Relay manufacturing method

Abstract

To remove a foreign matter 70 that has adhered to contacts 31 and 32 of an electromagnetic relay 10 due to Coulomb force from the contacts 31 and 32.SOLUTION: A manufacturing method of an electromagnetic relay 10 includes a first step of preparing the electromagnetic relay 10, and a second step of generating an arc discharge in a state where a magnetic field H acting in the magnetic field direction is generated between the fixed contact 32 and the movable contact 31. In the second step, with the position where the arc discharge occurs adjusted by the Lorentz force acting on the discharge current by the magnetic field H, foreign matter attached to the fixed contact 32 and the movable contact 31 by Coulomb force is separated by the impact force of the arc discharge, or the foreign matter is burned away by the arc discharge.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a relay.

Background Art

[0002] Conventionally, some relays include a fixed contact, a movable contact configured to be able to contact or separate from the fixed contact by displacement, and an electromagnetic coil that generates an electromagnetic force for displacing the movable contact (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Generally, glass fibers may be used as a reinforcing material contained in a resin material. When a resin product containing glass fibers is used in product manufacturing in a factory, if the glass fibers contained in the resin product come into contact with other members for some reason, triboelectrification may occur, and it is conceivable that the glass fibers are separated from the resin product in a charged state and float in the air.

[0005] Hereinafter, for convenience of explanation, at least one of the fixed contact and the movable contact of the electromagnetic relay is simply referred to as a contact. The contacts of the electromagnetic relay are made of a conductive material. Therefore, when charged glass fibers floating in the air approach the contacts, charges of a polarity different from the charging polarity of the glass fibers are induced on the surface of the contacts by the charges charged on the glass fibers.

[0006] Therefore, there is a risk that an attractive force due to Coulomb force will occur between the charge generated in the glass fiber and the charge induced on the surface of the contact, resulting in a problem that the glass fiber adheres to the surface of the contact as a foreign object.

[0007] The glass fiber has a very large contact area with the surface of the contact with respect to its volume, and a large attractive force due to Coulomb force is generated between the glass fiber and the surface of the contact. Therefore, simply blowing the air flow blown from the blower onto the glass fiber attached to the contact cannot remove the glass fiber from the contact.

[0008] On the other hand, if an arc discharge is generated near the glass fiber attached to the contact, the impact force of the arc discharge can separate the glass fiber from the contact or burn out the glass fiber by the arc discharge. However, it is difficult to generate an arc discharge near the glass fiber attached to the contact, that is, at the intended position.

[0009] Such a problem occurs not only with glass fibers but also when foreign substances made of resin materials, metal materials, etc. are charged by triboelectric charging and these foreign substances adhere to the contacts of the relay due to Coulomb force.

[0010] In view of the above points, an object of the present disclosure is to provide a method for manufacturing a relay that can satisfactorily remove foreign substances attached to the contacts by Coulomb force from the contacts.

Means for Solving the Problems

[0011] According to one aspect of the present disclosure, a method for manufacturing a relay includes a first step (S100) of preparing a relay (10) including a fixed contact (32) made of a conductive material and a movable contact (31) made of a conductive material and configured to be able to contact or separate from the fixed contact by displacement. Due to the impact force caused by the arc discharge occurring between the fixed contact and the movable contact, foreign matter adhering to at least one of the fixed contact and the movable contact by Coulomb force is separated from at least one of the contacts, or a second step (S110A) of burning off the foreign matter by the arc discharge is included. When the direction intersecting the direction connecting the fixed contact and the movable contact is defined as the magnetic field direction, and further when the current flowing between the fixed contact and the movable contact due to the arc discharge is defined as the discharge current. In the second step, with a magnetic field (H) passing in the magnetic field direction being generated between the fixed contact and the movable contact, by generating an arc discharge, the position where the arc discharge occurs is adjusted by the Lorentz force acting on the discharge current based on the magnetic field.

[0012] Therefore, since the position where the arc discharge occurs is adjusted by the Lorentz force, an arc discharge can be made to occur at the intended position. For this reason, an arc discharge can be made to occur near the foreign matter adhering to the contact of the relay. For this reason, a method for manufacturing a relay can be provided that can satisfactorily remove foreign matter adhering to the contact of the relay by Coulomb force from the contact.

[0013] According to another aspect of the present disclosure, a method for manufacturing a relay includes a first step (S100) of preparing a relay (10) including a fixed contact (32) made of a conductive material and a movable contact (31) made of a conductive material and configured to be able to contact or separate from the fixed contact by displacement. Due to the impact force caused by the arc discharge occurring between the fixed contact and the movable contact, foreign matter adhering to at least one of the fixed contact and the movable contact by Coulomb force is separated from at least one of the contacts, or a second step (S110A) of burning off the foreign matter by the arc discharge is included. When the direction intersecting the direction connecting the fixed contact and the movable contact is defined as the magnetic field direction, and further when the current flowing between the fixed contact and the movable contact due to the arc discharge is defined as the discharge current, and the direction in which the position where the arc discharge occurs is displaced is defined as the direction of arc discharge displacement. In the second step, when causing an arc discharge in a state where a magnetic field (H) passing in the magnetic field direction is generated between the fixed contact and the movable contact, the direction of the arc discharge displacement is controlled by changing the direction of the Lorentz force acting on the discharge current based on the magnetic field.

[0014] Therefore, foreign matter adhering to the contacts of the relay can be removed over a wide range of the contacts. As a result, it is possible to provide a method for manufacturing a relay capable of satisfactorily removing foreign matter adhering to the contacts by Coulomb force from the contacts.

[0015] Note that the reference numerals in parentheses attached to each component etc. indicate an example of the correspondence relationship between the component etc. and the specific components etc. described in the embodiments described later.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Figure 10

Figure 11

Figure 12

Figure 13

Figure 14

Figure 15

Mode for Carrying Out the Invention

[0017] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In the following embodiments, parts that are identical or equivalent to each other are denoted by the same reference numerals in the drawings for the sake of simplifying the description.

