Flexible Cable Lockout Actuator Frame
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Solution Overview
Problem
Existing high-power electrical switch systems lack robust locking mechanisms to prevent inadvertent reactivation of circuit breakers when the flexible cable is damaged or disconnected, posing a risk of unexpected machine activation.
Innovation Solution
A remote actuator system with a collar and slider mechanism that allows direct locking of the electrical switch using a padlock on the actuator frame, even without locking features in the lock itself, providing enhanced security against accidental switching by incorporating a longitudinal channel with openings for a lock shank to block motion from the 'off' to 'on' state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flexible cable assembly is used to connect the handle to the circuit breaker, then the circuit breaker can be remotely actuated, but the system lacks robust locking mechanisms to prevent inadvertent reactivation when the cable is damaged or disconnected
Solution Approach 1:
The locking mechanism is segmented into separate functional components: the actuator frame with integrated lockout feature, the flexible cable assembly, and the collar mechanism. This allows the locking function to be independently implemented on the actuator frame without complicating the entire system, as the lockout feature operates independently from the cable connection status
Solution Approach 2:
A rigid collar is introduced as an intermediary element between the flexible cable and the circuit breaker toggle. This collar provides a mechanical interface that maintains the breaker in the OFF position even when the flexible cable is damaged or disconnected, serving as a mediator that ensures reliable locking independent of cable integrity
2Reliability
If the handle is moved to the 'off' position to disconnect electrical power, then power is removed from the interior circuitry, but the cabinet door can still be opened allowing access to the interior circuitry and potential inadvertent reactivation
Solution Approach 1:
The locking function is extended from the handle-cable system to a new dimension at the circuit breaker level. The actuator frame incorporates a lockout feature that operates independently of the handle position, creating a secondary locking dimension that ensures electrical isolation even when the cabinet door is accessible
3Reliability
If a padlock is placed on the handle to prevent movement from 'off' to 'on' position, then the handle is locked, but this does not prevent damage or disconnection of the flexible cable which could still risk unexpected machine activation
Solution Approach 1:
The actuator frame is pre-configured with an integrated lockout feature and rigid collar that automatically maintain the breaker in the OFF position. This preliminary action ensures that even if the flexible cable is damaged or disconnected after the handle is locked, the breaker cannot be inadvertently activated, providing proactive protection before cable failure occurs
Data Source
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AI summary
A remote switching system for electrical switches in a cabinet provides an actuator frame and slider that may be assembled to the electrical switch to engage the switch actuator for remote control. The actuator frame includes an opening allowing insertion of a lock shank through the opening to block motion of the slider from an "off" state to an "on" state thereby allowing the actuator frame to also serve as a local lockout.