Mechanically-driven bistable relay

Abstract

The invention belongs to the technical field of relays, and provides a mechanical drive bistable relay, which comprises a cylinder body, a mechanical drive mechanism, an opening and closing mechanism and a piston, and is characterized in that the mechanical drive mechanism, the opening and closing mechanism and the piston are arranged on the cylinder body; the mechanical driving mechanism drives the piston, the piston is driven by the mechanical driving mechanism to reciprocate in the cylinder body, the opening and closing mechanism is controlled to be communicated, and a circuit is controlled to be switched on and off. The novel bistable relay has the advantages of being small in size, high in electrical bearing capacity, high in electrical isolation capacity, good in communication effect and wide in use temperature range, and the novel bistable relay can be manufactured only through precision casting.

Description

Technical Field

[0001] The present invention relates to a mechanically driven bistable relay, in particular to a bistable relay driven by a micro motor, which is applicable to electronic devices that require high electrical connection quality and stable switching states. Background Art

[0002] Relays are the most basic components in electronic and electrical engineering. The current development of relays mainly focuses on optimizing the switching cycle life, switching frequency, volume, etc. of the relays. However, these relays are still insufficient for some special electronic and electrical applications: for example, products such as "intelligent wire harnesses" will integrate hundreds of bistable relays for automatic circuit connection. Such applications require bistable relays to have high electrical connection quality, a sufficiently small volume, electrical isolation, and the ability to retain the connected state (i.e., bistable) when the device is powered off; but have lower requirements for switching cycle life, switching frequency, etc.

[0003] CN118919363A discloses a thermally variable bistable relay and its usage method, which uses a pneumatic method in which the volume of a liquid expands greatly when it boils into a gas, thereby increasing the pressure in the cavity and then pushing the piston to move; it uses the pressure generated when the liquid undergoes a phase change to switch the connected state of the relay. Finally, it can provide a wiring effect equivalent to wire welding connection, and its volume is smaller than the size of a conventional relay.

[0004] It is very suitable for applications with a low switching frequency but high requirements for volume and electrical connection quality;

[0005] However, the pneumatic method has the disadvantages of difficult part processing, complex technology, and air leakage in the cylinder.

[0006] Therefore, in view of the above disclosed patents, we have developed a new type of relay that eliminates the airtight components and can be manufactured only by precision casting. Summary of the Invention

[0007] To solve the problems raised in the above background art, the present invention provides a mechanically driven bistable relay, which is a new type of relay that can achieve fast and precise circuit switch control by utilizing the characteristics of mechanically driven materials and can be manufactured only by precision casting.

[0008] To achieve the above object, the present invention provides the following technical solution: a mechanically driven bistable relay, comprising a cylinder block, a mechanical driving mechanism, an opening and closing mechanism, and a piston. The mechanical driving mechanism, the opening and closing mechanism, and the piston are arranged on the cylinder block; the mechanical driving mechanism drives the piston to reciprocate inside the cylinder block to control the connection of the opening and closing mechanism, thereby realizing the control of the circuit switch.

[0009] The mechanical drive mechanism includes a motor, a screw, a nut, a ball bearing, and a guide rod. One end of the screw is connected to the motor, and the other end is connected to the ball bearing. The outer periphery is sleeved with the nut. The motor and the ball bearing are fixed on the cylinder block. One end of the nut is connected to the piston and reciprocates on the screw.

[0010] The opening and closing mechanism includes tab ears and heating sheets. The heating sheets are fixed on the cylinder block and are in contact with the tab ears. The tab ears are filled with soldering tin inside and are sleeved on the piston.

[0011] The motor is a micro planetary stepping motor. One end of the nut is connected to a support column, and the support column passes through the piston and reciprocates in the traveling space of the cylinder block.

[0012] The tab ears include tab ear one and tab ear two. The reciprocating motion of the piston connects or disconnects tab ear one and tab ear two. The heating sheet is made of ceramic material, and the heating sheet heats the soldering tin to facilitate the reciprocating motion of the piston.

[0013] The heating sheet is connected to electrical contacts, and the electrical contacts provide power for heating the heating sheet. After the electrical contacts are disconnected from the power supply, the piston is fixed on the tab ears by the cooling of the soldering tin.

[0014] The piston is a copper column piston.

[0015] The tab ears are connected with wire terminals, and the wiring terminals are embedded in the tab ears and are externally connected to a circuit.

[0016] The relay adjusts the reciprocating motion of the piston through a PI control system.

[0017] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0018] 1. Strong electrical load-bearing capacity. This relay can adjust its thickness, length, and structural shape parameters to improve the electrical load-bearing capacity. When connected, the relatively thick conductor copper column piston can bear the current, and the contacts in the tab ears are infiltrated by solder, having a very strong electrical load-bearing capacity. Compared with a reed relay, due to the physical property limitations of the reed material itself, it cannot be made large and bear a large current. Compared with a solid-state relay, it generates serious heat when bearing a large current and does not require an additional radiator to ensure the normal operation of the device. Compared with an electromagnetic relay, the contact resistance is relatively high, and the infiltration of solder in the tab ears makes the resistance extremely small when connected.

