Circuit Breaker Assembly Segmentation for Stability
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Solution Overview
Problem
Existing electrical installation switching devices face challenges in manufacturing complexity, dimensional, and positional stability, particularly due to manufacturing tolerances and the need for precise assembly of multiple components, which complicates both manual and automated production.
Innovation Solution
The device is designed with a prefabricated contact lever assembly and a separate link chain assembly that can be independently manufactured and assembled, with a stationary stop limiting the contact lever's movement to maintain precision and stability, reducing the complexity of assembly and production requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If the contact lever is opened by quick release when a short circuit is triggered, then the switching speed is improved, but the manufacturing precision and positional stability deteriorate due to mechanical distortions and play between levers
Solution Approach 1:
The device is divided into two separate assemblies: a contact lever assembly and a rear derailleur assembly. This segmentation allows each assembly to be manufactured and pre-assembled independently with higher precision, avoiding the accumulation of tolerances when multiple levers are riveted together. The contact lever assembly can be quickly released while maintaining dimensional stability because it is not part of a complex multi-lever structure.
Solution Approach 2:
The contact lever assembly is extracted as a separate prefabricated unit from the rear derailleur assembly. This extraction eliminates the need for precise rivet connections between multiple levers, reducing mechanical play and improving positional stability. The contact lever assembly can still achieve quick release functionality through its own simplified mechanism.
2Strength
If multiple levers are riveted together to form a rear derailleur assembly, then the structural integrity is improved, but the device complexity and manufacturing time increase
Solution Approach 1:
The complex multi-lever rear derailleur is segmented into a separate assembly that interfaces with the contact lever assembly through a single connection point. This reduces the overall device complexity by breaking down the intricate riveted lever structure into manageable modules, while each module maintains its structural integrity through optimized internal design.
Solution Approach 2:
Multiple lever functions are merged into two consolidated assemblies: the contact lever assembly and the rear derailleur assembly. This merging reduces the number of rivet connections and simplifies the overall structure, decreasing manufacturing time and assembly complexity while preserving the necessary structural strength through focused design of each assembly.
3Manufacturing precision
If the contact lever is part of a prefabricated assembly with tight tolerances, then the positional stability is improved, but the ease of manufacture deteriorates due to sensitive tolerances and rivet connections
Solution Approach 1:
The device is segmented into a contact lever assembly and a rear derailleur assembly that can be manufactured independently. The contact lever assembly maintains positional stability through its own optimized structure and mounting, while the rear derailleur assembly is simplified by removing sensitive rivet connections. This segmentation allows each assembly to be manufactured with appropriate tolerances for its specific function, improving overall ease of manufacture.
Solution Approach 2:
The contact lever assembly is extracted as an independent unit with a simplified mounting mechanism that eliminates sensitive rivet connections. This extraction allows the contact lever assembly to be manufactured with standard tolerances while maintaining positional stability, significantly improving ease of manufacture compared to being part of a tightly-toleranced multi-lever assembly.
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 design simplifies the assembly process, enhances dimensional and positional stability, and reduces the risk of mechanical distortions, allowing for both manual and automated production with improved reproducibility and reliability.
Implementation Method 1
the contact lever is acted upon by the force of a contact compression spring, which is directed onto the contact lever in such a way that it presses the movable contact piece against the fixed contact piece in the switched-on position, and pushes the movable contact piece away from the fixed contact piece in the switched-off position
Implementation Method 2
In the event of a short circuit, the magnet armature can act on the contact lever carrying the movable contact piece to open the contact point
Implementation Method 3
a thermal trigger, as well as a switch lock that can be triggered by the thermal and the magnetic trigger
Data Source
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AI summary
The invention relates to an electrical installation switching device, in particular a circuit breaker, comprising a magnetic release with a magnetic armature, a thermal release, a fixed and a movable contact piece, a switching lock that can be triggered by the thermal and magnetic release, and a latching point formed by a release lever and a latch lever rotatably mounted in a fixed position and having an elongated hole for guiding a shackle, wherein the magnetic armature can act on the contact lever carrying the movable contact piece to open the contact point in the event of a short circuit, and the switching lock can hold the contact lever permanently in the open position, comprising a toggle switch for manual actuation of the switching lock, and an intermediate lever which is articulated at one end to the contact lever and at the other end to the shackle, wherein the shackle is articulated to the toggle switch with at least one leg.The contact lever forms a first, prefabricated assembly that can be inserted into the housing of the installation switching device. Once inserted, it is pivotally mounted on a fixed axis connected to the housing. The switching knob, together with the release lever, the latch lever, the intermediate lever, and the bracket, forms a second, prefabricated assembly that can be inserted into the housing. Once inserted, this second assembly is pivotally connected to the first assembly at a separation point.