Contactor Bulb Test Bench With Moving-Magnet Actuation
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Solution Overview
Problem
Endurance tests for contactor bulbs using traditional electromagnetic actuators are excessively time-consuming, taking almost a month to complete a million cycles due to the slow actuation speed, making them impractical.
Innovation Solution
A test bench equipped with an electromagnetic actuator using moving magnets, which allows for adjustable force and speed, enabling faster and more efficient testing of contactor bulbs across various categories, compatible with different bulb sizes and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a standard electromagnetic actuator is used for endurance testing, then the test bench is simple and reliable, but the testing duration becomes excessively long (almost a month for one million cycles)
Solution Approach 1:
The patent changes the key parameter of actuator speed by replacing the standard electromagnetic actuator with a high-speed actuator capable of performing multiple closing/opening cycles per second. This parameter change directly addresses the contradiction by increasing productivity while the control system manages the transition to prevent new problems
2Loss of time
If a high-speed actuator is used to reduce test duration, then productivity improves, but the actuator must generate sufficient force to control opening and closing while being fast and repeatable
Solution Approach 1:
The patent applies dynamics by making the actuating device adjustable in both speed and force output. The high-speed actuator is equipped with control systems that allow force and speed to be modified according to the specific bulb category being tested, enabling the system to adapt to different force requirements while maintaining high productivity
3Productivity
If the actuator speed is increased to complete tests faster, then testing efficiency improves, but the actuator must remain compatible with bulbs of various categories with different characteristics
Solution Approach 1:
The patent achieves universality by designing a test bench with an adjustable actuator that can adapt to different bulb categories. The actuator's speed and force parameters can be modified to match the specific requirements of each bulb category, allowing a single device to perform multiple functions across different testing scenarios while maintaining high efficiency
4Reliability
If endurance tests are performed with one million cycles, then reliability data is obtained, but the testing process becomes impractical due to the month-long duration
Solution Approach 1:
The patent replaces the slow mechanical actuation system with a high-speed actuator system that can perform multiple cycles per second. This substitution maintains the reliability of endurance testing by completing one million cycles in less than three days, transforming an impractical month-long process into an operationally feasible test while preserving the integrity of reliability data
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 test bench significantly reduces the duration of endurance tests, allowing a million cycles to be completed in less than three days, making it practical and economical for testing various bulb categories.
Implementation Method 1
the actuating device is an electromagnetic actuator with moving magnets... a coil, which extends along the longitudinal axis, a cage, arranged radially to the longitudinal axis around the coil... and permanent magnets, carried by the cage and arranged around the coil, the cage being configured to be moved in translation relative to the coil along the longitudinal axis when the coil is excited by an electrical power signal
Data Source
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AI summary
This test bench (10) for a contactor bulb (100) comprises: - a frame (20), configured to hold the bulb (100), and - an actuation device (30), supported by the frame (20) and comprising an output shaft, centered on a longitudinal axis (A10) and movable in translation relative to the frame (20) parallel to the longitudinal axis (A10) between a front position and a rear position, the output shaft being configured to be connected to an actuation rod for the bulb. According to the invention, the actuation device (30) is an electromagnetic actuator with moving magnets.