Coil assembly and electromagnetic relay

Abstract

The utility model discloses a coil assembly and an electromagnetic relay, the coil assembly comprises a coil rack and an iron core arranged in the coil rack, the coil rack comprises two flange parts and a winding part arranged between the two flange parts; the cross section of the outer peripheral surface of the winding part is non-circular, the outer peripheral surface of the winding part comprises a plurality of outer cambered surfaces which are distributed at intervals in the circumferential direction of the winding part, and each outer cambered surface protrudes outwards; the number of the iron cores is multiple, the multiple iron cores are respectively in a rod shape, and the multiple iron cores are parallel to one another. Under the condition that the space size of the relay is small, the problems of winding size, electromagnetic attraction, enameled wire cost, iron core cost and the like of the coil rack can be considered, the overall cost of the relay is reduced, and the electromagnetic attraction of the magnetic circuit part of the relay is ensured to be large enough.

Description

Technical Field

[0001] This utility model relates to the field of relay technology, and in particular to a coil assembly and an electromagnetic relay. Background Technology

[0002] A relay mainly consists of a contact part and a coil assembly. The coil provides the electromagnetic attraction force, while the contact part provides the reaction force. The degree of matching between the electromagnetic attraction force and the reaction force of the spring directly affects the electrical durability cycles of the relay. Therefore, as the source of the attraction force, the rationality of the coil structure has a significant impact on the attraction force value. At the same time, the coil structure also directly affects the size of the enameled wire winding, meaning that different coil structures have significantly different costs. Therefore, the coil cost cannot be ignored in the overall cost of the relay. Optimizing the coil structure is essential to obtaining the best electromagnetic attraction force and the optimal cost.

[0003] The coil structure is determined by the shape of the winding portion of the coil frame. Currently, the cross-section of the outer circumference of the winding portion of the coil frame is generally a single circle or square. The iron core located in the coil frame is also a single circular or square iron core, or it may be composed of several square sheet-like iron cores stacked together. With the same core cross-sectional area, a circular iron core has a smaller circumference than a square iron core, allowing for more turns of the same length of enameled wire, resulting in a larger ampere-turns (IN) electromagnetic attraction. The finished coil is also closer to a circle, with a winding diameter of D. For a square iron core, after the coil is wound, its winding length L and width W are such that the diameter D of a circular winding with the same length of enameled wire falls between L and W. Therefore, in situations where the internal space of the relay is limited, a circular iron core may not be suitable. When space is limited, existing technical solutions use square iron cores. The coils with square iron cores are highly adaptable to the internal space of the relay, but their disadvantages are low utilization of enameled wire, high coil cost, and relatively large long side of the winding. At the same time, square iron core parts are sheet metal parts, which have low material utilization and high part processing costs, thus further increasing the cost of the relay. Utility Model Content

[0004] This utility model addresses the technical problems existing in the prior art by providing a coil assembly and an electromagnetic relay, which can take into account issues such as coil winding size, electromagnetic attraction, coil cost, and iron core cost.

[0005] The technical solution adopted by this utility model to solve its technical problem is: a coil assembly, including a coil frame and an iron core disposed in the coil frame. The coil frame includes two flange portions and a winding portion disposed between the two flange portions. The cross-section of the outer peripheral surface of the winding portion is non-circular, and the outer peripheral surface of the winding portion includes a plurality of outer arc surfaces distributed at intervals along its circumference, each outer arc surface protruding outward. The iron core is provided in a plurality of forms, each iron core being rod-shaped and parallel to each other.

[0006] In a preferred embodiment, the plurality of iron cores are arranged compactly together, such that each iron core is in contact with the side of an adjacent iron core.

[0007] In a preferred embodiment, there are at least three iron cores, each of which is adjacent to and in contact with at least two other iron cores.

[0008] In a preferred embodiment, the inner circumferential surface of the winding portion includes a plurality of inner arc surfaces that are spaced apart along its circumference and correspond one-to-one with the plurality of outer arc surfaces. Each inner arc surface protrudes outward, and an iron core is disposed on the inner side of each inner arc surface. Each inner arc surface is adapted to contact the side of the corresponding iron core or is in a gap fit.

[0009] In a preferred embodiment, the central angle of each inner arc surface is greater than or equal to 180°, and a transition arc surface is provided between adjacent inner arc surfaces, the transition arc surface protruding inward and located between two adjacent iron cores; or, the central angle of each inner arc surface is less than 180°, and an inner straight surface is provided between adjacent inner arc surfaces, the inner straight surface smoothly transitioning with its adjacent inner arc surface.

