Magnetic Switch Assembly for Reliable Contactor State Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing switch assemblies for medium to high voltage contactor devices in transportation vehicles have a low reliability due to the use of multiple mechanical components, which are prone to production errors, wear, and deformation.
Innovation Solution
A switch assembly with a reduced number of mechanical components, utilizing at least two fixed electric contacts and a moving contact actuated by a magnetic member to indicate the open or closed state of the contactor device, allowing for indirect detection through impedance measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mechanical components (buttons, rods, springs, leaf springs, levers) are used to transmit motion in the miniaturized switch, then the switch assembly can detect the open/closed state of the contactor device, but the reliability of the system decreases due to production errors, wear, and deformations
Solution Approach 1:
The patent replaces the mechanical component system (buttons, rods, springs, leaf springs, levers) with a magnetic field-based actuation system. The magnetic member generates magnetic force to directly move the moving contact, eliminating the need for mechanical transmission components. This substitution of mechanical system with magnetic field system resolves the contradiction by improving reliability through fewer mechanical parts while maintaining the switching function.
Solution Approach 2:
The patent extracts and removes the unnecessary mechanical transmission components (buttons, rods, springs, leaf springs, levers) from the miniaturized switch assembly, retaining only the essential elements (fixed contacts, moving contact, and magnetic actuator). This extraction eliminates sources of production errors, wear, and deformation while preserving the core switching functionality.
2Device complexity
If a magnetic member is used to actuate the moving contact, then the number of mechanical components is reduced and reliability is improved, but the device requires magnetic field control mechanisms
Solution Approach 1:
The patent replaces complex mechanical transmission mechanisms with a magnetic field-based actuation system. The magnetic member can be integrated into the existing contactor device structure, and its operation is controlled through the existing magnetic actuation mechanisms already present in contactor devices. This substitution simplifies the overall device by eliminating mechanical transmission components while utilizing the inherent magnetic control capabilities of the contactor device.
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 enhances reliability by minimizing mechanical wear and deformation, enabling accurate detection of the contactor device's state with improved durability and reduced mechanical complexity.
Implementation Method 1
at least one first magnetic member is comprised by or affixed to the at least one actuator and/or the moving contact configured to provide a magnetic force to move the moving contact into or away from the first position
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a switch assembly (10, 10', 10", 10‴, 10"") for switching medium to high voltage contactor devices in transportation vehicles, comprising: at least two first fixed electric contacts (2, 3) distanced from each other, at least one moving contact (6) configured to be movable between a first position to contact both of the at least two fixed electric contacts (2, 3) for electrically connecting the at least two first fixed electric contacts (2, 3) and a second position away from at least one of the at least two fixed electric contacts (2, 3) for disconnecting the at least two first fixed electric contacts (2, 3), and at least one actuator (9, 9', 9"") facing the at least one moving contact (6) and configured to be movable toward and away from the at least one moving contact (6), wherein at least one first magnetic member (8, 8', 8"") is comprised by or affixed to the at least one actuator (9, 9', 9"") and/or the moving contact (6) configured to provide a magnetic force to move the moving contact (6) in the first position depending on a distance (D) between the at least moving contact (6) and the at least one actuator (9, 9', 9ʺʺ).