[0018] (First Embodiment) The electromagnetic relay 10 of this embodiment is an electromagnetic relay device for opening or connecting an electric circuit mounted on, for example, an automobile. FIG. 1 is a perspective view showing the overall configuration of the electromagnetic relay 10, and FIG. 2 is a sectional view taken along line II-II in FIG. 1. Further, FIG. 4 is a schematic diagram of the electrical configuration of the electromagnetic relay 10.

[0019] As shown in FIGS. 1, 2, and 4, the electromagnetic relay 10 is a relay including a spool 21, a coil winding 26, a core 27, a yoke 28, an armature plate 29, a leaf spring 30, a movable contact 31, and a fixed contact 32.

[0020] The electromagnetic relay 10 includes a first load terminal 41, a second load terminal 42, a first coil terminal 46, a second coil terminal 47, and a base 51. In FIGS. 1 and 2, the illustration of the second coil terminal 47 is omitted.

[0021] Hereinafter, for convenience of explanation, the first load terminal 41, the second load terminal 42, the first coil terminal 46, and the second coil terminal 47 are collectively referred to as terminals 41, 42, 46, and 47. Further, the movable contact 31 and the fixed contact 32 are collectively referred to as contacts 31 and 32.

[0022] The base 51 is a base material that supports the spool 21, the coil winding 26, the core 27, the yoke 28, the armature plate 29, the leaf spring 30, the movable contact 31, and the fixed contact 32 from the other side in the coil axis direction Da. The base 51 is made of, for example, a resin material having electrical insulation properties.

[0023] The terminals 41, 42, 46, and 47 are each formed so as to protrude from the base 51 to the other side in the coil axis direction Da. The coil axis direction Da is the direction in which the coil axis CL extends.

[0024] The spool 21 is a bobbin portion formed in a substantially cylindrical shape with the coil axis CL as the center line. On the central side of the spool 21 with the coil axis CL as the center line, a spool through-hole 21a penetrating in the coil axis direction Da is provided. The spool 21 is made of, for example, a resin material having electrical insulation properties.

[0025] The coil winding 26 is an electromagnetic coil that generates a magnetic flux when energized. The coil winding 26 is formed by winding an electrical wire around the outer peripheral surface 21b of the spool 21.

[0026] The core 27 is made of a magnetic material and is formed in a substantially cylindrical shape centered on the coil axis CL. The core 27 forms a magnetic path through which the magnetic flux generated from the coil winding 26 passes. The core 27 is inserted into the spool through-hole 21a.

[0027] The core 27 generates an electromagnetic force as an attractive force that attracts the armature plate 29 by the magnetic flux generated from the coil winding 26. The yoke 28 is configured such that its cross-section is substantially L-shaped by a substantially plate-shaped member made of a magnetic material. Specifically, the yoke 28 has a first yoke plate portion 281 and a second yoke plate portion 282.

[0028] The first yoke plate portion 281 extends in the first crossing direction Db and the coil axis direction Da, and is formed in a plate shape with the second crossing direction Dc as the thickness direction. The second crossing direction Dc intersects (for example, is orthogonal to) the first crossing direction Db and also intersects (for example, is orthogonal to) the coil axis direction Da.

[0029] The first crossing direction Db is a direction that intersects the coil axis direction Da. The first yoke plate portion 281 is disposed on one side of the coil winding 26 in the second crossing direction Dc. The second yoke plate portion 282 extends in the first crossing direction Db and the second crossing direction Dc, and is formed in a plate shape with the coil axis direction Da as the thickness direction.

[0030] The second yoke plate portion 282 is formed to extend from the end portion on the other side in the coil axis direction Da of the first yoke plate portion 281 toward the other side in the second crossing direction Dc. The second yoke plate portion 282 is disposed on the other side in the coil axis direction Da with respect to the coil winding 26. Further, an end portion on the other side in the coil axis direction Da of the core 27 is caulked and fixed to the second yoke plate portion 282.

[0031] The armature plate 29 forms a magnetic path for allowing magnetic flux to pass between the core 27 and the first yoke plate portion 281. The armature plate 29 is made of a magnetic material, extends in the first crossing direction Db and the second crossing direction Dc, and is in a plate shape with the coil axis direction Da as the thickness direction.

[0032] The armature plate 29 has one end portion 291 provided on one side in the second crossing direction Dc. One end portion 291 of the armature plate 29 is held by the end portion on one side in the coil axis direction Da of the first yoke plate portion 281.

[0033] The armature plate 29 is swingable with one end portion 291 as a fulcrum. The armature plate 29 has an opposing surface 29a disposed on the other side in the second crossing direction Dc than the one end portion 291. This opposing surface 29a faces one end surface 27a on one side in the coil axis direction Da of the core 27.

[0034] With such a configuration, the armature plate 29 is magnetized by the magnetic flux generated from the coil winding 26 passing therethrough, and an electromagnetic force as an attractive force that attracts the core 27 acts thereon. Along with this, the armature plate 29 swings with one end portion 291 as a fulcrum by the electromagnetic force, and the opposing surface 29a approaches the core 27.

[0035] The leaf spring 30 is composed of a plate-like member made of a conductive metal material such as iron having elasticity. The leaf spring 30 is formed in a substantially L shape along the armature plate 29 and the first yoke plate portion 281.

[0036] The leaf spring 30 is caulked and fixed to the armature plate 29 at a portion along the armature plate 29. The leaf spring 30 is caulked and fixed to the first yoke plate portion 281 at a portion along the first yoke plate portion 281.

[0037] By its elastic force, the leaf spring 30 biases the armature plate 29 in a direction to separate the opposing surface 29a of the armature plate 29 from one end surface 27a of the core 27. The leaf spring 30 has a free end provided on the other side in the second crossing direction Dc.

