Opposed Solenoid Contactor Layout Against Mechanical Impulse Faults
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Solution Overview
Problem
High-voltage electrical contactor assemblies are prone to unexpected power interruptions or activations due to sudden mechanical impulses, which can cause unintended opening or closing of contacts, leading to undesirable electrical flows.
Innovation Solution
The arrangement of first and second electrical contactor assemblies within an enclosure, where each assembly has a linear solenoid with a plunger and spring, configured to maintain a commanded state despite mechanical impulses, with the solenoids' actuation directions pointing in opposite directions to prevent simultaneous perturbation of both assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contactor assemblies are arranged with solenoids pointing in the same direction, then the structure is simpler and easier to manufacture, but mechanical impulses can simultaneously perturb both contacts causing unintended power flow
Solution Approach 1:
The patent applies asymmetry by arranging the first and second linear solenoids to point in opposite directions rather than the same direction. This asymmetric configuration ensures that mechanical impulses affecting one solenoid do not simultaneously affect the other, preventing unintended simultaneous contact closure while maintaining structural manageability through deliberate directional differentiation.
Solution Approach 2:
The patent implements preliminary anti-action by pre-positioning the solenoids in opposite directions before any mechanical impulse occurs. This preliminary arrangement creates inherent resistance to simultaneous perturbation, as the opposite orientations mean that an impulse affecting one contactor assembly will have minimal effect on the other, thereby preventing the harmful condition of simultaneous contact closure.
2Reliability
If contactor assemblies are arranged with solenoids pointing in opposite directions, then mechanical impulse resistance is improved, but the arrangement complexity and space requirements increase
Solution Approach 1:
The patent utilizes dimensional arrangement by configuring the solenoids to point in opposite directions along the same linear axis rather than requiring separate spatial planes. This approach achieves the mechanical impulse resistance benefit of opposite-direction arrangement while minimizing the additional area required, as the opposing solenoids can be positioned adjacently within the enclosure rather than requiring distributed space across multiple dimensions.
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
This configuration ensures that only one contactor assembly is perturbed by a mechanical impulse, preventing simultaneous and unintended electrical flows, thus maintaining reliable high-voltage power control.
Implementation Method 1
a first coil disposed within the first housing and configured for urging the first plunger from the first open position to the first closed position along a first linear direction
Implementation Method 2
a first spring configured for biasing the first plunger in the first open position
Data Source
AI summary
An electrical contactor module includes a pair of contactor assemblies each having an input contact, an output contact spaced apart from the input contact, and a linear solenoid disposed proximate the input and output contacts. Each linear solenoid has a housing, a plunger disposed within the housing so as to permit axial displacement of the plunger between an open position in which an end of the plunger is spaced apart from the input and output contacts and a closed position in which the end mechanically contacts and electrically couples the input and output contacts, a spring for biasing the plunger in the open position, and a coil within the housing for urging the plunger from the open position to the closed position along a linear direction. The contactor assemblies are fastened and arranged within an enclosure, with the linear directions for the contactor assemblies pointing in generally opposite directions.