Short Circuit Release Magnetic Sheet Optimization
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Solution Overview
Problem
Existing short-circuit releases in circuit breakers face challenges with positioning and fixing the coil winding accurately due to larger adjustment ranges, inhomogeneous magnetic fields, and increased thermal budgets, leading to inefficient energy conversion and higher power losses at high switching capacities.
Innovation Solution
A short-circuit release design featuring a magnetic sheet arranged opposite the yoke plate without a direct connection, with a form-fit pairing and optimized installation space, reducing magnetic losses and allowing for precise manufacturing tolerances, and using non-platinized materials to minimize electrical resistance and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the coil winding is positioned with larger adjustment ranges to accommodate tolerances, then the positioning accuracy deteriorates, but the adaptability improves
Solution Approach 1:
The coil winding is pre-positioned and fixed in the mold cavity before final assembly. This preliminary positioning action ensures that the coil achieves its precise final position during molding, eliminating the need for post-assembly adjustments while maintaining manufacturing precision.
Solution Approach 2:
The mold cavity acts as an intermediary structure that precisely positions the coil winding during the molding process. This intermediary mechanism transfers the positioning function from post-assembly adjustment to the molding process itself, resolving the contradiction between adjustment range and positioning accuracy.
2Stability of the object's composition
If the coil winding is fixed rigidly to prevent shifting, then the positioning stability improves, but the coil deformation increases due to stress
Solution Approach 1:
The support structure provides localized support at specific points (bobbin flange or yoke) rather than rigid fixation across the entire coil. This local support mechanism maintains positioning stability while allowing the coil to accommodate thermal expansion and contraction without deformation.
Solution Approach 2:
The fixation system is designed to be dynamically adaptive, allowing the coil to expand and contract with temperature changes while maintaining its positioned relationship to the air gap. The support structure accommodates these dynamic changes without causing deformation.
3Loss of energy
If the yoke plate is made from platinized material to improve magnetic circuit, then the magnetic efficiency improves, but the power loss increases due to thermal budget constraints
Solution Approach 1:
The invention changes the material parameter of the yoke plate from platinized material to non-platinized magnetic sheet material. This parameter change reduces the thermal budget and power loss while maintaining adequate magnetic circuit efficiency through optimized magnetic sheet placement.
Solution Approach 2:
The magnetic sheet is strategically placed only in the area where it is required for magnet technology, rather than using platinized material throughout the entire yoke plate. This local optimization reduces overall thermal budget and power loss while maintaining magnetic efficiency where needed.
4Power
If the excitation force is increased to maintain force level with inefficient magnetic circuit, then the switching capacity improves, but the energy conversion efficiency deteriorates
Solution Approach 1:
The invention changes the magnetic circuit parameters by using non-platinized magnetic sheet material with optimized geometry, which improves energy conversion efficiency. This parameter change allows the system to achieve the required switching capacity with reduced excitation force, thereby improving overall energy efficiency.
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
This design achieves a more efficient magnetic circuit with reduced power losses, minimized space requirements, and cost-effective production, enabling high switching capacities while maintaining precise dimensions and tolerances.
Implementation Method 1
These short-circuit releases are designed as electromagnetic releases, which essentially comprise a coil winding, a bobbin, an armature, a pole, a plunger, a retaining spring and a yoke
Implementation Method 2
a magnetic sheet (10) is arranged on two legs (8, 9) of the terminal connection (7)... The additional magnetic sheet according to the invention significantly reduces the magnetic loss
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a short-circuit release (1), in particular for a circuit breaker, comprising an armature (2) and a pole (3) arranged within a coil former (4), as well as a yoke plate (6) and a terminal (7) arranged around the coil former (4). The invention is characterized in that a magnetic sheet (10) is arranged opposite the yoke plate (6) and abutting the terminal (7).