Circuit Breaker Trip Actuator Reset Assembly
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Solution Overview
Problem
Existing trip actuator assemblies in circuit breakers suffer from misalignment issues due to manufacturing tolerances and assembly errors, leading to inaccurate resetting and potential damage during over-rotation, which affects the reliability and performance of the circuit breaker.
Innovation Solution
A trip actuator reset assembly that includes a cradle assembly, a reset lever, a resilient element, and a guide member, which accommodates dimensional and assembly imperfections by guiding the cradle assembly into engagement with the resilient element to pivot the reset lever and reset the trip actuator, while the resilient element bends to absorb additional motion and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the trip actuator is fastened to the circuit breaker using hardware and multiple fasteners, then the trip actuator can be securely mounted, but misalignment occurs due to manufacturing tolerances and assembly errors
Solution Approach 1:
A resilient element is introduced as an intermediary component between the trip actuator and the circuit breaker housing. This resilient element absorbs dimensional variations and assembly errors, maintaining precise alignment of the trip actuator while securing it firmly to the housing.
Solution Approach 2:
The resilient element changes its physical parameters (deforms elastically) to accommodate dimensional variations in the housing and mounting structure. This parameter change allows the system to absorb manufacturing tolerances while maintaining the trip actuator in its precise predetermined position.
2Manufacturing precision
If the cradle assembly and reset lever are rigidly coupled, then the reset operation should be precise, but over-rotation occurs due to accumulated tolerance variations
Solution Approach 1:
The coupling between the cradle assembly and reset lever is changed from rigid to dynamic through the resilient element. The resilient element allows controlled movement and deformation during the reset operation, accommodating tolerance variations while preventing over-rotation damage to the trip actuator.
Solution Approach 2:
The resilient element is positioned to engage before the reset lever can over-rotate, providing cushioning protection in advance. This prevents damage to the trip actuator by absorbing excess motion energy before it can cause harm.
3Strength
If multiple components and fasteners are used in the trip actuator assembly, then the assembly can be securely mounted, but the complexity of installation and alignment increases
Solution Approach 1:
The resilient element combines multiple functions into a single component: it secures the trip actuator to the housing, maintains precise alignment, and protects against over-rotation. This eliminates the need for separate alignment fixtures and multiple fasteners, reducing overall assembly complexity.
Solution Approach 2:
The resilient element serves multiple purposes simultaneously: structural support, alignment maintenance, tolerance compensation, and damage protection. This multi-functionality reduces the total number of components needed in the trip actuator assembly.
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 ensures precise and consistent resetting of the trip actuator, preventing damage from over-rotation and improving the reliability of the circuit breaker by directly securing the trip actuator without intermediate components and reducing the number of fasteners required.
Implementation Method 1
the resilient element bends to accommodate any additional motion of the cradle assembly
Implementation Method 2
the guide member guides the cradle assembly into engagement with the resilient element which pivots the reset lever
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A trip actuator reset assembly for a circuit breaker includes a cradle assembly, a reset lever, a trip actuator, and a resilient element. The cradle assembly is pivotably coupled to the circuit breaker pole shaft. The reset lever includes first and second ends, and a pivot pivotably coupling the reset lever to the circuit breaker housing. The resilient element is pivotably coupled to the housing proximate the second end of the reset lever. In response to a trip condition, an actuating element of the trip actuator moves the first end of the reset lever. To reset the trip actuator, a guide member guides the cradle assembly into engagement with the resilient element which pivots the reset lever. The first end of the reset lever then resets the trip actuator. After reset, if the cradle assembly continues to move, then the resilient element bends to accommodate the additional motion.