Relay manufacturing method

Abstract

The present invention provides a method for manufacturing a relay that can improve the ability to remove foreign matter adhering to the contacts compared to the case where only air blowing is used. [Solution] By vibrating the semi-finished relay 60 and blowing air onto the fixed contact 31 and the movable contact 32, foreign matter adhering to at least one of the fixed contact 31 and the movable contact 32 is removed. Therefore, the synergistic effect of applying vibration and blowing air makes it possible to improve the removal ability of foreign matter adhering to the fixed contact 31 or the movable contact 32 compared to the case of air blowing alone.

Description

[[Technical Field]]

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

[0002] A relay opens and closes an electric circuit passing through contacts that face each other as the contacts come into contact and separate. This relay includes a resin component containing glass fibers as a filler. When glass fibers that have fallen off from the resin component are caught between the contacts, poor contact conduction of the relay may occur.

[0003] An electromagnetic relay effective for addressing such a problem is disclosed in Patent Document 1. According to Patent Document 1, the electromagnetic relay disclosed therein can enhance the effect of discharging foreign matter (for example, glass fibers) by air blowing during the assembly process of the electromagnetic relay. [[Prior Art Documents]] [[Patent Documents]]

[0004] [[Patent Document 1]] Japanese Unexamined Patent Application Publication No. 2014-86307 [[Summary of the Invention]] [[Problem to be Solved by the Invention]]

[0005] As described in Patent Document 1, foreign matter such as glass fibers adhering to contacts during the relay assembly process can be removed to some extent by air blowing. However, the inventors have found through detailed studies that it is conceivable that air blowing alone cannot sufficiently remove foreign matter adhering to contacts.

[0006] In view of the above points, an object of the present disclosure is to provide a method for manufacturing a relay that can improve the removal capability for removing foreign matter adhering to contacts compared to the case where only air blowing is used. [[Means for Solving the Problem]]

[0007] To achieve the above objective, a method for manufacturing a relay according to one aspect of this disclosure is: A method for manufacturing a relay (10) comprising conductive first contacts (31, 32) and conductive second contacts (32, 31) that can be moved in and out of contact with the first contacts, Prepare a semi-finished product (60) in which the first and second contacts of the relay are exposed (S010), The method includes removing foreign matter (Bx) adhering to at least one of the first and second contacts by blowing air onto the first and second contacts while vibrating the semi-finished product (S020).

[0008] In this way, the synergistic effect of applying vibration and blowing air makes it possible to improve the removal ability of foreign matter adhering to the first or second contact point compared to using air blowing alone. Furthermore, since the application of vibration and air blowing act on the foreign matter simultaneously, it is possible to improve the removal ability compared to applying vibration and air blowing separately.

[0009] In addition, each element in the application documents may be given a reference numeral in parentheses. In this case, the reference numeral merely indicates one example of the correspondence between the element and the specific configuration described in the embodiments described later. Therefore, this disclosure is not limited in any way by the inclusion of such reference numerals. [Brief explanation of the drawing]

[0010] [Figure 1] This is a perspective view showing the schematic configuration of a relay according to the first embodiment, in which the case of the relay is omitted from the illustration. [Figure 2] This is a cross-sectional view showing the II-II section of Figure 1 in the first embodiment, and it shows a relay in a cross-section that includes the coil axis. [Figure 3]In the first embodiment, this flowchart shows a step in the manufacturing process for a relay in which foreign matter adhering to the fixed contacts and movable contacts is removed before the relay is completed. [Figure 4] Figure 3 schematically shows the semi-finished relay prepared in the process shown, and the foreign matter removal device used in that process. [Figure 5] This figure schematically illustrates how foreign matter adhering to the contacts is removed by the foreign matter removal device shown in Figure 4. [Figure 6] In the first embodiment, Figure 4 shows a schematic time chart illustrating the change in the frequency of vibration applied to a semi-finished product by the vibration device of the foreign matter removal device. [Figure 7] In the second embodiment, Figure 4 shows a schematic time chart illustrating the change in the air velocity of the air blown by the blower of the foreign matter removal device onto both contact points of the semi-finished product. [Figure 8] In the third embodiment, the arrangement of the first to third blowers relative to the fixed contact and the movable contact is schematically shown in the view along the VIII direction in Figure 4. [Figure 9] In the third embodiment, Figure 4 shows a schematic time chart illustrating the transition between ON and OFF states for each of the first to third blowers in the foreign matter removal device. [Modes for carrying out the invention]

[0011] The embodiments will be described below with reference to the drawings. In the following embodiments, parts that are the same or equivalent to each other are denoted by the same reference numerals in the drawings.

