Modular Contactor Arrangement for Compact Safety Switching
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Solution Overview
Problem
Existing contactor arrangements in industrial automation systems require significant installation space and involve complex wiring, making them inefficient for safety-related applications.
Innovation Solution
A modular contactor arrangement where two contactor modules are coupled via a docking module, allowing for mechanical and electrical connection without external wiring, resulting in a compact design with an overall width determined by the narrow sides of the modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two separate contactors are used for safety-related switching, then functional safety is achieved through double switching, but the installation space increases significantly due to the sum of individual widths
Solution Approach 1:
The patent combines two separate contactor units into a single integrated contactor arrangement with a common housing. The first and second contactor modules are merged into one unified structure, sharing common components such as the housing, mounting rail interface, and electrical connections. This merging reduces the installation space from the sum of two separate widths to essentially one unit width, while maintaining the required functional safety through internal series connection of the contacts.
Solution Approach 2:
The contactor arrangement is segmented into two independent contactor modules (first contactor module with first contactor, second contactor module with second contactor) that are integrated within a single housing. Each module maintains its own switching functionality with normally open and normally closed contacts, but they are arranged and connected internally to achieve compact installation while preserving the safety-critical double switching function.
2Reliability
If two separate contactors are used for safety-related switching, then functional safety is achieved through double switching, but the wiring complexity increases as users must wire them manually
Solution Approach 1:
The patent combines the electrical connections of both contactor modules into a unified terminal structure. The first and second contactors are internally connected in series within the common housing, with common electrical terminals provided for external connection. This eliminates the need for users to perform complex manual wiring between separate contactors, as the internal connections are pre-established during manufacturing, while still achieving the required safety-related double switching function.
3Ease of manufacture
If contactors are attached laterally to a safety switching device, then the system is assembled, but the total width becomes large due to the sum of individual components
Solution Approach 1:
The contactor arrangement is designed as a single integrated unit with a common housing that accommodates both contactor modules. This unified structure can be attached laterally to the safety switching device as one component rather than as two separate contactors, reducing the total width from the sum of individual widths to essentially the width of one integrated unit, while maintaining ease of assembly through the standardized mounting interface.
Data Source
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AI summary
The invention relates to a modular contactor arrangement (180) for use in a security-related application. The modular contactor arrangement (180) according to the invention has two contactor modules (10, 11), which can be arranged one behind the other by means of a coupling module (70), wherein the contactor modules (10, 11) and the coupling module (70) must only be joined together without external wiring by a user in order to be mechanically and electrically coupled to each other. The contactor arrangement (180) has, in the assembled state, a reduced structural width, which is substantially delimited by the narrow sides (24, 25) of the contactor modules (10, 11). In particular, the structural width equals 22.5 mm.