Switch Fuse Assembly Busbar Contact Reliability

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Solution Overview

Problem

Existing fuse switch arrangements for busbar systems are either unreliable or costly to produce, and often require a complex assembly with numerous parts, leading to increased weight, reduced reliability, and shorter lifespan.

Innovation Solution

A simplified fuse switch arrangement with a switching finger that directly contacts the busbar, reducing the number of parts needed and incorporating 3-dimensional contact wires for efficient and cost-effective operation, while ensuring reliable contact and preventing wear and sparks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fuse switch arrangements are used, then reliable operation is achieved, but the number of parts and assembly complexity increases

Engineering Contradiction:

ImprovereliabilityVSAvoidnumber of parts

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple contact elements into a single integrated switching finger that directly contacts the busbar. This merging of components reduces the total number of parts while maintaining the reliable switching function, as the switching finger integrates the functions of multiple separate contact elements into one unified component

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The switching finger serves multiple functions simultaneously: it acts as a contact element, a switching mechanism, and a structural support component. This multi-functionality reduces the need for separate dedicated components, thereby reducing overall device complexity while preserving reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of operation

If traditional fuse switch arrangements are used, then switching function is achieved, but weight increases

Engineering Contradiction:

Improveswitching functionVSAvoidweight

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates unnecessary intermediate components from the switching mechanism. By removing redundant parts that do not contribute to the essential switching function, the overall weight of the moving components is reduced while the core switching capability is preserved

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The switching finger is designed as a thin, lightweight component that provides the necessary mechanical strength for switching operations. This thin-film approach reduces weight while maintaining the structural integrity needed for reliable switching function

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If multiple contact elements are used, then reliable contact is achieved, but manufacturing cost increases

Engineering Contradiction:

Improvecontact reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent merges multiple contact elements into a single switching finger component. This consolidation reduces the number of parts that need to be manufactured, assembled, and quality-checked, thereby reducing manufacturing costs while maintaining contact reliability through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The switching finger is designed as a universal component that performs multiple contact functions simultaneously. This multi-functionality reduces the total number of specialized parts needed, simplifying manufacturing processes and reducing overall production costs while ensuring reliable electrical contact

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Device complexity

If switching finger directly contacts busbar, then number of parts is reduced, but wear and sparks may occur

Engineering Contradiction:

Improvenumber of partsVSAvoidwear and sparks

Core Design Contradiction:

Device complexityVSObject-generated harmful factors

Solution Approach 1:

The patent converts the potentially harmful direct contact into a beneficial arrangement by designing the switching finger to rotate about contact points rather than slide. This rotational motion reduces wear and minimizes spark generation while maintaining the simplicity of direct busbar contact, thus converting a potential harm into an operational benefit

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 significantly reduces the number of parts and assembly complexity, enhancing reliability, lifespan, and reducing costs, while preventing sparks and wear, thus providing a more efficient and cost-effective fuse switch arrangement.

Implementation Method 1

this foot contact is kept under pretension by means of a spring device

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentEP2197010B1Switch fuse assembly for busbar systems

Publication Date: 2012.03.28 BRUCHMANN KLAUS

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AI summary

The circuit-protection assembly (10) comprises one or multiple circuit-protection units for receiving a fuse cartridge (22). Each circuit-protection unit has a base contact (30) for contacting a fuse cartridge and a switching unit. Each circuit-protection unit has a switch bar (100), where each switch bar is arranged movable between an on-position and an off position.