Movable Contact Holder Segmentation for Automated Assembly

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Solution Overview

Problem

The existing assembly methods for movable contact holders in electromagnetic contactors are difficult to automate due to the complexity of handling minute components like contact springs, which are required to be inserted sideways into narrow openings, preventing the use of automated machines for assembly.

Innovation Solution

A movable contact holder structure with recesses on one side for holding bridge contact assemblies and contact springs, and a cover that allows for the use of an assembling jig to compress and attach the components automatically, simplifying the assembly process by allowing direct insertion and compression within the recesses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Extent of automation

If contact springs are inserted sideways into narrow openings in the movable contact holder base, then the assembly can be completed with traditional manual methods, but automation becomes difficult due to the complexity of handling minute components

Engineering Contradiction:

Improveautomation of assemblyVSAvoidcomplexity of assembly process

Core Design Contradiction:

Extent of automationVSDevice complexity

Solution Approach 1:

The movable contact holder is divided into a base and a cover that can be separated. The base contains recesses with openings for inserting contact springs, and the cover is attached afterward to enclose the components. This segmentation allows automated insertion of contact springs into the base through openings, followed by simple attachment of the cover, thereby enabling automation while simplifying the overall assembly process.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact springs and bridge contact assemblies are inserted into the base and positioned in the recesses before the cover is attached. This preliminary action allows automated machines to perform the complex insertion and positioning operations while the components are accessible, and the cover is simply attached afterward to complete the assembly, making the process automatable.

Inventive Principle:

Principle #10Preliminary action

2Productivity

If manual assembly methods are used for attaching bridge contact assemblies and contact springs, then precise positioning can be achieved, but productivity is reduced due to the time-consuming nature of manual operations

Engineering Contradiction:

Improveassembly speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

By separating the movable contact holder into a base and a cover, the assembly process is divided into distinct stages: automated insertion of contact springs and bridge contact assemblies into the base, followed by attachment of the cover. This segmentation enables high-speed automated operations for the insertion steps while maintaining precise positioning through the structured recesses and openings in the base.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The base acts as an intermediary structure that receives and positions the contact springs and bridge contact assemblies through openings in its recesses. This intermediary design allows automated insertion tools to access and position the components precisely, then the cover is attached to complete the assembly, enabling both high productivity and precise positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If contact springs are compressed and inserted sideways into the movable contact holder base, then the components can be attached in a compact arrangement, but the assembly process becomes complex and difficult to automate

Engineering Contradiction:

Improvecompactness of component arrangementVSAvoidease of assembly

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The movable contact holder is segmented into a base and a cover. The base contains recesses with openings that allow contact springs to be inserted and compressed in a straightforward manner from the outside. The cover is then attached to enclose the compressed springs and secure the assembly. This segmentation maintains compact arrangement while significantly simplifying the manufacturing and assembly process, enabling automation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of inserting compressed contact springs sideways into the base as in traditional designs, the invention allows contact springs to be inserted from the outside through openings in the base, compressed in place, and then the cover is attached. This inverted approach—inserting before compression and enclosing afterward—maintains compact arrangement while making the process much easier to manufacture and automate.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS8093973B2Movable contact holder of electrical apparatus and assembling method of the movable contact holder

Publication Date: 2012.01.10 FUJI ELECTRIC FA COMPONENTS & SYST CO LTD

AI summary

A movable contact holder includes a movable contact holder base and a movable contact holder cover. One side of the movable contact holder base is opened to have a plurality of recesses each being formed for holding a contact pair, each contact pair include a bridge contact assembly and a contact spring inserted therein while being isolated from the other pairs. The other side of the movable contact holder base is formed as a bottom wall, and preferably includes openings through which an assembly jig can be inserted from outside the moveable contact holder. Alternatively, jig openings can be formed in lateral side walls of the recesses to allow the assembly jig to be inserted. The movable contact holder cover covers the movable contact holder base and is coupled thereto.