Toggle Joint Switch Lock for Spring Failure Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Low-voltage protection devices face a risk of undetected component failure due to aging, particularly with springs that become brittle with hydrogen, leading to potential hazards and unreliable operation, as they are often passive and only actuated during system faults, which are rare.
Innovation Solution
A switch lock mechanism with a knee joint and multiple opening springs, where the toggle joint remains stretched with two springs but moves into the off position when one spring fails, ensuring automatic shutdown and detection of faults before a dangerous situation arises.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the protective device remains passive and is only actuated during system faults, then the device structure can be simple, but components may fail unnoticed due to aging and the device becomes unreliable
Solution Approach 1:
The patent applies preliminary action by designing the switch lock mechanism to automatically test the opening springs during normal operation. The knee joint periodically moves between stretched and relaxed positions, preemptively verifying spring functionality before actual faults occur. This prevents undetected spring failures that would compromise reliability.
Solution Approach 2:
The patent implements feedback through the automatic testing mechanism where the position of the knee joint and handle provides continuous information about spring integrity. If a spring fails, the mechanism detects this through the inability to maintain proper positioning, providing immediate feedback about component status without requiring external monitoring.
2Reliability
If components in the switching mechanism are greatly oversized to minimize failure risk, then reliability improves, but device complexity and size increase
Solution Approach 1:
Instead of oversizing components, the patent uses preliminary testing during normal operation to verify component integrity. The automatic testing mechanism checks spring functionality regularly, allowing smaller, more compact components to be used while maintaining reliability through continuous verification rather than conservative over-engineering.
3Reliability
If extensive service life and long-term tests are carried out during development, then component reliability improves, but development time and cost increase
Solution Approach 1:
The patent applies self-service by designing the protective device to automatically test its own components during normal operation. The switching mechanism performs self-diagnosis of spring integrity without requiring external testing equipment or prolonged development testing, reducing development time while ensuring reliability through ongoing automatic verification.
4Reliability
If the switch lock mechanism automatically detects spring failure and switches off, then reliability improves, but the mechanism complexity increases
Solution Approach 1:
The switch lock mechanism performs self-diagnosis by monitoring its own operational parameters. The knee joint and handle positioning automatically indicate spring status, and the mechanism self-actuates to switch off when faults are detected. This self-monitoring and self-protection capability achieves high reliability without requiring complex external monitoring systems.
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
This design minimizes the risk of undetected material defects and ensures reliable operation by automatically switching off the low-voltage protection device if a spring fails, preventing dangerous situations and maintaining system safety.
Implementation Method 1
a spring element being arranged in the handle
Implementation Method 2
at least one opening spring is preloaded in the switching mechanism
Data Source
Figure 1
Figure 2
AI summary
The lock has a U-shaped bolt fastened at a handle (2) e.g. tooth rocker, of a toggle joint. The bolt is operatively mechanically connected to a latch (7). The latch is operatively mechanically connected to a switching lever (9) by another U-shaped bolt. A spring element e.g. torsion spring, is arranged in the handle such that the toggle joint remains elongated when loaded by opening springs (12, 13) e.g. pull-springs, and moves into a switched-off position when loaded by one of the opening springs. An end of one of the opening springs is fastened at the switching lever.