JP2735539B2 - Fully automatic breaker and its assembly method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION U.S. Pat. No. 3,464,040 to David B. Powell is 1/2 inch
(12.7mm) Discloses a small sliver and breaker structure for manufacturing residential sash and breaker. The shears and breaker parts are designed to be assembled and economically obtained in a mass production facility. When assembling the individual components during the manufacturing process, it takes some time to ensure that these components are assembled in the proper manner. In addition, there is a need for time to calibrate each piece or breaker individually in order to determine if the piece or breaker is tripped within a specified time for a constant test current. If the breaker does not trip within the specified time limit, the breaker is discarded for subsequent calibration. A detailed understanding of the components of the miniature wrench or breaker can be obtained from the above-mentioned US Pat. No. 3,464,040, which is hereby incorporated by reference. It is an object of the present invention to provide an economically designed residential ladder and breaker that can be fully assembled and calibrated by an automated assembly method. The design of a fully automatic assembling house sword and breaker uses a guide groove and a modified mold case with a retaining groove formed in the guide groove, which allows the case to be used in an automated assembly method. Used as a convenient assembly fixture.
An L-shaped magnet and contact assembly, a tightly wound mechanism spring, and a modified bimetal trip element allow the robot to assemble the breaker components into the case guides, grooves and retaining slots. An automatic having a plurality of recesses (hereinafter also referred to as "holding slots" or "guide slots" or "grooves depending on the application") formed to form a mounting fixture for robot-type assembly of shear and breaker components. FIG. 1 shows a case 10 manufactured in a formula. The case includes a protruding upper rail 11, a lower rail 12, a rear rail 13, and a front rail 14. A handle recess 15 similar to that disclosed in the aforementioned U.S. Pat. No. 3,464,040 is formed in the case with a plurality of screws or stud holes 7. A latch spring retaining slot 16 is formed below the upper rail together with the calibration screw slot 1. A retaining groove hole 17 for the trip assembly is formed between the right supporting wall 18 and the left supporting wall 19 extending upward from the case, and a protruding terminal groove 6A is formed between the bottom of the left supporting wall 19 and the inclined arc-shaped supporting wall 23. Formed by The trip assembly retaining slot is provided with a pair of bosses 85 extending from the left support wall 19.
And a contact portion 86 facing the right support wall 18. The arc-shaped ventilation groove 29A is located at the bottom of the arc-shaped support wall 23 and the lower rail 1 of the case.
Composed between two. A magnet stop 8 is integrally formed in the upper portion of the inclined arcuate support wall 23 and is used to stop the forward movement of the magnet in a manner similar to that described in U.S. Pat. No. 3,464,040. A terminal slot 25 is formed between the terminal support wall 24 and the bottom portion of the rear rail 13. The cradle, which will be described in detail below, is supported by a cradle support pivot 26 which projects in combination with the cradle bearing wall 27. Braided wire and contact blade grooves, generally designated 22, are formed between the left support wall 20 and the right support wall 21. A specially designed trip unit and terminal assembly 30 is shown in FIG. 2, which comprises a terminal lug 31 carrying a fixed screw 32 and attached to a bimetal strip 36 by means of a folded connecting strip 33. The bent connecting strip 33 is attached to the bimetal strip 36 by a weld 34. Yoke end
Contact blade including 41 and protruding eccentric contact end 39 and contact 40
38 is attached at one end to the braided conductor 37 by the weld 34 and at the opposite end to the conductor 35 by the weld 34. A handle cooperating tab 91 is formed from the contact blade 38 at the yoke end and engages in a slot 89 formed in the handle 5 as best seen in FIG. 7B. Braided conductor 37
Is a pair of tabs 84 extending from the contact blade 38 near the weld