[0038] A movable contact 31 is fixed to the free end of the leaf spring 30. The movable contact 31 is connected to the first load terminal 41 via the leaf spring 30. The leaf spring 30 constitutes a conductive member that electrically connects between the movable contact 31 and the first load terminal 41.

[0039] The free end of the leaf spring 30 is supported from one side in the coil axis direction Da by a stopper 90. The position of the free end of the leaf spring 30 in the coil axis direction Da is set by the stopper 90. The stopper 90 is supported by the base 51 or the like. In FIG. 2, the illustration of the stopper 90 is omitted.

[0040] The first load terminal 41 is made of a conductive metal material such as iron. The movable contact 31 is made of a conductive metal material such as iron (that is, a conductive material). The fixed contact 32 is connected to the second load terminal 42. The second load terminal 42 is fixed to the base 51.

[0041] The second load terminal 42 is made of a conductive metal material such as iron. The fixed contact 32 is disposed on the other side in the coil axis direction Da with respect to the movable contact 31. The fixed contact 32 is made of a conductive metal material such as iron (that is, a conductive material).

[0042] The first coil terminal 46 is connected to one end of the coil winding 26. The second coil terminal 47 is connected to the other end of the coil winding 26 other than the one end. The coil winding 26 is connected between the first coil terminal 46 and the second coil terminal 47. The first coil terminal 46 and the second coil terminal 47 are each made of a conductive metal material such as iron.

[0043] Next, the operation of the electromagnetic relay 10 of the present embodiment will be described.

[0044] First, when a voltage is applied between the first coil terminal 46 and the second coil terminal 47 and a current flows through the coil winding 26, a magnetic flux is generated from the coil winding 26 by the current flowing through the coil winding 26. This magnetic flux passes through a magnetic path as a closed circuit constituted by the core 27, the yoke 28, and the armature plate 29.

[0045] At this time, the armature plate 29 and the core 27 are magnetized by the magnetic flux. Therefore, an electromagnetic force as an attractive force that attracts the armature plate 29 to the core 27 acts on the armature plate 29.

[0046] Accordingly, while the leaf spring 30 is elastically deformed, the armature plate 29 swings with one end portion 291 as a fulcrum. For this reason, the opposing surface 29a of the armature plate 29 approaches one end surface 27a on one side in the coil axis direction Da of the core 27.

[0047] Therefore, the movable contact 31 is displaced to the other side in the coil axis direction Da. As a result, the movable contact 31 comes into contact with the fixed contact 32. As a result, the first load terminal 41 and the second load terminal 42 are electrically connected via the leaf spring 30, the movable contact 31, and the fixed contact 32.

[0048] Also, when the application of the voltage between the first coil terminal 46 and the second coil terminal 47 is stopped, the current no longer flows through the coil winding 26. In this case, the magnetic flux no longer generates from the coil winding 26.

[0049] At this time, since the magnetizations of the core 27 and the armature plate 29 disappear respectively, the electromagnetic force as the above-described attracting force does not act on the armature plate 29. Along with this, the elastic deformation of the leaf spring 30 returns.

[0050] As a result, the armature plate 29 swings about one end portion 291 as a fulcrum so that the opposing surface 29a moves away from one end surface 27a of the core 27 by the elastic force of the leaf spring 30. For this reason, the opposing surface 29a of the armature plate 29 moves away from one end surface 27a on one side of the core 27.

[0051] Along with this, the movable contact 31 is displaced to one side in the coil axis direction Da. As a result, the movable contact 31 moves away from the fixed contact 32. Thereby, between the first load terminal 41 and the second load terminal 42 will be opened by the movable contact 31 and the fixed contact 32.

[0052] In this way, depending on the presence or absence of energization of the coil winding 26, the movable contact 31 contacts the fixed contact 32 or the movable contact 31 moves away from the fixed contact 32. Along with this, between the first load terminal 41 and the second load terminal 42 is connected or opened.

[0053] Next, the manufacturing process of the electromagnetic relay 10 of the present embodiment will be described with reference to FIGS. 3 to 9.

[0054] FIG. 3 is a flowchart showing the manufacturing process of the electromagnetic relay 10 of the present embodiment. FIG. 4 is a view showing a state in which a high voltage generator 60 as a first jig used in the manufacturing process of the electromagnetic relay 10 is connected to the electromagnetic relay 10 and an electric blower 61 as a second jig is installed near the electromagnetic relay 10.

[0055] FIG. 5 is a schematic diagram showing the arrangement relationship between the N poles and S poles of the electromagnets 80A and 80B and the electromagnetic relay 10. FIG. 6 is a perspective view showing a state in which the electromagnetic relay 10 is arranged between the N poles and S poles of the electromagnets 80A and 80B. FIG. 7 is a diagram showing a state in which a foreign object 70 is attached to each of the contacts 31 and 32 before an arc discharge occurs between the contacts 31 and 32.

[0056] FIG. 8 is a diagram showing a state in which the foreign object 70 is separated from the contacts 31 and 32 by the impact force associated with the arc discharge between the contacts 31 and 32. FIG. 9 is a diagram showing an example in which the foreign object 70 remains attached to the contacts 31 and 32 even when an arc discharge occurs between the contacts 31 and 32.

[0057] First, in the first step of step S100, an electromagnetic relay 10 assembled with a spool 21, a coil winding 26, a core 27, a yoke 28, an armature plate 29, a leaf spring 30, contacts 31 and 32, terminals 41, 42, 46, 47, and a base 51 is prepared.

[0058] At this time, in the electromagnetic relay 10, the contacts 31 and 32 are arranged between the N pole 81N of the electromagnet 80A and the S pole 82S of the electromagnet 80B.

