Spring Guide Alignment for Circuit Breaker Carrier Assembly
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Solution Overview
Problem
Existing circuit breaker carrier assembly designs are complex, difficult to assemble, and sensitive to dimensional variations, leading to inconsistent spring force and reduced withstand ratings, with potential for nuisance blow or excessive current leakage.
Innovation Solution
A spring guide system that maintains alignment between contact springs and movable contact arms, reducing the number of springs needed and allowing for larger, more robust springs, facilitating easier assembly and adjustment to achieve higher withstand ratings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional carrier assembly designs with multiple contact springs are used, then the circuit breaker can provide contact pressure and accommodate wear, but the assembly becomes complex and difficult to assemble with numerous parts
Solution Approach 1:
The patent combines multiple contact springs into a single integrated spring assembly that provides the necessary contact pressure for multiple contact arms. This merging of multiple separate spring components into one unified structure reduces the total number of parts while maintaining the required mechanical function of providing and maintaining contact pressure across all contacts.
2Reliability
If traditional carrier assembly designs are used, then the structure can provide blow off functionality, but the assembly is sensitive to dimensional variations resulting in inconsistent spring force
Solution Approach 1:
The patent introduces a carrier assembly that acts as an intermediary structure between the contact springs and the contact arms. This carrier assembly provides a standardized interface and mounting structure that isolates the spring force application from dimensional variations in the contact arms, ensuring consistent spring force delivery regardless of variations in the contact arm dimensions.
3Reliability
If traditional carrier assembly designs with many contact springs are used, then the assembly can maintain contact pressure, but the alignment of springs with contact arms becomes difficult and time-consuming
Solution Approach 1:
The patent incorporates preliminary alignment features directly into the carrier assembly structure, such as pre-positioned spring mounts and guide features that automatically align the contact springs with the corresponding contact arms during assembly. This preliminary preparation of alignment features eliminates the need for time-consuming manual alignment procedures while ensuring consistent contact pressure maintenance.
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 spring guide system simplifies assembly, ensures consistent spring force, and enhances the circuit breaker's withstand rating, increasing production yield and reducing rejections by allowing for precise adjustment within engineering specifications.
Implementation Method 1
The carrier assembly includes a plurality of contact springs which are structured to bias the fingers and corresponding movable contacts disposed thereon against the stationary contacts in order to provide and maintain contact pressure
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A spring guide is provided for a carrier assembly of an electrical switching apparatus such as, for example, a circuit breaker. The carrier assembly includes a carrier body, a plurality of movable contact arms (104) pivotably coupled to the carrier body, and a plurality of contact springs (108). Each of the contact springs is disposed between a portion of the carrier body and a corresponding number of the movable contact arms. Each spring guide includes a guide member (112) disposed between a corresponding one of the contact springs and the corresponding number of movable contact arms to maintains alignment therebetween. The guide member preferably includes a planar portion (116) including a first side, which spans a pair of adjacent movable contact arms, and a second side, which includes a projection (124). The projection is disposed within the coils of the corresponding one of the contact springs.