Contactor Fastener Temperature Sensing for Thermal Degradation
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Solution Overview
Problem
Conventional contactor arrangements in power distribution systems face challenges with increased heat generation due to resistive heating, leading to potential reliability issues and the need for periodic replacement, especially in aircraft electrical systems where contactors handle high currents and are sensitive to thermal effects.
Innovation Solution
A contactor arrangement with integrated temperature sensors, such as thermistors or thermocouples, coupled to the fastener via epoxy or solder, provides real-time monitoring of contactor health by comparing temperature data with specification, design, and warning limits, allowing for proactive maintenance and service scheduling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If contactors are used to handle high currents in power distribution systems, then power transmission capability is improved, but heat generation from resistive heating increases leading to reduced reliability
Solution Approach 1:
The patent applies preliminary action by bonding a temperature sensor to the fastener before the contactor operates, enabling continuous temperature monitoring from the outset. This allows detection of thermal degradation trends before they lead to failure, maintaining reliability while preserving high power transmission capability.
Solution Approach 2:
The patent implements feedback through continuous temperature measurement by the sensor and comparison against specification, design, and warning limits. When temperature exceeds thresholds, the system generates alerts for maintenance scheduling, creating a closed-loop system that prevents thermal failure while allowing maximum power transmission.
2Reliability
If temperature monitoring is implemented to detect incipient degradation, then contactor reliability is improved, but device complexity increases due to additional sensors and monitoring systems
Solution Approach 1:
The patent uses an intermediary approach by bonding the temperature sensor to the fastener rather than directly to the contactor terminals. The fastener serves as a thermal intermediary that conducts heat from the contactor assembly, enabling reliable temperature monitoring while maintaining electrical isolation and simplifying the overall system architecture.
Solution Approach 2:
The monitoring system performs self-service by automatically comparing sensor readings against pre-stored specification and warning limits within the control module. This eliminates the need for external monitoring equipment or manual temperature checks, improving reliability while minimizing added complexity through self-contained functionality.
3Reliability
If periodic replacement of contactors is performed to address thermal degradation, then reliability is maintained, but loss of time due to unscheduled downtime increases
Solution Approach 1:
The system performs preliminary action by continuously monitoring temperature and comparing it against warning limits before thermal degradation leads to contactor failure. When thresholds are exceeded, the system alerts operators to schedule maintenance during planned downtime, preventing unexpected failures and eliminating unscheduled outages.
Solution Approach 2:
The feedback mechanism provides real-time temperature data and automated alerts when specification or warning limits are exceeded. This enables proactive maintenance scheduling based on actual thermal conditions rather than fixed replacement intervals, optimizing the timing of maintenance activities to minimize downtime while ensuring reliability.
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
Enhances contactor reliability by detecting incipient degradation and flagging contactors for immediate or scheduled maintenance, thereby reducing unexpected failures and minimizing downtime, thus enhancing the reliability and efficiency of the power distribution panels.
Implementation Method 1
a temperature sensor in thermal communication with the fastener to provide a signal indicative of the thermal health of the contactor
Implementation Method 2
The sensor can be coupled to the contactor arrangement by epoxy or solder. The sensor is electrically isolated from electrical surfaces carrying high electrical current
Data Source
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AI summary
A contactor arrangement includes a post (124), a fastener (132) and a temperature sensor (144). The post defines a post axis (126). The fastener is fixed to the post along the post axis. The temperature sensor is in thermal communication with the contactor conductor and post through the fastener and is electrically insulated from the post for monitoring resistive heat generation in a contactor fixed to the post by the fastener.