[0012] (First Embodiment) The relay 10 of this embodiment is mounted, for example, on a vehicle. The relay 10 is an electromagnetic relay that opens and closes the power supply path to vehicle components in response to switching between energizing and de-energizing an electromagnet. This relay 10 is also called a relay device.

[0013] In the description of the present embodiment, the first direction D1, the second direction D2, and the third direction D3 shown in FIGS. 1 and 2 may be used to represent orientations in the relay 10. The first direction D1, the second direction D2, and the third direction D3 are directions that intersect each other, or more strictly, directions perpendicular to each other.

[0014] As shown in FIGS. 1 and 2, the relay 10 includes a spool 21, a coil winding 26, a core 27, a yoke 28, an armature plate 29, a leaf spring 30, a fixed contact 31, a movable contact 32, a stopper 33, a first load terminal 41, a second load terminal 42, a pair of coil terminals 46, a case 50, a base 51, and the like. For example, the spool 21, the case 50, and the base 51 are each made of a filler-containing resin. In other words, the spool 21, the case 50, and the base 51 are each resin components containing a filler. In the present embodiment, the filler contained in the resin component is specifically glass fiber.

[0015] The case 50 and the base 51 of the relay 10 form an outer shell of the relay 10. An in-case space 50a is formed inside the case 50. The spool 21, the coil winding 26, the core 27, the yoke 28, the armature plate 29, the leaf spring 30, the fixed contact 31, the movable contact 32, and the stopper 33 are accommodated in the in-case space 50a.

[0016] The base 51 closes the in-case space 50a from a side where the terminals 41, 42, and 46 are provided, and is fixed to the case 50. For example, the spool 21, the yoke 28, and the like accommodated in the case 50 are fixed to the base 51. Further, each of the terminals 41, 42, and 46 of the relay 10 protrudes outward from the base 51.

[0017] The relay 10 is mounted on an unillustrated electric substrate on which a circuit pattern is formed, and each of the terminals 41, 42, and 46 of the relay 10 is soldered to the electric substrate. Each of these terminals 41, 42, and 46 is made of a highly conductive metal material such as copper alloy, for example. In FIG. 1, illustration of the case 50 is omitted to show the internal structure of the relay 10.

[0018] The spool 21 includes a spool shaft portion 22, a one-side spool base portion 23, and an other-side spool base portion 24. The spool shaft portion 22, the one-side spool base portion 23, and the other-side spool base portion 24 are integrated. For example, the spool 21 is configured as a single component including the spool shaft portion 22, the one-side spool base portion 23, and the other-side spool base portion 24.

[0019] The spool shaft portion 22 is a bobbin portion of the spool 21 around which the coil winding 26 is wound, and has a cylindrical shape extending in the first direction D1. That is, both the spool shaft portion 22 and the coil winding 26 have a cylindrical shape with a common axis CL along the first direction D1 as the center line. Therefore, the first direction D1 is the axial direction of the spool shaft portion 22 and also the axial direction of the coil winding 26. Further, the radial direction Dr of the coil winding 26 is also the radial direction of the spool shaft portion 22. In the description of the present embodiment, the axis CL of the coil winding 26 is also referred to as the coil axis CL, and the radial direction Dr of the coil winding 26 is also referred to as the coil radial direction Dr.

[0020] The one-side spool base portion 23 is provided on one side in the first direction D1 with respect to the coil winding 26 and the spool shaft portion 22, and one end of the spool shaft portion 22 is connected to the one-side spool base portion 23. The one-side spool base portion 23 is formed so as to expand from the spool shaft portion 22 in the second direction D2 and the third direction D3 respectively. Therefore, it can also be said that the one-side spool base portion 23 is formed so as to expand from the spool shaft portion 22 in the coil radial direction Dr. For example, the one-side spool base portion 23 is formed to expand outward of the coil winding 26 in the coil radial direction Dr.

