Modular Rotary Switch With Arc Prevention And Simultaneous Contact
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Solution Overview
Problem
Existing rotary switches face issues with arc firing due to asymmetric support and clearance between contact modules, leading to non-simultaneous function and difficult mounting of stationary and movable contacts, especially in multipole configurations.
Innovation Solution
A modular rotary switch design with overlapping contact modules featuring a rectangular base body with rail fasteners and mounting brackets, where stationary contacts are arranged at opposite corners, and movable contacts with spring elements and arc wings to prevent arc firing and facilitate quick mounting, along with a mechanism that limits switch axis rotation to 135 degrees to ensure simultaneous contact operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact poles are placed as far as possible from each other to reduce arc firing risk, then arc firing risk is reduced, but device size increases and mounting complexity increases
Solution Approach 1:
The switch is divided into multiple contact modules, each handling a specific contact pole. This segmentation allows each module to be independently designed with optimized contact spacing, reducing arc firing risk while maintaining a compact overall structure through modular assembly.
Solution Approach 2:
Contact modules are nested or overlapped with each other in a compact arrangement. The rectangular base body with rail fasteners enables multiple modules to be stacked or positioned closely together, reducing the overall device size while maintaining adequate clearance between contact poles to prevent arc firing.
2Ease of manufacture
If asymmetric support is used in contact modules, then mounting flexibility is improved, but clearance permits swinging of contact portion leading to non-simultaneous function
Solution Approach 1:
The stationary contact features an asymmetric design with a support portion at one end and a contact portion extending at an angle. This asymmetric configuration provides stable mounting while maintaining precise alignment, preventing unwanted swinging motion that would cause non-simultaneous contact operation.
Solution Approach 2:
Instead of allowing clearance to provide mounting flexibility, the design inverts the approach by using a fixed angular configuration where the support portion and contact portion form a rigid structure. This eliminates the swinging problem while maintaining ease of manufacture through the standardized angular design.
3Reliability
If cardboard insulation is used in contact modules, then insulation is provided, but mounting of stationary and movable contacts becomes difficult
Solution Approach 1:
The design replaces cardboard insulation with a composite structure integrating the insulating function into the modular contact module housing. The rectangular base body with rail fasteners provides both structural support and electrical insulation, eliminating the need for separate cardboard insulating layers and simplifying the mounting process.
Data Source
AI summary
A stationary contact for a rotary switch is provided. The stationary contact includes a connection portion for connecting to a conductor and a first portion being a contact portion for connecting the stationary contact to a rotary contact. The stationary contact also includes a second portion being a support portion for supporting the stationary contact to a switch body. The contact portion and support portion extend in the same angle from the connection portion. A method of mounting a rotary switch is also provided.