Abstract:
Traditional contactors utilize a magnetic circuit that requires its coil to be continuously powered up to hold contacts together. They are heavy and bulky with the type, quality and size of materials used to develop sufficient magnetic force to hold contacts together. They are inefficient, costly and are a safety concern due to potential overheating which could result into fire or damage to connected loads. The current invention utilizes a solenoid actuator assembly with locking and unlocking mechanism in place of the yoke and armature assembly used in traditional magnetic contactors. It does not require the coil to be continuously powered up during operation and the contactor could be manually, electronically or electrically controlled thereby avoiding unnecessary power loss. They are very efficient, safe to users and connected loads, and have long service life expectancy. They are also more cost-effective and smaller in size than traditional magnetic contactors.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Continuation-In-Part of U.S. patent application Ser. No. 12/758,790 filed on Apr. 12, 2010. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention involves an apparatus, system and method used in lieu of and/or in conjunction with traditional electromagnetically-operated control devices and equipment such as and including magnetic contactors, relays and circuit breakers. For exemplary purposes, the contactor will be used although the current invention could be used in many other applications. Existing electromagnetic contactors are typically used for among other purposes, to control the operation of electric motors, A/C or D/C and therefore are the main components for motor starters. Said electromagnetic contactors typically use an electromagnetic element which pulls or pushes the movable contacts towards the stationary contacts to establish electrical connection between the line and load terminals of the contactor. The electromagnetic element is typically a metallic core with a coil or winding to form a magnetic circuit which is activated when power is applied to the coil. Said magnetic circuit requires that power be continuously on to keep the magnetic contactor at “ON” position where the movable and stationary contacts are engaged. With the current invention, the electromagnetic element of the contactor is replaced by a solenoid actuator with an integrated locking and unlocking mechanism which do not require power to be continuously on to maintain the contactor contacts at “ON” position. 
     For purposes of this invention, the following terms are used and mean the same as or substitute for the other:
         a) AC—in electrical terms, this refers to alternating current   b) DC—in electrical terms, this refers to direct current   c) LINE-SIDE—means that part of an electrical circuit, equipment or device which is intended for connection to the power supply.   d) LOAD-SIDE—means that part of an electrical circuit, equipment or device which is intended for connection to an electrical load.   e) OFF—term to indicate a contact or switch position being OFF, a button designation for OFF position, turn OFF or turned OFF, switch or switched OFF. This term also mean that the contactor movable and stationary contacts are disengaged.   f) ON—term to indicate a contact or switch position being ON, a button designation for “ON” position, turn ON or turned ON, power up or powered up. This term also mean that the contactor movable and stationary contacts are engaged.   g) SOLENOID-ACTUATED—also mean electromagnetically-actuated, pertains to the method of actuating the operating mechanism of an equipment, device or system.   h) SOLENOID—refers to an assembly consisting of among others, a coil or winding on a core to produce a uniform magnetic field and a plunger which is actuated by the magnetic field which in turn attaches to a movable fixture   i) CONTACTOR—refers to an electromagnetic contactor, magnetic contactor, or any other type of contactor which operates to establish electrical connection between two terminals       

     SUMMARY OF THE INVENTION 
     The present invention involves an apparatus, system and method used in lieu of and/or in conjunction with traditional electromagnetically-operated control devices and equipment such as and including relays, contactors and circuit breakers. The current invention replaces the magnetic elements of a traditional contactor with a solenoid actuator with an integrated locking and unlocking mechanism which do not require power to be continuously on to maintain the contactor at “ON” position. It also provides a means to operate the contactor manually, semi-automatically, or automatically, by electrical or electronic control circuits, thereby reducing power usage, increasing device efficiency, extending lifespan, improving safety levels of operation, and reducing cost, among other benefits. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIGS. 1 to 3  show details and elements of the solenoid actuator disclosed in Tomimbang Patent Application No. 12758790 filed on Apr. 12, 2010. 
         FIG. 4  details a part of a contactor using a solenoid actuator disclosed in Tomimbang Patent Application No. 12758790 filed on Apr. 12, 2010. 
