Contactor Wedge Lock Mechanism Against Contact Levitation
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Solution Overview
Problem
Existing contactors fail to efficiently address the electromagnetic repulsion and electromagnetic repulsion generated by the flow of current through the contacts, leading to contact levitation, improper closure, and arcing, which can be destructive and require larger structures to counteract these issues.
Innovation Solution
A contactor assembly with a housing, coupling member, and actuator assembly that uses a contact bridge engaging wedge to lock the contact bridge in a closed position, providing a high mechanical contact force to maintain the contact bridge engaging wedge to lock the contact bridge in a closed position, providing a high mechanical contact force to maintain the contact force to maintain the contact bridge in a closed position, providing a high mechanical contact force to maintain the contact bridge in place, reducing levitation and arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large spring force is provided to overcome electromagnetic repulsion and maintain contact closure, then contact reliability is improved, but the size of the contactor assembly must be increased
Solution Approach 1:
The contactor assembly is segmented into functional modules: the electromagnetic actuator assembly (with coil and armature) is separated from the contact bridge assembly. This allows the spring mechanism to be integrated within the actuator assembly rather than requiring a separate large spring mechanism, reducing overall assembly size while maintaining sufficient contact force.
Solution Approach 2:
The invention transitions from a purely mechanical spring-force approach to a combined electromagnetic-mechanical approach. The electromagnetic field generated by the coil provides additional force dimension, allowing smaller mechanical components to achieve the same contact pressure that would otherwise require larger springs.
2Force
If the size of the contactor assembly is increased to provide larger springs and electromagnets for high current applications, then contact force is improved, but the complexity and size of the structure increase
Solution Approach 1:
The electromagnetic actuator assembly serves multiple functions: it actuates the contact bridge open/closed, provides holding force against electromagnetic repulsion during current flow, and integrates the return spring mechanism. This multi-functionality eliminates the need for separate dedicated components for each function, reducing overall structural complexity.
Solution Approach 2:
The invention merges the actuator mechanism and the return spring mechanism into a single integrated assembly. The armature of the electromagnetic coil directly connects to the contact bridge, and the return spring is integrated within the same housing, creating a compact unified structure rather than separate assemblies.
3Power
If high current flows through the contacts, then power transmission is improved, but electromagnetic repulsion causes contact levitation and arcing
Solution Approach 1:
The return spring is pre-loaded to provide initial contact pressure before current flow begins. This preliminary mechanical force counteracts the electromagnetic repulsion that will be generated when high current flows through the contacts, preventing contact levitation and associated arcing.
Solution Approach 2:
The armature serves as an intermediary mechanical element between the electromagnetic coil and the contact bridge. It transmits and amplifies the electromagnetic force while maintaining mechanical coupling, ensuring that the contact bridge remains firmly pressed against the contact surface even under high electromagnetic repulsion conditions.
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 assembly effectively maintains contact closure under high transient currents and voltages, preventing levitation and arcing, ensuring reliable electrical connections without increasing the assembly's size.
Implementation Method 1
When an electric current is passed through the coil assembly it generates a magnetic field that attracts the armature
Implementation Method 2
When the current to the coil is switched off, the armature is returned by the spring force of the return spring toward its relaxed position
Implementation Method 3
contact levitation caused by electromagnetic repulsion generated by the flow of current through the contacts
Data Source
Figure 1~8
Figure 2~3
Figure 4~5
AI summary
A contactor assembly (12) having a housing (26, 40) defining an interior compartment (46). Current carrying contacts (34, 36) are disposed in the interior compartment (46) of the housing (26, 40). A coupling member (60) is positioned in the interior compartment (46) of the housing (26, 40), the coupling member (60) has conductive areas (56) for engaging the current carrying contacts (34, 36). A contact bridge (62) extends from a first end of the coupling member (60) to a second end of the coupling member (60). The contact bridge (62) has a wedge engaging opening (64) extending therethrough. A contact bridge engaging wedge (82) is positioned in the wedge engaging opening (64). An actuator assembly (58) extends through the wedge engaging opening (64) to spread the contact bridge engaging wedge (82). The actuator assembly (58) moves the coupling member (60) between a closed position in which the conductive areas (56) of the coupling member (60) engage the current carrying contacts (34, 36) and an open position in which the conductive areas (56) of the coupling member (60) are disengaged from the current carrying contacts (34, 36).