An improved relay assembly

Abstract

The application discloses an improved relay assembly, which comprises a shell, an outer cover, an electromagnetic control assembly arranged in the shell and a fastening assembly matched with the electromagnetic control assembly and arranged on the outer cover. The electromagnetic control assembly comprises an I-shaped mounting framework, a static iron core, a magnetic yoke, a moving iron sheet and a coil package. The static iron core is coaxially wrapped in the middle part of the mounting framework. The magnetic yoke extends along one end of the static iron core to the other end of the static iron core around the outer periphery of the mounting framework, and the moving iron sheet is connected with the magnetic yoke. The coil package is located on the outer periphery of the middle part of the mounting framework. The application re-designs the magnetic circuit structure, fixes the static iron core, forms a high-efficiency closed magnetic circuit by using the embedded structure of the magnetic yoke and the moving iron sheet, and no longer depends on the magnetic flux of the thin-wall shell. The magnetic circuit width is increased, and the magnetic circuit efficiency is significantly improved. After power-on, the moving iron sheet can quickly complete the attraction action, and the overall power consumption is greatly reduced.

Description

Technical Field

[0001] This invention belongs to the field of relay technology, and specifically relates to an improved relay assembly. Background Technology

[0002] Relays, as electronic control devices, are widely used in various automated control circuits. The core working principle of existing intermittent relays relies on the magnetic field generated by an energized coil, which attracts the moving core assembly 28 with contacts. This causes the moving contact 26 to retract closer to the fixed contact 27, thus energizing the fixed contacts 27 on both sides and achieving the function of a switch. After de-energization, a spring pushes the moving core assembly 28 back to its original position, moving the moving contact 26 away from the fixed contact 27, thereby breaking the circuit. Figure 11 , Figure 12 As shown.

[0003] In the aforementioned existing relays, the magnetic circuit generated by the coil mainly relies on the thin-walled outer casing to form a loop, resulting in a narrow magnetic circuit width and low magnetic efficiency. Furthermore, to meet the magnetic force required for the moving core assembly 28 to engage, the stationary core requires an additional large-force spring to assist in resetting. The resetting resistance of this spring forces the coil to generate a larger magnetic field to overcome the spring force, resulting in significant wasted energy. This structure not only requires a larger current delivery but also necessitates increasing the number of coil turns to meet operational demands, leading to high coil power consumption and inefficient magnetic circuit design. Actual calculations show that the coil package of existing relays typically weighs over twenty grams, resulting in high material costs.

[0004] Due to low magnetic circuit efficiency and the need to overcome the reset resistance of a large spring, existing relay coils require a large current to generate sufficient magnetic force to engage the moving core assembly 28. Under high current operation, the coil heat generation increases significantly, and the coil is prone to burnout if the energizing time is slightly longer (more than 15-18 minutes), seriously affecting the reliability and service life of the product.

[0005] To prevent components from burning out due to high current, the wiring screws of existing relays need to be made of copper. Copper screws are not only expensive in terms of material cost, but also complex to manufacture. They account for an excessively high proportion of the total product cost, severely compressing profit margins. Summary of the Invention

[0006] This invention addresses the technical shortcomings of existing relays, such as low magnetic circuit efficiency, high coil power consumption, and high cost of wiring screws. It provides an improved relay assembly, aiming to improve magnetic circuit efficiency, reduce coil power consumption and current carrying capacity by redesigning the magnetic circuit structure of the electromagnetic control components, thereby reducing manufacturing costs.

[0007] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: An improved relay assembly includes a housing, an outer cover, an electromagnetic control component disposed within the housing, and a fastening component that cooperates with the electromagnetic control component and is mounted on the outer cover.

[0008] The electromagnetic control assembly includes an I-shaped mounting frame, a stationary iron core, a magnetic yoke, a moving iron plate, and a coil coil. The stationary iron core is coaxially wrapped around the center of the mounting frame. The magnetic yoke extends along one end of the stationary iron core around the outer periphery of the mounting frame to the other end of the stationary iron core, and the moving iron plate is connected to the magnetic yoke. The coil coil is located on the outer periphery of the center of the mounting frame.