       FIG.  5 —same as  FIG. 4  but with the plunger extended above the retainer cap to allow manual operation of the contactor. 
         FIG. 6  shows an exploded view of the solenoid actuator disclosed in Tomimbang Patent Application No. 12758790 filed on Apr. 12, 2010. 
       FIG.  7 —shows a section inside a traditional magnetic contactor with its basic components. 
       FIG.  8 —shows a section inside the contactor of the current invention, incorporating a solenoid actuator with an integrated locking and unlocking mechanism. 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     References will now be made in detail to describe the exemplary embodiments of the present invention, which are in part illustrated in the accompanying drawings. Details disclosed herein are not to be interpreted as limiting, but rather as basis for the claims and teaching one skilled in the art how the present invention could be employed in any appropriately detailed system, structure or manner. Wherever possible, the same reference numbers are used throughout the drawings to refer to the same or like components, or functions. Illustrations and references made are basic, illustrative and not to be interpreted as limiting, where an actual product incorporating the current invention may involve other components to satisfy specific design requirements but with the same principles and intents of the current invention. While the invention has been described with preferred embodiments, it is not intended to limit the scope of the invention to the particular form set forth, but on the contrary, it is intended to cover such alternatives, modifications, and equivalents as may be included within the spirit and scope of the invention as defined by the appended claims. 
     The present invention involves an apparatus, system and method used in lieu of and/or in conjunction with traditional electromagnetic-operated control devices and equipment such as and including relays, contactors, circuit breakers, electrical outlets for AFCI and GFCI, electrical plugs. For exemplary purposes, the magnetic contactor will be used, although the invention applies to many other devices, equipment or systems. Traditional electromagnetic contactors are typically used to control the operation of electric motors, A/C or D/C and is the main component for motor starters. Said electromagnetic contactors typically use an electromagnetic element which pulls or pushes the movable contacts towards the stationary contacts to establish connection between the line and load terminals of the contactor. The electromagnetic element of said contactors is typically a metallic core with a coil or winding to form a magnetic circuit which is activated when power is applied to the coil. Said magnetic circuit requires that power be continuously on to keep the traditional magnetic contactor at “ON” position. With the current invention, the electromagnetic element of the traditional magnetic contactor is replaced by a solenoid actuator with an integrated locking and unlocking mechanism. 
     The current invention incorporates a solenoid actuator with an integrated locking and unlocking mechanism disclosed in Tomimbang Patent Application No. 12758790 filed on Apr. 12, 2010 into a contactor, relay, circuit breaker and any other control devices, equipment and systems.  FIG. 1  shows the main elements of the said solenoid actuator  1 ,  2 ,  3 ,  4  and its basic internal components are shown in an exploded view in  FIG. 2 , is composed of an actuator frame  1 , actuator coil  2 , retainer cap  3 , plunger  4 , displacement and locking guide stem  5 , actuator shaft  6 , locking stem  7 , saw-tooth projections  7   a , bottom of saw-tooth projections  7   b , ribs  7   c , displacement stem  8 , guide ribs  8   a , saw-tooth projections  8   b , and spring  9 . The operation of said solenoid actuator is as disclosed in the Tomimbang patent application above, and  FIG. 3  details the surface view of the locking and unlocking mechanism components essential for the retractable motion of the solenoid actuator assembly. The disclosed configuration of these components are basically for illustration purposes only and may be re-configured or other components may be added to satisfy specific technical requirements to suit the assembly to a particular application, within the same principles and objectives disclosed in this patent application. 
