3D Overlap Rotary Switch Layers for Higher Breaking Capacity
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Solution Overview
Problem
Existing photovoltaic direct current switches face challenges in achieving increased breaking capacity while maintaining compact size without significant cost increases, as conventional solutions often result in increased size or complexity. The technical problem is the inability to effectively manage the voltage and current requirements in a compact form factor. The existing photovoltaic direct current switch is unable to handle the increasing voltage and current without generating excessive arcs, leading to failure or burnout.
Innovation Solution
A multi-layered switch layer structure is designed with stationary contact conductive elements extending in each switch layer, allowing the moving contact conductive element to partially overlap the stationary contact conductive element in a three-dimensional space, increasing the diameter of the moving contact conductive element without increasing the housing size, thereby enhancing breaking capacity and miniaturization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the diameter of the moving contact conductive element is increased to improve breaking capacity, then the breaking capacity is improved, but the housing size must be increased
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial arrangement by allowing the moving contact conductive element to overlap with the stationary contact conductive element in the axial direction. This enables the moving contact element to have a larger diameter without increasing the radial housing size, as the additional space is utilized in the axial dimension rather than the radial dimension.
Solution Approach 2:
The patent implements a nested configuration where the moving contact conductive element is positioned within the axial space occupied by the stationary contact conductive element. The moving contact element overlaps with the stationary contact element along the axial direction, effectively nesting the contacts in the third dimension to maximize space utilization.
2Reliability
If conventional technical means are used to improve breaking capacity (increasing rotation speed, adding magnets, arc extinguishing grid, or increasing contact diameter), then the breaking capacity is improved, but the cost or size of the switch increases
Solution Approach 1:
The patent divides the contact system into distinct moving and stationary contact conductive elements with separate functional zones. The moving contact element is segmented from the stationary contact element, allowing independent optimization of each component's diameter and shape without requiring additional arc control mechanisms.
Solution Approach 2:
The patent changes the spatial arrangement parameter from a side-by-side configuration to an overlapping three-dimensional configuration. This parameter change allows the moving contact element diameter to be increased while maintaining the same housing footprint, improving breaking capacity without adding complexity.
Data Source
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Figure 3A~3B
AI summary
The present application discloses a rotary electric switch. The rotary electric switch includes at least one switch layer and an actuation control assembly operatively coupled to the at least one switch layer. The space between two adjacent switch layers in the rotary electric switch is utilized to ingeniously design a way in which a stationary contact conductive element extends in each switch layer, whereby a moving contact conductive element and the stationary contact conductive element at least partially overlap along an axial direction of the rotary electric switch in a three-dimensional space. In this way, the size of a housing may be not increased while the diameter of the moving contact conductive element is increased. That is, it is compatible to increase the unit breaking capacity and to miniaturize the rotary electric switch without greatly increasing the cost or even without increasing the cost.