Circuit Breaker Mounting Assembly with Isolation Posts
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Solution Overview
Problem
The existing mounting configurations for circuit breaker mechanisms either directly attach to 'live' components, leading to tolerance stack-up issues, or isolate them using intermediate components, which increases manufacturing complexity and cost.
Innovation Solution
A mounting assembly featuring mounting posts and pins that protrude through a mid-cover to securely attach the circuit breaker mechanism to the base, providing isolation while minimizing tolerance stack-up and manufacturing challenges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the mechanism is mounted directly to the base close to live components, then the device complexity is reduced, but the reliability deteriorates due to tolerance stack-up issues
Solution Approach 1:
The patent introduces mounting posts as intermediary elements that extend from the base through the mid-cover to the outer surface. These posts serve as mediators between the base and the mechanism, providing a stable mounting interface that reduces tolerance stack-up while maintaining direct coupling. The posts act as rigid connectors that minimize cumulative dimensional variations across multiple assembly interfaces.
2Reliability
If the mechanism is isolated on the outer surface of the mid-cover, then the reliability is improved through isolation from live components, but the device complexity increases due to intermediate mounting components
Solution Approach 1:
The mounting posts serve multiple functions simultaneously: they provide structural support for the mid-cover, enable electrical connection between the base and mechanism, and serve as mounting elements for the mechanism itself. This multi-functionality reduces the need for separate intermediate components, thereby maintaining reliability through isolation while controlling device complexity.
3Reliability
If intermediate mounting components are used to isolate the mechanism, then the reliability is improved, but the ease of manufacture deteriorates due to increased manufacturing challenges and cost
Solution Approach 1:
The patent merges the mounting function with the existing base and mid-cover structure by having mounting posts extend from the base through the mid-cover. This integration eliminates the need for separate intermediate mounting components, reducing manufacturing steps and assembly complexity while maintaining the isolation benefit for mechanism mounting.
Data Source
AI summary
A mounting assembly for a circuit breaker mechanism includes a base and a mid-cover disposed adjacent the base. Also included is a first pair of mounting posts comprising a first mounting post and a second mounting post extending from the base, the first pair of mounting posts each protruding through the mid-cover. Further included is a first mount hole defined by the first mounting post and a second mount hole defined by the second mounting post. Yet further included is a first pin extending through the first mount hole, the second mount hole and a circuit breaker mechanism frame to retain the circuit breaker mechanism to the base.