Adjustable Contact Bridge Spacing for Secure Circuit Isolation
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Solution Overview
Problem
Existing switching devices for electrical loads, such as power contactors, face challenges in achieving secure isolation of battery circuits due to manufacturing and assembly tolerances, which can result in inconsistent contact spacings that do not meet required standards, making it difficult to adjust the distance between movable and fixed contact elements post-manufacturing.
Innovation Solution
A switching device with a movable shaft and a setting device, such as an adjusting nut or screw, allows for stepless adjustment of the distance between the contact bridge and fixed contact elements, using a contact spring for counterforce and locking mechanisms to maintain the adjusted position, ensuring compliance with minimum spacing requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manufacturing and assembly are performed with standard tolerances, then production efficiency and ease of manufacture are improved, but contact spacing precision deteriorates and may not meet minimum spacing requirements
Solution Approach 1:
The patent applies preliminary action by providing adjusting means that allow contact spacing to be set and adjusted before final assembly and testing. The adjusting means enable the contact bridge position to be pre-adjusted to achieve precise spacing, ensuring minimum spacing requirements are met before the product leaves the manufacturing line, thus resolving the contradiction between ease of manufacture and manufacturing precision.
2Device complexity
If contact spacing is fixed during manufacturing, then manufacturing process is simplified, but adaptability to meet different spacing requirements deteriorates
Solution Approach 1:
The patent applies dynamics by providing adjustable contact spacing through the adjusting means, which allow the contact bridge position to be dynamically changed after manufacturing. This enables the switching device to adapt to different spacing requirements and application needs without requiring complex redesign or remanufacturing, thus resolving the contradiction between device complexity and adaptability.
3Device complexity
If standard manufacturing tolerances are used, then production cost and complexity are reduced, but reliability of secure isolation deteriorates
Solution Approach 1:
The patent applies preliminary action by enabling pre-adjustment of contact spacing using the adjusting means before final assembly. This ensures that minimum spacing requirements for secure isolation are met, thereby improving reliability without significantly increasing device complexity. The adjusting means allow precise spacing control to be implemented cost-effectively during the manufacturing process.
4Ease of operation
If contact bridge position is fixed, then assembly is simplified, but ability to correct incorrect spacings deteriorates
Solution Approach 1:
The patent applies dynamics by providing adjustable contact spacing through the adjusting means, which allow the contact bridge position to be changed after assembly. This enables correction of incorrect spacings and facilitates maintenance and repair operations without requiring disassembly or specialized tools, thus resolving the contradiction between ease of operation and ease of repair.
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
Enables precise and adjustable contact spacing, ensuring secure isolation and compliance with standards like IEC 60664-1, even after manufacturing, by allowing for post-manufacturing adjustment of the contact bridge distance from the fixed contact elements, thereby enhancing the reliability of switching devices in applications like hybrid and electric vehicles.
Implementation Method 1
a contact spring (60) for exerting a force on an underside (U30) of the contact bridge (30)
Implementation Method 2
a magnetic drive (80) having a movable shaft (40), substantially embodied in the form of a rod, for moving the contact bridge (30)
Data Source
AI summary
In an embodiment a switching device includes a first fixed contact element, a second fixed contact element, a movable contact bridge, a movable shaft configured to move the contact bridge, wherein the contact bridge is arranged at an end of the shaft, wherein the shaft is movable to a first position at which the contact bridge contacts the first and second contact elements, and wherein the shaft is movable to a second position at which the contact bridge is arranged at a distance from the first and second contact elements and a setting device configured to set the distance between the contact bridge and the first and second contact elements in the second position, wherein the setting device is arranged at the end of the shaft, and wherein the switching device is configured to switch an electrical load.