[0010] In a preferred embodiment, an outer straight surface is provided between each pair of adjacent outer arc surfaces, and the outer straight surface smoothly transitions with the adjacent outer arc surface.

[0011] In a preferred embodiment, the core has a circular cross-section; the core includes two ends and a core body located between the two ends, the two ends being located outside the winding portion of the coil frame, and at least one end having a diameter smaller than the diameter of the core body.

[0012] In a preferred embodiment, the winding portion is wound with a coil; it also includes a yoke connected to the plurality of iron cores; the yoke is fitted with an armature portion.

[0013] In a preferred embodiment, the yoke is L-shaped, and there are two yokes. One side of each yoke is respectively fitted to both ends of the coil frame in the axial direction. One end of each of the plurality of iron cores is fixedly connected to one side of one of the yokes, and the other end of each of the plurality of iron cores is fixedly connected to one side of the other yoke. The other sides of the two yokes are located on the same side of the coil frame and are arranged opposite to each other. The armature portion is rotatably arranged and is I-shaped. The other sides of the two yokes are respectively fitted to the recesses on both sides of the armature portion.

[0014] This utility model also provides an electromagnetic relay, including the coil assembly as described above.

[0015] Compared with the prior art, the present invention has the following beneficial effects:

[0016] 1. Because the cross-section of the outer circumferential surface of the winding section is non-circular, and the outer circumferential surface includes multiple outer arc surfaces spaced apart along its circumference, each protruding outward, this structure of the coil frame of this invention is highly adaptable to the internal space dimensions of the relay, which is more conducive to reducing the space occupied. Compared with a coil frame whose outer circumferential surface of the winding section has a square cross-section, more turns of enameled wire can be wound with the same iron core cross-sectional area and the same length, thereby improving the utilization rate of the enameled wire and increasing the electromagnetic attraction. In addition, this invention uses multiple iron cores, each rod-shaped and parallel to each other, allowing multiple iron cores to be matched with the winding section of the coil frame, and eliminating the need for die stamping to form the iron cores, thus reducing the processing cost of the iron cores. Therefore, this invention, with a small relay space, can balance the winding size of the coil frame, electromagnetic attraction, enameled wire cost, and iron core cost, which is beneficial to reducing the overall cost of the relay while ensuring that the electromagnetic attraction of the relay's magnetic circuit is sufficiently large.

[0017] 2. Multiple iron cores are arranged compactly together, so that each iron core touches the side of the adjacent iron core, which helps to reduce the overall space size of the coil frame.

[0018] 3. The inner circumferential surface of the winding section includes multiple inner arc surfaces that are spaced apart along its circumference and correspond one-to-one with the multiple outer arc surfaces. Each inner arc surface protrudes outward, and an iron core is disposed on the inner side of each inner arc surface. Each inner arc surface is adapted to contact the side of the corresponding iron core or is in a gap fit. On the one hand, this can further reduce the space size of the entire coil frame, and on the other hand, it can make the coil wound on the winding section better compatible with the iron core, thereby improving the magnetization effect of the iron core.

[0019] 4. The central angle of each inner arc surface is greater than or equal to 180°, and a transition arc surface is provided between adjacent inner arc surfaces. The transition arc surface protrudes inward and is located between two adjacent iron cores. On the one hand, it can improve the degree of envelopment of the iron core by the inner arc surface. On the other hand, it can make the local wall thickness of the winding part larger, which is conducive to improving the strength of the winding part and making the winding part less prone to deformation or even damage during the winding process.

[0020] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments; however, the coil assembly and electromagnetic relay of the present invention are not limited to the embodiments. Attached Figure Description

[0021] Figure 1 This is a three-dimensional structural schematic diagram of the coil assembly of this utility model (excluding the armature part);

[0022] Figure 2 This is a front view of the coil frame of this utility model according to embodiment;

[0023] Figure 3 This is a three-dimensional structural schematic diagram of the coil frame of a utility model according to an embodiment;

[0024] Figure 4 This is a top view of the coil frame of a utility model according to an embodiment;

[0025] Figure 5 This is a three-dimensional structural schematic diagram of the iron core of a utility model, as shown in the embodiment.

