Contact Arm Assembly for Circuit Breaker Cost Reduction
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Solution Overview
Problem
Existing circuit breakers with multiple components are costly to manufacture, and designers face challenges in converting double break breakers into single break breakers within a similar housing configuration, leading to increased manufacturing costs.
Innovation Solution
A contact arm assembly with a first contact arm, side plates, and spring support pins, along with a pivot pin and springs, which allows for a single break breaker configuration similar to a double break breaker, reducing component count and manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a double break breaker configuration is used, then safety and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The breaker is segmented into modular contact arm assemblies that can be configured in different arrangements (single break or double break) within the same housing, allowing reliability to be improved through redundancy while managing complexity through standardization of modular units
Solution Approach 2:
The housing and support structures are designed with universal compatibility to accommodate both single break and double break configurations using the same basic components, enabling the system to provide enhanced safety through configurable redundancy without proportionally increasing manufacturing complexity
2Ease of manufacture
If a double break breaker is converted to a single break breaker, then manufacturing cost is reduced, but housing compatibility and design flexibility are limited
Solution Approach 1:
The housing design incorporates universal mounting features and standardized dimensions that allow the same housing to accommodate both single break and double break configurations, enabling cost reduction through single break assembly while maintaining design flexibility for future upgrades or variations
Solution Approach 2:
The contact arm assembly uses a standardized pivot and mounting interface that allows dynamic reconfiguration between single and double break arrangements, providing housing compatibility and design adaptability while enabling manufacturing cost optimization through standardized component reuse
3Reliability
If multiple components are used in contact arms, then functionality and reliability are improved, but manufacturing cost increases
Solution Approach 1:
Multiple functional components (contact elements, springs, insulators, mounting structures) are merged into integrated contact arm assemblies that maintain comprehensive functionality while reducing the total number of discrete parts, thereby improving ease of manufacture through reduced assembly complexity and inventory requirements
Solution Approach 2:
The contact arm assemblies are designed as universal modules that incorporate multiple functions (electrical conduction, mechanical movement, spring tensioning, insulation) within standardized components, enabling reliability to be maintained through integrated functionality while reducing manufacturing cost through standardized production
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 contact arm assembly enables a single break breaker configuration with a reduced number of components, thereby minimizing manufacturing costs while maintaining functionality similar to double break breakers.
Implementation Method 1
a first spring disposed between the first spring holder portion of the first contact arm and the first spring support pin
Data Source
Figure 1
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AI summary
A contact arm assembly (30) and a method for assembling the contact arm assembly are provided. The contact arm assembly (30) includes a first contact arm (56) having a first end portion (140) and a second end portion (140). The first end portion (140) has a first contact (76) disposed thereon and a first spring holder portion (148) disposed thereon. The second end portion (142) has a first tab member (150) for coupling a first braided strap (106) thereto. The first contact arm (56) has a first pivot aperture (144) extending therethrough. The contact arm assembly (30) further includes first and second side plates (82, 80). The first side plate (82) is disposed proximate to a first side of the first contact arm (56) and the second side plate (80) is disposed proximate to a second side of the first contact arm (56).