A high-efficiency coil assembly for a magnetic latching relay

Abstract

The present invention belongs to the technical field of magnetic latching relays, and specifically is a high-efficiency coil assembly of a magnetic latching relay, including a bobbin, an iron core, a yoke and a unique copper wire group. The copper wire group contains double coils with different wire diameters. The first coil has a relatively thick wire diameter, and can cope with large current conditions such as motor starting. It conducts current smoothly according to Ohm's law and uses the electromagnetic principle to quickly drive the armature to switch contacts. The second coil is thinner and focuses on sensing on-off signals. The two are electrically isolated and synergistically adapted to complex electrical scenarios, broadening the application boundaries. The second coil is wound around the periphery of the first coil, and a convex strip is provided in the middle isolation sleeve, which can not only prevent magnetic field interference, but also form a coil heat dissipation channel, temperature control to ensure performance and extend service life. The assembly hole and the iron core are square, which improves assembly efficiency, enhances structural stability, optimizes the magnetic circuit, increases the number of winding turns, improves copper wire utilization and magnetic field strength, and helps to integrate miniaturization with high performance, with strong practicality.

Description

Technical Field

[0001] The invention belongs to the technical field of magnetic latching relays, in particular to a high-efficiency coil component of a magnetic latching relay. Background Art

[0002] The magnetic latching relay is a special and efficient relay with significant advantages, including outstanding energy saving, strong stability, no interference from power supply fluctuations, long contact life, low wear during operation, various parameters such as rated voltage and current, and adaptability to different circuits. It is widely used in scenarios such as smart home appliance control, prepaid electricity meters, and industrial automation production lines, and is highly favored. The coil assembly is an important component of the relay.

[0003] The existing coil assembly is mainly composed of the following parts: coil frame, enameled wire, and the working principle is as follows: the coil is energized, and the current passes through the coil winding, generating a magnetic field that interacts with the permanent magnet. Like polarities repel each other, and opposite polarities attract each other, thereby completing the setting operation of the relay and making the circuit conductive.

[0004] The coil assembly in the existing technology has the following disadvantages: in the current electrical field, traditional relay technology has many shortcomings. The coil has a single function and is mostly a single coil. When dealing with high-power conditions, it is limited in carrying large currents, has a weak magnetic field and slow response. In weak current scenarios, it has poor accuracy in capturing tiny signals, low versatility, and is difficult to adapt to complex electrical needs; the structure is poor, the conventional round iron core and assembly hole combination has low assembly efficiency and is easy to loosen, the magnetic flux fluctuates greatly, the space utilization is poor, and the number of winding turns is small, which hinders the integration of miniaturization and high performance and does not meet modern needs; therefore, a high-efficiency coil assembly for a magnetic holding relay is proposed to address the above problems. Summary of the invention

[0005] In order to make up for the shortcomings of existing coil assemblies, a high-efficiency coil assembly for a magnetic latching relay is proposed.

[0006] The technical solution adopted by the present invention to solve its technical problem is: the high-efficiency coil assembly of a magnetic latching relay described in the present invention includes a wire rack, an iron core is installed in an assembly hole on the wire rack, a yoke is also installed on the wire rack, a copper wire group is wound on the wire rack, and the copper wire group includes a first coil for carrying large current and responding quickly, and a second coil for sensing the on-off state of the circuit breaker.

[0007] Preferably, the second coil is wound around the periphery of the first coil, and an isolation sleeve is provided between the two, and a plurality of convex strips are equidistantly provided on the isolation sleeve on the contact surface between the first coil and the second coil.

[0008] Preferably, the wire rack is provided with a first pin and a second pin electrically connected to the first coil and the second coil, respectively.

[0009] Preferably, the wire rack is provided with positioning ribs for positioning the yoke, and the positioning ribs are provided with grooves for facilitating the assembly of the yoke.

[0010] Preferably, riveted parts are provided at both ends of the iron core, riveted holes cooperating with the riveted parts are provided on the yoke, and riveted chamfers are provided in the riveted holes.