[0059] Here, as shown in FIGS. 5 and 6, the electromagnet 80A is arranged on one side of the first crossing direction Db with respect to the electromagnetic relay 10. The electromagnet 80B is arranged on the other side of the first crossing direction Db with respect to the electromagnetic relay 10.

[0060] When the electromagnet 80A is energized, an N pole 81N is generated on the other side of the first crossing direction Db, and an S pole 81S is generated on one side of the first crossing direction Db. On the other hand, when the electromagnet 80B is energized, an N pole 82N is generated on the other side of the first crossing direction Db, and an S pole 82S is generated on one side of the first crossing direction Db.

[0061] In this case, a magnetic field H passing from the N pole 81N of the electromagnet 80A toward the S pole 82S of the electromagnet 80B is generated. The direction of the magnetic field H generated between the N pole 81N and the S pole 82S is the first crossing direction Db.

[0062] Therefore, the electromagnetic relay 10 is arranged such that the direction connecting the contacts 31 and 32 (i.e., the coil axis direction Da) intersects (e.g., is orthogonal to) the direction of the magnetic field H. In this case, the direction of the magnetic field H is on the other side of the first intersection direction Db, as shown by the arrow Yg in FIG. 5.

[0063] When the direction of energization (i.e., current) to the electromagnet 80A is changed, as shown in FIG. 13, an S pole 81S is generated on the other side of the first intersection direction Db, and an N pole 81N is generated on one side of the first intersection direction Db. On the other hand, when the direction of energization (i.e., current) to the electromagnet 80B is changed, an S pole 82S is generated on the other side of the first intersection direction Db, and an N pole 82N is generated on one side of the first intersection direction Db.

[0064] In this case, a magnetic field H is generated that passes from the N pole 82N of the electromagnet 80B toward the S pole 81S of the electromagnet 80A. The direction of the magnetic field H generated between the N pole 82N and the S pole 81S is the first intersection direction Db.

[0065] Therefore, the electromagnetic relay 10 is arranged such that the direction connecting the contacts 31 and 32 (i.e., the coil axis direction Da) intersects (e.g., is orthogonal to) the direction of the magnetic field H. In this case, the direction of the magnetic field H is on one side of the first intersection direction Db, as shown by the arrow Yg in FIG. 13.

[0066] Thus, by changing the direction of the current to the electromagnets 80A and 80B, the direction of the magnetic field H passing between the electromagnets 80A and 80B can be changed. In contrast, in the present embodiment, as shown in FIG. 7, a case where a foreign object 70 charged, for example, to the positive electrode by triboelectrification adheres to the contacts 31 and 32 will be described.

[0067] First, before an arc discharge occurs between the contacts 31 and 32 of the electromagnetic relay 10, as shown in FIG. 7, on the surface of the fixed contact 32, negative charges are induced by the positive charges generated in the foreign object 70.

[0068] Therefore, an attractive force due to Coulomb force is generated between the positive charge generated on the foreign object 70 and the negative charge generated on the surface of the fixed contact 32. Accordingly, the foreign object 70 is attached to the fixed contact 32 by the attractive force due to Coulomb force.

[0069] Similarly, on the surface of the movable contact 31 of the electromagnetic relay 10, a negative charge is induced by the positive charge generated on the foreign object 70. Therefore, an attractive force due to Coulomb force is generated between the positive charge generated on the foreign object 70 and the negative charge generated on the surface of the movable contact 31. Accordingly, the foreign object 70 is attached to the movable contact 31 by the attractive force due to Coulomb force.

[0070] Next, in the second step of step S110, a magnetic field H passing between the electromagnets 80A and 80B is generated. In addition to this, with no electromagnetic force generated from the core 27, the movable contact 31 being separated from the fixed contact 32, and a magnetic field H passing between the electromagnets 80A and 80B being generated, a high voltage is output from the high voltage generator 60 between the first load terminal 41 and the second load terminal 42.

[0071] Therefore, a high voltage is applied between the contacts 31 and 32. Along with this, the electrical insulation by the air between the contacts 31 and 32 is broken and a discharge current flows between the contacts 31 and 32. That is, an arc discharge occurs between the contacts 31 and 32 with the application of the high voltage.

[0072] For example, as shown in FIG. 8, the high voltage generator 60 applies a high voltage between the contacts 31 and 32 such that the movable contact 31 becomes the negative electrode and the fixed contact 32 becomes the positive electrode. Along with this, with the application of the high voltage, the insulation by the air between the contacts 31 and 32 is broken and the discharge current flows from the fixed contact 32 to the movable contact 31.

[0073] At this time, if the direction in which the current flows is defined as the coil axis direction Da and the direction in which the magnetic field H passes (i.e., the direction of the magnetic field H) is defined as the first crossing direction Db, the direction in which the discharge current flows will be perpendicular to the direction of the magnetic field H.

[0074] Therefore, a Lorentz force based on the magnetic field H acts on the discharge current flowing between the contacts 31 and 32. At this time, as shown in FIG. 5, when a magnetic field H is generated that passes from the N pole 81N of the electromagnet 80A toward the S pole 82S of the electromagnet 80B, the Lorentz force acts on the discharge current between the contacts 31 and 32 on the other side of the second crossing direction Dc, as indicated by the arrow F in FIG. 8.

[0075] Therefore, due to the Lorentz force acting on the discharge current based on the magnetic field H, the position where the discharge current flows between the contacts 31 and 32 is displaced to the other side of the second crossing direction Dc. That is, due to the Lorentz force acting on the discharge current based on the magnetic field H, the position where the arc discharge occurs between the contacts 31 and 32 is displaced to the other side of the second crossing direction Dc, as shown in FIG. 8.

