Helical Torsion Spring with I-Shaped Cross-Section for High Voltage Circuit Breakers
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Solution Overview
Problem
Traditional torsion springs used in high voltage circuit breakers are inefficient due to high inertial forces and material stress, making them heavy, costly, and difficult to manufacture and inspect for cracks.
Innovation Solution
A torsion spring with a cross-section featuring flanges aligned with the central axis and a web extending perpendicular to it, optimizing the distribution of stress to reduce mass and increase structural strength, allowing for a lighter, cheaper, and easier-to-manufacture design with reduced inertial forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a traditional solid circular cross-section spring wire is used, then the spring has sufficient structural strength, but the mass and inertial forces are high
Solution Approach 1:
The spring wire cross-section is designed with non-uniform material distribution: the flanges (at the ends of the web) have higher material concentration to withstand bending stresses, while the center of the web has reduced material where stresses are lower. This local quality variation optimizes the strength-to-weight ratio by placing material only where structurally necessary.
Solution Approach 2:
The cross-section transitions from a symmetric circular shape to an asymmetric I-shaped or H-shaped profile with distinct flanges and web. This asymmetric geometry better matches the stress distribution pattern in torsion springs, concentrating material at the flanges where bending stresses are highest and reducing material in the web center where stresses are lower, thereby reducing mass while maintaining strength.
2Strength
If more material is used in the spring wire, then the structural strength increases, but the inertial forces and cost increase
Solution Approach 1:
The spring wire cross-section is designed with non-uniform material distribution: the flanges (at the ends of the web) have higher material concentration to withstand bending stresses, while the center of the web has reduced material where stresses are lower. This local quality variation optimizes the strength-to-weight ratio by placing material only where structurally necessary.
Solution Approach 2:
The cross-sectional geometry parameters are optimized by varying the flange width, web thickness, and overall height to achieve the minimum mass required for sufficient strength. The I-shaped or H-shaped profile with specific dimensional ratios allows the spring to withstand torsional loads with less material than a solid circular section, reducing both mass and inertial forces.
3Weight of moving object
If a hollow spring wire is used, then the mass is reduced, but the manufacturing complexity and crack detection difficulty increase
Solution Approach 1:
The spring wire cross-section is designed with non-uniform material distribution: the flanges (at the ends of the web) have higher material concentration to withstand bending stresses, while the center of the web has reduced material where stresses are lower. This local quality variation optimizes the strength-to-weight ratio by placing material only where structurally necessary.
4Ease of manufacture
If a traditional circular cross-section is used, then the manufacturing is simple, but the material utilization efficiency is low
Solution Approach 1:
The spring wire cross-section is designed with non-uniform material distribution: the flanges (at the ends of the web) have higher material concentration to withstand bending stresses, while the center of the web has reduced material where stresses are lower. This local quality variation optimizes the strength-to-weight ratio by placing material only where structurally necessary.
Solution Approach 2:
The cross-section transitions from a symmetric circular shape to an asymmetric I-shaped or H-shaped profile with distinct flanges and web. This asymmetric geometry better matches the stress distribution pattern in torsion springs, concentrating material at the flanges where bending stresses are highest and reducing material in the web center where stresses are lower, thereby reducing mass while maintaining strength.
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 optimized torsion spring design significantly reduces mass and inertia while maintaining operating torque, enhancing efficiency and ease of manufacturing and crack detection, making it suitable for high voltage circuit breakers and other applications.
Implementation Method 1
A helical torsion spring works by torsion and includes a spring wire in the shape of a helix. The torsion spring is loaded by applying torsion to the ends of the spring so that the diameter of the spring increases or decreases. The spring wire stores mechanical energy when the torsion spring is winded.
Implementation Method 2
The spring wire stores mechanical energy when the torsion spring is winded. When the spring wire is loaded, the torsion spring exerts a torque in a direction opposite the winding direction, and proportional to the amount it is winded.
Implementation Method 3
when a helical torsion spring is subjected to torsion, the spring wire forming the helical torsion spring is subjected to bending
Implementation Method 4
By arranging the web so that the longitudinal axis of the web is perpendicular to the central axis of the spring, no bending stresses occur in a center part of the web while maximum stresses occur in the ends of the web. By arranging the flange at the end of the web, and aligning the flange with the central axis of the spring, the flange is positioned where the spring is subjected to most stress due to the bending forces.
Data Source
Figure 1~6
Figure 7
AI summary
The present invention relates to a torsion spring comprising a helical spring wire wound around a central axis (A). The spring wire has across-section formed by at least one flange (3,4) aligned with the central axis (A) of the spring and a web (5) connected to the flange and extending in a direction perpendicular to the central axis.