Modular Circuit Breaker Subassemblies for Connection Adaptability
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Solution Overview
Problem
Selective circuit breakers face challenges in adapting to different connection formats due to varying national regulations and traditional practices, leading to distinct architectures for conductor fixation and clipping on bars, which complicates manufacturing and assembly.
Innovation Solution
The selective circuit breaker is designed with modular, autonomous subassemblies that can be easily assembled and handled as individual components, allowing for a unified architecture regardless of connection type, with components fixed together to form 'super components' for automated assembly and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If distinct architectures are designed for different connection formats (conductor fixation vs. clipping on bars), then each connection type can be optimized for its specific requirements, but the device complexity and manufacturing complexity increase due to maintaining multiple architecture variants
Solution Approach 1:
The patent applies universality by designing a unified internal architecture that can accommodate multiple connection formats (conductor fixation and clipping on bars) through peripheral modifications only. The core functional components (main circuit sub-assembly, arc breaking sub-assembly, secondary circuit sub-assembly, lock sub-assembly) remain identical across different connection types, allowing the same base design to serve multiple connection purposes without increasing internal complexity.
Solution Approach 2:
The patent segments the circuit breaker into distinct autonomous sub-assemblies (main circuit, arc breaking, secondary circuit, and lock sub-assemblies) that can be independently manufactured and assembled. This segmentation allows different connection formats to be implemented as separate modular components attached to the unified internal architecture, resolving the contradiction by isolating connection-specific complexity to peripheral segments rather than the core structure.
2Adaptability or versatility
If distinct architectures are designed for different connection formats, then each connection type can be optimized, but the manufacturing cost and assembly complexity increase due to requiring different assembly lines
Solution Approach 1:
The patent implements universality in manufacturing by creating a single unified internal architecture that serves as the common platform for all connection formats. This allows different connection types (conductor fixation and clipping on bars) to be produced on the same assembly line, with connection-specific components being attached peripherally rather than requiring separate manufacturing processes for the core structure.
Solution Approach 2:
By segmenting the device into autonomous sub-assemblies with a unified internal core, the patent enables modular manufacturing where the core components can be mass-produced identically for all variants, and connection-specific peripherals can be added in separate attachment steps. This reduces overall manufacturing complexity while maintaining support for multiple connection solutions.
3Productivity
If autonomous subassemblies are used to simplify assembly, then the assembly process becomes simpler and production costs reduce, but the challenge increases in ensuring proper spatial arrangement and functional coordination of these subassemblies
Solution Approach 1:
The patent segments the circuit breaker into four autonomous sub-assemblies (main circuit, arc breaking, secondary circuit, and lock sub-assemblies) that can be independently manufactured and tested. This segmentation enables parallel production and simplified assembly operations, as each sub-assembly can be prepared separately and then coordinated through standardized interfaces and mounting procedures.
Solution Approach 2:
The patent merges the four autonomous sub-assemblies into a unified internal architecture with standardized spatial relationships and coordination mechanisms. The sub-assemblies are positioned and connected in a coordinated manner that ensures proper functional interaction while maintaining the benefits of independent manufacturing, thus resolving the spatial arrangement challenge through integrated design.
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 approach simplifies the assembly process, reduces production costs, and allows for manufacturing on similar assembly lines, while maintaining functional integrity across different connection solutions, with a 20% reduction in component count compared to prior art.
Implementation Method 1
a main magnetic actuator capable of to separate said contacts in the event of a short-circuit in the circuit to be protected
Implementation Method 2
a mechanical lock actuated, for the opening of the main and secondary moving contacts, by the main and secondary thermal actuators
Data Source
Figure 1~3
Figure 2~4
Figure 5~7
AI summary
The breaker has a set of distinct and autonomous sub-assemblies arranged in a case, and a main circuit sub-assembly (10) including a magnetic coil (24), main thermal bimetallic strip (21), main mobile contact, secondary fixed contact and an arc sheet of arc cut-off chamber. An arc cut-off sub-assembly includes a stack of anti-ion plates, side cheek portions provided with an armor plate and a main fixed contact. A secondary circuit sub-assembly (15) includes a resistor, secondary thermal bimetallic strip (17) and a secondary mobile contact.