Overload Relay Trip Mechanism With Integrated Reset And Test Button
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Solution Overview
Problem
Overload relays require multiple intermediary parts to function, making them complex and prone to being defeated or jammed, particularly in their reset and test features, which complicates the process of protecting electrical equipment from current overloads.
Innovation Solution
A simplified overload relay trip mechanism using a housing, a reset button with a spring and actuator, and a test button with dual-rate springs, allowing for selective opening and closing of control circuits with fewer components, enabling efficient resetting and testing while preventing jamming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple intermediary parts are used in the reset button mechanism, then the overload relay can provide trip-free functionality and prevent defeat, but the device complexity increases and the number of components increases
Solution Approach 1:
The patent combines the reset button and test button into a single integrated mechanism. The single button performs multiple functions: normal operation, trip-free resetting, and testing capabilities. This merging eliminates the need for separate intermediary parts for each function, reducing component count while maintaining reliability.
Solution Approach 2:
The single button mechanism is designed to perform multiple functions: it serves as the reset button for normal operation, provides trip-free functionality through its mechanical design, and acts as a test button for verifying relay functionality. This multi-functionality reduces the overall number of components needed in the system.
2Adaptability or versatility
If multiple separate mechanisms are provided for reset, test-stop, and test-trip features, then each function can be performed independently, but the device complexity increases and ease of operation decreases
Solution Approach 1:
The patent merges the reset, test-stop, and test-trip mechanisms into a single button operation. The button's travel distance and mechanical design enable it to perform all three functions sequentially or selectively, eliminating the need for separate controls and simplifying the user interface.
Solution Approach 2:
The single button is designed with universal functionality to handle normal resetting, trip-free operation, test-stop, and test-trip capabilities. This multi-functional design maintains independent function capability while significantly improving ease of operation by reducing the number of separate controls the user must manage.
3Reliability
If several intermediary parts are used beyond the reset button, then the overload relay can accomplish resetting function with trip-free capability, but the manufacturing complexity increases
Solution Approach 1:
The patent combines multiple intermediary parts into a single integrated button assembly. The reset button and test button are merged into one component structure, reducing the number of separate parts that need to be manufactured, assembled, and quality-checked, thereby simplifying the manufacturing process while maintaining the resetting function.
Solution Approach 2:
The single button mechanism is designed to provide trip-free resetting capability along with test functions, eliminating the need for multiple separate mechanisms. This reduces manufacturing complexity by decreasing the total number of components that need to be produced and assembled, while still delivering the required reliability for resetting operations.
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 solution reduces the number of components needed for resetting and testing, enhancing reliability and ease of operation by allowing the overload relay to function effectively with fewer parts, thus improving the protection of electrical equipment from overloads.
Implementation Method 1
The spring has a first end and a second opposing end. The first end of the spring is supported by the housing and the second end of the spring is flexibly coupled with the shaft portion or the button portion of the reset button.
Implementation Method 2
The actuator has a closed position in which the moveable contact is electrically connectable with a corresponding fixed contact and an open position in which the moveable contact is electrically disconnected from the corresponding fixed contact.
Data Source
AI summary
An overload relay trip mechanism includes a housing, a reset button, a leaf spring, a test button, a coil spring, and an actuator. The reset button can be actuated from a normal position to a reset position to cause the leaf spring to transition from a first position to a second position, which causes a reset actuator-engaging element to move the actuator from a tripped position to a closed position. The test button can be actuated from a normal position to a test-stop position to cause a first test actuator-engaging element to move a moveable contact from an electrically connected position to an electrically disconnected position. The test button can further be moved from the test-stop position to the test-trip position to cause a second test actuator-engaging element to move the actuator from the closed position to the tripped position.