[0009] The magnetic yoke and the moving iron piece have an interlocking structure, which allows them to maintain a stable relative sliding, so that when the coil is energized, the moving iron piece moves vertically toward or away from the stationary iron core along the edge of the magnetic yoke.

[0010] The same moving spring is riveted to the outer side of both the magnetic yoke and the moving iron plate.

[0011] The outer side of the coil has a first connecting plate and a second connecting plate connected to the fastening assembly. The ends of the first connecting plate and the second connecting plate are installed by cooperating with the outer cover, the other end of the first connecting plate is connected to the magnetic yoke, and the other end of the second connecting plate is cooperating with the movable spring.

[0012] Furthermore, each of the magnetic yokes and the moving iron plate has a U-shaped notch at the connection point, and a limiting contact is placed inside the U-shaped notch.

[0013] Furthermore, the magnetic yoke and the moving iron plate are made of iron.

[0014] Furthermore, a metal braided strip is provided between the magnetic yoke and the movable spring, with both ends of the metal braided strip connected to the magnetic yoke and the movable spring, respectively.

[0015] Furthermore, grounding terminals and coil terminals are respectively inserted into the mounting frame. The inlet and outlet wires of the enameled wire of the coil are connected to the corresponding grounding terminals and coil terminals, respectively, and the enameled wires are led out to the outside of the relay and / or the inner wall of the housing for electrical connection through the grounding terminals and coil terminals.

[0016] Furthermore, the magnetic yoke is generally L-shaped, with a pin at its upper end that mates with the outer cover for installation.

[0017] Furthermore, the fastening assembly includes screws, nuts, and washers.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention redesigns the magnetic circuit structure, fixing the fixed iron core and utilizing the interlocking structure of the magnetic yoke and the moving iron piece to form a highly efficient closed magnetic circuit. It no longer relies on the thin-walled outer shell for magnetic transfer, increasing the magnetic circuit width and significantly improving its efficiency. Upon energization, the moving iron piece can quickly complete the attraction action, resulting in a substantial reduction in overall power consumption.

[0019] Due to the improved magnetic circuit efficiency, the weight of the coil can be reduced from over twenty grams in the original design to 3-4 grams, significantly reducing the amount of copper used and lowering material costs and overall product weight. The operating current is also greatly reduced, eliminating the need for high-cost copper screws; iron or copper-plated screws can be used instead, resulting in a substantial decrease in unit cost.

[0020] Compared to existing relays, since there is no need to overcome the reset resistance of a large spring, the coil operating current is significantly reduced (to only a few tenths of an ampere), heat generation is reduced, and the coil is less likely to burn out under continuous energizing conditions. Attached Figure Description

[0021] Figure 1 A three-dimensional structural diagram illustrating a specific embodiment of the present invention; Figure 2 This is a schematic diagram illustrating the exploded structure of a specific embodiment of the present invention; Figure 3 A top view diagram illustrating a specific embodiment of the present invention; Figure 4 for Figure 3 Schematic diagram of the cross-sectional structure of AA; Figure 5 for Figure 3 Schematic diagram of the cross-sectional structure of BB; Figure 6 This is a bottom view diagram illustrating a specific embodiment of the present invention after removing the outer shell; Figure 7 This is a three-dimensional structural diagram (view 1) showing the specific embodiment of the present invention after the outer shell has been removed. Figure 8 This is a three-dimensional structural diagram (perspective two) showing the specific embodiment of the present invention after the outer shell has been removed. Figure 9 A three-dimensional structural diagram of the electromagnetic control component is provided to illustrate a specific embodiment of the present invention; Figure 10 This is a three-dimensional structural diagram illustrating the magnetic yoke and moving iron plate in a specific embodiment of the present invention; Figure 11 This is a cross-sectional view of an existing relay. Figure 12 This is a partial three-dimensional structural diagram of an existing relay; The reference numerals in the accompanying drawings include: 1. Outer shell 2. Mounting frame 3. Stationary iron core 4. Magnetic yoke 5. Moving iron plate 6. Coil coil 7. Moving spring 8. First connecting plate 9. Second connecting plate 10. U-shaped notch 11. Limiting contact 12. Concave surface 13. Stop ear 14. Metal braided strap 15. Grounding terminal 16. Coil wiring terminal 17. Plug 18. Fastening assembly 19. Silver contact 22. Moving contact 26. Fixed contact 27. Moving core assembly 28. Detailed Implementation

[0022] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0023] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this patent. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product.