[0026] Figure 6 This is a cross-sectional view of a coil assembly of a utility model according to an embodiment;

[0027] Figure 7 This is a three-dimensional structural schematic diagram (including the armature part) of a coil assembly of a utility model according to an embodiment;

[0028] Figure 8 This is a three-dimensional structural schematic diagram of an electromagnetic relay of the present invention, as described in the embodiment.

[0029] Figure 9 This is a cross-sectional view of an electromagnetic relay of the present invention, as described in the embodiment.

[0030] Figure 10 This is a cross-sectional view (showing a portion) of the coil assembly of this utility model in Embodiment 2;

[0031] Figure 11 This is a cross-sectional view (showing a portion) of the coil assembly of this utility model in Embodiment 3;

[0032] In the diagram, 1. Coil frame; 11. Flange; 12. Winding section; 121. Outer arc surface; 122. Inner arc surface; 123. Transition arc surface; 124. Outer straight surface; 125. Inner straight surface; 2. Iron core; 21. Iron core body; 22. End; 3. Coil; 4. Yoke; 5. Armature section; 51. Insulator; 52. Armature; 53. Permanent magnet; 6. Base; 7. Moving spring section; 71. Moving spring plate; 72. Moving spring lead-out plate; 73. Moving contact; 8. Stationary spring section; 81. Stationary spring plate; 82. Stationary contact; 9. Push clip. Detailed Implementation

[0033] Example 1

[0034] Please see Figures 1-7 As shown, a coil assembly of this utility model includes a coil frame 1 and iron cores 2 disposed in the coil frame 1. The coil frame 1 includes two flange portions 11 and a winding portion 12 disposed between the two flange portions 11, with a coil 3 wound on the winding portion 12. The cross-section of the outer peripheral surface of the winding portion 12 is non-circular, and the outer peripheral surface of the winding portion 12 includes a plurality of outer arc surfaces 121 distributed circumferentially, each outer arc surface 121 protruding outward. There are multiple iron cores 2, each of which is rod-shaped and parallel to each other. In the description of this utility model, unless otherwise stated, "multiple" means two or more.

[0035] Multiple iron cores 2 are respectively inserted into the coil frame 1, and each iron core 2 extends along the axial direction of the coil frame 1. The multiple iron cores 2 are arranged compactly together, such that each iron core 2 is in contact with the side of an adjacent iron core 2. Preferably, there are at least three iron cores 2, and each iron core 2 is adjacent to and in contact with at least two iron cores 2. In this embodiment, three iron cores 2 are used as an example, so the three iron cores 2 are arranged in a triangular distribution. In other embodiments, there are two iron cores 2.

[0036] like Figure 2 , Figure 3 As shown, the inner circumferential surface of the winding portion 12 includes a plurality of inner arc surfaces 122 distributed circumferentially and corresponding to the plurality of outer arc surfaces 121 in one-to-one. Each inner arc surface 122 protrudes outward, and an iron core 2 is disposed on the inner side of each inner arc surface 122. Each inner arc surface 122 is adapted to contact the side of the corresponding iron core 2 or is in a gap fit. Therefore, the part of the side of the iron core 2 that contacts the inner arc surface 122 is also an arc surface. Specifically, in this embodiment, the cross-section of the iron core 2 is circular.

[0037] In this embodiment, the central angle of each inner arc surface 122 is greater than or equal to 180°, and a transition arc surface 123 is provided between adjacent inner arc surfaces 122. The transition arc surface 123 protrudes inward and is located between two adjacent iron cores 2. This not only improves the degree of wrapping of the iron core 2 by the inner arc surface 122, but also allows for a larger local wall thickness of the winding portion 12, thereby improving the strength of the winding portion 12 and making it less prone to deformation or even damage during winding. In this embodiment, "outward" refers to the direction outside the coil frame 1, and "inward" refers to the direction inside the coil frame 1.

[0038] In this embodiment, an outer straight surface 124 is provided between each pair of adjacent outer arc surfaces 121, and the outer straight surface 124 smoothly transitions with its adjacent outer arc surface 121. Since there are three iron cores 2, the outer peripheral surface of the winding part 12 has a total of three outer arc surfaces 121 and three outer straight surfaces 124, and the inner peripheral surface of the winding part 12 has a total of three inner arc surfaces 122 and three transition arc surfaces 123.

