsistency occurs between different auxiliary switches

Engineering Contradiction:

Improvearc gap measurement accuracyVSAvoidconsistency between auxiliary switches

Core Design Contradiction:

Measurement precisionVSStability of the object's composition

Solution Approach 1:

The adjustment nut provides a universal adjustment mechanism that can be applied to all auxiliary switches in the same manner, ensuring consistent arc gap settings across multiple switches without dependence on operator skill or manual measurement variations

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Manufacturing precision

If repetitive disassembly and reassembly is required to adjust arc gaps, then desired measurements can be achieved, but manufacturing efficiency decreases and costs increase

Engineering Contradiction:

Improvearc gap measurement accuracyVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12512287B2System and method for setting arc gaps on a plurality of auxiliary switches of an electrical contactor

Publication Date: 2025.12.30 SAFRAN POWER USA LLC

AI summary

An electrical contactor auxiliary switch assembly includes an auxiliary switch actuator that includes an upper portion, a middle portion, and a lower portion. The electrical contactor auxiliary switch assembly also includes a plurality of auxiliary switches that are attached to the middle portion of the auxiliary switch actuator. The electrical contactor auxiliary switch assembly further includes an adjustment nut that is disposed underneath the plurality of auxiliary switches to accept the lower portion of the auxiliary switch actuator and is configured to be accessed and rotated to a predetermined amount during assembly of the electrical contactor to set respective arc gaps on each of the plurality of auxiliary switches.