You will be guided in the meantime. This is to prevent the braided conductor from bending at the weld and to prevent the braided conductor from coming loose when the contact blade moves. The conductor 35 is attached to the bimetal piece 36 by a weld 34 to complete the assembly. A mechanism spring tab 41 extends from the eccentric contact end 39. The trip unit / terminal assembly 30 is bent into a retaining slot 17 which positions the protruding terminal 31 within the terminal slot 6A and positions the contact blade 30 and the braided lead 37 within the braided lead and contact blade slot 22. The band 33 is retained in the case 10 of FIG. 1 by inserting it. The magnet assembly 42 is shown in FIG. 3 and includes an armature 44 and a magnetic core 43 which is a molded piece of a magnetic material. The armature 44 is made of a single piece of steel and has a shape with a pair of tabs 46, which are common to the calibration screw slot 1 and the latch spring holding slot 16 in the case shown in FIG. The latch spring boss 52 abuts against the side wall 9 and the latch spring retaining slot 16 when the magnet assembly is inserted into the case. The armature includes a narrow upper portion 51, a flat lower portion 49, and a folded lower portion 53 to facilitate magnetic transfer between the armature and the core. A shelf portion 48 is provided on the armature 44 to receive and support the hook extension 47 formed on the magnetic core 43 and to help maintain proper spacing between the armature 44 and the magnetic core 43. A folded lower portion 54 provided on the magnetic core 43 cooperates with the flat lower portion 49 and the bent lower portion 53 of the armature to provide a tight magnetic loop, the loop between the armature 44 and the core 43. Strengthen electromagnetic coupling. Bosses 55 formed in the lower portion 54 of the core 43 define the spacing between the bimetal 36 and the core 43 shown in FIG. 2 when the magnet assembly is positioned around the bimetal. Hook extension 47
The first purpose is to provide electromagnetic coupling between the bimetal 36 and the armature 44 so that the bimetal 36
In contacting the boss 55 at the bottom of 43, the purpose is to move the armature 44. This is because the hook extension 47 and the armature are moved from the cradle 56 shown in FIG.
Pull 43 apart. The location of the hook extension 47 near the center of the magnet 43 provides a close mechanical connection of the core 43 to the armature 44 to allow rapid movement of the armature 44 during a heat trip operation. However, since the hook extension 47 is a part of the magnetic core 43, the hook extension 47 and the bent lower portion 54
Some electromagnetic coupling occurs on the side facing the. This provides a magnetic force that tends to resist movement of the armature 44 toward the core 43 during magnetic tripping. The extension 47 is hooked in the middle of the upper part 45 and the lower part 54.
The arrangement of the hook extension is such that the closer the extension 47 is to the turning and folding upper part 45, the less the mechanical advantage against the movement of the armature 44 towards the core 43 during the magnetic tripping operation is reduced. This is because the reverse magnetic effect generated by the portion 47 is considerably reduced. Providing the L-shaped core 43 and the L-shaped armature 44 causes the magnet assembly 42 to face downward in the horizontal plane, i.
It can be inserted into the case 10 shown. This is true for the magnet assembly described in U.S. Pat. No. 3,464,040.
This is not possible with a profiled section because the armature and core cannot be assembled downward around the trip unit.
A latch opening 50 formed in the flat lower portion 49 of the armature 44
Supports a cradle latch portion 63 formed at the end of the cradle 56 shown in FIG. A highly polished stainless steel insert 81 located at the bottom of the latch opening 50 minimizes friction between the cradle latch portion 63 and the armature 44 and during high overcurrent or thermal tripping. To
When the bimetal 36 connected via the magnet hook extension 47 moves the armature 44 and the latch opening 50 away from the cradle latch portion 63, the cradle is pulled when the armature 44 is magnetically attracted to the magnetic core 43. The latch portion 63 is smoothly slid away from the latch opening 50. The reasonably coordinated function of the polished insert 81 greatly increases the efficiency of the assembly and calibration operation. Cradle 56 is formed primarily of a U-shaped barrel portion 60 having a slotted opening 62. The handle tab 61 and the mating fold tab 64 provide similar functions as described for the cradle disclosed in U.S. Pat. No. 3,464,040. The mechanism spring tab 59 is a contact blade shown in FIG.
In cooperation with the mechanism spring tab 41 of 38, a mechanism spring 65 shown in FIG. 5 is supported. To provide a simple and precise method of pivotally supporting the cradle 56 in the case, a circular end member 57 is formed at the end of the U-shaped body 60 opposite the latch portion. The opening formed in the circular end member 57 is
The outer peripheral edge of the circular end member 57 surrounds the protruding cradle support pivot 26 formed in the case 10 shown in the drawing, and the protruding cradle support pivot 26 and the cradle bearing wall 27.