[0076] Note that in FIG. 8, an example is shown in which the magnetic field H passes from the back side in the direction perpendicular to the paper surface toward the front side in the direction perpendicular to the paper surface. On the other hand, as shown in FIG. 13, when a magnetic field H is generated that passes from the N pole 82N of the electromagnet 80B toward the S pole 81S of the electromagnet 80A, the Lorentz force acts on the discharge current between the contacts 31 and 32 on one side of the second crossing direction Dc.

[0077] Therefore, due to the Lorentz force acting on the discharge current based on the magnetic field H, the position where the discharge current flows between the contacts 31 and 32 is displaced to one side of the second crossing direction Dc. That is, due to the Lorentz force acting on the discharge current based on the magnetic field H, the position where the arc discharge occurs between the contacts 31 and 32 is displaced to one side of the second crossing direction Dc.

[0078] As described above, in this embodiment, the position where the arc discharge occurs is adjusted by the Lorentz force acting on the discharge current based on the magnetic field H. Thereby, an arc discharge can be caused to occur at an intended position between the contacts 31 and 32.

[0079] As the intended positions, for example, at each of the contacts 31 and 32, contact portions 31a and 32a that actually make contact are assumed. The magnitude of the Lorentz force is determined by the magnitude of the magnetic field H and the magnitude of the discharge current at the contacts 31 and 32.

[0080] At this time, with the arc discharge at the intended position between the contacts 31 and 32, an air flow that rapidly flows from the discharge path of the arc discharge between the contacts 31 and 32 toward the surroundings is generated. For this reason, the foreign matter 70 is separated from the surfaces of the contacts 31 and 32 by the air flow.

[0081] That is, due to the impact force associated with the arc discharge, the foreign matter 70 can be appropriately separated from the contact portions 31a and 32a of the contacts 31 and 32. Alternatively, the foreign matter 70 adhering to the contact portions 31a and 32a of the contacts 31 and 32 can be appropriately burned off by the arc discharge.

[0082] Next, in the third step of step S120, the air flow blown out from the electric blower 61 is blown onto the contacts 31 and 32. Along with this, due to the impact force of the arc discharge, the foreign matter 70 separated from the contacts 31 and 32 is blown far away from the contacts 31 and 32 by the air flow.

[0083] Also, when the foreign matter 70 is burned off by the arc discharge, the residue generated by the burning off of the foreign matter 70 is blown far away from the contacts 31 and 32 by the air flow. Therefore, the foreign matter 70 adhering to the contacts 31 and 32 of the electromagnetic relay 10 can be removed from the contacts 31 and 32 by the Coulomb force.

[0084] Also, even when the foreign matter 70 made of a resin material, a metal material, etc. instead of glass fiber adheres to the surfaces of the contacts 31 and 32 due to the Coulomb force, the foreign matter 70 can be removed from the contacts 31 and 32 by the arc discharge and the blowing from the electric blower 61.

[0085] Here, the direction of the magnetic field H is not limited to the case where it is the second crossing direction Dc, and the direction of the magnetic field H may be the first crossing direction Db. Further, the direction of the magnetic field H may be a direction crossing the first crossing direction Db or a direction crossing the second crossing direction Dc.

[0086] Such arc discharge and air blowing can obtain a similar effect even when a foreign object 70 adheres to the contacts 31 and 32, because the foreign object 70 is charged to the negative electrode by triboelectrification and positive charges are induced on the surfaces of the contacts 31 and 32 by the negative charges generated on the foreign object 70.

[0087] As described above, the foreign object 70 is removed from the contacts 31 and 32 of the electromagnetic relay 10. Thereby, the manufacturing of the electromagnetic relay 10 of the present embodiment is completed.

[0088] The manufacturing method of the electromagnetic relay 10 of the present embodiment described above includes a first step of preparing the electromagnetic relay 10 and a second step of generating an arc discharge in a state where a magnetic field H acting in the magnetic field direction is generated between the fixed contact 32 and the movable contact 31.

[0089] The electromagnetic relay 10 includes a fixed contact 32 made of a conductive metal material and a movable contact 31 configured to be able to contact or separate from the fixed contact 32 by displacement due to electromagnetic force. The crossing direction crossing the direction connecting the contacts 31 and 32 is defined as the magnetic field direction.

[0090] In the second step, an arc discharge is generated between the contacts 31 and 32 in a state where the position where the arc discharge is generated by the Lorentz force acting on the discharge current by the magnetic field H is adjusted. Thereby, an arc discharge can be generated at an intended position between the contacts 31 and 32. The discharge current is the current flowing between the contacts 31 and 32 when an arc discharge occurs between the contacts 31 and 32.

[0091] As a result, the foreign matter 70 adhering to the contacts 31 and 32 due to the Coulomb force is separated from the contacts 31 and 32 by the impact force of the arc discharge. Alternatively, the foreign matter 70 adhering to the contacts 31 and 32 is burned away by the arc discharge.

[0092] In the third step, the air flow blown out from the electric blower 61 is blown onto the contacts 31 and 32. Along with this, the foreign matter 70 separated from the contacts 31 and 32 by the impact force of the arc discharge is blown far away from the contacts 31 and 32 by the air flow.

[0093] Alternatively, when the foreign matter 70 is burned away by the arc discharge, the residue generated by the burning away of the foreign matter 70 is blown far away from the contacts 31 and 32 by the air flow blown out from the electric blower 61.

[0094] As described above, the foreign matter 70 adhering to the contacts 31 and 32 of the electromagnetic relay 10 due to the Coulomb force can be removed from the contacts 31 and 32.

[0095] Here, when no magnetic field H is generated between the contacts 31 and 32, even if the high-voltage generator 60 applies a high voltage between the contacts 31 and 32, it is difficult to generate an arc discharge at the intended position between the contacts 31 and 32.

[0096] For this reason, when an arc discharge occurs at a position away from the foreign matter 70 between the contacts 31 and 32 as shown in FIG. 9, the foreign matter 70 cannot be separated from the contacts 31 and 32 by the impact force of the arc discharge.