[0011] Preferably, a soft pad is provided on the contact surface where the yoke and the armature assembly contact and cooperate.

[0012] Preferably, the assembly hole and the iron core are both matching square structures.

[0013] Beneficial effects of the present invention:

[0014] 1. The copper wire group is innovatively designed with a double-coil structure. The first coil has a thicker wire diameter and is designed to carry large currents and achieve rapid action. When facing high-power demand conditions such as motor starting and heavy-load equipment switching in industrial automation production lines, the first coil can smoothly carry large currents according to Ohm's law, generate strong magnetic fields through the Ampere loop and electromagnetic induction, and drive the armature to switch contacts at high speed, with rapid response; the second coil is based on Faraday's law of electromagnetic induction, closely relying on the change of magnetic flux caused by the change of the on-off state of the relay, sensitively inducing electromotive force, and accurately capturing and efficiently processing the electromotive force by connecting to external professional sensors, converting weak current signals into effective information for users to intuitively monitor the on-off state of the relay, providing users with accurate and real-time feedback on the on-off state of the relay, greatly improving the visibility of the system operation status. This design breaks the limitations of the traditional single coil and is widely adapted to complex electrical architectures in multiple fields such as industry and home, greatly broadening the application boundaries of relays and demonstrating excellent versatility;

[0015] 2. The isolation sleeve ensures the independence of the electromagnetic environment of the double coils and avoids magnetic field interference. The convex strips can not only assist the coils in winding steadily, but also form a heat dissipation channel, reduce the coil temperature, extend the service life, and maintain the stability and reliability of the relay operation;

[0016] 3. The square structure of the assembly hole and the iron core improves assembly efficiency, enhances structural stability, and reduces magnetic circuit-related problems. At the same time, under the same conditions, it can increase the number of winding turns, improve copper wire utilization and magnetic field strength, and help miniaturize and improve product performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings described herein are used to provide a further understanding of the present invention and constitute a part of this application. The exemplary embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an improper limitation of the present invention. In the drawings:

[0018] Figure 1 It is a three-dimensional exploded view of the structure of the present invention as a whole;

[0019] Figure 2 It is a structural stereogram of the whole of the present invention;

[0020] Figure 3 yes Figure 2 A sectional view from the side;

[0021] Figure 4 It is a cross-sectional view of the wire rack and copper wire group from a top view;

[0022] Figure 5 yes Figure 4 A magnified view of the structure at center A;

[0023] Legend:

[0024] 1. Wire rack; 2. Assembly hole; 3. Iron core; 301. Riveted part; 4. Yoke; 401. Riveted hole; 4011. Riveted chamfer; 5. Copper wire group; 501. First coil; 502. Second coil; 6. First stitch; 7. Second stitch; 8. Isolation sleeve; 801. Raised strip; 9. Positioning rib; 901. Groove; 10. Cushion. DETAILED DESCRIPTION

[0025] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0026] Specific examples are given below.

[0027] See also Figure 1-Figure 5The present invention discloses a high-efficiency coil assembly of a magnetic latching relay, comprising a wire rack 1, wherein an iron core 3 is assembled in an assembly hole 2 on the wire rack 1, and a yoke 4 is also assembled on the wire rack 1, and a copper wire group 5 is wound on the wire rack 1, wherein the copper wire group 5 comprises a first coil 501 for carrying a large current and reacting quickly, and a second coil 502 for sensing the on-off state of the circuit breaker, and the wire rack 1 is respectively provided with a first pin 6 and a second pin 7 electrically connected to the first coil 501 and the second coil 502; during operation, when faced with scenes such as motor starting and switching of heavy-load electrical equipment that urgently require the relay to change the contact state quickly and forcefully, a strong current will flow into the first coil 501 with a relatively thick wire diameter through the first pin 6, and according to Ampere's loop law, the current passes through the first coil 501. When the current is in the air, a magnetic field will be generated around it, and the strength of the magnetic field is proportional to the current. At the same time, according to the principle of electromagnetic induction, a thicker wire has a lower resistance. According to Ohm's law, under the same supply voltage, a larger current can be allowed to pass smoothly, thereby generating a strong and stable magnetic field and forming a strong magnetomotive force. The iron core 3, as a core component with high magnetic permeability, can efficiently gather these divergent magnetic lines of force, guide and constrain the magnetic flux to a predetermined path with high density, and achieve a strong "magnetic concentration" effect; the yoke 4, as a key part of the closed-loop construction of the magnetic circuit, receives the magnetic lines of force passing through the iron core 3, cleverly gathers, regularizes and extends the magnetic circuit, and causes the armature in the magnetic holding relay to be subjected to a strong and precisely directed electromagnetic suction force, driving the armature to move quickly and decisively, realizing high-speed switching of the contacts, and greatly shortening the response time;