Sit in the middle to further support the cradle 56 during the turn. The mechanism spring 65 shown in FIG. 5 includes a body member 66 and an upper eye 69 separated by a spring leg extension 67 which engages the mechanism spring tab 41 on the cradle 56 shown in FIG. ,
It comprises a lower eye 68 which engages the mechanism spring tab 41 on the contact blade 38 shown in FIG. Upper and lower spring eyes 69,6
By providing 8, the robot “Finga”
Prior to retracting the robot fingers so that the spring tension exerted by lowering the spring eyes 69,68 on the mechanism spring tabs 41,59 and extending the spring body member 66 on these tabs, the spring body members are retracted. As the 66 is inserted into both spring eyes to extend slightly, the mechanism spring tab 41 on the contact blade and the mechanism spring tab 59 on the cradle 56 are quickly engaged with the robot. The closed loop eye provides a spring that does not become tangled during partial feed to the robot. The circular end member of the cradle 56 which engages the raised cradle holding pivot 26 on the gripper and breaker case of FIG. 1 and the upstanding projections such as the mechanical spring tabs 41, 59 shown in FIGS. It has been determined that an efficient robotic assembly can be achieved by providing a circular shape to the shears and breaker components, such as 57 and spring eyes 69,68. As described above, the trip unit / terminal assembly 30, magnet assembly 42, and cradle 56 shown in FIGS.
And springs 65 are configured to cooperate with respective slots formed in case 10 shown in FIG. 1 to facilitate robotic assembly. What is important during the assembly process is the order in which the parts of the shears and breakers are assembled in the case 10. This assembly sequence is shown in FIGS. 7A and 7B as follows.
Make sure that the case 10 is
In a horizontal plane. First, the armature 44 is assembled by lowering the armature 44 into the case with the tab 46 pointing into one edge of the latch spring slot 16 and the latch opening 50 pointing in a vertical plane. Next, the trip unit / terminal assembly 30 is
The trip assembly connecting strip 33 is connected to the trip assembly connecting strip 33 such that the protruding terminal 31 is seated in the terminal slot 6A and the contact braid 38 and the flexible braided conductor 37 are seated in the groove 22. It is assembled by disposing it in the holding slot 17. Next, the bent upper portion 45 of the magnetic core 43 is inserted into the latch spring slot 16 adjacent to the armature tab 46, and the bent bottom portion 54 is inserted together with the bottom portion 49 and the bent bottom portion 53 of the armature 44. The core 43 is disposed in a box-shaped portion around the bimetal 36 of the trip unit / terminal assembly 30.
Assemble. Next, the handle 5 is disposed in the handle concave portion 15 formed in the case 10, and the cradle 56 is assembled by disposing the cradle circular end member 57 around the protruding cradle support pivot 26. The handle 5 includes flat portions 87, 88 on both sides for marking the "ON" or "OFF" state of the sign or breaker. For example, one part 87 may be displayed in red to indicate red when the handle 5 is in the “ON” position, and the other part 88 may be white when the handle 5 is in the “OFF” position. Is displayed in white. Move the mechanism spring 65
Assemble 69 by attaching mechanism spring tab 59 of cradle 56 and mechanism spring eye 68 to mechanism spring tab 41 of contact blade 30. The latch spring 4 is inserted into the latch spring slot 16 and is engaged with the latch spring boss 52 of the armature 44. The terminal clip assembly 3 is inserted into the terminal slot 25, and the terminal clip spring 80 is disposed as shown in FIG. The arc-shaped gutter groove 82 holds the arc-shaped gutter 28 fitted between the case 10 and the cover 70. Calibration screw assembly 2
Is press-fitted into the slot 1 for the calibration screw, the cover 70 is arranged on the completed assembly, and the cover 70 and the case 10 are tightened using a screw or a stud 83. The assembled miniature wrench or breaker 76 can be seen with reference to FIG. 8, where the cover is removed to represent the assembled parts, and all those parts are