[0021] Furthermore, the spool base 23 on one side is formed in a plate shape with the first direction D1 as the thickness direction. The spool base 23 on one side is in contact with the coil winding 26 in the first direction D1. In short, the spool base 23 on one side is in contact with the coil winding 26.

[0022] The other spool base 24 is provided on the opposite side of the coil winding 26 and the spool shaft 22 in the first direction D1, and the other end of the spool shaft 22 is connected to the other spool base 24. The other spool base 24 is formed to extend from the spool shaft 22 in the second direction D2 and the third direction D3, respectively. Therefore, it can also be said that the other spool base 24 is formed to extend from the spool shaft 22 in the coil radial direction Dr. For example, the other spool base 24 is formed to extend outward in the coil radial direction Dr beyond the coil winding 26.

[0023] Furthermore, the other spool base 24 is formed in a plate shape with the first direction D1 as the thickness direction. The other spool base 24 is in contact with the coil winding 26 in the first direction D1. In short, the other spool base 24 is in contact with the coil winding 26.

[0024] Furthermore, the spool 21 has a spool through-hole 21a that passes through the inside of the spool shaft portion 22 and penetrates one spool base portion 23 and the other spool base portion 24. This spool through-hole 21a extends in a first direction D1 with the coil axis CL as its centerline.

[0025] The coil winding 26 is an electromagnetic coil that generates magnetic force when energized. The coil winding 26 is constructed by winding a wire along the outer circumferential wall surface of the spool shaft portion 22.

[0026] The core 27 forms the magnetic path and is made of a magnetic metal material. It is formed in a substantially cylindrical shape with the coil axis CL as its center. The core 27 is inserted into the spool through-hole 21a. As a result, when the coil winding 26 is energized, the coil winding 26 forms a magnetic field, causing the core 27 to generate a magnetic attraction force.

[0027] The yoke 28 forms a magnetic path and is composed of a plate-shaped member of a magnetic metal material, and is substantially L-shaped. Specifically, the yoke 28 has a first yoke plate portion 281 and a second yoke plate portion 282. The first yoke plate portion 281 is plate-shaped with the second direction D2 as the thickness direction and is formed to extend in the first direction D1. The first yoke plate portion 281 is positioned away from the coil winding 26 on one side in the second direction D2 with respect to the coil winding 26.

[0028] The second yoke plate portion 282 is plate-shaped with the first direction D1 as its thickness direction, and is formed to extend from the other end of the first yoke plate portion 281 in the direction of the first direction D1 to the other end in the second direction D2. The second yoke plate portion 282 is positioned on the other side of the coil winding 26 in the direction of the first direction D1, with the other side spool base portion 24 sandwiched between it and the coil winding 26. The other end of the core 27 in the direction of the first direction D1 is crimped and fixed to the second yoke plate portion 282.

[0029] The armature plate 29 forms a magnetic path and is made of a magnetic metal material and is plate-shaped. The armature plate 29 has a plate end 291 which is one end provided on one side in the second direction D2. This plate end 291 is held by the yoke end 281a which is one end of the first yoke plate portion 281 in the first direction D1. The armature plate 29 is pivotable with the plate end 291 as the pivot point.

[0030] Furthermore, the armature plate 29 has an opposing surface 29a located on the other side in the second direction D2 from one end 291 of the plate. This opposing surface 29a faces one end surface 27a of the core 27 on one side in the first direction D1.

[0031] With this configuration, when the coil winding 26 is energized, the armature plate 29 is attracted by the magnetic attraction of the core 27, causing it to pivot around one end 291 of the plate as a pivot point, and the opposing surface 29a is attracted to the core 27.

[0032] The fixed contact 31 and the movable contact 32 are conductive, metallic electrical contact members used to switch between electrical connection and disconnection between the first load terminal 41 and the second load terminal 42. These fixed contact 31, the movable contact 32, the first load terminal 41, and the second load terminal 42 each constitute a part of the current path opened and closed by the relay 10. For example, silver alloy is used as the material for the fixed contact 31 and the movable contact 32. One of the fixed contact 31 and the movable contact 32 corresponds to the first contact of this disclosure, and the other of the fixed contact 31 and the movable contact 32 corresponds to the second contact of this disclosure.

