Door Handle Coupler for Tool-Less Circuit Breaker Mounting
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Solution Overview
Problem
Existing coupling members for motor protection circuit breakers require tool-assisted installation and alignment, which can be cumbersome and hazardous, especially when located within enclosures, and lack a secure, tool-less mounting mechanism.
Innovation Solution
A door handle coupler system comprising an upper sleeve, a lower sleeve, and a locking lever that allows for tool-less alignment and mounting to the motor protection circuit breaker, utilizing a spring for retention and a locking lever for secure orientation and lock-out features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a coupling member is mounted to a circuit breaker within an enclosure using traditional methods, then the mounting is secure, but the installation requires tools and alignment procedures that are cumbersome and hazardous
Solution Approach 1:
The coupling member is divided into two separate members: a first member that engages the disconnect switch and a second member that receives the shaft. This segmentation allows each member to be optimized for its specific function and enables tool-less installation through complementary coupling portions that snap together without requiring alignment tools or fastening devices.
Solution Approach 2:
The complementary coupling portions are designed with nested geometries where one portion fits into the other through interference fit or snap-fit mechanisms. The first member includes a coupling portion that receives a complementary coupling portion on the second member, creating a secure connection without tools by nesting the geometric features together.
2Ease of operation
If manual activation of the circuit breaker is provided through an opening in the enclosure, then access is enabled, but alignment and mounting require hazardous entry into the enclosure
Solution Approach 1:
The coupling member acts as an intermediary mechanism that bridges the external shaft and the internal circuit breaker actuator. By mounting the coupling member to the circuit breaker through tool-less complementary coupling portions, the system enables external control without requiring personnel to enter the hazardous enclosure, as the shaft can be operated from outside through the door activator.
3Reliability
If the coupling member uses a secure mounting mechanism, then retention is reliable, but installation requires tools that defeat tool-less mounting goals
Solution Approach 1:
The complementary coupling portions are pre-configured with geometric features that automatically align and engage when the members are brought together. The first member includes a coupling portion configured to engage a complementary coupling portion on the second member, creating a secure interference fit or snap-fit connection that requires no preliminary alignment tools or fastening operations.
Solution Approach 2:
The coupling members are designed to self-align and self-secure through their complementary geometric features. When the first member and second member are brought together, the coupling portions automatically engage through interference fit or snap-fit mechanisms, allowing the assembly to secure itself without external tools or additional fastening steps.
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
Facilitates safe, tool-less installation and secure mounting of the coupling member to the motor protection circuit breaker, ensuring proper alignment and preventing accidental activation during maintenance, while providing a local lock-out feature for enhanced safety.
Implementation Method 1
A spring inside the door handle coupler applies a biasing force between the coupling portions of the door handle coupler and the electronic protection device to positively retain the door handle coupler to the electronic protection device
Implementation Method 2
The locking lever is operatively connected between the first member and the second member and is configured to transfer the rotational force from the second member to the first member
Data Source
AI summary
A coupler between an activator mounted on an enclosure and an electronic protection device located within the enclosure facilitates alignment between the coupler and the electronic protection device during installation and requires no tool for installation. The coupler is positioned over an opening in the electronic protection device and oriented such that a first coupling portion is configured to engage a complementary coupling portion on the electronic protection device. The coupler may be manually mounted, engaging the complementary coupling portions on the door handle coupler and the electronic protection device without requiring a tool for installation. The coupler includes an upper sleeve configured to receive an axle, connected to the activator, that rotates independently of a lower sleeve which is mounted to the electronic protection device, facilitating orientation of the activator on the outside of the enclosure. The coupler provides for local lock-out of the electronic protection device.