The finished shim and breaker 76 are tightly engaged within case 10 so that they can move without disturbing the placement of any components. This is a disadvantage for robotic assembly because the sheath and breaker case and components are often transported on a moving conveyor system during the assembly process before the cover is placed on the case and riveted to it. An important feature. 8, the terminal scissor assembly 3, the scissors 79, the spring 80, and the fixed contacts 77 are shown positioned within the slot 25. In FIG. The arc gutter 28 is shown positioned within an arc gutter groove 82 intermediate the fixed contact 77 and the movable contact 40. The cradle 56 is supported and mounted by a circular end member 57 surrounding the cradle support pivot 26. The mechanism spring 65 is supported on the contact blade 38 by the mechanism spring tab 41 and on the cradle 56 by the mechanism spring tab 59. The latch spring 4, armature tab 46 and core upper portion 45 are shown mounted within the latch spring slot 16. The trip assembly connecting strip 33 is shown in the retaining slot 17 and the protruding terminal 31 is shown in the protruding terminal groove 6A. The eccentric boss 85 cooperates with the abutment 86 to grasp the strip 33 in a press fit relationship and to secure the trip unit 30 in place during the next assembly stage of the breaker component. This is an important feature of the present invention since no other clamping device is required.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a plan view of a case used for an automatically manufactured slasher or breaker according to the present invention, and FIG. 2 is an automatically manufactured slasher or breaker of the present invention. FIG. 3 is a front perspective view of a trip unit and terminal assembly used in the present invention, and FIG. 3 is a front perspective view of a magnetic component assembly including a contact and a magnetic core used in the automatically manufactured sash and breaker of the present invention. FIG. 4 is a front perspective view of a cradle used for the automatically manufactured sliver and breaker of the present invention, and FIG. 5 is a mechanical spring used for the automatically manufactured sliver and breaker of the present invention. FIG. 6 is a front perspective view, FIG. 6 is a plan view of a cover used for the automatically manufactured sliver and breaker of the present invention, and FIGS. 7A and 7B are the automatically manufactured sever and shredder of the present invention. 8 is an isometric upper perspective view in which components used in a tool are arranged in the order of assembly, and FIG. It is an assembled plan view. 1 Slot for calibration screw 2 Calibration screw assembly 3 Terminal clamp assembly 4 Latch spring 5 Handle 6A Slot for protruding terminal (case) 6B Terminal holder Groove (cover) 7 Screw hole 8 Magnet 9 Common side wall 10 Case 11 Upper rail 12 Lower rail 13 Rear rail 14 Front rail 15 … Recessed recess 16 for handle… Latch hole for latch spring 17… Retained pit hole for trip assembly 18… Right support wall 19… Left support wall 20… Left support wall 21… Right support wall 22… … Groove for contact blade, 23… Slope arc-shaped support wall 24… Terminal support wall, 25… Groove for terminal 26… Cradle support pivot 27… Cradle bearing wall 28… Terminal 29A… Ventilation groove ( Case) 29B ... vent groove (cover) 30 ... trip unit / terminal assembly 31 ... protruding terminal, 32 ... Fixed screw 33 ... Bend connecting strip, 34 ... Welded part 35 ... Conductor, 36 ... Bimetal piece 37 ... Braid wire, 38 ... Contact blade 39 ... Eccentric contact end, 40 ... Contact 41 ... … Mechanism spring tab, 42… magnet assembly 43… magnetic core, 44… armature tab 45… bending upper part, 46 …… armature 47… hook extension part, 48… shelf part 49 … Flat lower part, 50… Latch opening 51… Narrow upper part, 52… Latch spring boss 53… Bending lower part, 54… Bending lower part 55… Boss, 56… Cradle 57: Circular end member, 58: Opening 59: Tab for mechanism spring, 60: Cradle trunk 61: Tab for handle cooperation 62: Slot for slot, 63: Latch 64: Joint break Eye tab, 65 ... Mechanical spring 66 ... Spring body member, 67 ... Spring leg extension 68,69 ... Spring eye, 70 ... Cover 71 ... Recess for handle, 72 ... Clade Bearing wall 73: inclined-arc-shaped support wall 74: support wall 76: shear-breaker assembly 77: fixed contact 79 terminal scissors 80 spring 81: insert 82 Arc-shaped gutter groove, 83… Screw 84… Tab, 85… Eccentric boss 86… Contact part, 87, 88… Flat part 89… Groove hole 91… Tab for handle cooperation

   ────────────────────────────────────────────────── ─── Continuation of front page    (72) Inventor: Joseph Michael Palmieri               United States Connecticut State Sa               Usington Orchid Lane 58 (72) Inventor William J. Ames Ashyu Line               United States Connecticut               Ristor Kamppu Street 721 (72) Inventor Dennis Jiyon Doutey               United States Connecticut               Rainville Spring Street                 17                (56) References JP-A-56-106330 (JP, A)                 58-8836 (JP, U)

Claims (1)

(57) [Claims] A molded plastic case (10), a protruding terminal (31) provided at one end, and a protruding terminal (31) provided at an opposite end connected to the protruding terminal via a bimetal piece (36) and a braided conducting wire (37). And a contact unit (30) having an upper end and a lower end, and an armature (44) and a magnetic core (43). Is formed of a single L-shaped piece of metal and has a narrow upper portion (51) and a wider bent lower portion (49,5) including a latch opening (50).