[0024] like Figure 1 - Figure 12 As shown, the present invention provides an improved relay assembly, including a housing 1, an outer cover 2, an electromagnetic control component housed within the housing 1, and a fastening component 19 that cooperates with the electromagnetic control component and is mounted on the outer cover 2. The housing 1 and the outer cover 2 together constitute the external protective structure of the relay.

[0025] like Figures 3 to 10 As shown, the electromagnetic control component is the core part of the present invention, including an I-shaped mounting frame 3, a stationary iron core 4, a magnetic yoke 5, a moving iron sheet 6, and a coil coil 7.

[0026] The mounting frame 3 is made of insulating plastic, with a stationary iron core 4 coaxially wrapped around its center. The magnetic yoke 5 extends from one end of the stationary iron core 4 around the outer periphery of the mounting frame 3 to the other end, and the moving iron plate 6 is connected to the magnetic yoke 5. The coil coil 7 is located on the outer periphery of the center of the mounting frame 3 and is made of enameled wire. Actual testing shows that the coil coil 7 in this embodiment weighs only 3-4 grams, far lower than the coil weight of over 20 grams in existing similar products, significantly reducing material costs.

[0027] The magnetic yoke 5 and the moving iron piece 6 have an interlocking structure, which allows them to maintain a stable relative sliding, so that when the coil 7 is energized, the moving iron piece 6 moves vertically toward or away from the stationary iron core 4 along the edge of the magnetic yoke 5.

[0028] Specifically, such as Figure 4As shown, the magnetic yoke 5 and the moving iron plate 6 each have a U-shaped notch 11 at their connection points, and a limiting contact 12 placed inside the U-shaped notch 11. The limiting contact 12 has a concave surface 13 on the side near the magnetic yoke 5, and the magnetic yoke 5 is inserted vertically into the concave surface 13. The moving iron plate 6 has a stop ear 14 near the concave surface 13 that can cooperate with the side of the magnetic yoke 5. The thickness of the magnetic yoke 5 is less than the width of the concave surface 13, which restricts the lateral freedom of the moving iron plate 6, allowing it to move only along the depth direction of the U-shaped notch 11 of the magnetic yoke 5, ensuring the smoothness and accuracy of the movement of the moving iron plate 6. Both the magnetic yoke 5 and the moving iron plate 6 are made of iron to ensure that the magnetic field performance meets the requirements. According to actual testing, in this embodiment, because the magnetic circuit uses a thicker iron magnetic yoke 5 for magnetic conduction, the magnetic conduction efficiency is significantly higher than that of the traditional scheme that relies on a thin-walled shell for magnetic conduction. After being energized, the moving iron plate 6 can quickly complete the attraction action, and the overall power consumption is lower.

[0029] The same moving spring 8 is riveted to the outer side of both the magnetic yoke 5 and the moving iron plate 6.

[0030] The moving spring 8 is made of phosphor bronze, which has both good conductivity and excellent elasticity. It can drive the moving iron piece 6 to reset itself after the coil winding 7 is de-energized. In this embodiment, the moving spring 8 is simultaneously fixed to the outer side of the magnetic yoke 5 and the moving iron piece 6 by riveting, ensuring reliable connection.

[0031] The outer side of the coil coil 7 has a first connecting plate 9 and a second connecting plate 10 connected to a fastening assembly. The ends of the first connecting plate 9 and the second connecting plate 10 are fixed by engaging with the outer cover 2, wherein one end of the first connecting plate 9 and the second connecting plate 10 extends outside the outer cover 2 for connection with the fastening assembly. The other end of the first connecting plate 9 is connected to the magnetic yoke 5, and the other end of the second connecting plate 10 engages with the movable spring 8.

