Modular Overload Relay With Pogo Pin Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Overload relays face challenges with a large number of catalog numbers needed, increased size and cost due to limited current range and lack of built-in voltage sensing capabilities, as well as electrical contact wear from mechanical motion between modules.
Innovation Solution
A modular overload relay assembly with integrated phase current conductors, a controller module, and a communication module that includes voltage sensing capabilities, allowing for easy connection and configuration, reducing catalog numbers, and minimizing electrical contact wear through a robust attachment configuration and flexible circuit board connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional overload relays are designed for specific current ranges with fixed functional options, then each relay is optimized for its designated application, but a large number of catalog numbers must be manufactured and warehoused to cover all applications
Solution Approach 1:
The overload relay is divided into separate functional modules: a base unit and interchangeable functional modules that can be attached as needed. This segmentation allows a single base unit to serve multiple applications by swapping modules, eliminating the need for numerous complete relay variants and reducing catalog numbers while maintaining adaptability across different current ranges and functional requirements
Solution Approach 2:
The base unit is designed with universal mounting features and electrical connections that can accommodate different functional modules. This universality allows one base unit to support multiple current ranges and functional configurations through module interchangeability, reducing the total number of catalog numbers needed while maintaining broad adaptability
2Device complexity
If overload relays are designed to accommodate a wider range of currents, then fewer catalog numbers are needed, but the device size, cost, and heat generation increase
Solution Approach 1:
By segmenting the relay into a compact base unit and separate functional modules, each component can be optimized for its specific function without requiring the entire device to be oversized. The base unit remains small while modules can be attached only when needed, avoiding the need to permanently incorporate all possible current handling capabilities into a single enlarged device
Solution Approach 2:
The functional modules are designed to attach to or nest within the base unit structure, allowing the relay to maintain a compact form factor when modules are not in use. The modular architecture enables the system to expand functionally only when modules are attached, keeping the base unit small and avoiding permanent size increases
3Ease of operation
If modules are mechanically connected to allow easy assembly and disassembly, then ease of operation improves, but electrical contact wear increases due to relative mechanical motion
Solution Approach 1:
The patent replaces traditional mechanical electrical contacts with a spring-loaded pogo pin contact system. The pogo pins are resilient and maintain constant pressure against the contact surface, allowing for repeated connection and disconnection cycles without significant wear. This substitution of the contact mechanism enables easy module assembly and disassembly while maintaining reliability and minimizing electrical contact wear
Solution Approach 2:
The resilient pogo pin contacts are designed to absorb mechanical shock and motion during module connection and disconnection. The spring-loaded design provides cushioning that protects the electrical contacts from wear during the assembly and disassembly process, allowing easy operation while maintaining contact reliability over many cycles
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A mating connector assembly for electrically coupling modular electrical devices. A first stationary connector is coupled to a first rigid circuit board positioned within a first housing of a first modular electrical device. The first floating connector is coupled to a flexible circuit element positioned within a second housing of a second modular electrical device, the flexible circuit element coupled to a circuit board positioned within a second housing of a second modular electrical device. The second housing includes a first latch plate adjustable between an unlatched position and a latched position, the first latch plate including a biasing member, such that, when the first modular electronic device is pressed together with the second modular electronic device, the biasing member applies a force to the first floating connector during a latch plate transition position to ensure that the first floating connector has fully mated with the first stationary connector.