Tri-stable Flexure Mechanism for Circuit Breaker Actuation
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Solution Overview
Problem
Conventional circuit breaker mechanisms are complex, difficult to assemble, and prone to performance uncertainties due to multiple moving components, leading to larger size and slower operation speeds, which fail to meet design criteria for quick make-break transitions and repeatability.
Innovation Solution
The use of tri-stable planar flexure mechanisms with resilient components, such as leaf flexure elements, volute springs, or collapsible compression springs, that store and release elastic strain energy to rapidly transition between closed, open, and tripped states, reducing complexity and improving reliability by integrating elastic strain energy storage and structural functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional circuit breaker mechanisms use multiple moving components to achieve reliable operation, then reliability is improved, but device complexity increases and assembly difficulty increases
Solution Approach 1:
The patent combines multiple moving components into a single integrated flexure mechanism that provides both the structural support and the actuation function. The flexure mechanism integrates the functions of traditional links, pivots, and springs into one monolithic component, reducing the number of parts while maintaining operational reliability through its inherent flexibility and stress distribution characteristics.
Solution Approach 2:
The flexure mechanism serves multiple functions simultaneously: it acts as a structural link, a spring element for energy storage, and a actuator for contact separation. This multi-functionality eliminates the need for separate components for each function, thereby reducing device complexity while maintaining the reliability needed for circuit breaker operation.
2Reliability
If conventional mechanisms use multiple moving components, then reliability is improved, but ease of manufacture deteriorates
Solution Approach 1:
By merging multiple components into a single flexure mechanism, the patent eliminates the need for complex assembly processes. The monolithic structure can be manufactured as one piece through processes like injection molding or precision machining, significantly improving ease of manufacture while maintaining performance repeatability through consistent material properties and geometry.
3Volume of moving object
If conventional circuit breaker mechanisms are designed to fit in predefined casing, then size is reduced, but opening speed deteriorates
Solution Approach 1:
The flexure mechanism incorporates dynamic characteristics through its flexible structure that allows for rapid energy release. The curved geometry and material selection enable the mechanism to achieve high opening speeds within a compact volume by optimizing the balance between structural integrity and dynamic response, allowing the mechanism to fit in predefined casings while maintaining fast operation.
4Adaptability or versatility
If conventional mechanisms have multiple moving components, then adaptability is improved, but productivity deteriorates
Solution Approach 1:
The integration of multiple functions into a single flexure mechanism dramatically reduces assembly time since the mechanism can be installed as one component rather than assembling multiple separate parts. The design maintains operational versatility through its ability to perform multiple functions within the unified structure, such as providing both mechanical support and actuation capability.
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 enables faster opening times, more repeatable displacement or force inputs, and reduced size, enhancing the scalability and reliability of circuit breakers while maintaining high-speed operation and minimizing arcing.
Implementation Method 1
the resilient component is elastically deformed and stores elastic strain energy in one of a first stable state or a second stable state
Data Source
AI summary
Embodiments of a tri-stable flexure mechanism are described where a resilient component is present that serves as both a structural component in the kinematic chain of the mechanism and as energy storing component of the mechanism. The resilient component maintains a movable arm and an input link in either a first stable state or a second stable state when the ends of the resilient component are held in place so that the resilient component has a state of high elastic strain energy. In a third stable state, where the resilient component is in a relaxed state of lower elastic strain energy, the mechanism may be in a tripped state distinct from the closed and open states.