Contactor Fastening Device for Simultaneous Electrical and Mechanical Connection
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Solution Overview
Problem
The existing contactor manufacturing process is costly and time-consuming due to the need for multiple stages of cable connections between the electrical circuit board and the coil, making it difficult to replace the circuit board and increasing the risk of mechanical and electrical disconnection in bumpy environments.
Innovation Solution
A contactor design that incorporates a fastening device for simultaneous mechanical and electrical connection of the circuit board's output terminals to the coil's input terminals, eliminating the need for cables and reducing the mounting steps to one, using connectors or clamping devices for stable connections, and allowing for easy module replacement and secure enclosure within a casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cable connections are used to connect the circuit board and the coil, then the connection can accommodate bumpy movements, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent merges the mechanical connection function and electrical connection function into a single integrated connector assembly. The connector simultaneously provides structural support and electrical conductivity, eliminating the need for separate cable connections and reducing the mounting process to a single operation while maintaining reliability in bumpy environments.
Solution Approach 2:
The connector is designed as a multi-functional component that performs multiple roles: mechanical fastening, electrical conduction, and positional alignment. This universal design allows a single component to replace what previously required multiple separate elements (cables, connectors, fasteners), simplifying both the device structure and the manufacturing process.
2Adaptability or versatility
If cable connections are used to connect the circuit board and the coil, then flexibility in movement is achieved, but the replacement of circuit board becomes difficult
Solution Approach 1:
The patent segments the contactor into modular components (frame, coil assembly, circuit board assembly) that can be independently replaced. The connector is designed to facilitate quick disconnection and reconnection, allowing the circuit board to be replaced without dismantling cable connections, thus improving ease of repair while maintaining movement flexibility through the robust connector design.
3Reliability
If two-stage mounting process is used for cable connections, then reliable electrical connection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The connector is pre-assembled with the coil and circuit board terminals during manufacturing, so that the electrical connection is already established before the final assembly step. This preliminary action eliminates the need for on-site cable connection work, reducing manufacturing time and cost while ensuring reliable electrical connections through factory-quality assembly.
Solution Approach 2:
The patent combines the electrical connection function and mechanical fastening function into a single integrated connector that is installed in one step. This merging of functions eliminates the two-stage mounting process, allowing workers to complete both mechanical assembly and electrical connection simultaneously, thereby improving manufacturing efficiency without compromising connection 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
This design reduces manufacturing time and costs, enhances stability in bumpy environments, and simplifies the replacement of circuit boards, while ensuring a secure and reliable electrical connection.
Implementation Method 1
an electromagnet apparatus and a contact system. The electromagnet apparatus is used to operate (open or close) a contact system of a contactor
Implementation Method 2
a fastening device arranged for mechanically and electrically connecting one of output terminals to a corresponding input terminal of the coil
Data Source
Figure 1
Figure 2a~3c
Figure 4
AI summary
The present invention relates to a contactor (1) comprising a frame including a base unit (3), a coil (4) provided on the base unit (3) and including input terminals (14, 14'), and a module (20) comprising a circuit board (22) for electrically controlling the coil (4), the circuit board including input terminals (24, 24') for power supply and output terminals for providing an electrical connection to the coil. The contactor further comprises a fastening device (26, 26', 10, 10', 36, 36', 16, 16') arranged f or mechanically and electrically connecting one of output terminals to a corresponding input terminal of the coil, and the module is designed such that the fastening device connects the output terminal of the circuit board to the input terminal of the coil while at the same time the module is connected to the frame.