Variable Gear Ratio Electrical Circuit Switch
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Solution Overview
Problem
Existing electrical circuit switches face issues with contact wear and arc generation due to high-speed contact closure, leading to reduced electrical lifetime and increased heat generation, particularly in high-current applications.
Innovation Solution
An electrical circuit switch design featuring a first movable element pivotally arranged with a second movable element in a joint, allowing a force applied parallel to one axis to move a movable contact parallel to a second axis, forming an angle, thereby controlling the movement ratio and reducing the force required to maintain contact, which can be optimized for compactness and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a direct connection or fixed gear ratio mechanism is used to transfer energy from the electromagnet to the moving contact, then the switch can close the electrical circuit, but the moving contact meets the stationary contact with high speed causing contact wear and arc generation that reduces electrical lifetime
Solution Approach 1:
The patent applies a variable gear ratio mechanism where the gear ratio changes during the closing operation. The mechanism starts with a higher gear ratio to slow down the moving contact during approach, then transitions to a lower gear ratio for the final contact phase. This dynamic adjustment of the gear ratio allows control over the closing speed profile, reducing impact speed and contact bounce while maintaining reliable circuit closure.
2Productivity
If the moving contact is forced into contact with the stationary contact at high speed, then the circuit closes quickly, but contact bounces are created and arcs are generated that reduce the electrical lifetime
Solution Approach 1:
The variable gear ratio mechanism creates a periodic action pattern in the closing operation. The mechanism progresses through different gear ratio phases: an initial phase with higher ratio for controlled approach, a transition phase, and a final phase with lower ratio for firm contact. This periodic variation in gear ratio allows the system to achieve both fast overall closing time and reduced impact effects during critical phases.
3Speed
If a variable speed mechanism is implemented using sliding elements with different slopes or cam disks, then the contact closure speed can be dampened, but the device complexity increases
Solution Approach 1:
The patent merges the variable gear ratio mechanism with the existing electromagnet and contact structure into an integrated assembly. The mechanism combines the driving force transmission, speed variation, and contact actuation functions into a unified mechanical system. This integration reduces the number of separate components and simplifies the overall structure compared to using separate sliding elements or cam disks, while still achieving the desired speed dampening effect.
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 reduces contact resistance and heat generation, enabling higher current usage without overheating, while improving the mechanical and electrical lifetimes of the contacts by controlling the movement ratio and using a variable gear mechanism.
Implementation Method 1
the first movable element and the second movable element are pivotally arranged to each other in a first joint... the ratio of the movement parallel to the first axis of the section of the first element on which the force is applied and the movement of the movable contact parallel to the second axis, may be variable
Data Source
AI summary
An electrical circuit switch including: a first movable element configured for being movable by a force applied to the first movable element, the force having a direction parallel to a first axis; and a second movable element including a movable contact and being configured for, by means of the force, moving the movable contact in parallel to a second axis between an open and a closed position, corresponding to the switch opening or closing an electrical circuit. The first axis forms an angle to the second axis and the first movable element and the second movable element are pivotally arranged to each other in a first joint.