Modular Carrier Shaft Torsion Inhibiting Connecting Module
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Solution Overview
Problem
Existing electromechanical switching devices, such as circuit breakers, face challenges with the rigidity and wear resistance of connecting modules, which can lead to damage and increased weight due to torsion-inhibiting metal connections.
Innovation Solution
A carrier shaft with a modular structure comprising a first and second carrier module and a torsion-inhibiting connecting module, where the connecting module has a main body and a connecting device, providing increased rigidity and wear resistance through a multipart design with different materials and form-fitting components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plastic connecting module is used between carrier modules, then the device complexity is reduced and manufacturing is simplified, but the rigidity between individual carrier modules is insufficient
Solution Approach 1:
The connecting module uses a composite structure combining plastic and metal components. The plastic body provides ease of manufacture and integration, while embedded metal reinforcing elements (such as metal inserts or metal connecting pieces) provide the necessary rigidity and mechanical strength. This composite approach allows the connecting module to be manufactured as a single integrated component while achieving both manufacturing simplicity and structural rigidity.
2Strength
If metal shafts are used to mechanically connect rotor housings, then rigidity between individual rotor housings is improved, but the overall weight of the circuit breaker increases
Solution Approach 1:
The connecting module employs a hybrid plastic-metal construction where the primary body is made of lightweight plastic material, significantly reducing weight compared to full metal shafts. Metal reinforcing elements are strategically placed only where structural rigidity is critically needed, providing the necessary mechanical strength while minimizing weight addition. This selective use of materials achieves the desired rigidity without the penalty of overall weight increase.
Solution Approach 2:
Instead of using metal throughout the entire connecting structure, the invention applies metal material locally only in specific critical areas where rigidity and strength are required (such as load-bearing connection points). The remaining portions of the connecting module are made of plastic, optimizing the weight-to-strength ratio by matching material properties to functional requirements.
3Ease of manufacture
If traditional plastic connecting modules are used, then manufacturing is simplified, but wear resistance and service life are reduced
Solution Approach 1:
The connecting module integrates metal reinforcing elements within the plastic structure specifically at contact surfaces and load-bearing areas. These metal components provide superior wear resistance and durability compared to pure plastic, while the plastic body maintains manufacturing simplicity through injection molding or similar processes. The metal inserts can be embedded during the molding process or installed subsequently, preserving ease of manufacture while dramatically improving wear resistance and service life.
Data Source
AI summary
A carrier shaft with a modular structure for an electromechanical switching device of an embodiment includes at least one first carrier module, at least one second carrier module and at least one connecting module, arranged in a torsion-inhibiting manner between the at least one first carrier module and the at least one second carrier module. The connecting module includes a main body and at least one connecting device and the connecting device are arranged in the main body, the at least one first carrier module and the at least one second carrier module. Another embodiment relates to an electromechanical switching device with the carrier shaft.