[0019] 2. Strong electrical isolation ability and bistable state. Isolation mainly means that the controlled circuit will not leak electricity into the control circuit. In the present invention, through the isolation of the cylinder block, the control circuit will not leak electricity into the control circuit.

[0020] 3. The relay of the present invention heats the solder in the tab through a ceramic heating sheet to make the copper column piston reciprocate on the tab to control the on-off. After the solder cools, the copper column piston is also fixed on the tab. This connection effect is equivalent to the wiring effect of wire welding, and it has excellent anti-vibration performance.

[0021] 4. A very wide operating temperature range. In a sub-zero environment, electromagnetic relays are prone to short circuits or inability to turn on or off due to internal condensation or icing. In an overheated environment above 80 degrees Celsius, electromagnetic relays will demagnetize and fail, and solid-state relays may burn out. This mechanical drive bistable relay can work normally below the solder melting point of about 183 degrees Celsius.

[0022] 5. A new type of relay that can be manufactured only by precision casting. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Figure 1 It is a schematic diagram of the relay module of the present invention;

[0024] Figure 2 It is a schematic diagram of the cylinder block of the present invention;

[0025] Figure 3 It is a schematic diagram of the internal structure of the cylinder block of the present invention.

[0026] In the figure: 1. Cylinder block; 101. Traveling space; 2. Mechanical drive structure; 201. Motor; 202. Screw; 203. Nut; 204. Guide rod; 205. Ball bearing; 206. Support column; 3. Opening and closing mechanism; 301. Tab one; 302. Tab two; 303. Heating sheet; 304. Terminal; 305. Electrical contact; 4. Piston. DETAILED DESCRIPTION OF THE INVENTION

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0028] As Figures 1 - 3 shown, the present invention provides a mechanical drive bistable relay, including a cylinder block 1, a mechanical drive mechanism 2, an opening and closing mechanism 3, and a piston 4. The mechanical drive mechanism 2, the opening and closing mechanism 3, and the piston 4 are arranged on the cylinder block 1; the mechanical drive mechanism 2 drives the piston 4 to drive the piston 4 to reciprocate inside the cylinder block, and the piston 4 connects or disconnects the opening and closing mechanism 3 to control the circuit switch; the cylinder block 1 is preferably made of polyimide (PI) material, with high temperature resistance and strong electrical isolation ability.

[0029] The mechanical drive mechanism 2 includes a motor 201, a screw rod 202, a nut 203, a ball bearing 205, and a guide rod 204. One end of the screw rod 202 is connected to the motor 201, and the other end is connected to the ball bearing 205. The outer periphery is sleeved with the nut 203, and the nut 203 is also synchronously sleeved on the guide rod 204. The motor 201 and the ball bearing 205 are fixed on the cylinder block 1. One end of the nut 203 is connected to the piston 4 and reciprocates on the screw rod 202 along the guide rod 204. The motor 201 is a micro planetary stepping motor. One end of the nut 203 is connected to a support column 206, and the support column 206 reciprocates in the traveling space 101 of the cylinder block 1 through the piston 4. The micro planetary stepping motor preferably has an outer diameter of Φ10mm, a length of 15mm (including the reduction gearbox), a holding torque of 0.02 - 0.03 N·m (when the reduction ratio is 5:1), and a step angle of 1.8° (full step). The micro planetary stepping motor is arranged on one side of the cylinder block and is isolated from the tab and the heating sheet 303 through the spatial design of the cylinder block 1.

[0030] The opening and closing mechanism 3 includes a tab and a heating sheet 303. The heating sheet 303 is fixed on the cylinder block 1 and contacts the tab. The tab is filled with solder inside and is sleeved on the piston 4. The tab includes tab one 301 and tab two 302. The reciprocating movement of the piston 4 connects or disconnects tab one 301 and tab two 302. The heating sheet 303 is made of ceramic material. The heating sheet 303 heats the solder to facilitate the reciprocating movement of the piston 4. The heating sheet 303 is preferably an aluminum nitride ceramic-based thick film heating sheet with a power density of 20W / cm 2 , and the response time is shortened to reach the solder melting point within 3 seconds.

[0031] The heating sheet 303 is connected to an electrical contact 305, and the electrical contact 305 provides power for heating the heating sheet 303. After the electrical contact 305 is disconnected from the power supply, the piston 4 is fixed on the tab by the cooling of the solder.

[0032] The piston 4 is a copper column piston. Preferably, the end of the copper column piston is designed with a microgroove array to increase the solder contact area and reduce the contact resistance ≤1mΩ.

[0033] The tab connection terminal 304, and the connection terminal 304 is embedded in the tab and is externally connected to a circuit.

[0034] The relay adjusts the reciprocating movement of the piston 4 through a PI control system.

