Rotatable Contactor Assembly for Vibration-Resistant Power Switching
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Solution Overview
Problem
Existing contactor systems in power distribution systems, particularly in aircraft, face challenges in reliably disconnecting or connecting power supplies due to environmental vibrations, which can cause contact bouncing and unreliable connections.
Innovation Solution
A contactor assembly with a rotatable conductor and interdigitally arranged protrusions, controlled by a magnetic field generated by a controller module, allows for precise conductive or non-conductive contact between conductors, ensuring reliable connection or disconnection by rotating the conductor to align conductive or non-conductive faces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional contactor systems are used in power distribution, then the structure is simple and manufacturing is easy, but environmental vibrations cause contact bouncing and unreliable connections
Solution Approach 1:
The contactor uses a rotatable conductor that can dynamically adjust its rotational position based on magnetic field activation. The conductor rotates between connected and disconnected positions, allowing dynamic response to control signals while maintaining stable contact through controlled rotation rather than static positioning.
Solution Approach 2:
The patent replaces traditional mechanical spring-loaded contact mechanisms with a magnetically controlled rotational system. The controller module generates magnetic fields that directly actuate the rotatable conductor, eliminating mechanical springs and reducing contact bouncing caused by mechanical vibration.
2Reliability
If a rotatable conductor with interdigitally arranged protrusions is used, then vibration resistance and connection reliability improve, but manufacturing complexity and cost increase
Solution Approach 1:
The contactor assembly is divided into modular components: a rotatable conductor with protrusions, stationary conductors with corresponding protrusions, and a controller module. This segmentation allows each component to be manufactured separately using standard techniques, then assembled together, reducing overall manufacturing complexity despite the sophisticated geometry of individual parts.
Solution Approach 2:
The contactor employs composite structural elements combining conductive materials for electrical contact with mechanically robust materials for the protrusions and housing. This composite approach enables the interdigitally arranged protrusions to withstand vibration while maintaining electrical conductivity and geometric precision.
3Reliability
If magnetic field control is used to rotate the conductor, then connection reliability improves, but energy consumption increases
Solution Approach 1:
The controller module generates magnetic fields in periodic pulses rather than continuous operation. Magnetic fields are activated only during transition periods when the conductor needs to rotate between connected and disconnected positions. Once the conductor reaches its target position, the magnetic field is deactivated, allowing the conductor to remain stationary without continuous energy input.
Solution Approach 2:
The patent extracts the magnetic field generation function into a separate controller module that operates independently from the rotatable conductor. This separation allows the magnetic field to be applied only when needed for actuation, rather than requiring continuous energy consumption to maintain the conductor's position.
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 provides superior reliability in connecting and disconnecting power sources, reducing susceptibility to vibrations and enabling a compact design with reduced manufacturing costs, suitable for various power distribution systems.
Implementation Method 1
a magnetic coil surrounding at least a portion of the rotatable conductor and configured to generate a magnetic field to rotate the rotatable conductor
Data Source
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AI summary
A contactor assembly 50 and method for operating the contactor assembly 50 can include a first conductor 72 having a first set of axially extending protrusions 80 and a second conductor 56 having a second set of axially extending protrusions 84 interdigitally arranged with the first set of protrusion 80. At least a subset of the first set of extending protrusions 80 and at least a subset of the second set of protrusions 84 can be conductively connected.