UPS Bypass Contactor Pressing Force Mechanism

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Solution Overview

Problem

Uninterruptible power supply devices fail to supply AC power to loads when the electromagnetic contactor in the bypass switch cannot be turned on, leading to potential power outages.

Innovation Solution

Incorporating a control device that manages a switch and electromagnetic contactor, with a manual switch and pressing force mechanism to ensure AC power supply from the AC power source to the load, even if the electromagnetic contactor fails to activate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If an electromagnetic contactor is used in the bypass switch to enable automatic bypass power feeding, then the ease of operation is improved, but the reliability deteriorates because the contactor may fail to turn on

Engineering Contradiction:

Improveautomatic bypass power feedingVSAvoidcontactor failure

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

A pressing force applying mechanism is introduced as an intermediary device between the control signal and the electromagnetic contactor. When the contactor fails to activate, the mechanism automatically applies pressing force to the contactor's actuating mechanism, ensuring the bypass switch closes and power feeding continues without interruption.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system prepares a pressing force applying mechanism in advance that can be activated when the electromagnetic contactor fails. This pre-positioned backup mechanism ensures that if the primary electromagnetic actuation fails, the bypass switch can still be closed through mechanical pressing force, cushioning against the potential power interruption.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Reliability

If a pressing force applying mechanism is added to ensure contactor activation, then the reliability is improved, but the device complexity increases

Engineering Contradiction:

Improvepower feeding continuityVSAvoidpressing force mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The pressing force applying mechanism is designed to operate autonomously based on detection of contactor failure. The control device monitors the contactor's activation state and automatically activates the pressing mechanism when failure is detected, eliminating the need for additional manual intervention or complex external control systems.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system replaces the unreliable electromagnetic actuation with a mechanical pressing force application when failure occurs. The pressing mechanism uses direct mechanical force to close the bypass switch contacts, substituting the failed electromagnetic field-based actuation with a more reliable mechanical action.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Prevents power outages by enabling the bypass of the electromagnetic contactor failure, ensuring continuous AC power supply to the load through the manual switch and pressing force mechanism.

Implementation Method 1

The electromagnetic contactor is turned on when a contact is closed by excitation of a coil according to a control signal from the control device

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

The uninterruptible power supply device further includes a pressing force applying mechanism that applies a pressing force to the manual switch

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS11444482B2Uninterruptible power supply device

Publication Date: 2022.09.13 TMEIC CORP

AI summary

An electromagnetic contactor (15) is connected between an AC power supply (1) and a load (18), and is turned on during bypass power feeding. A control device (20) turns on a switch (14) and turns off the electromagnetic contactor (15) when an inverter (10) has a failure during inverter power feeding. The electromagnetic contactor (15) is turned on when a contact is closed by excitation of a coil according to a control signal from the control device (20). The electromagnetic contactor (15) has a manual switch that can close the contact by being pressed from outside. An uninterruptible power supply device (100) includes a pressing force applying mechanism (22, 26, 27) that applies a pressing force to the manual switch, and a control circuit (24, 28) that operates the pressing force applying mechanism when there occurs a failure that the electromagnetic contactor (15) cannot be turned on regardless of the control signal from the control device (20).