Rotary Power Switch With Compressible Stack
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Solution Overview
Problem
Existing power shutoff switches struggle to provide high force connections that can be easily operated by hand, leading to increased resistance and reduced performance in disconnecting and reconnecting electrical power sources.
Innovation Solution
A rotary handle with a lead screw and a compressible stack that gradually builds force to establish a high force, low resistance connection, allowing manual operation and secure disconnection of electrical power sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If increased force is applied at the point of separable electrical contact, then resistance of the contact is reduced and performance is improved, but it becomes difficult to provide sufficient force by hand
Solution Approach 1:
A compressible stack (intermediary element) is introduced between the user-applied force and the electrical contact. This stack gradually builds up force over a longer distance, converting small manual movements into high contact force without requiring the user to directly apply large forces. The compressible stack acts as a mechanical mediator that amplifies the user's input force into the high contact force needed for low resistance electrical connection.
Solution Approach 2:
The patent replaces direct manual force application with a mechanical system consisting of a lead screw and compressible stack. Instead of the user directly pressing contacts together, the user rotates a handle that drives the lead screw, which in turn compresses the stack to generate the required contact force. This mechanical substitution allows easy manual operation while achieving high contact force.
2Ease of operation
If a lead screw with compressible stack is used to build force gradually, then high force connection is achieved with manual operation, but the device complexity increases
Solution Approach 1:
The rotary handle serves multiple functions: it provides the user interface for operation, drives the lead screw mechanism, and can incorporate an activation switch. The compressible stack both builds force and maintains contact pressure. By designing components to perform multiple functions, the patent reduces overall device complexity despite incorporating force multiplication mechanisms.
Solution Approach 2:
The compressible stack is designed to automatically build up force as the lead screw rotates, without requiring external control mechanisms. The mechanical advantage is inherent in the lead screw geometry and stack compliance, allowing the system to self-regulate the force buildup process based on user input alone.
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
Enables efficient and safe manual operation of power shutoff switches with high force, low resistance connections, reducing power loss and improving electrical performance while ensuring easy operation and safety.
Implementation Method 1
A lead screw positioned within a recess of the switch housing moves the compressible stack in response to rotation of the rotary handle
Implementation Method 2
A compressible stack positioned within a recess of a seat that also retains a conductive element provides for gradual buildup of force to the conductive element
Implementation Method 3
as the lead screw is turned by a user to overcome a spring and contact a first post and a second post
Data Source
AI summary
An improved electrical switch that provides for manual connection and disconnect of power by hand by utilizing a compressible stack of elements to load force over a radial distance as rotated by a user of the switch to establish a high force, low resistance connection.