[0028] When monitoring the state of the magnetic latching relay, according to Faraday's law of electromagnetic induction, when the environment or the working state of the magnetic latching relay changes, causing the magnetic flux passing through the second coil 502 to change, the second coil 502 will generate an induced electromotive force. Specifically, during the operation of the relay, whether it is a sudden change in the magnetic field caused by the power-on and power-off of the first coil 501, or the position movement of the armature due to the action of the first coil, resulting in a change in the surrounding magnetic field distribution, the magnetic flux passing through the second coil 502 will change accordingly. According to the formula of Faraday's law of electromagnetic induction, as long as the rate of change of the magnetic flux is not zero, the second coil 502 can sensitively generate a corresponding subtle but precise induced electromotive force and The second coil 502 is connected to an externally installed sensor (which may be an electromagnetic induction sensor, a Hall sensor, etc.) through the second pin 7. The sensor can capture, amplify, filter, and perform a series of processing on the weak induced electromotive force generated by the second coil 502 according to the electromagnetic induction principle, thereby accurately capturing, identifying, and transmitting various weak current signals. Since the second coil 502 and the first coil 501 are effectively isolated from each other by the isolation sleeve 8 in terms of physical structure, and are also independent of each other in terms of electrical characteristics, when the first coil 501 carries a large current and generates a strong magnetic field, the electromagnetic environment of the second coil 502 is still relatively stable, ensuring that the weak current signal generated by it is not interfered with, and can independently and accurately complete the signal monitoring and feedback functions;

[0029] In the operation of the entire relay, the first coil 501 is responsible for achieving fast and powerful contact switching actions to meet the needs of high-voltage scenarios; the second coil 502 focuses on the sensing and processing of weak-voltage signals. The two have clear division of labor and operate in a complex and diverse electrical system architecture in a coordinated and orderly manner. From the perspective of multi-functional adaptation, this dual-coil architecture breaks the limitations of the traditional single coil and single function, and greatly broadens the adaptation boundaries of relays in various fields. Whether it is the scene in the industrial manufacturing field where automated production lines have frequent start and stop of high-power drive equipment and require real-time and accurate sensing feedback of the equipment status, or the scene in the smart home ecosystem that takes into account both large-scale electrical appliances High-power on-off control and intelligent module weak-voltage fine control, it can be perfectly embedded and demonstrate excellent versatility.