       FIGS. 4 to 6  provide details of a solenoid actuator assembly with an integrated locking and unlocking mechanism incorporating movable contact assemblies  10 ,  11 . The two contact points shown with the movable contact assemblies  10 ,  11  could be electrically connected by a variety of means through among others, a metallic plate, or wire. A spring or alternative material may be used under the contact points or plates to serve as cushion and to establish a good electrical connection with the stationary contacts when the contactor is on. The contactor shown is for a 2-pole configuration but it could be configured using the same principle for use on any number of poles, i.e., 1-pole, 3-pole, etc. These figures show that the movable contact assemblies  10  and  11  are facing up, meaning that the stationary contacts, which are not shown, are facing down to have the movable and stationary contacts engage with each other when the contactor is turned on. Alternatively, the movable contacts assemblies  10 ,  11  may be configured facing down, meaning that the stationary contacts, which are not shown, are facing up to have the movable and stationary contacts engage with each other when the contactor is turned on. In either case, the lever arm for movable contacts assemblies  12  need to be properly configured to the actual design requirement. The solenoid actuator could be designed to operate in a pull or push direction according to the position of the movable contacts assemblies  10 ,  11  in relation with the stationary contacts assemblies, which are not shown. The stationary contacts assemblies are made and constructed of matching configuration to mate properly with the movable contacts assemblies  10 ,  11 . The stationary and movable contact assemblies are oriented to move in the opposing directions to be able to engage when the contactor is turned on. The lever arm guide and retainer cap  3 ,  3   a ,  3   b ,  13  is made of such configuration to allow smooth movement of the lever arm for movable contacts assemblies  12 , and may also be blanked at top or with an opening for movement of a plunger  4  as actual design requirement may call for. In lieu of said lever arm guide and retainer cap  3 ,  3   a ,  3   b  a recess on the stationary contacts assembly or frame made of matching configuration may be used to serve the same purposes. The plunger  4  may also be used to manually turn the contactor ON or OFF, with or without power to the coil  2 . 
       FIG. 7  shows a section inside a typical magnetic contactor with its basic components. The movable contacts  23 ,  24  are assembled into the armature  18  through the movable contacts assembly  26 . When the coil  16  is powered up or the contactor is switched on, the yoke  15  is magnetized, pulling toward itself armature  18  and in the process, pulling the movable contacts assembly  26  toward the stationary contacts assemblies  27 ,  28 , thereby making the movable and stationary contacts  22  and  24 ,  21  and  23  engaged with each other. The coil  16  needs to be continuously powered up to maintain the magnetic attachment between the yoke  15  and the armature  18 , and the movable contacts  23 ,  24  and the stationary contacts  21 ,  22  remaining electrically connected. When power to the coil  16  is switched off or interrupted, the yoke  15  is demagnetized and the springs  17  push the armature  18  away from the yoke to separate them, thereby separating the stationary and movable contacts  21 ,  22 ,  23 ,  24  where at this point the contactor is turned off. While the movable contacts  23 ,  24  are configured facing down in  FIG. 7  since the stationary contacts  21 ,  22  are facing up, the contactor could also be re-configured such that the movable contacts  23 ,  24  would be facing up, the stationary contacts  21 ,  22  facing down, and, the stationary contacts assemblies  27 ,  28  and the movable contacts assembly  26  accordingly need to be re-positioned to ensure proper engagement of contacts when contactor is turned on. 
     It is very common with traditional electromagnetic contactors that the yoke  15  and armature  18  build up heat over a certain period of usage that the magnetic force decreases which cause chattering as characterized by a hammering sound between the yoke  15  and armature  18 . Chattering in effect causes an unstable electrical connection between the movable and stationary contacts  21 ,  22 ,  23 ,  24  that could result into arcs, and ultimately, burning of the contacts. This as well could ultimately affect the connected loads and other ancillary devices and may damage them. Since the coil  16  in a traditional magnetic contactor requires continuous power supply to maintain the magnetic attachment between the yoke  15  and the armature  18 , this accounts to unnecessary power loss as well as decreased service lifespan for the contactor due to the continuous exposure of the contactor components or elements to the heat built up on the yoke  15 , coil  16  and armature  18  during operation. The other standard contactor components shown in  FIG. 7  include the housing  14 , line and load side wiring terminals  19 ,  20 , and contactor position indicator  25 . 
