Modular Contact Block Tool-Free Conversion
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Solution Overview
Problem
Conventional electrical contactors require additional parts and complex configurations for expanding pole count and switching states, leading to increased inventory costs and reduced reliability due to carbon scarring from high voltage arcs.
Innovation Solution
A modular contact block design with a fixation lever and interchangeable spacers allows for tool-free conversion between normally open and normally closed contacts, enabling easy expansion and state changes without removing the entire block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional contacts are required in conventional contact blocks, then the number of contacts is increased, but the entire contact block must be removed and replaced, increasing installation complexity and downtime
Solution Approach 1:
The contact block is divided into modular units where individual contact assemblies can be independently added or removed. Each contact assembly includes a contact, pusher, and associated components that function as a self-contained module, allowing selective expansion without replacing the entire block.
Solution Approach 2:
The contact block design incorporates dynamic configurability through tool-free mechanisms that allow users to add, remove, or reconfigure contact assemblies during operation. The spring-loaded pushers and snap-fit connections enable flexible modification of the contact configuration without fixed predetermined arrangements.
2Adaptability or versatility
If different variations of contact assemblies are provided to meet different operational requirements, then versatility is improved, but parts inventory and cost increase
Solution Approach 1:
A universal contact assembly design is implemented where the same basic components (contact, pusher, spacer, fixation lever) can be configured to provide multiple contact states. The spacer component, in particular, serves multiple functions by determining contact timing and state, eliminating the need for specialized parts for normally open, normally closed, or timed contact variations.
Solution Approach 2:
Instead of providing different specialized parts for different contact states, the invention inverts the approach by providing a single standardized contact assembly that can be configured to achieve different states through the position and orientation of interchangeable spacers. This reverses the conventional paradigm of specialized parts for specialized functions.
3Ease of manufacture
If conventional contact blocks are used without modular capabilities, then manufacturing simplicity is maintained, but expansion requires complete replacement increasing loss of time
Solution Approach 1:
The contact block is segmented into standardized modular units that can be manufactured independently and assembled through simple tool-free mechanisms. Each module contains pre-assembled contact assemblies with spring pushers and fixation levers, allowing rapid field installation and expansion without complex manufacturing or specialized tools.
4Power
If high voltage arcs occur during contact operation, then electrical switching function is achieved, but carbon scarring reduces reliability over time
Solution Approach 1:
The contact assembly incorporates self-cleaning channels that use the natural motion of contacts during operation to remove carbon deposits. The spring-loaded pushers and movable contact assemblies create cleaning actions during normal switching cycles, eliminating the need for external maintenance or specialized cleaning mechanisms while maintaining reliability.
Data Source
Figure 1
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AI summary
The present invention relates to an auxiliary contact block. The auxiliary contact block comprises a housing (204) and a tool free latching mechanism. The tool free latching mechanism further comprising a stationary member integral to the housing (204) and a latching bar. The latching bar comprising a button in communication with a moveable member by a central body.