Contactor Crossbar Segmentation for Synchronized Contact Timing
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Solution Overview
Problem
The circuit breaker in Patent Literature 1 experiences uneven timing in opening and closing contact points due to rotary movement of the crossbar, leading to differential wear and reduced lifespan of contact points, as arcs are generated for longer periods between certain contact points.
Innovation Solution
A contactor design with a movable and fixed iron core, operation coil, tripping spring, and push spring, where the second movable bar moves in conjunction with the first movable bar to ensure synchronized opening and closing of contact points, reducing wear and arc duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the crossbar performs rotary movement to operate the opening/closing lever, then the contactor can be remotely opened and closed, but the movable contact becomes tilted resulting in uneven opening/closing timing between different contact points
Solution Approach 1:
The crossbar is divided into multiple segments (first crossbar portion, second crossbar portion, third crossbar portion) that can move independently or in coordinated fashion. This segmentation allows the distal end to perform rotary movement for remote operation while the proximal end maintains linear movement to keep the movable contact horizontal, thereby resolving the timing synchronization issue.
Solution Approach 2:
The opening/closing lever acts as an intermediary mechanism between the crossbar and the movable contact. By designing the lever with specific geometric relationships and pivot points, it converts the rotary movement of the crossbar's distal end into synchronized linear movement that maintains the horizontal orientation of the movable contact, ensuring uniform opening/closing timing across all contact points.
2Ease of operation
If the movable contact is tilted at an angle, then remote opening/closing operation is enabled, but arcs are generated for longer periods causing accelerated wear on contact points
Solution Approach 1:
Dividing the crossbar into multiple portions allows independent optimization of movement paths. The distal end can rotate to enable remote operation while the proximal end moves linearly to maintain contact horizontality, minimizing arc duration and protecting contact point reliability.
Solution Approach 2:
Instead of tilting the entire movable contact to achieve remote operation, the invention inverts the approach by keeping the movable contact horizontal and achieving remote operation through rotary movement of the crossbar's distal end only, transmitted through the opening/closing lever mechanism.
3Reliability
If the first movable bar is fixed to the movable iron core, then the opening lever can push the second movable bar to open contact points during overcurrent, but the structure becomes more complex
Solution Approach 1:
The first movable bar and second movable bar are merged into a single integrated movable bar structure that performs both functions: being pushed by the opening lever during overcurrent and holding the movable contact. This merging simplifies the overall structure while maintaining the required overcurrent protection functionality.
Solution Approach 2:
The movable bar is designed as a multi-functional component that serves multiple purposes: it transmits force from the opening lever, holds the movable contact, and participates in the electromagnetic actuation mechanism. This multi-functionality reduces the total number of separate components needed in the system.
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 contactor effectively opens contact points during overcurrents while minimizing wear on contact points, ensuring consistent and prolonged operation by synchronizing the opening and closing timing of all contact points.
Implementation Method 1
an operation coil provided around the movable iron core, the operation coil being configured to generate, by a current supplied from an outside of the contactor, an electromagnetic force that brings the movable iron core into contact with the fixed iron core
Implementation Method 2
a trip coil connected to the fixed contact; and a plunger that is operated by an electromagnetic force generated in the trip coil when a current of a predetermined value or higher flows through the trip coil
Data Source
AI summary
A contactor includes a fixed iron core, a movable iron core, an operation coil, a first crossbar, a tripping spring, and a second crossbar. The contactor includes a push spring to push a movable contact toward a fixed contact, a trip coil connected to the fixed contact, and a plunger that is operated by an electromagnetic force generated in the trip coil when a current of a predetermined value or higher flows through the trip coil. The contactor includes an opening lever to push the second crossbar in a direction away from the first crossbar in conjunction with the operation of the plunger.