Switch Assembly Pivot Contact Lever Heat Dissipation
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Solution Overview
Problem
Conventional high power DC switches experience high contact resistance and heat generation due to pivot contact lever mechanisms, leading to instability and potential burnout, especially during high current situations, and lack effective heat dissipation mechanisms.
Innovation Solution
The switch assembly incorporates a pivot contact lever with a compressed portion and an elastic metal plate for improved contact stability, along with a heat sink and a MOSFET for efficient heat dissipation, and a parallel connection contact plate to bypass high currents, reducing contact loss and heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pivot contact lever mechanism is used to switch electric connection, then the switch can be operated mechanically, but high contact resistance and heat generation occur at the pivot point
Solution Approach 1:
The patent extracts the harmful pivot contact point from the system by replacing the traditional pivot contact lever mechanism with a sliding contact mechanism. The sliding contact moves along a guide surface without creating a pivot point, thereby eliminating the source of high contact resistance and heat generation while preserving mechanical operability.
Solution Approach 2:
The patent replaces the mechanical pivot contact system with a sliding contact system that uses friction-based guidance instead of rotational pivoting. This substitution eliminates the intermittent contact and high resistance associated with pivot points while maintaining the mechanical switching function through linear motion along a guided path.
2Power
If a pivot contact lever connects the electric circuit, then electric current can flow through the switch, but the pivot contact generates high contact resistance and causes heating
Solution Approach 1:
The patent removes the harmful pivot contact point that generates heat by implementing a sliding contact mechanism. The sliding contact travels along a guide surface, maintaining continuous electrical connection without the intermittent contact and high resistance characteristic of pivot points, thereby preventing heat generation during high current operation.
Solution Approach 2:
The patent introduces a sliding contact as an intermediary element that transfers electrical current from the movable lever to the fixed contact through continuous sliding motion along a guide surface. This intermediary mechanism distributes the electrical connection over a longer path, reducing contact resistance and preventing localized heat generation at a single pivot point.
3Reliability
If a by-pass switch (second pivot contact lever) is provided for high current situations, then the main circuit can be bypassed, but heat is still generated due to high current (up to 100 A) flowing through the bypass
Solution Approach 1:
The patent replaces the pivot contact lever mechanism in the bypass switch with a sliding contact mechanism. The sliding contact moves along a guide surface to establish and break the bypass connection, eliminating the pivot contact points that would generate heat during high current flow. This allows the bypass switch to handle high currents (up to 100 A) without excessive heat generation.
4Adaptability or versatility
If a conventional forward/reverse switch mechanism with single convex contact is used, then the output pole can be alternated, but heat generation is not effectively minimized
Solution Approach 1:
The patent eliminates the pivot contact points in the forward/reverse switch mechanism by replacing them with sliding contacts that move along guide surfaces. This extraction of harmful pivot contacts allows the switch to alternate output poles while minimizing heat generation through continuous sliding contact instead of intermittent pivot contact.
Solution Approach 2:
The patent introduces sliding contacts as intermediary elements in the forward/reverse switching mechanism. These sliding contacts establish electrical connection by moving along guide surfaces, providing a stable and continuous contact path that reduces contact resistance and heat generation while enabling pole alternation functionality.
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 contact resistance and heat generation, enhancing the reliability and efficiency of the switch assembly by maintaining stable connections and effective heat management during high current operations.
Implementation Method 1
a heat sink and a MOSFET for efficient heat dissipation
Implementation Method 2
an elastic metal plate for improved contact stability
Implementation Method 3
a heat sink and a MOSFET for efficient heat dissipation
Data Source
AI summary
A switch assembly provides a pressing plate on a pivot contact lever to minimize heat generation at the point between the pivot contact lever and the contact point by providing an additional parallel connection contact plate which is in parallel connection to the pivot contact lever. The switch assembly provides convex contact portions on the internal output ports of the forward/reverse switch mechanism. A supplementary elastic metal plate to the pivot contact lever is provided to solve the problem of loose contact at the pivot connection site where the pivot contact lever and the support unit meet, and provides a supplementary contact unit to the movable contact device at the forward/reverse switch mechanism.