[0032] At least one set of silver contacts 22 are provided on the contact surfaces of the ends of the movable spring 8 and the second connecting plate 10. Specifically, the inner surface of the end of the movable spring 8 is provided with a first silver contact, and the outer surface of the end of the second connecting plate 10 is provided with a second silver contact in a position opposite to it, and the two are arranged opposite to each other.

[0033] Because the contact resistance of silver is much lower than that of copper, it effectively reduces the contact resistance between the moving spring 8 and the second connecting plate 10, minimizing heat generation and arc erosion caused by excessive resistance at the contact surface during energization. This significantly extends the electrical life of the relay. Actual testing shows that using silver contacts 22 increases the relay's electrical life to 100,000 to 1 million cycles under non-overload conditions, far exceeding the 10,000-cycle lifespan of traditional relays using copper contacts 26 and 27. This represents an improvement in reliability by more than an order of magnitude. Furthermore, lower contact resistance means less heat generation at the contacts under the same current conditions, further reducing the risk of product failure.

[0034] In this relay design, when the coil 7 is energized, a magnetic field is generated. The magnetic circuit forms a closed loop through the stationary iron core 4, the magnetic yoke 5, and the moving iron piece 6. The magnetic field is conducted to the moving iron piece 6 via the magnetic yoke 5, forming a complete magnetic circuit. Under the action of magnetic force, the moving iron piece 6 moves laterally (closer to the stationary iron core 4) along the depth direction of the U-shaped notch 11 of the magnetic yoke 5, causing the moving spring 8 to bend. This causes the silver contact 22 at the end of the moving spring 8 to abut against the silver contact 22 at the end of the second connecting plate 10, thus achieving conduction between the first connecting plate 9 and the second connecting plate 10, and energizing the external wires connected to the fastening assembly 19.

[0035] When the coil 7 is de-energized, the magnetic field disappears. The bent moving spring 8, relying on its own elasticity, drives the moving iron piece 6 to move away from the stationary iron core 4 along the U-shaped notch 11 of the magnetic yoke 5 and back to its original position. The silver contact 22 at the end of the moving spring 8 is separated from the silver contact 22 at the end of the second connecting plate 10, and the first connecting plate 9 is disconnected from the second connecting plate 10.

[0036] Compared to existing relays that rely on the retraction of the moving core assembly 28 and the moving contact 26 to approach the fixed contact 27 to achieve conduction, this invention uses the linkage design of the moving iron piece 6 and the moving spring 8 to allow the bending action of the moving spring 8 to directly drive the silver contact 22 to contact and conduct with the silver contact 22 of the second connecting plate 10. This eliminates the large elastic spring reset element in the traditional structure, reduces intermediate transmission links, makes the structure more compact, and provides a faster response. At the same time, it avoids the risk of failure due to spring fatigue.

[0037] Preferably, a metal braided strip 15 (preferably copper braided strip) is provided between the magnetic yoke 5 and the moving spring 8. The two ends of the metal braided strip 15 are connected to the magnetic yoke 5 and the moving spring 8 respectively (e.g., by spot welding). The function of the metal braided strip 15 is to shunt the current, which is equivalent to increasing the effective conductive area of ​​the moving spring 8, reducing the resistance, and enabling the relay to be suitable for high-voltage and high-current operating scenarios.

[0038] like Figure 2 , Figure 4 , Figure 5 , Figure 8 As shown, a grounding terminal 16 and a coil terminal 17 are also inserted into the mounting frame 3. The inlet and outlet wires of the enameled wire of the coil coil 7 are connected to the corresponding grounding terminal 16 and coil terminal 17, respectively, and the enameled wire is led out to the outside of the relay and / or the inner wall of the housing 1 through the grounding terminal 16 and the coil terminal 17 for electrical connection.

