Hot-Swap Module Relay Arc Prevention via Locking Sensor
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Solution Overview
Problem
Existing systems with plug-in modules face safety risks due to the potential establishment of electric arcs during module removal if relays are not properly opened before extraction, especially when removed in service.
Innovation Solution
A system incorporating a base and module with a mechanical locking member, a module presence sensor, and a blocking sensor that automatically opens the relay upon detection of the unlocked state or module absence, ensuring safe disconnection by preventing reconnection during removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the module is removed without properly opening the relays first, then the removal operation can be performed quickly, but electric arcs may be established between the contacts causing safety risks
Solution Approach 1:
The system performs preliminary action by automatically opening the relay contacts before the module is physically removed from the base. The sensor detects when the locking member is in the unlocked state and triggers the relay to open in advance, ensuring that the electrical circuit is broken before any potential arc formation during contact separation. This eliminates the safety hazard while allowing quick module removal.
2Reliability
If the relay is opened automatically when the blocking member is unlocked, then operator safety is improved, but the system complexity increases due to additional sensors and control means
Solution Approach 1:
The system merges the blocking member's mechanical function with the sensor detection function. The blocking member serves both as a mechanical lock and as a trigger for the sensor that controls the relay. This integration reduces the need for separate, independent components and simplifies the overall control system while maintaining safety functionality.
Solution Approach 2:
The system implements self-service by automatically detecting the unlocked state through the sensor and autonomously opening the relay without requiring manual intervention from the operator. The system monitors its own state and takes appropriate action, reducing complexity compared to manual control systems while enhancing safety.
3Ease of operation
If the blocking member allows unlocking at any position, then the ease of operation is improved, but the risk of reconnection during removal increases
Solution Approach 1:
The system uses feedback from the sensor that continuously monitors the position of the blocking member. When the sensor detects that the blocking member is in the unlocked state, it sends a signal to open the relay. This feedback mechanism ensures that the relay remains open throughout the removal process, preventing any risk of reconnection while allowing the operator to unlock the module at any convenient position.
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
Enables hot-pluggable module removal without risk of electric arcs, ensuring operator safety by ensuring the relay remains open until the module is fully disconnected.
Implementation Method 1
the sensors are of the Hall effect type
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
The invention relates to a system comprising a base (2) and a module (4) inserted into this base (2), an electrical relay (26) for electrically disconnecting the module (4) from the base (2), and a locking element (11) movable between a locked and an unlocked state. The system includes a presence sensor (19) for the module (4) in the base (2) and a locking sensor (16) for detecting the state of the locking element (11), and means for opening the relay (26) as soon as the locking element (11) is unlocked or the module (4) is absent. The locking element (11) can only leave its unlocked state when the module (4) has been moved within the base (2) by a distance greater than the detection range of the presence sensor (19).