Bistable Relay Motorized Switch Mechanism

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing electrical switch mechanisms, such as those using electromagnets or permanent magnets, face limitations in size, power consumption, and speed, particularly in Scotch yoke designs with DC motors, which restrict their operational efficiency and reliability.

Innovation Solution

A bistable electrical relay with a motor, pair of springs, and cams, where a linearly actuating member with a cam follower surface controls the movement of contact arms between closed and open positions, utilizing the motor to increase spring potential energy and switch the relay configurations efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If an electromagnet is used to generate operating force, then the contacts can be operated quickly, but the size and required operating power increase

Engineering Contradiction:

Improvecontact operation speedVSAvoidmechanism size

Core Design Contradiction:

SpeedVSWeight of moving object

Solution Approach 1:

The patent employs a bistable mechanism with permanent magnets that operates periodically between two stable states (open and closed positions). The mechanism uses spring-loaded arms with magnetic latching to maintain positions without continuous power, achieving quick operation only when needed while minimizing overall power consumption and size compared to continuously powered electromagnet systems.

Inventive Principle:

Principle #19Periodic action

Solution Approach 2:

The patent replaces the electromagnetic actuation system with a mechanical bistable system using permanent magnets and spring-loaded arms. This substitution eliminates the need for continuous electromagnetic fields, reducing both size and power requirements while maintaining quick contact operation capability through the mechanical energy storage in springs.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Use of energy by moving object

If permanent magnets are used to hold contacts in closed or opened positions, then power consumption is reduced, but the electromagnet size needed to overcome magnetic force increases

Engineering Contradiction:

Improvepower consumptionVSAvoidelectromagnet size

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent replaces the electromagnet system with a purely mechanical bistable mechanism using permanent magnets and spring-loaded arms. The permanent magnets provide holding force in both open and closed positions, eliminating the need for an electromagnet entirely. This substitution achieves minimal power consumption (only for actuation, not for holding) while reducing the size of electromagnetic components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The bistable mechanism uses the inherent magnetic fields of permanent magnets and the elastic potential energy of springs to maintain contact positions autonomously without requiring external power. The system serves itself by using stored mechanical energy and magnetic forces to hold positions, eliminating the need for continuous electromagnetic actuation.

Inventive Principle:

Principle #25Self-service

3Ease of operation

If a Scotch yoke mechanism is used with a DC motor, then the relay can be actuated, but the operation is limited by motor speed

Engineering Contradiction:

Improverelay actuation capabilityVSAvoidoperation speed

Core Design Contradiction:

Ease of operationVSSpeed

Solution Approach 1:

The patent replaces the DC motor-driven Scotch yoke mechanism with a spring-loaded bistable mechanism. This substitution eliminates the speed limitations of motor actuation by using pre-stored mechanical energy in springs to rapidly drive the contact arms between positions. The spring-loaded system can respond much faster than motor-driven mechanisms while maintaining ease of operation through simple actuation signals.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enables efficient control of current flow by effectively switching between closed and open positions, minimizing power consumption and size constraints, while maintaining reliable operation across various applications.

Implementation Method 1

a motor, a pair of springs, a pair of cams driven by the motor

Methodology Applied

Scientific EffectElectromagnetic conversion: Electromagnetic Induction

Implementation Method 2

an increase in potential energy of two springs attached to the cams

Methodology Applied

Scientific EffectElastic potential energy: Spring

Implementation Method 3

a linearly actuating member connected to the contacts and configured to move the contacts from the first configuration to the second configuration, the member including a cam follower surface

Methodology Applied

Scientific EffectCam mechanism: Cam

Data Source

PatentUS9013174B2Motorized electrical switch mechanism

Publication Date: 2015.04.21 ELSTER SOLUTIONS LLC

AI summary

A bistable relay may include a pair of contact arms. Each contact arm is configured to have a first end and a second end, such that, when the relay is in the closed position, current flows from the first end to the second ends of each of the contact arms, and when the relay is in an open position, current does not flow from the first ends to the second ends of the contact arms. The relay further includes a motor, a pair of springs, a pair of cams driven by the motor, and a linearly actuating member configured to move the contact arms from the first configuration to the second configuration, the member including a cam follower surface.