[0039] like Figure 5 As shown, the iron core 2 includes two ends 22 and an iron core body 21 located between the two ends 22. The two ends 22 are respectively located outside the winding portion 12 of the coil frame 1, and the diameter of at least one end 22 is smaller than the diameter of the iron core body 21. Specifically, in this embodiment, the two ends 22 of the iron core 2 are respectively smaller than the diameter of the iron core body 21, but it is not limited to this. In other embodiments, only one end of the iron core is smaller than the diameter of the iron core body. The end 22 with a diameter smaller than that of the iron core body 21 can be used to rivet the yoke, and the step formed between the end 22 and the iron core body 21 can be used to support and limit the yoke.

[0040] This utility model also includes a yoke 4, which is connected to multiple iron cores 2 and has an armature portion 5. Specifically, the yoke 4 is L-shaped, and there are two yokes 4. One side of each of the two yokes 4 is respectively fitted to both ends of the coil frame 1 in the axial direction. One end of each of the multiple iron cores 2 is fixedly connected to one side of one of the yokes 4 by riveting or welding, and the other end of each of the multiple iron cores 2 is fixedly connected to one side of the other yoke 4 by riveting or welding. The other sides of the two yokes 4 are located on the same side of the coil frame 1 and are arranged opposite each other. The armature portion 5 is rotatably arranged and is approximately I-shaped. The other sides of the two yokes 4 are respectively fitted to the recesses on both sides of the armature portion 5. In other embodiments, the yoke 4 is set as one, and the yoke 4 is L-shaped. One side of the yoke 4 is located at one end of the coil frame 1 and is fixedly connected to one end of multiple iron cores 2. The other side of the yoke 4 is located outside the coil frame 1 and extends to the other end of the coil frame 1. The armature part 5 is oscillatingly set at the knife edge set on the other side of the yoke 4.

[0041] This invention discloses a coil assembly in which the outer peripheral surface of the winding portion 12 of the coil frame 1 has both multiple outer arc surfaces 121 and multiple outer straight surfaces 124. Therefore, the coil frame 1 of this invention combines the advantages of the two existing coil frame designs, making it highly adaptable to the internal space dimensions of the relay and helping to reduce space occupation. Furthermore, compared with existing coil frames where the outer peripheral surface of the winding portion has a square cross-section, more turns of enameled wire can be wound with the same cross-sectional area and length, thereby improving the utilization rate of the enameled wire and thus enhancing electromagnetic attraction. In addition, this invention provides multiple iron cores 2, which can be matched with the structure of the winding portion 12, ensuring a large overall cross-sectional magnetic conductive area for the multiple iron cores 2, thereby improving magnetic conductivity. In particular, the iron cores 2 are rod-shaped, eliminating the need for die stamping and forming, thus reducing the processing cost of the iron cores 2. Therefore, this utility model can take into account the issues of coil frame 1 winding size, electromagnetic attraction, enameled wire cost and iron core 2 cost when the relay space size is small. It is beneficial to reduce the overall cost of the relay and ensure that the electromagnetic attraction of the relay magnetic circuit part is large enough.

[0042] Please see Figures 1-9 As shown, an electromagnetic relay of this utility model includes a coil assembly as described above. The electromagnetic relay of this utility model also includes a base 6, a moving spring portion 7, and a stationary spring portion 8. The moving spring portion 7 includes an elastically deformable moving spring piece 71, a moving spring lead-out piece 72, and a moving contact 73. The lower end of the moving spring lead-out piece 72 is inserted into the base 6. The upper end of the moving spring piece 71 is fixedly connected to the upper end of the moving spring lead-out piece 72 by riveting. The moving contact 73 is disposed on the moving spring piece 71 and faces away from the moving spring lead-out piece 72. The stationary spring portion 8 includes a stationary spring piece 81 and a stationary contact 82. The lower end of the stationary spring piece 81 is inserted into the base 6, and the stationary contact 82 is disposed at the upper end of the stationary spring piece 81, which is opposite to the moving contact 73. The armature portion 5 is rotatably connected to the base 6 and connected to the moving spring piece 71 of the moving spring portion 7 via a push clip 9. The armature portion 5 specifically includes an insulating member 51, two armatures 52 disposed within the insulating member 51, and a permanent magnet 53 sandwiched between the two armatures 52. Therefore, this utility model constitutes a magnetic latching relay, but the type of relay of this utility model is not limited to this.

[0043] Example 2

[0044] Please see Figure 10 As shown, the coil assembly and electromagnetic relay of this utility model differ from the first embodiment described above in that: there are four iron cores 2, and the four iron cores 2 are distributed in a parallelogram shape. Correspondingly, the cross-section of the winding portion 12 is approximately a parallelogram shape. In other embodiments, the four iron cores 2 are distributed in a rectangular shape.

