Voltage Sensor Contact for Modular Overload Relay
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Solution Overview
Problem
Overload relays face challenges with a large number of catalog numbers needed, increased size and cost due to limited current range and lack of built-in voltage sensing capabilities, along with difficulties in reliable electronic interconnection and connection to electromechanical contactors subjected to mechanical stress.
Innovation Solution
A modular overload relay assembly with integrated voltage sensing capabilities, allowing for a reduction in catalog numbers and easy user configuration, featuring a sensing module, controller module, and communication module aligned in a horizontal format with preformed phase current conductors and voltage sensor contacts, enabling reliable mechanical and electrical connections without increasing width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If voltage sensing capabilities are added to overload relays, then the functional versatility is improved, but the device width and cost increase
Solution Approach 1:
The voltage sensor contact is nested within the existing overload relay housing structure, utilizing the internal space between the phase conductor and the circuit board. This allows voltage sensing functionality to be integrated without increasing the overall device width, as the sensor is contained within the existing form factor rather than adding external dimensions.
Solution Approach 2:
The voltage sensor contact extends in the vertical dimension between the circuit board and phase conductor, rather than expanding the device horizontally. By utilizing the z-axis space within the existing housing, the design adds functionality without increasing the width footprint that would affect panel mounting constraints.
2Adaptability or versatility
If modular components are used, then the adaptability is improved, but electrical contact wear increases due to relative mechanical motion
Solution Approach 1:
The overload relay is divided into modular components (sensing module, controller module, communication module) that can be independently configured. The voltage sensor contact is integrated into the sensing module, allowing it to be installed or replaced without affecting other modules, thus maintaining adaptability while managing contact wear through modular replacement capability.
Solution Approach 2:
The system allows dynamic configuration where modules can be added, removed, or reconfigured based on application needs. The voltage sensor contact design accommodates this modularity while minimizing wear through proper electrical connection design that reduces relative motion between connected components.
3Ease of operation
If overload relays are directly mounted to electromechanical contactors, then the installation simplicity is improved, but the device durability worsens due to shock-like operations
Solution Approach 1:
The voltage sensor contact design incorporates features that cushion against the shock-like operations experienced during contactor operations. The electrical connection is designed to accommodate mechanical stress and vibration, protecting the solder joints and conductive paths from damage during direct mounting to electromechanical contactors.
Solution Approach 2:
The voltage sensor contact integrates the voltage sensing function directly into the overload relay assembly that is mounted to the contactor. This merging of functions allows the sensor to share the mounting structure and withstand the same environmental conditions, simplifying installation while ensuring the sensor design accounts for the mechanical stress of direct contactor mounting.
4Ease of manufacture
If a fixed current range is used, then the manufacturing complexity is reduced, but the product versatility worsens
Solution Approach 1:
The voltage sensor contact design is universal and can be used across different current ranges and module configurations. The same basic sensor structure and connection method work with various sensing modules, controller modules, and communication modules, allowing a single design to serve multiple current range applications without requiring current-specific variations.
Solution Approach 2:
The system allows parameter changes in current range through modular configuration rather than requiring different physical sensor designs. The voltage sensor contact maintains consistent design while the overall system adapts to different current ranges through the modular architecture, separating the universal voltage sensing function from the application-specific current monitoring parameters.
Data Source
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AI summary
A voltage sensing system includes a sensing system housing, a circuit board positioned with the sensing system housing, and a phase conductor extending through the sensing system housing, the phase conductor to carry a load current. The system also includes a voltage sensor contact, the voltage sensor contact including a first end and a second end, the first end being electrically coupled to the circuit board and the second end being electrically coupled to the phase conductor.