Relay Contactor Plate Motion to Reduce Arcing and Contact Bounce
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing relay contactors with linearly moveable conductors experience increased voltage drop and heating due to arcing wear on electrical contact surfaces, as the materials required for low voltage drop and high current carrying capability are not robust against degradation.
Innovation Solution
A relay contactor design incorporating combined linear and rotational movements, where the contact points make or break with a wiping or sliding surface motion, directing arcing to non-critical areas and using materials optimized for arc resistance and conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional linear motion mechanisms are used in relay contactors, then the plate moves in a straightforward linear path, but the mechanism is prone to binding, sticking, and contact bounce
Solution Approach 1:
The patent applies curved or arc-shaped motion paths for the plate instead of straight linear motion. The plate follows a curved trajectory during actuation, which eliminates binding and sticking issues associated with linear mechanisms while maintaining reliability. This curvature principle transforms the motion geometry to achieve smoother operation.
Solution Approach 2:
The mechanism transitions from static linear guidance to dynamic curved motion. The plate's movement is designed to follow a predetermined curved path that adapts to the mechanical constraints and forces during actuation, allowing the system to dynamically adjust the motion trajectory to avoid binding and sticking.
2Reliability
If the plate is held against stops during actuation, then the mechanism is simple, but contact bounce occurs and reduces reliability
Solution Approach 1:
The plate follows a curved motion path that naturally guides it into the closed position without abrupt impacts against stops. The curved trajectory reduces impact forces and eliminates contact bounce by maintaining continuous contact guidance throughout the actuation stroke, improving both reliability and operational smoothness.
3Reliability
If linear motion is used in high-voltage applications, then the design is simple, but arcing and pitting occur reducing reliability
Solution Approach 1:
The curved motion path of the plate creates an arcing motion between contacts during actuation. This curved trajectory reduces direct linear impact and arcing between contacts, minimizing pitting and erosion in high-voltage applications while maintaining design simplicity.
4Reliability
If conventional linear mechanisms are used, then manufacturing is straightforward, but the mechanism binds and sticks under varying conditions
Solution Approach 1:
The curved motion path is integrated into the basic structure of the relay contactor, allowing the plate to follow an arc-shaped trajectory without requiring complex external guidance mechanisms. This approach prevents binding and sticking under varying operational conditions while maintaining ease of manufacture through straightforward structural design.
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
Minimizes arcing-induced degradation on critical contact surfaces, maintaining low voltage drop and reducing heating effects while extending the electrical life of the contactor.
Implementation Method 1
a movement of the plate relative to the leads comprises at least a non-linear, rotational or an abnormally linear component
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A relay contactor is provided and includes a shaft assembly (330) comprising a plate (332), which is movable between an open position at which the plate is displaced from leads and a closed position at which the plate contacts the leads and an actuation system configured to selectively move the plate into the closed position. At least one of the shaft assembly and the actuation system is configured such that, as the plate moves into and away from the closed position, a movement of the plate relative to the leads comprises at least a non-linear, rotational or an abnormally linear component.