Solid-State Auxiliary Switches for Electrical Contactors
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Solution Overview
Problem
Conventional electrical switching apparatus, such as relays and contactors, require multiple mechanical adjustments for auxiliary switches to ensure proper function, which complicates maintenance and reduces reliability, and are susceptible to foreign object debris and contaminants.
Innovation Solution
A control system that monitors the magnetic field and current characteristics of a coil to automatically adjust the state of auxiliary switches, eliminating the need for mechanical adjustments and improving reliability by detecting a predetermined current 'glitch' indicative of normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electromechanical auxiliary switches are used in conventional contactors, then auxiliary contact functions can be provided, but multiple mechanical adjustments are required to ensure proper function and the switches are susceptible to foreign object debris and contaminants
Solution Approach 1:
The patent replaces electromechanical auxiliary switches with solid-state electronic switches (such as MOSFETs or IGBTs) that are controlled by electronic control logic. This substitution eliminates mechanical moving parts, contacts, and adjustments while providing the same auxiliary contact functions. The electronic switches are controlled based on detected characteristics of the coil current waveform, thereby improving reliability by removing susceptibility to foreign object debris and contaminants that affect mechanical components.
2Reliability
If multiple mechanical adjustments are made for auxiliary switches, then proper function can be ensured, but maintenance complexity increases and life expectancy decreases
Solution Approach 1:
The patent eliminates mechanical adjustments by replacing electromechanical auxiliary switches with solid-state electronic switches controlled by electronic logic. The control system automatically detects coil current waveform characteristics and actuates the electronic auxiliary switches accordingly, removing the need for manual mechanical adjustments for wear allowance. This results in reduced maintenance complexity and increased life expectancy since there are no mechanical parts to wear or adjust.
3Adaptability or versatility
If electromechanical auxiliary switches are used, then auxiliary contact functions are provided, but the switches are susceptible to foreign object debris and contaminants
Solution Approach 1:
The patent replaces electromechanical auxiliary switches with solid-state electronic switches that have no exposed mechanical contacts or moving parts. The electronic switches are controlled by control logic that monitors coil current waveform characteristics. This substitution eliminates the susceptibility to foreign object debris and contaminants that plagues electromechanical switches, while maintaining all auxiliary contact functions through electronic control.
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 system ensures auxiliary switches are in their proper state without mechanical adjustments, enhancing reliability and life expectancy while being resistant to debris and contaminants, thus improving the overall performance of electrical switching apparatus.
Implementation Method 1
a coil which controls main contacts, a magnetic frame cooperating with the coil
Implementation Method 2
monitoring a magnetic field of the magnetic frame
Implementation Method 3
the predetermined characteristic is a momentary decrease in the current flowing through the coil before subsequently reaching a larger current value
Data Source
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AI summary
An electrical switching apparatus (130) includes a coil (54), a magnetic frame (50) cooperating with the coil, a number of separable contacts (137) controlled by the coil, a number of auxiliary switches (22), a current sensor (114) structured to sense a current (108) flowing through the coil, and a magnetic sensor (120) structured to sense a magnetic field (66,106) of the magnetic frame. A circuit (24) is structured (180) to detect a predetermined characteristic (94) of the sensed current (126) flowing through the coil and output a control signal (27) responsive to the magnetic field being greater than a predetermined value (112) and the predetermined characteristic being detected. The control signal is structured to cause a change in state of the number of auxiliary switches.