Cam-Actuated Circuit Disconnect Switch for Fast High-Current Breaking
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Solution Overview
Problem
Existing manual independent switches for disconnecting electrical circuits are complex and costly, making them unsuitable for all current ratings, and semi-independent switches are limited to lower current applications due to their design.
Innovation Solution
A switch design featuring a first cam engageable by a user and a second cam with an axial and transverse cam portion, where the transverse cam portion has a protrusion and detents at an oblique angle, and biasing members exert force on the second cam to facilitate independent rotation and quick make and break operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If manual independent switches are used to achieve rapid make and break operations for high current applications, then the make and break speed is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The switch mechanism is divided into two separate cams: a first cam for manual rotation and a second cam with transverse and axial portions for executing the switching action. This segmentation allows each cam to have a specialized function, simplifying the overall design while maintaining rapid operation capability
Solution Approach 2:
The second cam acts as an intermediary between the manual input (first cam) and the contact bridge. The transverse cam portion receives force from the first cam and transfers it through the axial cam portion to rapidly move the contact bridge, enabling fast make and break operations without requiring complex direct actuation mechanisms
2Speed
If manual independent switches are used to achieve rapid make and break operations, then the make and break speed is improved, but the device size and manufacturing cost increase
Solution Approach 1:
The second cam utilizes both transverse (radial) and axial dimensions to achieve the switching action. The transverse cam portion provides leverage for rapid rotation, while the axial cam portion directly actuates the contact bridge vertically. This multi-dimensional approach enables compact design while maintaining fast operation
Solution Approach 2:
The biasing members are pre-configured to exert force on the transverse cam portion, storing potential energy that is released during the switching operation. This preliminary preparation allows the second cam to rotate rapidly in response to manual input, achieving fast make and break without requiring large or complex energy storage mechanisms
3Device complexity
If semi-independent switches are used for lower current applications, then the device complexity is reduced, but the application range is limited
Solution Approach 1:
The design allows the oblique angle θ between the detents to be adjusted to optimize performance for different current ratings. By changing this geometric parameter, the same basic mechanism can be adapted for various applications from low to high current, expanding versatility without increasing complexity
Solution Approach 2:
The switch mechanism is designed with universal applicability across different current ratings. The cam-follower arrangement with adjustable detent angle can accommodate various load requirements, allowing a single design platform to serve multiple applications rather than requiring separate specialized switches for different current levels
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 switch provides a simpler, smaller, and more cost-effective manual independent operation suitable for all current ratings, with improved make and break speed and reduced arcing, enabling efficient high-current applications.
Implementation Method 1
one or more biasing members configured to exert a force on the transverse cam portion of the second cam
Data Source
AI summary
A switch for disconnecting or connecting an electrical circuit and a method of operating said switch. The switch comprises a first cam engageable by a user and axially rotatable around a first axis by an operating angle between an on position and an off position. The switch further comprises a second cam contacting the first cam, wherein rotation of the first cam causes rotation of the second cam around the first axis. The second cam comprises an axial cam portion and a transverse cam portion, the transverse cam portion comprising a protrusion extending along a direction perpendicular to the first axis and two detents arranged symmetrically either side of the protrusion, wherein the two detents are arranged at an oblique angle, θ, with respect to each other. The switch further comprises one or more biasing members configured to exert a force on the transverse cam portion of the second cam.