Integrated Trip-Reset Core Unit for Compact Leakage Interrupters
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional leakage current detection and interruption devices have large core units that occupy significant internal space, making it difficult to incorporate additional functions and affecting the device's aesthetics and usability.
Innovation Solution
A compact core unit design for leakage current detection and interruption devices that uses fewer components and a more compact structure, incorporating a control circuit board, a drive coil assembly, and a magnetic movement assembly to achieve trip and reset functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional core unit structures are used, then trip and reset functions are achieved, but device size becomes large and internal space is occupied
Solution Approach 1:
The patent combines the trip mechanism and reset mechanism into a single integrated core unit structure. The trip unit and reset unit share common components such as the bimetallic plate, spring mechanisms, and housing structure, merging previously separate functional elements into one compact assembly that achieves both trip and reset functions without requiring separate mechanical systems.
Solution Approach 2:
The core unit is designed as a multi-functional integrated structure where single components serve multiple purposes. For example, the bimetallic plate simultaneously acts as the sensing element for overload detection and the actuating element for both trip and reset operations. The spring mechanisms provide both the tripping force and the resetting force, eliminating the need for separate dedicated components for each function.
2Reliability
If conventional core unit structures are used, then trip and reset functions are achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent reduces structural complexity by merging the trip and reset mechanisms into a single integrated core unit. Common components such as the bimetallic plate, spring assemblies, and housing are shared between both functions, eliminating redundant parts and simplifying the overall structure. This integration reduces the number of separate mechanical systems while maintaining both trip and reset functionalities.
3Reliability
If conventional core unit structures are used, then trip and reset functions are achieved, but additional functions cannot be incorporated and aesthetics are affected
Solution Approach 1:
The patent creates a compact integrated core unit that consolidates trip and reset functions into a space-efficient design. This reduction in size and complexity of the core mechanism frees up internal space within the device housing, allowing manufacturers to incorporate additional functional modules such as communication interfaces, display units, or advanced sensing elements without increasing the overall device footprint.
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 compact design reduces the size of the device, enhances versatility, and lowers manufacturing costs, while maintaining effective trip and reset functions for leakage current protection.
Implementation Method 1
the solenoid is configured to generate a magnetic field having a predetermined direction and a predetermined magnitude when it is energized, and wherein the magnetic field of the solenoid induces a magnetic field in the iron core having a direction identical to that of the magnetic field of the solenoid and another predetermined magnitude
Implementation Method 2
a magnetic attraction force exerted by the permanent magnet on the iron core when the solenoid is not energized is greater than a sum of spring forces of the core spring and the trip spring
Data Source
AI summary
A core unit for a leakage current detection and interruption device includes a control circuit board; a drive coil assembly coupled to the circuit board, including a coil holder frame and an input or output assembly connected thereto; and a magnetic movement assembly nested with the drive coil assembly, including a magnetic movement frame and the output or input assembly connected thereto. In response to relative movements between the drive coil assembly and the magnetic movement assembly away from or toward each other, the input and output assemblies are disconnected from or connected to each other, respectively. The core unit achieves reset function and trip function by the coordination of the drive coil assembly and magnetic movement assembly, effectively ensuring power connection and disconnection while reducing the number of components. This design reduces the size of the device and reduces assembly cost.