Starter Auxiliary Module Assembly With Optical Status Sensing
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Solution Overview
Problem
Conventional starter assemblies for electric motors face complexity and cost issues due to extensive cabling, mechanical vibration-induced connection failures, and reliability concerns related to electrical contacts, particularly in multipolar circuit breakers and electromagnetic contactors.
Innovation Solution
An auxiliary module assembly for starter assemblies that uses optical sensors and movable rods to indicate and receive status signals from multipolar circuit breakers and electromagnetic contactors, connected via mechanical couplings without tools, ensuring reliable communication and interchangeability across different sizes and types.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cabling is used to electrically connect the electromagnetic contactor command to the power supply and auxiliary contacts to the logical processing unit, then the starter assembly can be assembled, but the assembly becomes complex and costly due to the amount of cables used and the time spent in assembling them
Solution Approach 1:
The patent combines multiple electrical connection functions into a single integrated connector assembly. The connector includes multiple contacts that simultaneously establish electrical connections for the electromagnetic contactor command, auxiliary contacts monitoring, and power supply connections, replacing what would traditionally require separate cables and connection points.
Solution Approach 2:
The connector assembly serves multiple functions simultaneously: it provides power supply connection, electromagnetic contactor command signaling, and auxiliary contacts monitoring. This multi-functional design eliminates the need for separate dedicated cables for each function, simplifying the overall cabling structure.
2Reliability
If electrical contacts are used in the auxiliary module to indicate status through electrical signals, then monitoring can be achieved, but the solution brings complicated elements for assembly with high cost and low reliability due to the use of mechanisms for handling electrical contacts which are liable to contamination or premature wear
Solution Approach 1:
The patent replaces mechanical electrical contacts with an optical detection system. A visual indicator element (such as a colored window or light-emitting component) provides status indication, and an optical sensor detects the status without physical contact. This eliminates wear, contamination, and mechanical failure modes associated with traditional electrical contacts.
Solution Approach 2:
The patent introduces an optical intermediary (light or visual indicator) between the electrical status and the detection system. The electrical state is converted into an optical signal that can be detected without direct electrical contact, providing isolation and eliminating the need for fragile electrical contact mechanisms in the auxiliary module.
3Adaptability or versatility
If the connector is housed in the auxiliary module associated with the electromagnetic contactor, then integration is achieved, but the electromagnetic contactor commonly has high mechanical vibrations which may induce connection failures and loss of communication signal in the cabling between them
Solution Approach 1:
The patent extracts the connector from the high-vibration electromagnetic contactor environment and relocates it to the auxiliary module housing. This physical separation removes the connector from the harmful vibration field while maintaining electrical and functional integration through the auxiliary module's internal connections.
Solution Approach 2:
The patent provides mechanical isolation and vibration damping for the connector through its mounting in the auxiliary module housing. The housing structure and mounting mechanism are designed to cushion and isolate the connector from vibrations, preventing connection failures before they occur.
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 provides a cost-effective, reliable, and efficient means to remotely monitor and control the status of electric motor starter assemblies, reducing mechanical vibrations and connection failures, while enabling quick assembly and interchangeability.
Implementation Method 1
uses optical sensors and movable rods to indicate and receive status signals
Data Source
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AI summary
A starter assembly (1), comprising a circuit breaker (2), an electromagnetic contactor (3), coupled to an auxiliary modules assembly (4), comprising an upper auxiliary module (4a) associated with the circuit breaker (2), comprising a first printed circuit board (4ad) associated with the first position sensor (4ak) and the external connector (4ae), said upper auxiliary module (4a) coupled by cable (5) to the lower auxiliary module (4b) associated with the contactor (3), comprising a second printed circuit board (4bd) associated with one second sensor (4bk), in which the second board (4bd) connects to the electric control coil of the said contactor (3), said auxiliary modules assembly (4) being connectable by means of a cable (6) to a controller (7) or through wireless communication means to send and receive signals from the programmable controller (7), and alternatively comprising a lower auxiliary module (4b') identical to the said lower auxiliary module (4b) installed on top of another contactor (3') and connected to said lower auxiliary module (4b) by means of a cable (8) between the printed circuit boards (4bd, 4bd ').