[0097] Therefore, in order to generate an arc discharge near the foreign matter 70, it is necessary for the high-voltage generator 60 to generate a large number of arc discharges between the contacts 31 and 32 so as to generate an arc discharge across the entire contacts 31 and 32.

[0098] Here, when the electromagnetic relay 10 is turned on with foreign matter 70 adhering to the contact portions 31a and 32a of the contacts 31 and 32, the electromagnetic relay 10 may bite the foreign matter 70 between the contacts 31 and 32, resulting in a concern of poor conduction between the contacts 31 and 32.

[0099] In contrast, in the present embodiment, as described above, based on the magnetic field H, by the Lorentz force acting on the discharge current, the position where arc discharge occurs between the contacts 31 and 32 can be adjusted.

[0100] Therefore, by the Lorentz force, as shown in FIG. 8, an arc discharge can be caused at an intended position (that is, the contact portions 31a and 32a) between the contacts 31 and 32. Thereby, a manufacturing method of the electromagnetic relay 10 capable of satisfactorily removing the foreign matter 70 adhering to the contacts 31 and 32 from the contacts by the Coulomb force can be provided.

[0101] (Second Embodiment) In the above first embodiment, an example in which an arc discharge is caused at an intended position between the contacts 31 and 32 by the Lorentz force due to the magnetic field H has been described. However, instead of this, a second embodiment will be described in which the direction of the Lorentz force acting on the discharge current based on the magnetic field H is changed to control the direction of the arc discharge displacement between the contacts 31 and 32.

[0102] The direction of the arc discharge displacement is the direction in which the position where the arc discharge occurs between the contacts 31 and 32 is displaced. In the present embodiment and the above first embodiment, the configuration of the electromagnetic relay 10 is the same, and the manufacturing method of the electromagnetic relay 10 is different.

[0103] Therefore, next, the manufacturing process of the electromagnetic relay 10 of the present embodiment will be described with reference to FIGS. 10 to 15. FIG. 10 is a flowchart showing the details of the manufacturing process of the electromagnetic relay 10 of the present embodiment.

[0104] FIG. 11 is a diagram showing a state in which a foreign object 70 is attached to each of the contacts 31 and 32 before an arc discharge occurs between the contacts 31 and 32. FIG. 12 is a diagram showing a state in which an arc discharge has occurred on the other side of the second crossing direction Dc between the contacts 31 and 32.

[0105] FIG. 13 is a schematic diagram showing the arrangement relationship between the N poles and S poles of the electromagnets 80A and 80B and the electromagnetic relay 10. FIG. 14 is a diagram showing a state in which the position where an arc discharge occurs between the contacts 31 and 32 is moving to one side of the second crossing direction Dc. FIG. 15 is a diagram showing a state in which an arc discharge has occurred on one side of the second crossing direction Dc between the contacts 31 and 32.

[0106] First, in the first step of step S100, an electromagnetic relay 10 is prepared and the electromagnetic relay 10 is arranged so that the contacts 31 and 32 are positioned between the N pole 81N and the S pole 82S. For this purpose, similar to the first embodiment, the electromagnetic relay 10 is arranged so that the direction of the magnetic field H intersects the direction connecting the contacts 31 and 32 (for example, the coil axis direction Da).

[0107] Hereinafter, as shown in FIG. 11, a case will be described in which a foreign object 70 charged, for example, to the positive electrode by triboelectrification is attached to the contacts 31 and 32 by the attractive force due to the Coulomb force.

[0108] Next, in the second step of step S110A, as shown in FIG. 13, a magnetic field H passing from the N pole 81N of the electromagnet 80A toward the S pole 82S of the electromagnet 80B is generated between the contacts 31 and 32.

[0109] For this reason, the magnetic field H passes between the contacts 31 and 32 toward the other side of the first crossing direction Db. Note that the magnetic field H in FIG. 12 shows a state of passing from the back side in the direction perpendicular to the paper surface toward the front side in the direction perpendicular to the paper surface.

[0110] In addition to this, with no electromagnetic force generated from the core 27, the movable contact 31 being separated from the fixed contact 32, and a magnetic field generated between the N pole 81N and the S pole 82S, a high voltage is output between the first load terminal 41 and the second load terminal 42 from the high voltage generator 60.

[0111] For example, as shown in FIG. 12, the high voltage generator 60 applies a high voltage between the contacts 31 and 32 such that the movable contact 31 becomes the negative electrode and the fixed contact 32 becomes the positive electrode. In this case, with the application of the high voltage, the insulation of the air between the contacts 31 and 32 is broken and a discharge current flows from the fixed contact 32 to the movable contact 31. That is, with the application of the high voltage, an arc discharge occurs between the contacts 31 and 32.

[0112] At this time, when the direction in which the discharge current flows is defined as the coil axis direction Da and the direction of the magnetic field H is defined as the first crossing direction Db, the direction in which the discharge current flows is perpendicular to the direction of the magnetic field H, similar to the first embodiment.

[0113] Therefore, a Lorentz force based on the magnetic field H acts on the discharge current flowing between the contacts 31 and 32. At this time, the Lorentz force acts on the other side in the second crossing direction Dc with respect to the discharge current between the contacts 31 and 32, as indicated by the arrow F in FIG. 12.

[0114] Therefore, in this embodiment, the position where the discharge current flows between the contacts 31 and 32 is displaced to the other side in the second crossing direction Dc by the Lorentz force. As a result, the position where the arc discharge occurs between the contacts 31 and 32 can be displaced to the other side in the second crossing direction Dc by the Lorentz force based on the magnetic field H.

[0115] As a result, as shown in FIG. 12, an arc discharge can be generated on the other side in the second crossing direction Dc between the contacts 31 and 32 by the Lorentz force. The magnitude of the Lorentz force is determined by the magnitude of the magnetic field H and the magnitude of the current between the contacts 31 and 32.

