Contactor Wedge Locking Mechanism Against Contact Levitation
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Solution Overview
Problem
Existing contactor assemblies face issues with contact levitation and arcing due to electromagnetic repulsion, requiring larger sizes and increased spring forces to maintain contact pressure, which leads to potential device destruction.
Innovation Solution
A contactor assembly with a contact bridge and a contact bridge engaging wedge mechanism that locks the contact bridge in the closed position using a wedge engaging opening and angled sections to provide a high mechanical retention force, reducing electromagnetic repulsion and arcing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large spring force is provided to overcome electromagnetic repulsion and maintain contact pressure, then contact reliability is improved, but the size of the contactor assembly must be increased
Solution Approach 1:
The contactor assembly is segmented into distinct functional components: a contact bridge with multiple contacts, a separate wedge member for applying force, and an actuator assembly. This segmentation allows the wedge member to be positioned optimally for mechanical advantage without increasing overall assembly size, as each component performs a specific function efficiently.
Solution Approach 2:
The wedge member introduces a dimensional advantage by converting linear actuator motion into amplified contact force through its inclined geometry. The wedge angle transforms small actuator displacements into large contact forces, effectively adding a mechanical advantage dimension that reduces the need for larger springs or actuators.
2Reliability
If a large spring force is provided to maintain contact pressure against electromagnetic repulsion, then contact stability is improved, but the complexity of the contactor assembly increases
Solution Approach 1:
The wedge member combines multiple functions into a single component: it acts as both the force application mechanism and the contact pressure regulator. By integrating the wedge geometry directly into the contact bridge structure, the design eliminates the need for separate large springs and complex adjustment mechanisms, reducing overall assembly complexity while maintaining contact stability.
3Force
If the size of the contactor assembly is increased to provide sufficient electromagnet force, then contact closing force is improved, but the overall device size increases
Solution Approach 1:
The contactor employs dynamic force multiplication through the wedge mechanism rather than relying solely on static electromagnet size. The wedge angle provides mechanical advantage that dynamically amplifies the electromagnet's closing force, allowing a smaller electromagnet to achieve the same contact force that would require a much larger device without the wedge mechanism.
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 mechanism maintains reliable electrical connections and prevents unwanted arcing, allowing the contactor assembly to handle high transient currents without size or complexity increases.
Implementation Method 1
In the closed position the wedge spreader engages the wedge, locking the bridge contact in the closed position
Implementation Method 2
A contact bridge engaging wedge is positioned in the wedge engaging opening. An actuator assembly extends through the wedge engaging opening to spread the contact bridge engaging wedge. The actuator assembly moves the coupling member between a closed position
Implementation Method 3
contact levitation caused by electromagnetic repulsion generated by the constriction of the flow of current through the contacts
Data Source
AI summary
A contactor assembly having a housing defining an interior compartment. Current carrying contacts are disposed in the interior compartment of the housing. A coupling member is positioned in the interior compartment of the housing, the coupling member has conductive areas for engaging the current carrying contacts. A contact bridge extends from a first end of the coupling member to a second of the coupling member. The contact bridge has a wedge engaging opening extending therethrough. A contact bridge engaging wedge is positioned in the wedge engaging opening. An actuator assembly extends through the wedge engaging opening to spread the contact bridge engaging wedge. The actuator assembly moves the coupling member between a closed position in which the conductive areas of the coupling member engage the current carrying contacts and an open position in which the conductive areas of the coupling member are disengaged from the current carrying contacts.