3), wherein the magnetic core is formed of a single L-shaped metal piece, and an upper bent portion (45), a lower bent portion (54), and a lower bent portion (54) constituting a pivot with respect to the magnetic core. A magnet assembly having a hook extension (47) that engages the lower armature portion to form a closed magnetic loop in cooperation with the portion; The U-shaped unit has a handle tab (61) on the top for engaging the handle (5), a latch portion (63) on one leg for releasably engaging the latch opening, and another leg. Part having a circular end member (57),
A cradle (56) pivotally supported in the case by the circular end member, and connecting between the cradle and the contact blade;
When the operating handle (5) is in the closed position, the movable contact (40) of the contact blade is brought into contact with the fixed contact (77) supported on the case to pass current through the two contacts, And a mechanism spring (65) for rapidly biasing the two contacts away from each other when the trip unit releases the cradle latch portion from the latch opening when an excessive current flows through the two contacts. The trip unit / terminal assembly, the cradle, and the magnet assembly are all held in a plurality of recesses (6A, 17, 22) formed in the case; Fully automatic including a plastic mold cover (70) having a plurality of recesses therein cooperating with a plurality of recesses in the case to hold the solid, the cradle and the magnet assembly Tatsushiki breaker. 2. 2. The fully automatic breaker of claim 1 wherein said case includes a protruding cradle holding pivot (26) for receiving said cradle circular end member and pivotally supporting said cradle within said case. 3. The mechanism spring includes a body portion (66) and a pair of closed loop-shaped spring eyes (68, 69) provided one at each end of the body portion. One surrounds and engages a spring tab (59) on the top of the cradle, and the other spring eye surrounds and engages a spring tab (41) intermediate the upper and lower ends of the contact blade. 2. The fully automatic assemblable circuit breaker according to claim 1, wherein said circuit breaker is engaged. 4. At the bottom of the armature latch opening, a polished steel insert (8
1) having a sliding engagement with the cradle latch portion;
2. A fully automatic assembling circuit breaker according to claim 1, wherein the movement of said cradle latch portion disengaging from said latch opening is reduced friction movement. 5. 2. The armature lower portion of claim 1, wherein said lower armature portion includes a shelf portion (48) which cooperates with a hook extension of said core to ensure that said core and said armature are held in close magnetic relation. The fully automatic assemblable breaker described. 6. The armature upper portion further includes a pair of tabs (46) abutting and supported by a side wall (9) formed in the case, wherein the side wall is formed in a calibration recess (46) formed in the case. 2. A fully automatic circuit breaker according to claim 1, wherein the latch spring recess is separated from the latch spring. 7. The armature upper portion further includes a latch spring boss (52) formed thereon for positioning and supporting the latch spring when the latch spring (4) is inserted into the latch spring recess. The fully automatic assembling type circuit breaker according to claim 6, wherein 8. 2. The fully automatic shut-off of claim 1 including an arc trough (28) disposed in an arc trough (82) formed in said case proximate said fixed contact. vessel. 9. The invention of claim 1 wherein said braided wire joins said contact blade between a pair of upstanding tabs (84) on said contact blade to inhibit flexing of said braid member during movement of said contact blade. Fully automatic breaker. 10. The magnetic core hook extension portion is provided between the magnetic core bending upper portion and the magnetic core bending lower portion, and mechanically connects the bimetal and the armature to each other so that the armature is magnetically tripped when the circuit breaker is tripped. 2. A fully automatic circuit breaker as claimed in claim 1, wherein the force resisting the movement of the circuit breaker is minimized. 11. The trip unit includes a bent connection member (33) for fixedly connecting one end of the bimetal disposed in one of the plurality of recesses and the protruding terminal, and holding the bent connection member. The holding recess (17) includes a pair of bosses (85) on one side of the recess to fix and hold the trip unit to the case, and the holding recess (17) on the opposite side across the bent connecting member. 2. A fully automatic circuit breaker according to claim 1, including an abutment (86). 12. The handle includes first and second flat surfaces (87, 88) each having a colored marker, whereby the first surface is in a second position when the handle is in the ON position. 1 color and the handle is OFF