[0045] In this embodiment, the central angle of each inner arc surface 122 is less than 180°, and an inner straight surface 125 is provided between adjacent inner arc surfaces 122, which smoothly transitions with its adjacent inner arc surface 122. Therefore, in this embodiment, the outer peripheral surface of the winding portion 12 includes four outer arc surfaces 121 and four outer straight surfaces 124, and the inner peripheral surface of the winding portion 12 includes four inner arc surfaces 122 and four inner straight surfaces 125.

[0046] Example 3

[0047] Please see Figure 8 As shown, the coil assembly of this utility model differs from any of the above embodiments in that: there are five iron cores 2, and the five iron cores 2 are distributed in an isosceles trapezoidal shape. Therefore, the cross-section of the winding part 12 is approximately an isosceles trapezoidal.

[0048] In this embodiment, the central angle of each inner arc surface 122 is less than 180°, and an inner straight surface 125 is provided between adjacent inner arc surfaces 122, which smoothly transitions with its adjacent inner arc surface 122. Therefore, in this embodiment, the outer peripheral surface of the winding portion 12 includes five outer arc surfaces 121 and four or five outer straight surfaces 124, and the inner peripheral surface of the winding portion 12 includes five inner arc surfaces 122 and five inner straight surfaces 125.

[0049] The present invention relates to a coil assembly and an electromagnetic relay. The parts not described herein are the same as or can be implemented using existing technologies.

[0050] The above embodiments are only used to further illustrate a coil assembly and electromagnetic relay of the present invention. However, the present invention is not limited to the embodiments. Any simple modifications, equivalent changes and alterations made to the above embodiments based on the technical essence of the present invention shall fall within the protection scope of the technical solution of the present invention.

Claims

1. A coil assembly comprising a coil former and a core disposed in the coil former, the coil former comprising two flange portions and a winding portion disposed between the two flange portions; characterized in that: The outer circumferential surface of the winding portion is non-circular in cross-section, and comprises a plurality of outer arc surfaces spaced along the circumferential direction, each of which protrudes outward.

2. The coil assembly of claim 1, wherein: The plurality of cores are arranged compactly together, so that each core is in contact with the side surface of an adjacent core.

3. A coil assembly according to claim 1 or 2, characterised in that: The plurality of cores are arranged compactly together, so that each core is in contact with the side surface of an adjacent core.

4. The coil assembly of claim 1, wherein: The inner circumferential surface of the winding portion comprises a plurality of inner arc surfaces spaced along the circumferential direction and corresponding one-to-one with the plurality of outer arc surfaces, each of which protrudes outward, and each of which is configured with one core on the inner side, and each of which is in adaptive contact with the side surface of the corresponding core or in clearance fit.

5. The coil assembly of claim 4, wherein: The central angle of each inner arc surface is greater than or equal to 180°, and a transition arc surface is provided between adjacent inner arc surfaces, which protrudes inward and is located between the two adjacent cores; or, the central angle of each inner arc surface is less than 180°, and an inner straight surface is provided between adjacent inner arc surfaces, which smoothly transitions with the adjacent inner arc surfaces.

6. The coil assembly of claim 1, wherein: An outer straight surface is provided between each pair of adjacent outer arc surfaces, which smoothly transitions with the adjacent outer arc surfaces.

7. The coil assembly of claim 1 or 4, wherein: The cross-section of the core is circular; the core comprises two end portions and a core body located between the two end portions, the two end portions are located outside the winding portion of the coil holder, and the diameter of at least one end portion is smaller than the diameter of the core body.

8. The coil assembly of claim 1, wherein: The winding portion is wound with a coil; further comprising a yoke connected to the plurality of cores; the yoke is fitted with an armature portion.

9. The coil assembly of claim 8, wherein: The yoke is L-shaped, and the yoke is provided with two, one side of each of the two yokes is fitted at the two ends of the coil holder in the axial direction, one end of the plurality of cores is fixedly connected to one side of one of the yokes, the other end of the plurality of cores is fixedly connected to one side of the other yoke, the other sides of the two yokes are located on the same side of the coil holder and are oppositely arranged; the armature portion is rotatably arranged, and the armature portion is H-shaped, and the other sides of the two yokes are fitted into the recesses on both sides of the armature portion.

10. An electromagnetic relay characterized by comprising: The coil assembly comprises the coil assembly according to any one of claims 1-9.

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