       FIG. 8  shows a section inside a contactor of the current invention, incorporating a solenoid actuator with an integrated locking and unlocking mechanism disclosed in the Tomimbang patent application above, with the basic elements of a traditional contactor. Although for purposes of disclosure not all components of an actual contactor are shown, the contactor in this invention comprises a housing  29 , a solenoid actuator assembly with integrated locking and unlocking mechanism  37  as illustrated in  FIGS. 1 to 6 , movable contacts  33  and movable contacts assembly  34  with spring tensioners  35 , stationary contacts  32  and stationary contact assemblies  36 , line-side and load-side terminals  30 ,  31 , a manual reset mechanism or plunger  4 , and other standard contactor elements which though not shown include arc chutes or protectors, springs, test and reset buttons, auxiliary contacts, indicator lights, and visual indicators for contactor condition, among others. 
     The contactor in this invention could be built with any number of poles using the same principles disclosed herein and the coil  2  may be designed to operate in either AC or DC power supply. 
     With the current invention utilizing a solenoid actuator with an integrated locking and unlocking mechanism where the actuator shaft  6 , which is also called a solenoid plunger, becomes the equivalent of the armature  18  in a traditional magnetic contactor, the space is minimized and therefore could reduce the overall size of a magnetic contactor. Traditional magnetic contactors could be very bulky due to the size of yoke  15  and armature  18  needed to develop the magnetic force to pull the armature  18  towards the yoke  15  to engage the movable and stationary contacts  21  and  23 ,  22  and  24  together and turn the contactor on. 
     The current invention utilizing a solenoid actuator with an integrated locking and unlocking mechanism requires only a pulse or momentary power supply to the coil  2  to turn the contactor on or off and remain in that position until the next time the coil is powered up through electronic control or by any other means. 
     The solenoid actuator with an integrated locking and unlocking mechanism used in the current invention could be manufactured as a sub-assembly, reducing cost in the manufacturing of contactors. As a sub-assembly, it could also be used as a mechanical switching element for other equipment, system and devices including circuit breakers, relays, door openers, alarm systems, among a number of applications. 
     While  FIG. 8  details a configuration with a particular orientation of the movable contacts  33  with the stationary contacts  32 , using the same principles, it could be configured a number of ways depending on the desired construction of the contactor. 
     The solenoid actuator with an integrated locking and unlocking mechanism may be configured to either push or pull type motion, depending on the design and orientation of the movable and stationary contacts  32 ,  33  and with the contactor housing. 
     The current invention utilizes a solenoid actuator with an integrated locking and unlocking mechanism with a retractable motion, which means that every time the coil  2  is powered up, it causes the assembly to go either on an extended or retracted position corresponding to the contactor&#39;s on or off positions, depending on how the movable and stationary contacts are configured. With this retractable mechanism, the plunger  28  could be used independently as a manual switch to turn the contactor on or off, without powering up the coil  2 . The contact assemblies  34 ,  36  with matching fixtures, could be incorporated with accessories such as and including auxiliary contacts for control purposes and visual indicators such as for indication of position of the contactor contacts, whether on or off, among other features. 
     With the solenoid actuator with an integrated locking and unlocking mechanism, the current invention could be controlled manually, electrically and electronically or by any combinations thereof. Having a retractable locking and unlocking mechanism, offers a multitude of choices on how the contactor could be used for different applications as never before possible with the traditional magnetic contactors. A contact position indicator through auxiliary contacts which are either normally open (NO) or normally close (NC) may be incorporated into the contactor for better control and manageability, monitoring and other functions in an electrical or electronic control system. 
     With the solenoid actuator with an integrated locking and unlocking mechanism where the coil  2  is only momentarily powered up then powered off as a pulse-switched device, the contactor efficiency is increased and power consumption is minimized when compared with the traditional magnetic contactor which requires its coil  16  to be continuously powered up when the contactor is in operation. 
     With the solenoid actuator with an integrated locking and unlocking mechanism, the current invention could be designed to be much smaller in size than traditional magnetic contactors and provides better flexibility in its housing  29  design.