[0030] Furthermore, the second coil 502 is wound around the periphery of the first coil 501, and an isolation sleeve 8 is provided between the two. The isolation sleeve 8 is provided with a number of convex strips 801 at equal intervals on the contact surface between the first coil 501 and the second coil 502. During operation, when the current shuttles between the first coil 501 and the second coil 502, when the first coil 501 is injected with a large current, a strong alternating magnetic field is immediately generated around it. If the isolation sleeve 8 barrier is missing, the strong magnetic field lines are like a runaway horse, which can easily interfere with the adjacent second coil 502 and seriously interfere with its high-sensitivity and precise sensing operation of small current signals. Similarly, the weak magnetic field changes generated by the second coil 502 when it is working will also be reversely "eroded" and interfered if there is no isolation protection. The isolation sleeve 8 "circles" the two coils independently. , pure electromagnetic environment, and the design of the convex strip 801, in the initial winding assembly stage, relies on the friction between it and the coil, just like a "invisible positioning pile", assisting workers to wind the coil more accurately and steadily, ensuring that each turn of the coil is closely dependent and arranged neatly, and achieving the ideal winding process standard. In addition, the convex strips 801 are evenly arranged to form a number of heat dissipation channels. When the relay is working, the current generates heat through the coil, and the heat is transferred to the isolation sleeve 8 by heat conduction. Due to the raised structure of the convex strip 801, a tiny air gap is left between the isolation sleeve 8 and the coil. These gaps are interconnected to form a heat dissipation channel, which accelerates the dissipation of heat to the surrounding environment, effectively reducing the temperature increase of the coil caused by heat accumulation during long-term operation, maintaining the coil working in a reasonable temperature range, and ensuring its electromagnetic performance is stable.

[0031] Furthermore, the wire rack 1 is provided with a positioning rib 9 for positioning the yoke 4, and the positioning rib 9 is provided with a groove 901 for assembling the yoke 4; during operation and assembly, the operator accurately aligns the yoke 4 with the groove 901 on the positioning rib 9, and the groove 901 is just like a "guide rail slide". With its ingenious tilt angle and adaptive width, a smooth introduction path is "tailor-made" for the yoke 4, and the problem of subtle alignment deviations that are inevitable due to machining tolerances and difficult to avoid in manual assembly is ingeniously overcome. After the yoke 4 is stably in place, the positioning rib 9 tightly embraces and firmly contacts the side of the yoke 4 from multiple dimensions, just like putting a pair of "mechanical shackles" on the yoke 4, strictly limiting its displacement in the plane, firmly "locking" the yoke 4, and comprehensively ensuring its relative position accuracy with the iron core 3, consolidating the foundation of the magnetic circuit structure, and ensuring that the magnetic lines of force are transmitted unimpeded along the preset efficient path.

[0032] Furthermore, riveted parts 301 are provided at both ends of the iron core 3, riveted holes 401 cooperating with the riveted parts 301 are provided on the yoke 4, and riveted chamfers 4011 are provided in the riveted holes 401; during operation, when the yoke 4 and the iron core 3 are fixed, the riveted parts 301 of the iron core 3 are aligned with the riveted holes 401 on the yoke 4, and then precise external force is applied with the help of professional riveting equipment to cause the material of the riveted parts 301 to undergo deformation, tightly fill the riveted holes 401 and the riveted chamfers 4011, and stabilize the connection structure.

[0033] Furthermore, a soft pad 10 is provided on the contact surface where the yoke 4 contacts and cooperates with the armature assembly; during operation, in the cyclic process of the relay's repetitive action, the armature is acted upon by the electromagnetic force and continuously approaches or moves away from the yoke 4. At the moment when the two touch, the soft pad 10 relies on the elastic buffering mechanism to efficiently absorb the collision kinetic energy, and avoids the "erosion" damage to the surface of the component caused by the instantaneous high stress caused by hard contact. When the armature and the yoke 4 are attracted and maintain a "tacit understanding" stage, the soft pad 10 itself has excellent compressible and conformable characteristics, and intelligently and adaptively fills the microscopic uneven "grooves" between the two, deeply optimizes the degree of fit of the contact interface, greatly reduces the air gap, improves the continuity of the magnetic circuit, assists in making the magnetic lines uniform, and effectively suppresses the generation and propagation path of collision noise, significantly improves the acoustic environment of equipment operation, and perfectly meets the rigid demand for use in noise-sensitive application scenarios such as office spaces and residential living areas.