[0116] At this time, with the arc discharge between the contacts 31 and 32, an air flow rapidly flowing from the arc discharge path between the contacts 31 and 32 toward the surroundings is generated. For this reason, the foreign matter 70 is separated from the surfaces of the contacts 31 and 32 by the air flow.

[0117] That is, the foreign matter 70 can be appropriately separated from the contacts 31 and 32 by the impact force accompanying the arc discharge. Alternatively, the foreign matter 70 attached to the contacts 31 and 32 can be appropriately burned off by the arc discharge.

[0118] Thereafter, the direction of the current flowing through the electromagnet 80A is changed, and as shown in FIG. 13, an S pole 81S is generated on the other side of the first crossing direction Db in the electromagnet 80A. On the other hand, the direction of the current flowing through the electromagnet 80B is changed, and an N pole 82N is generated on one side of the first crossing direction Db in the electromagnet 80B.

[0119] For this reason, between the contacts 31 and 32, a magnetic field H passing from the N pole 82N of the electromagnet 80B toward the S pole 81S of the electromagnet 80A is generated as indicated by the arrow Yg in FIG. 13. That is, by changing the direction of the current flowing through each of the electromagnets 80A and 80B, the direction of the magnetic field H generated between the electromagnets 80A and 80B is changed. For this reason, the direction of the Lorentz force acting on the discharge current flowing between the contacts 31 and 32 is changed.

[0120] As a result, a Lorentz force acting on one side of the second crossing direction Dc is applied to the discharge current flowing between the contacts 31 and 32, as shown in FIG. 14. Along with this, the position where the discharge current is generated between the contacts 31 and 32 is displaced to one side of the second crossing direction Dc. That is, the position where the arc discharge occurs is displaced to one side of the second crossing direction Dc at the contacts 31 and 32.

[0121] That is, by changing the direction of the Lorentz force acting on the discharge current based on the magnetic field H from the other side of the second intersection direction Dc to one side of the second intersection direction Dc as indicated by the arrow F in FIGS. 12 and 14, the direction of the arc discharge displacement is controlled. Along with this, the direction of the arc discharge displacement changes from the other side of the second intersection direction Dc to one side of the second intersection direction Dc.

[0122] Thereafter, as shown in FIG. 14, arc discharge also occurs at the contact portions 31a and 32a between the contacts 31 and 32. Further thereafter, as shown in FIG. 15, arc discharge also occurs on one side of the second intersection direction Dc between the contacts 31 and 32.

[0123] In this way, arc discharge can be caused to occur over a wide range including one side of the second intersection direction Dc, the other side of the second intersection direction Dc, and the contact portions 31a and 32a among the contacts 31 and 32.

[0124] At this time, along with the arc discharge between the contacts 31 and 32, an air flow rapidly flowing from the arc discharge path between the contacts 31 and 32 toward the surroundings is generated. For this reason, the foreign matter 70 is separated from the respective surfaces of the contacts 31 and 32 by the air flow. Alternatively, the foreign matter 70 attached to the contacts 31 and 32 can be burned away by the arc discharge.

[0125] Note that, in order to change the direction of the Lorentz force that displaces the position of the arc discharge between the contacts 31 and 32, it is possible not only to change the direction of the magnetic field H but also to change the current flowing between the contacts 31 and 32 to change the direction of the Lorentz force.

[0126] In the present embodiment, not limited to the case where the position where arc discharge occurs between the contacts 31 and 32 of the electromagnetic relay 10 is displaced in the second intersection direction Dc, the position where arc discharge occurs between the contacts 31 and 32 may be displaced in the first intersection direction Db. Between the contacts 31 and 32 of the electromagnetic relay 10, the position where arc discharge occurs may be displaced in a direction intersecting the first intersection direction Db or the second intersection direction Dc.

[0127] Next, in the third step of step S120, the air flow blown out from the electric blower 61 is blown against the contacts 31 and 32. Along with this, the foreign matter 70 separated from the contacts 31 and 32 by the impact force of the arc discharge is blown far away from the contacts 31 and 32 by the air flow.

[0128] Also, when the foreign matter 70 is burned away by the arc discharge, the residue generated by the burning away of the foreign matter 70 is blown far away from the contacts 31 and 32 by the air flow blown out from the electric blower 61.

[0129] Therefore, the foreign matter 70 adhering to the contacts 31 and 32 of the electromagnetic relay 10 can be removed from the contacts 31 and 32 by the Coulomb force. As a result, the foreign matter 70 is removed from the contacts 31 and 32 of the electromagnetic relay 10. For this reason, the manufacturing of the electromagnetic relay 10 in the present embodiment is completed.

[0130] The manufacturing method of the electromagnetic relay 10 of the present embodiment described above includes a first step in step S100 of preparing the electromagnetic relay 10 and a second step in step S110A of removing foreign matter from the contacts 31 and 32.

[0131] The electromagnetic relay 10 includes a fixed contact 32 and a movable contact 31 configured to be able to contact or separate from the fixed contact 32 by displacement due to electromagnetic force.

[0132] In the second step, by the impact force of the arc discharge, the foreign matter 70 adhering to at least one of the contacts 31 and 32 by the Coulomb force is separated from at least one of the contacts, or the foreign matter 70 is burned away by the arc discharge. The direction intersecting the direction connecting the contacts 31 and 32 is defined as the magnetic field direction.

[0133] In the second step, when an arc discharge is generated between the contacts 31 and 32, a magnetic field H passing in the magnetic field direction is generated between the contacts 31 and 32, and by changing the direction of the Lorentz force based on the magnetic field H, the direction of the arc discharge displacement is controlled. The direction of the arc discharge displacement is, as described above, the direction in which the position where the arc discharge occurs between the contacts 31 and 32 is displaced.