2. A fully automatic circuit breaker according to claim 1, wherein said second surface exhibits a second color when in said position. 13. a) Molded plastic case (10), b)
A protruding terminal (31) provided at one end, and a contact blade (38) provided at the opposite end connected to the protruding terminal via a bimetal piece (36) and a braided conductor (37). A trip unit / terminal assembly (30) wherein the contact blade has an upper end and a lower end; c) an armature (44)
And the magnetic core (43), said armature being formed of a single piece of L-shaped metal and having a narrow upper portion (51) and a wide bent lower portion (49,53) including a latch opening (50). ) Wherein the core is formed of a single piece of L-shaped metal and has an upwardly bent portion (45) forming a pivot for the core.
It has a lower fold (54) and a hook extension (47) that engages the lower armature to form a closed magnetic loop in cooperation with the lower armature. Magnet assembly, d) formed of a U-shaped unit, the U-shaped unit having a handle tab (61) on its top for engaging the handle (5)
A latch portion (63) releasably engaging the latch opening on one leg, and a circular end member (57) on the other leg.
And a cradle (56) pivotally supported in the case by the circular end member; and e) a connection between the cradle and the contact blade, wherein the operating handle (5) is in the closed position. When the movable contact (40) of the contact blade is brought into contact with the fixed contact (77) supported on the case, a current passes through the two contacts and a current passes through the two contacts. If the trip unit releases the cradle latch portion from the latch opening in the event of excess, the mechanism includes a mechanism spring (65) for rapidly biasing the two contacts away from each other; f) the trip unit terminal The assembly, the cradle, and the magnet assembly are all held in a plurality of recesses (6A, 17, 22) formed in the case; and g) the trip unit / terminal assembly and the magnet assembly. A method of automatically assembling a circuit breaker further including a plastic mold cover (70) having a plurality of recesses therein cooperating with a plurality of recesses in the case to hold a cradle and the magnet assembly. Inserting the armature (44) into a first holding recess formed in the case, and disposing the trip unit / terminal assembly (30) on the armature in the case. The magnetic core (43) is inserted above the trip unit / terminal assembly and the armature, and the hook extension (47) of the magnetic core is mounted on the shelf (48) of the armature. Arranging the handle member (5) in the second case formed in the case;
The cradle member (56) is inserted, the circular end member (57) is fitted to a pivot (26) formed in the case, and the cradle member Latch part (63)
Is operably disposed in the latch opening (50) of the armature, and one of the closed loop-shaped spring eyes (68) formed at both ends of the mechanism spring (65) is connected to the contact blade. By engaging the spring tab (41) and the other of the spring eyes (69) on the spring tab (59) of the cradle, the mechanism spring is moved between the cradle and the contact blade. A latch spring (4) is inserted into a third recess (16) formed in the case, close to the top end of the armature, and an arc trough (28) and a fixed contact (77) is connected to the fourth contact formed in the case in an operable relationship with the contact blade.
The plastic mold cover () is provided in the recess (82) of the plastic mold and has a plurality of corresponding recesses formed therein so as to cooperate with the plurality of recesses formed in the case. 70) Automatic assembly method of circuit breaker including each process of fixing.