Hermetic Contactor Coil Layout to Reduce Arcing and Seal Stress
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Solution Overview
Problem
Existing electromagnetic contactors face issues with electrode misalignment due to wear and stress, leading to arcing and compromised hermetic seals, and have complex designs with increased part count, mass, and volume.
Innovation Solution
A contactor design featuring a hermetically sealed enclosure with a single moving contact member and a deformable connector, actuated by an electromagnetic coil without mechanical linkage, reducing part count and stress on seals, and incorporating a heat sink for improved thermal dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cross bar is used to connect two stationary electrodes, then the circuit can be made, but electrode misalignment occurs due to wear and stress leading to arcing and compromised hermetic seals
Solution Approach 1:
The invention extracts the problematic cross bar component and replaces it with a deformable connector. This removes the source of misalignment and stress transmission to the hermetic seal, while still achieving the electrical connection function through the deformable connector that can accommodate movement without compromising the seal.
Solution Approach 2:
The invention changes the physical state and properties of the connector from rigid to deformable. The deformable connector can change its shape and flexibility to accommodate electrode movement and misalignment, preventing arcing while maintaining reliable electrical contact without transmitting stress to the hermetic seal.
2Reliability
If a cross bar connects two stationary electrodes, then the circuit is completed, but the forcing of the cross bar into contact position causes stresses and compromises the hermetic seal
Solution Approach 1:
The invention removes the cross bar that transmits mechanical stress to the hermetic seal. Instead, a deformable connector is used that absorbs the mechanical stress through its flexibility, maintaining circuit continuity while protecting the hermetic seal from compromising forces.
Solution Approach 2:
The deformable connector acts as a cushioning element that anticipates and absorbs mechanical stresses before they can reach the hermetic seal. The connector's deformability provides a buffer zone that protects the seal from stress during the contact-making process.
3Reliability
If an axially movable rod is used instead of a cross bar, then electrode connection is achieved, but the movable rod protruding outside the casing makes the arrangement cumbersome and complicated
Solution Approach 1:
The invention merges the electrical connection function with the hermetic enclosure by using a deformable connector that remains entirely within the sealed casing. This eliminates the need for external mechanical linkages and protruding components, simplifying the overall device structure while maintaining reliable electrode connection.
Solution Approach 2:
The invention replaces the complex mechanical linkage system with a simpler deformable connector that uses elastic deformation rather than rigid mechanical movement. This substitution eliminates the need for external rods and complex actuation mechanisms, reducing device complexity while achieving the same electrical connection function.
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 design reduces wear, arc formation, part count, and weight, while enhancing stability and thermal dissipation, resulting in a more reliable and compact contactor with reduced failure points and energy consumption.
Implementation Method 1
an electromagnetic arrangement comprising an electromagnetic coil and at least a part of the actuator assembly, wherein, when the coil is energised, the coil generates a magnetic field and thereby the actuation assembly is caused to move under the influence of the magnetic field
Data Source
AI summary
A contactor (1) comprising a first contact member (3) fixed and connected to a first conductor (5) of an electrical circuit; a second contact member (7) connected to a second conductor (9) of the electrical circuit by a connector (11); wherein the second contact member moves between a break position, in which the first and second contact members are out of contact, and a make position, in which the first and second contact members are in contact; an actuator assembly (15) coupled to the second contact member such that actuation of the actuator assembly translates into movement of the second contact member; an electromagnetic arrangement comprising an electromagnetic coil (17) and at least a part of the actuator assembly, wherein, when the coil is energised, the coil generates a magnetic field and thereby the actuation assembly is caused to move under the influence of the magnetic field, which in turn causes the second contact member to move; a hermetically sealable enclosure (2); wherein the first and second contact members, the connector, and the actuation assembly are inside the enclosure; and the coil is outside the enclosure.