[0134] In the third step, the air flow blown out from the electric blower 61 is blown onto the contacts 31 and 32. Along with this, the foreign matter 70 separated from the contacts 31 and 32 by the impact force of the arc discharge is blown far away by the air flow. When the foreign matter 70 is burned away by the arc discharge, the residue generated by the burning away of the foreign matter 70 is blown far away by the air flow.

[0135] As described above, by changing the direction of the Lorentz force acting on the discharge current based on the magnetic field H, the direction of the arc discharge displacement can be controlled. Therefore, the foreign matter 70 attached to the contacts 31 and 32 can be removed over a wide range of the contacts 31 and 32.

[0136] Thus, a method for manufacturing the electromagnetic relay 10 that can satisfactorily remove the foreign matter 70 attached to the contacts 31 and 32 from the contacts 31 and 32 by the Coulomb force can be provided.

[0137] In the present embodiment, similar to the first embodiment, even when the foreign matter 70 made of a resin material, a metal material, etc. instead of glass fiber adheres to the surfaces of the contacts 31 and 32 by the Coulomb force, the foreign matter 70 can be removed from the contacts 31 and 32 by the arc discharge and the blowing. (Other embodiments)

[0138] (1) In the above first and second embodiments, an example in which the electromagnetic relay 10 that displaces the movable contact 31 by electromagnetic force and brings it into contact with the fixed contact 32 is used as the relay of the present disclosure has been described. Instead of this, a manual relay in which the movable contact 31 is brought into contact with the fixed contact 32 manually by an operator may be used as the relay of the present disclosure.

[0139] (2) In the above first and second embodiments, an example in which the electromagnetic relay 10 that brings the movable contact 31 into contact with the fixed contact 32 by electromagnetic force is used as the relay of the present disclosure has been described. Instead of this, an electromagnetic relay 10 that separates the movable contact 31 from the fixed contact 32 by electromagnetic force may be used as the relay of the present disclosure.

[0140] (3) In the above first and second embodiments, an example in which the relay of the present disclosure is the electromagnetic relay 10 for vehicles has been described. However, instead of this, the relay of the present disclosure may be an electromagnetic relay 10 used for various applications other than vehicles.

[0141] (4) In the above first and second embodiments, an axial flow fan is illustrated as the electric blower 61. However, the present invention is not limited to this, and various centrifugal blowers or the like other than the axial flow fan may be used as the electric blower 61.

[0142] (5) In the above first and second embodiments, the electromagnetic relay 10 including the movable contact 31 configured to be able to contact or separate from the fixed contact 32 has been described as the relay of the present disclosure.

[0143] Instead of this, an electromagnetic relay 10 including two fixed contacts and a movable piece including two movable contacts configured to be able to contact or separate from the two fixed contacts may be used as the relay of the present disclosure.

[0144] (6) In the above first and second embodiments, an example in which the N pole 81N and the S pole 82S are constituted by two electromagnets 80A and 80B has been described. However, instead of this, the N pole 81N and the S pole 82S may be constituted by one electromagnet.

[0145] (7) Note that the present disclosure is not limited to the above-described embodiments, and can be appropriately modified within the scope described in the claims. Also, the above embodiments are not independent of each other, and can be appropriately combined except when the combination is clearly impossible. Further, in each of the above embodiments, it goes without saying that the elements constituting the embodiment are not necessarily essential, except when it is explicitly stated that they are essential or when they are considered to be clearly essential in principle. Also, in each of the above embodiments, when numerical values such as the number, numerical value, quantity, range, etc. of the components of the embodiment are mentioned, they are not limited to the specific number, except when it is explicitly stated that they are essential or when they are clearly limited to a specific number in principle. Also, in each of the above embodiments, when referring to the shape, positional relationship, etc. of the components, etc., they are not limited to the specific shape, positional relationship, etc., except when it is explicitly stated or when they are clearly limited to a specific shape, positional relationship, etc. in principle.

Explanation of Reference Numerals

[0146] 10 Electromagnetic relay 32 Fixed contact 31 Movable contact H Magnetic field

Claims

1. A first step (S100) of preparing a relay (10) including a fixed contact (32) made of a conductive material and a movable contact (31) made of a conductive material and configured to be able to contact or separate from the fixed contact by displacement; A second step (S110A) of separating foreign matter attached to at least one of the fixed contact and the movable contact by Coulomb force from the at least one contact or burning out the foreign matter by the impact force caused by arc discharge occurring between the fixed contact and the movable contact; When a direction intersecting the direction connecting the fixed contact and the movable contact is defined as the magnetic field direction, and further when the current flowing between the fixed contact and the movable contact by the arc discharge is defined as the discharge current, A method for manufacturing a relay, in which in the second step, with a magnetic field (H) passing in the magnetic field direction between the fixed contact and the movable contact generated, the arc discharge is generated, and the position where the arc discharge occurs is adjusted by the Lorentz force acting on the discharge current based on the magnetic field.

2. A first step (S100) of preparing a relay (10) including a fixed contact (32) made of a conductive material and a movable contact (31) made of a conductive material and configured to be able to contact or separate from the fixed contact by displacement; A second step (S110A) of separating foreign matter attached to at least one of the fixed contact and the movable contact by Coulomb force from the at least one contact or burning out the foreign matter by the impact force caused by arc discharge occurring between the fixed contact and the movable contact; When a direction intersecting the direction connecting the fixed contact and the movable contact is defined as the magnetic field direction, the current flowing between the fixed contact and the movable contact by the arc discharge is defined as the discharge current, and further when the direction in which the position where the arc discharge occurs is displaced is defined as the direction of arc discharge displacement, In the second step, when generating the arc discharge, while generating a magnetic field (H) passing in the magnetic field direction between the fixed contact and the movable contact, a method for manufacturing a relay that controls the direction of the arc discharge displacement by changing the direction of the Lorentz force acting on the discharge current based on the magnetic field.

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