Short Circuit Trigger Optimized Coil Connection
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Solution Overview
Problem
Existing short-circuit releases in circuit breakers face challenges in accurately positioning the coil winding within the air gap between the armature and pole, especially with larger settings, leading to potential shifting and deformation under high short-circuit currents, which complicates maintaining response limits and increases power loss.
Innovation Solution
A short-circuit release design where the coil is wound onto the coil body with both ends welded from the same side, allowing for a straight connection to the terminal without additional connecting pieces, optimizing the magnetic circuit and reducing electrical resistance by using a U-shaped yoke plate and magnetic sheet to minimize magnetic loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the coil winding is positioned with larger supporting cross-sections and fewer turns to accommodate larger setting ranges, then the coil can handle higher currents, but the positioning accuracy deteriorates and the coil shifts under high short-circuit currents
Solution Approach 1:
The coil winding is pre-positioned on the coil body with positioning elements that ensure accurate alignment with the air gap before the assembly is finalized. This preliminary positioning action prevents shifting during operation under high currents.
Solution Approach 2:
Positioning elements act as intermediaries between the coil winding and the coil body, maintaining precise spatial relationship without requiring the coil to be directly fixed to the magnetic circuit components.
2Stability of the object's composition
If the coil winding is fixed rigidly to prevent shifting under high currents, then positioning stability improves, but the coil cannot accommodate manufacturing tolerances and may deform
Solution Approach 1:
The coil body serves as a flexible intermediary structure that can accommodate manufacturing tolerances through its geometric design, while the positioning elements provide stable positioning without rigid constraints that would cause deformation.
Solution Approach 2:
The design allows for parameter variations in the coil body geometry and positioning element dimensions to compensate for manufacturing tolerances while maintaining stable coil positioning and preventing deformation under operational loads.
3Reliability
If additional connecting pieces are used to attach the coil ends, then connection reliability improves, but the manufacturing complexity and assembly time increase
Solution Approach 1:
The coil body is designed to integrate the functions of mechanical support, magnetic circuit, and electrical connection into a single component. The coil ends are directly attached to the coil body without additional connecting pieces, simplifying the manufacturing process while maintaining connection reliability.
Solution Approach 2:
The coil body serves multiple functions simultaneously: it provides mechanical support for the coil winding, forms part of the magnetic circuit, and serves as the electrical connection point for the coil ends, eliminating the need for separate connecting components.
4Temperature
If the magnetic circuit is designed for higher switching capacities, then the thermal stress handling improves, but the power loss increases
Solution Approach 1:
The magnetic circuit components are designed with optimized local geometries and material properties in the areas where coil connections are made, reducing magnetic losses at critical locations while maintaining overall thermal stress resistance for high switching capacities.
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 ensures precise positioning, reduces the risk of coil deformation, and maintains standard-compliant performance by minimizing power loss and thermal stress, enabling efficient operation at high switching capacities.
Implementation Method 1
These short-circuit releases are designed as electromagnetic releases, which essentially comprise a coil winding, a coil former, an armature, a pole, a plunger, a retaining spring and a yoke
Implementation Method 2
both ends of which can be welded to corresponding coil connections from the same side
Data Source
AI summary
The trigger (1) has an armature and a pole that are arranged within a coil body. A yoke metal plate and a clamp terminal (7) are arranged around a bobbin. A coil (5) is rolled up on the bobbin, where two ends (14, 15) at same side of the coil are welded corresponding to coil terminals. One end of the coil is pulled straight and parallel to a bimetal part, and another end of the coil is pulled straight and directly to the clamp terminal. A magnet metal sheet faces the yoke plate resting against the clamp terminal.