Magnet System for Circuit Breaker Assembly
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Solution Overview
Problem
Circuit breakers with magnetic systems require multiple mechanical parts for assembly, making them time-consuming and expensive, and the air gap in the magnetic circuit is often dependent on manufacturing tolerances, leading to complex design measures.
Innovation Solution
A simplified magnet system with fewer parts, where the magnetic core serves as both a core and a holding element, and the air gap is adjusted via bearing elements within the insulating housing, reducing the need for separate holding devices and allowing for precise adjustment independent of manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mechanical parts are used in the magnet system for assembly, then the functional reliability is improved, but the assembly time and cost increase
Solution Approach 1:
The patent combines multiple mechanical parts into an integrated magnet system assembly. The magnet armature, plunger, return spring, and yoke are merged into a single pre-assembled unit that can be installed as one component, reducing assembly time while maintaining functional reliability through the integrated design.
Solution Approach 2:
The magnet system is pre-assembled with all mechanical parts (armature, plunger, spring, yoke) configured and positioned correctly before installation into the circuit breaker. This preliminary assembly ensures proper functional reliability is achieved while eliminating the need for time-consuming on-site assembly of multiple individual parts.
2Reliability
If multiple mechanical parts are used in the magnet system, then the functional reliability is improved, but the production cost increases
Solution Approach 1:
By merging multiple mechanical parts into a single integrated magnet system assembly, the patent reduces the number of separate components that need to be manufactured, stored, and handled. This consolidation lowers production costs through economies of scale and simplified manufacturing processes while preserving the functional reliability achieved through the integrated design.
Solution Approach 2:
The integrated magnet system assembly serves multiple functions simultaneously - the yoke provides magnetic flux path, the armature provides movable contact, the plunger provides actuation, and the spring provides return force. This multi-functionality in a single assembly reduces the need for multiple specialized parts, lowering production costs while maintaining comprehensive functional reliability.
3Device complexity
If the air gap is determined by manufacturing tolerances of multiple parts, then the assembly is simpler, but the air gap precision deteriorates
Solution Approach 1:
The patent introduces a dedicated air gap adjustment mechanism as an intermediary component between the magnet armature and the fixed contact. This separate adjustment device allows precise control of the air gap dimension independent of manufacturing tolerances of other parts, achieving high air gap precision without complicating the overall assembly process.
Solution Approach 2:
The air gap is designed to be dynamically adjustable rather than fixed by manufacturing tolerances. The adjustment mechanism allows the air gap to be precisely set and fine-tuned during assembly or maintenance, ensuring optimal precision while maintaining assembly simplicity through a dedicated adjustment feature.
4Manufacturing precision
If complex design measures are implemented to control the air gap, then the air gap precision is improved, but the device complexity increases
Solution Approach 1:
The patent uses a dedicated air gap adjustment mechanism as a specialized intermediary component that handles the complex precision control function. This isolates the complexity to a single adjustable element rather than requiring complex design measures across the entire magnet system, achieving high air gap precision with minimal overall device 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
The solution enables easier, faster assembly of the circuit breaker with reduced part complexity and improved tolerance independence of the air gap, resulting in a more reliable and cost-effective magnetic system.
Implementation Method 1
the coil essentially is arranged around the armature and/or the yoke sleeve... If the current in the coil is greater than a predetermined triggering current, the armature is displaced by the resulting magnetic field of the coil
Implementation Method 2
the armature and the plunger must be held in a defined rest position by a tether spring in order to ensure a defined response of the circuit breaker
Data Source
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AI summary
The invention relates to a magnet system (1) for a line circuit breaker (2), with a yoke (3), a coil (4), a sleeve (5), a magnet core (6), a plunger (7), a magnet armature (8) and a restraint spring (9), wherein a conductor piece (10) is formed on the yoke (3) and bears a fixed contact piece (11), and wherein the magnet armature (8) is guided movably in the sleeve (5) counter to the force of the restraint spring (9). The magnet core (6) is fastened on the conductor piece (10), the sleeve (5) is in engagement with the magnet core (6) at the first end of said sleeve, and the magnet armature (8) can be guided into and out of the sleeve (5) at the second end of the sleeve (5).