Cam-Actuated Circuit Switch for Rapid Manual-Independent Breaking
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Solution Overview
Problem
Existing manual independent switches are complex and costly, limiting their use to high-current applications, while semi-independent switches are not suitable for rapid make and break operations.
Innovation Solution
A switch design featuring a first cam engageable by a user and a second cam with a transverse cam portion and biasing members, allowing for manual-independent make and break operations through a toggle point mechanism, facilitating quicker and easier switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional switch with separate contact blades and springs is used, then the switching function is achieved, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The patent combines the contact blade and spring into a single integrated contact element. The contact element includes a contact blade portion and a spring portion that is elastically deformable, eliminating the need for separate contact blades and springs. This merging reduces the number of parts while maintaining the switching function and reliable contact connection through the inherent elasticity of the integrated element.
2Productivity
If multiple separate components (contact blades, springs, insulating pieces) are assembled, then the switch can be manufactured using standard assembly processes, but assembly time increases and productivity decreases
Solution Approach 1:
The contact element is provided as a single integrated component that combines the contact blade and spring functions, eliminating the need to assemble multiple separate parts. This significantly reduces assembly time and increases productivity while the insulating pieces and housing remain as separate components for structural support and electrical isolation, maintaining ease of manufacture through modular assembly of the reduced component set.
3Ease of repair
If conventional switches with multiple separate parts are used, then replacement is straightforward, but the likelihood of assembly errors increases during maintenance
Solution Approach 1:
The integrated contact element eliminates assembly errors during replacement because there are no separate contact blades and springs that could be assembled incorrectly. The single component design ensures proper alignment and connection geometry built into the manufacturing process. The insulating pieces remain as separate components to guide proper installation, maintaining ease of repair while significantly improving assembly correctness and reducing the likelihood of errors during maintenance operations.
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 rapid and reliable manual-independent make and break operations suitable for both low and high current applications, reducing manufacturing complexity and cost.
Implementation Method 1
the switch element ( 10 ) has a first end ( 11 ) and a second end ( 12 ), the second end ( 12 ) being designed as a lever end ( 12 ) having a lever action about the longitudinal axis ( L )
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Provided herein is 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. The axial cam portion is configured, upon rotation of the second cam by the first cam and/ or a rotation of the second cam in response to the force exerted by the one or more biasing members, to cause opening and closing of a current conduction path through the switch. In this way, the electrical circuit is disconnected or connected.