Modular Contactor Architecture for Faster Module-Level Repair
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Solution Overview
Problem
Traditional contactors have an integrated structure, making maintenance and repair time-consuming and inefficient, as the entire unit often needs to be disassembled and replaced, which increases costs and labor.
Innovation Solution
A modular contactor design with detachable modules, including a driving module, intermediate connecting module, breaking module, upper application interface module, and lower application interface module, allowing for easy replacement and maintenance without disassembling the entire unit, and reducing the need to loosen connecting wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a traditional integrated contactor structure is used, then the structure is simple and reliable, but maintenance and repair require disassembling the entire unit which is time-consuming and labor-intensive
Solution Approach 1:
The contactor is divided into multiple independent modules: driving module, intermediate connecting module, breaking module, upper application interface module, and lower application interface module. Each module can be detached and replaced independently, eliminating the need to disassemble the entire integrated unit for maintenance or repair.
Solution Approach 2:
The breaking module is extracted as a separate detachable component that can be independently removed from the intermediate connecting module. This allows repair personnel to replace only the damaged breaking module without affecting other components, significantly reducing maintenance time and labor.
2Reliability
If the entire contactor is replaced when components are damaged, then reliability is restored, but costs increase and repair efficiency decreases
Solution Approach 1:
Instead of discarding the entire contactor when one component fails, the design allows selective replacement of only the damaged module (breaking unit, coil, or circuit board). The functional modules remain in use, reducing replacement costs and improving repair efficiency while restoring reliability.
3Adaptability or versatility
If the contactor has an integrated structure, then manufacturing is simpler, but adaptability to different application requirements is limited
Solution Approach 1:
The intermediate connecting module serves as a universal platform that can accommodate different breaking modules with varying numbers and configurations of breaking units. The standardized interfaces (snap-fitted and screw-based connections) allow the same intermediate module to support multiple application scenarios, enhancing adaptability without proportionally increasing overall complexity.
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 modular design significantly reduces maintenance and repair time and costs, improving efficiency and flexibility by allowing individual module replacement and simplifying the process, while maintaining electrical connectivity through snap-fitted and screw-based connections.
Implementation Method 1
the driving module includes a static iron core, a coil and a control component; the intermediate connecting module includes a movable iron core; and the breaking module includes a plurality of breaking units. The driving module is detachably connected to a first side of the intermediate connecting module so as to be able to drive the movable iron core to move under a control of the control component
Data Source
AI summary
A modular contactor. The modular contactor includes a driving module (1), an intermediate connection module (2), a breaking module (3), an upper application interface module (4), and a lower application interface module (5); the driving module (1) is detachably connected to a first side of the intermediate connection module (2); the breaking module (3) is detachably connected to a second side of the intermediate connection module (2); the upper application interface module (4) is detachably connected to the top of the breaking module (3) so as to be electrically connected to upper static contacts of the multiple breaking units; the lower application interface module (5) is detachably connected to the bottom of the breaking module (3) so as to be electrically connected to lower static contacts of the multiple breaking units.