Modular Contactor Auxiliary Module Integration on Mounting Rail
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Solution Overview
Problem
Modular contactors cannot be directly connected to a standard busbar, limiting their configuration and functionality in electrical assemblies.
Innovation Solution
A modular electrical device and auxiliary module assembly that allows connection via a standard comb, maintaining the device's size and enabling downstream device connection without increasing its dimensions, featuring a recess for an auxiliary module or trim to maintain size consistency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modular contactors are equipped with auxiliary modules for signaling open or closed state, then the functionality and reliability of the electrical assembly is improved, but the device complexity and space occupation increase
Solution Approach 1:
The auxiliary module is integrated with the contactor housing to form a unified assembly. The auxiliary module's housing is received within a recess of the contactor housing, creating a compact combined structure that provides both contactor and auxiliary signaling functions without requiring separate mounting spaces.
Solution Approach 2:
The auxiliary module serves multiple functions: it provides signaling for open/closed state, maintains the compact 63mm width standard, and enables direct connection to standard buses through its terminal configuration. The single auxiliary module can signal both states through its internal switch arrangement.
2Reliability
If auxiliary modules are added to modular contactors, then the signaling capability is improved, but the manufacturing cost and device complexity increase
Solution Approach 1:
The electrical assembly is divided into modular components: the contactor unit and the auxiliary module as separate but complementary parts. This segmentation allows each module to be manufactured independently using standardized processes, then assembled together, maintaining manufacturing efficiency while adding functionality.
Solution Approach 2:
The auxiliary module uses a standard 63mm width dimension that matches the contactor width, allowing both components to be manufactured with compatible tolerances and assembly fixtures. This parameter standardization simplifies the manufacturing process and reduces tooling costs.
3Adaptability or versatility
If the device width is maintained at 63mm, then the adaptability to standard mounting rails is improved, but the space available for internal components is limited
Solution Approach 1:
The auxiliary module is positioned in the depth dimension of the contactor assembly rather than increasing the width. The auxiliary module's housing is received within a recess that extends into the contactor housing depth, allowing both modules to fit within the 63mm width while accommodating additional components in the third dimension.
Solution Approach 2:
The auxiliary module is nested within the contactor housing structure. The auxiliary module's housing fits into a recess of the contactor housing, creating a nested arrangement where the auxiliary components are housed within the overall 63mm width envelope of the contactor assembly.
Data Source
Figure 1
Figure 1a
Figure 2
AI summary
The present invention relates to an assembly comprising a modular electrical device and a modular auxiliary suitable for being associated with said device on a mounting rail, said electrical device being housed in a box of substantially parallelepiped shape and having on one of its faces, a set of terminals called upstream, and on a face opposite to the previous one with respect to the rail, a set of terminals called downstream.This assembly is characterized in that the aforementioned housing referred to as first (3) has a recess (i) suitable for receiving the aforementioned auxiliary module (2) or a piece forming a trim piece having substantially the same dimensions as the aforementioned auxiliary (2), and in that one (5) of the terminal sets, referred to as first, has terminals having a pitch corresponding to that of a standard comb and extends over substantially the entire width of the device (1), while the other (6) of the two terminal sets (5,6), referred to as second, has terminals having a reduced pitch compared to the previous one and extends over only part of the width of the electrical device (1), so that the association of this auxiliary module (2) with the aforementioned electrical device (1) does not increase the dimensions of the device to which it is associated, and allows the electrical connection of the terminals of said first terminal set (5) to a standard comb.