Residual-Current Circuit Breaker Test Circuit Simplification
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Solution Overview
Problem
Residual-current circuit breakers face challenges in design and manufacturing due to complex test circuits requiring soldering operations and wires, which increase production costs and reduce reliability and safety.
Innovation Solution
A residual-current circuit breaker with a test circuit that eliminates the need for soldering and wires, featuring a contoured stainless steel blade, a spring mechanism, and an elastic test contact plate that engages an electrical wire without manual assembly, allowing for a simpler and safer assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional test circuits with soldering and wires are used, then functional reliability is maintained, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the test button, elastic contact plate, and test circuit into a single integrated assembly that is pre-assembled as one unit. This eliminates the need for separate wires and multiple soldering operations, directly reducing manufacturing complexity while maintaining functional reliability.
Solution Approach 2:
The patent extracts the wiring and soldering operations from the test circuit assembly process by using an integrated design where electrical connections are made through direct mechanical contact of the elastic contact plate with blade contacts, eliminating the need for separate wire connections.
2Productivity
If traditional test circuits with wires are used, then electrical connectivity is ensured, but production costs and assembly time increase
Solution Approach 1:
The test button, elastic contact plate, and electrical connection elements are merged into a single integrated assembly, reducing the number of discrete components from multiple separate parts to one unified unit, thereby increasing assembly speed and productivity.
Solution Approach 2:
The elastic contact plate automatically makes and breaks electrical connections through its own elastic deformation when the test button is pressed, eliminating the need for separate actuation mechanisms and reducing the overall component count.
3Reliability
If soldering operations are used, then reliable electrical connections are achieved, but manufacturing reliability and safety are reduced
Solution Approach 1:
The patent replaces the thermal soldering process with a mechanical connection system where the elastic contact plate makes direct electrical contact with blade contacts through mechanical force, eliminating heat-related safety hazards while maintaining reliable electrical connections.
Solution Approach 2:
The elastic contact plate is designed as a simple, replaceable component that can be easily manufactured without complex soldering processes, improving safety by eliminating hot work operations while maintaining adequate electrical connection reliability for test circuit applications.
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
The solution provides a constructively simpler and more reliable test circuit that enhances safety and reduces production costs by eliminating soldering and wire usage, ensuring effective operation without compromising reliability or safety.
Implementation Method 1
The test circuit also has a spring 12 on which a button 13 that can be accessed from the outside acts.
Implementation Method 2
The test contact elastic plate 14 is coupled to a resistor 15 and is in contact with the spring 12.
Data Source
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AI summary
A residual-current circuit breaker, characterized in that it includes at least one movable contact that acts on a fixed contact; the movable contact is connected to a first terminal and the fixed contact is connected to a second terminal; a test circuit has a contoured blade that is connected to the second terminal, a button acting on a spring, said button being accessed from the outside; when the button is pressed, the spring closes the test circuit, making contact with the contoured blade; the test circuit also has a test contact elastic plate and a resistor; the test contact elastic plate is coupled to the resistor and is in contact with the spring; the elastic plate is in contact with the movable contact when the movable contact is in the closed position, in contact with the fixed contact.