[0034] Furthermore, the assembly hole 2 and the iron core 3 are both matching square structures; during operation, when assembling the magnetic latching relay coil assembly, the square iron core 3 is assembled to the equally square assembly hole 2 on the wire rack 1. Due to the unique geometric characteristics of the square structure, compared with the conventional circular structure, its sides are parallel and perpendicular to each other. During the insertion process, the four sides naturally form a positioning guide reference, and the operator pushes the iron core 3 along the corresponding side of the assembly hole 2. Each side limits the translational freedom of the iron core 3 in the direction perpendicular to the side, effectively avoiding the rotational offset and other adverse conditions of the iron core 3 during the assembly process. In terms of structural stability, the square fitting structure enhances the stability of the iron core 3 in the wire rack 1. When the equipment is faced with vibration and impact during long-term operation, compared with the disadvantages of the round structure that is easy to roll and loosen, the square iron core 3 is firmly "locked" in the assembly hole 2, effectively suppressing its displacement and shaking, ensuring the stability of the magnetic circuit, and reducing In order to solve the problems of magnetic leakage and magnetic resistance change caused by the looseness of the iron core 3, it is ensured that the iron core 3 can enter the predetermined position accurately and straightly. In terms of space utilization and winding advantages, under the condition of the same circumscribed circle diameter, the square assembly hole 2 has better space utilization characteristics than the circular assembly hole 2. There are more "corner" spaces inside the circular assembly 2 that are difficult to fully utilize due to the circular curvature, while the four right angles and relatively regular side walls of the square assembly hole 2 can arrange the winding coils more tightly and regularly. Under the same radial size limit, the number of coil turns that can be wound around the square assembly hole can be increased by about 10% to 15% compared with the circular assembly hole. This not only improves the utilization efficiency of the copper wire and reduces material waste, but also can enhance the magnetic field strength generated by the coil in a limited space, optimize the electromagnetic performance of the relay, and further help to realize the integration of product miniaturization and high performance, and meet the dual demands of modern electrical equipment for compact and efficient components.

[0035] In the description of this specification, the description with reference to the terms "one embodiment", "example", "specific example", etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the present invention. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0036] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments, and the above embodiments and descriptions are only for explaining the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention to be protected.

Claims

1. A high-efficiency coil assembly for a magnetic latching relay, comprising a bobbin (1), an iron core (3) being mounted in a mounting hole (2) on the bobbin (1), and a yoke (4) being further mounted on the bobbin (1), characterized in that: A copper wire group (5) is wound on the wire rack (1), and the copper wire group (5) comprises a first coil (501) for carrying a large current and reacting quickly, and a second coil (502) for sensing the on / off state of the circuit breaker.

2. A magnetic latching relay high efficiency coil assembly according to claim 1, characterized in that: The second coil (502) is wound around the periphery of the first coil (501), and an isolation sleeve (8) is provided between the two, and a plurality of convex strips (801) are equidistantly provided on the isolation sleeve (8) on the contact surface with the first coil (501) and the second coil (502).

3. The high-efficiency coil assembly of a magnetic latching relay according to claim 1, characterized in that: The wire rack (1) is provided with a first pin (6) and a second pin (7) which are electrically connected to the first coil (501) and the second coil (502), respectively.

4. The high-efficiency coil assembly of a magnetic latching relay according to claim 1, characterized in that: The wire rack (1) is provided with a positioning rib (9) for positioning the yoke (4), and the positioning rib (9) is provided with a groove (901) for facilitating the assembly of the yoke (4).

5. The high-efficiency coil assembly of a magnetic latching relay according to claim 1, characterized in that: Riveted portions (301) are provided at both ends of the iron core (3), and riveted holes (401) cooperating with the riveted portions (301) are provided on the yoke (4), and riveted chamfers (4011) are provided in the riveted holes (401).

6. The high-efficiency coil assembly of a magnetic latching relay according to claim 1, characterized in that: A soft pad (10) is provided on the contact surface where the yoke (4) contacts and cooperates with the armature assembly.

7. The high-efficiency coil assembly of a magnetic latching relay according to claim 1, characterized in that: The assembly hole (2) and the iron core (3) are both matching square structures.

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