Segmented Movable Contact Branches for Switching Block Current Capacity

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing contactors used for applications with a small number of current making and breaking operations are oversized, leading to increased installation costs and inefficient current passage due to non-optimized design for maximum permanent current in a minimum volume.

Innovation Solution

A unitary switching block with two movable current passage branches and a second switching branch, each mounted on a movable contact carrier with contact pressure springs, allowing for staggered movement and optimized dimensioning for specific functions, reducing material usage and enhancing current capacity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If contactors are designed to perform a large number of current making and breaking operations, then reliability is improved, but device size and installation cost increase when used for applications requiring only a small number of operations

Engineering Contradiction:

Improvecurrent making and breaking operation capacityVSAvoidcontactor volume

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The movable contact is divided into two separate branches: a first current passage branch and a second switching branch. Each branch is independently dimensioned for its specific function, allowing the contactor to be optimized for applications with a small number of operations while maintaining reliability when needed.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different parts of the movable contact have different properties: the first current passage branch is designed for permanent current carrying with appropriate cross-section, while the second switching branch is designed for making and breaking operations. This local differentiation allows each part to be optimized for its specific role, reducing overall device volume.

Inventive Principle:

Principle #3Local quality

2Reliability

If contactor electrical contact pads are oversized to carry out a large number of operations, then reliability is improved, but installation cost increases

Engineering Contradiction:

Improvecontact pad durabilityVSAvoidinstallation cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The contact pads are designed with different dimensions and materials according to their specific function. The first current passage branch contact pads are optimized for permanent current carrying, while the second switching branch contact pads are optimized for making and breaking operations. This allows cost-effective manufacturing by not oversizing all contact pads uniformly.

Inventive Principle:

Principle #3Local quality

3Ease of manufacture

If the current passage line is not optimized, then manufacturing is simplified, but maximum permanent current passage in minimum volume is reduced

Engineering Contradiction:

Improvecurrent passage line design simplicityVSAvoidcurrent carrying capacity per volume

Core Design Contradiction:

Ease of manufactureVSQuantity of substance

Solution Approach 1:

The current passage line is optimized by giving the first current passage branch a cross-section specifically dimensioned for permanent current carrying. This branch has larger dimensions and is positioned to handle the main current flow, while the second switching branch has smaller dimensions appropriate for its switching function, thereby maximizing current carrying capacity per volume.

Inventive Principle:

Principle #3Local quality

4Device complexity

If a single movable branch is used, then device complexity is reduced, but allowable current within given volume decreases

Engineering Contradiction:

Improvemovable contact structureVSAvoidallowable current

Core Design Contradiction:

Device complexityVSQuantity of substance

Solution Approach 1:

The movable contact is segmented into two branches that can be independently dimensioned. The first current passage branch has a cross-section optimized for permanent current carrying, while the second switching branch is optimized for switching operations. This segmentation allows the total allowable current to be increased within the same volume compared to a single unified branch.

Inventive Principle:

Principle #1Segmentation

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 achieves a 40% gain in allowable current within a given volume compared to traditional contactors with a single movable branch, while minimizing material consumption and reducing the risk of electrodynamic repulsion and arc-related issues.

Implementation Method 1

a first contact pressure spring applying a first contact pressure force

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2779190B1Individual switching block and switching device comprising at least one such block

Publication Date: 2017.10.18 SCHNEIDER ELECTRIC IND SAS

AI summary

The invention relates to a unit switching block (80) comprising electrical switching means including two fixed contacts (320) and a moving contact (330) having a bridge having two ends each able to collaborate with a fixed contact (320); The moving contact (330) has a first branch (331) and a second branch (332) intended to connect respectively the two fixed contacts (320) and being movable relative to each other such that: - the first branch (331) is away from the fixed contacts (320) while the second branch (332) is still in contact with said contacts at the time of the opening of the contacts; - the second branch (332) is in contact with the fixed contacts (320) while the first branch (331) is away from said contacts at the time of the closing of the contacts.