[0039] The external control component triggers control information to activate the electromagnetic control assembly via the grounding terminal 16 and / or the coil terminal 17, thereby triggering the connection and disconnection of the first connecting plate 9 and the second connecting plate 10, thus realizing the connection and disconnection of the external cable.

[0040] The magnetic yoke 5 is generally L-shaped, and its upper end is provided with a pin 18 that can be installed with the outer cover 2, which facilitates the assembly and positioning of the electromagnetic control components and the outer cover 2.

[0041] Fastening assembly 19 includes screws, nuts, and washers, used to connect external cables to the relay. Due to the improved magnetic circuit efficiency and reduced operating current of this invention, iron screws or copper-plated screws can be used instead of traditional copper screws, significantly reducing material costs while maintaining conductivity. Actual testing shows that the cost of a single copper-plated iron screw is only 1-2 cents, compared to approximately 7-9 cents per screw for a traditional pure copper screw, saving more than 1 yuan per relay. Furthermore, because the operating current is much lower than that of traditional structures, the coil winding 7 will not burn out even with continuous energization.

[0042] It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.

Claims

1. An improved relay assembly, comprising a housing (1), an outer cover (2), an electromagnetic control component disposed within the housing (1), and a fastening component (19), characterized in that: The electromagnetic control assembly includes an I-shaped mounting frame (3), a stationary iron core (4), a magnetic yoke (5), a moving iron plate (6), a coil coil (7), and a moving spring plate (8). The mounting frame (3) is coaxially wrapped with the stationary iron core (4) in the middle. The magnetic yoke (5) extends along one end of the stationary iron core (4) around the outer periphery of the mounting frame (3) to the other end of the stationary iron core (4). The moving iron piece (6) is connected to the magnetic yoke (5). The magnetic yoke (5) and the moving iron piece (6) have an interlocking structure, which can maintain a stable relative sliding so that the moving iron piece (6) moves along the edge of the magnetic yoke (5) closer to or further away from the stationary iron core (4). The same moving spring (8) is riveted to the outer side of both the magnetic yoke (5) and the moving iron plate (6).

2. The improved relay assembly according to claim 1, characterized in that: The fitting structure includes a U-shaped notch (11) on the magnetic yoke (5) and a limiting contact (12) on the moving iron plate (6) that cooperates with the inside of the U-shaped notch (11).

3. The improved relay assembly according to claim 2, characterized in that: The limiting contact (12) has a concave surface (13) on the side near the magnetic yoke (5), and the magnetic yoke (5) is vertically inserted into the concave surface (13). The moving iron plate (6) has a stop ear (14) near the concave surface (13) that cooperates with the side of the magnetic yoke (5).

4. The improved relay assembly according to any one of claims 1 to 3, characterized in that: The outer side of the coil (7) has a first connecting plate (9) and a second connecting plate (10) connected to the fastening assembly (19). The first connecting plate (9) is connected to the magnetic yoke (5), and the second connecting plate (10) is engaged with the moving spring (8).

5. The improved relay assembly according to claim 4, characterized in that: At least one set of silver contacts (22) are provided on the contact surfaces of the end of the moving spring (8) and the end of the second connecting plate (10) respectively.

6. The improved relay assembly according to claim 1, characterized in that: A metal braided strip (15) is also provided between the magnetic yoke (5) and the movable spring (8), and the two ends of the metal braided strip (15) are respectively connected to the magnetic yoke (5) and the movable spring (8).

7. The improved relay assembly according to claim 1, characterized in that: The mounting frame (3) is also equipped with a grounding terminal (16) and a coil wiring terminal (17).

8. The improved relay assembly according to claim 1, characterized in that: The magnetic yoke (5) is L-shaped, and the upper end of the magnetic yoke (5) is provided with a pin (18) that is installed in conjunction with the outer cover (2).

9. The improved relay assembly according to claim 1, characterized in that: The fastening assembly (19) includes iron screws or copper-plated screws.

10. The improved relay assembly according to claim 1, characterized in that: The material of the moving spring (8) is phosphor bronze.

Images