[0035] Relay working process and physical mechanism:

[0036] 1. Disconnection process (the copper column piston 4 is pushed forward by the motor 201). The motor 201 drives the copper column piston 4 to move forward. The copper column piston 4 forces the ear 1 301 to separate from the ear 2 302, and the circuit is disconnected. When moving forward, the solder state is heated by the ceramic heating element 303 to facilitate the lubrication of the copper column piston 4; after the forward movement ends, the ceramic heating element 303 is not heated, the solder remains solid, and the ear 2 302 is fixed to the copper column piston 4. Moving forward refers to the nut 203 driving the copper column piston 4 away from the motor 201.

[0037] 2. Connection process (the copper column piston 4 is pulled backward by the motor 201). The motor 201 drives the copper column piston 4 to move backward, and the ear 1 301 and the ear 2 302 are connected by the copper column piston 4. Solder state during backward movement, heating stage: The ceramic heating element 303 is powered on and heated to the melting point of the solder (such as 183 °C), the solder liquefies, and the liquid solder fills the microscopic gaps on the contact surface between the ear and the piston 4 under capillary action, providing a lubricating effect; after the backward movement ends, the ceramic heating element 303 is not heated, the solder remains solid, and the ear 1 301, the ear 2 302 and the copper column piston 4 are fixed. Moving backward refers to the nut 203 driving the copper column piston 4 closer to the motor 201.

[0038] After cutting off the heating power supply, the solder solidifies, rigidly fixing the ear to the piston 4 and eliminating the poor contact caused by mechanical vibration. When the solder melts, it acts as a liquid lubricant, reducing the frictional resistance between the ear and the piston 4 and avoiding scratches on the metal surface.

[0039] Solder selection, the melting point needs to be lower than the maximum temperature that the ceramic heating element 303 can withstand. Preferred: Sn63Pb37 (melting point 183 °C).

[0040] Heating power control, ensuring rapid heating to the melting point of the solder and avoiding overheating damage. The power density of the ceramic heating element is greater than 5 W / cm 2 and less than or equal to 20 W / cm 2 .

[0041] Principle of low resistance:

[0042] Maximizing the contact area: The solder fills the gaps on the contact surfaces between the ears and between the ears and the copper column piston 4, making the effective conductive area close to 100%. Oxidation inhibition: The solder layer isolates the air, preventing the formation of metal surface oxide films (such as CuO) and reducing the contact resistance. Interface alloying: The solder forms a eutectic alloy layer (such as Cu6Sn5) with the copper column piston 4, improving the conductivity.

[0043] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variant thereof are intended to cover non-exclusive inclusion, such that a process, method, article or device comprising a series of elements not only includes those elements but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0044] Although the embodiments of the present invention have been shown and described, those of ordinary skill in the art can understand that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A mechanically driven bistable relay, characterized in that: It includes a cylinder body, a mechanical drive mechanism, an opening and closing mechanism, and a piston, wherein the mechanical drive mechanism, the opening and closing mechanism, and the piston are arranged on the cylinder body; the mechanical drive mechanism drives the piston to reciprocate inside the cylinder body to control the connection of the opening and closing mechanism.

2. The mechanically driven bistable relay according to claim 1, characterized in that: The mechanical driving mechanism includes a motor, a screw, a nut, a ball bearing, and a guide rod. One end of the screw is connected to the motor, and the other end is connected to the ball bearing, and the outer periphery is sleeved by a nut; the motor and the ball bearing are fixed on the cylinder body; one end of the nut is connected to the piston and reciprocates on the screw.

3. The mechanically driven bistable relay according to claim 1, characterized in that: The opening and closing mechanism comprises a pole ear and a heating plate. The heating plate is fixed on the cylinder body and contacts the pole ear. The pole ear is filled with solder and is sleeved on the piston.

4. The mechanically driven bistable relay according to claim 2, characterized in that: The motor is a micro planetary stepping motor, one end of the nut is connected to a support column, and the support column passes through the piston and reciprocates in the travel space of the cylinder body.

5. The mechanically driven bistable relay according to claim 3, characterized in that: The pole ears include pole ear 1 and pole ear 2, and the reciprocating motion of the piston connects or disconnects pole ear 1 and pole ear 2; the heating plate is made of ceramic material, and the heating plate heats the soldering to facilitate the reciprocating motion of the piston.

6. The mechanically driven bistable relay according to claim 5, characterized in that: The heating plate is connected to an electric contact, and power is provided for heating the heating plate through the electric contact; after the electric contact is disconnected from the power supply, the piston is cooled and fixed on the pole ear through soldering.

7. The mechanically driven bistable relay according to claim 1, characterized in that: The piston is a copper column piston.

8. The mechanically driven bistable relay according to claim 5, characterized in that: The pole ear is connected to the wire terminal, and the wiring terminal is embedded in the pole ear to connect to the external circuit.

9. The mechanically driven bistable relay according to any one of claims 1 to 8, characterized in that: The relay regulates the reciprocating motion of the piston through a PI control system.

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