External-Coil Hermetic Switch Module for High-Voltage Reliability
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Solution Overview
Problem
Conventional hermetically sealed contactors face challenges such as complex and costly manufacturing due to internal coil assemblies, pressure imbalances affecting plunger movement, and difficulties in repairing or replacing internal solenoids.
Innovation Solution
The solution involves a hermetically sealed switching module with a cylindrical core that allows the coil assembly to be mounted externally, improving manufacturing efficiency and reducing costs. Additionally, an improved plunger shaft structure and auxiliary switch arrangements enhance reliability and operation at high voltages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil assembly is placed inside the hermetically sealed housing, then the contactor can operate in a controlled environment, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The contactor is divided into two separate modules: a hermetically sealed housing containing the contacts and plunger, and an external coil assembly. The sealed housing is evacuated to suppress arc formation, while the coil operates externally, eliminating the need to seal the entire assembly and reducing manufacturing complexity.
Solution Approach 2:
The coil assembly is extracted from the hermetically sealed housing and positioned externally. This allows the housing to be sealed and evacuated without the coil, simplifying the sealing process and reducing manufacturing difficulty while maintaining the reliability benefits of the controlled environment for the contacts.
2Volume of moving object
If the solenoid is placed inside the hermetically sealed housing, then the contactor structure is compact, but pressure build-up during plunger travel slows plunger movement and reduces solenoid performance
Solution Approach 1:
The solenoid is removed from the sealed housing and placed externally. This eliminates the pressure build-up problem inside the sealed housing during plunger travel, allowing the plunger to move at full speed without resistance from trapped gas, while the compact housing design is preserved.
3Device complexity
If the solenoid is placed inside the hermetically sealed housing, then the contactor structure is integrated, but repair and replacement of the solenoid become difficult
Solution Approach 1:
The contactor is segmented into a sealed housing module and an external coil module. This separation allows the coil to be independently accessed, removed, and replaced without disassembling the hermetically sealed housing, significantly improving maintenance ease while maintaining structural integrity during operation.
4Temperature
If ceramic housing is used, then the contactor can operate at high voltage and temperature, but the manufacturing cost and difficulty increase
Solution Approach 1:
The high-temperature ceramic material is used only for the housing that requires thermal stability, while the coil assembly operates externally where different material requirements apply. This segmented approach allows the ceramic housing to provide high-temperature and high-voltage capability without requiring the entire assembly to be manufactured from ceramic, reducing overall manufacturing complexity.
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 configuration reduces manufacturing complexities and costs, improves plunger movement efficiency, and facilitates easier maintenance by allowing external access to the solenoid, while maintaining high voltage and temperature operational capabilities.
Implementation Method 1
a coil assembly (18) arranged outside said core and arranged to provide a magnetic field in response to an electrical signal
Implementation Method 2
magnetically conductive components can be included to provide a magnetic flux path to conduct the magnetic field from the solenoid to the core
Implementation Method 3
air is removed from the contactor housing to create a vacuum that suppresses arc formation
Implementation Method 4
the evacuated chamber can be backfilled under pressure with an insulating gas, which allows the contactor to operate with good arc-suppressing properties
Data Source
AI summary
Switching devices comprising a hermitically sealed switching modules with a core or housing structure that allow for the coil assembly to be mounted outside the hermitically sealed housing. This helps avoid some of the complex manufacturing and testing requirements necessary for conventional coil assemblies arranged inside the sealed housing. The present inventions also provides for improved and more reliable auxiliary switch arrangements, with some embodiments comprising an improved auxiliary arm and auxiliary carrier. The present invention also provides for an improved lunger or shaft structure that allows for operation at high voltage, with some embodiments comprising heat resistance and isolation components particularly arranged to accommodate high voltage operation.