[0033] The leaf spring 30 is made of an elastic metal plate-like member and is formed in a substantially L-shape along the armature plate 29 and the first yoke plate portion 281. That is, the leaf spring 30 has a first plate portion 301 along the armature plate 29, a second plate portion 302 along the first yoke plate portion 281, and a connecting plate portion 303 that connects the first plate portion 301 and the second plate portion 302.

[0034] The first plate portion 301 of the leaf spring 30 is positioned on one side in the first direction D1 relative to the armature plate 29 and is crimped and fixed to the armature plate 29. Therefore, the first plate portion 301 and the armature plate 29, which are integrated by the crimping and fixing, together constitute a swinging part that extends in the second direction D2 and is pivotable with one end 291 of the plate as the pivot point.

[0035] Furthermore, the second plate portion 302 is positioned on one side of the second direction D2 relative to the first yoke plate portion 281 and is crimped and fixed to the first yoke plate portion 281. The leaf spring 30 biases the armature plate 29 in a direction that moves the opposing surface 29a of the armature plate 29 away from one end surface 27a of the core 27.

[0036] Furthermore, the first plate portion 301 of the leaf spring 30 has a contact connection portion 301a, which is a free end provided on the other side in the second direction D2, and this contact connection portion 301a is located on the other side in the second direction D2 from the armature plate 29. A movable contact 32 is connected to this contact connection portion 301a. In detail, the movable contact 32 is crimped and fixed to the contact connection portion 301a. The contact connection portion 301a of this leaf spring 30 is located away in the second direction D2 from the plate end 291, which functions as a pivot point for the swinging motion of the first plate portion 301 and the armature plate 29.

[0037] The movable contact 32 is electrically connected to the second load terminal 42 via a leaf spring 30. On the other hand, the first load terminal 41 has a contact base portion 411 at one end of the first direction D1, and the fixed contact 31 is crimped and fixed to the contact base portion 411. As a result, the fixed contact 31 is electrically connected to the first load terminal 41.

[0038] As shown in Figures 1 and 2, a fixed contact 31 is positioned on the other side of the first direction D1 relative to the movable contact 32, and a stopper 33 is positioned on one side of the first direction D1 relative to the movable contact 32. That is, the stopper 33, the movable contact 32, and the fixed contact 31 are arranged in the first direction D1 in the order of stopper 33, movable contact 32, and fixed contact 31 from one side of the first direction D1. Furthermore, the stopper 33, the movable contact 32, and the fixed contact 31 are positioned on the other side of the armature plate 29 in the second direction D2, and the movable contact 32 and the fixed contact 31 face the first direction D1.

[0039] More specifically, the fixed contact 31 has a fixed contact surface 311 that faces the opposing movable contact 32. The fixed contact surface 311 is positioned on one side of the first direction D1 from the contact base portion 411 and faces that side of the first direction D1.

[0040] In contrast, the movable contact 32 has a movable contact surface 321 that faces the fixed contact surface 311 in the first direction D1. The movable contact surface 321 is positioned on the other side of the first direction D1 from the contact connecting portion 301a of the leaf spring 30 and faces the other side of the first direction D1.

[0041] Then, the armature plate 29 and the first plate portion 301 of the leaf spring 30 swing with one end 291 of the plate as a pivot point, causing the movable contact surface 321 to move toward and toward the fixed contact surface 311 in a first direction D1. This movement of the movable contact surface 321 toward and toward the fixed contact surface 311 consists of the movable contact surface 321 making contact with the fixed contact surface 311 and moving toward and away from the fixed contact surface 311. In addition, the current path including the fixed contact 31 and the movable contact 32 is opened and closed by the movement of the movable contact surface 321 toward and toward the fixed contact surface 311.

[0042] Specifically, when current is supplied to the coil winding 26, the armature plate 29 is attracted to the core 27 by the current supplied to the coil winding 26, and consequently the movable contact 32 moves to the other side in the first direction D1 and comes into contact with the fixed contact 31. That is, the surface of the movable contact 321 comes into contact with the surface of the fixed contact 311. As a result, the first load terminal 41 and the second load terminal 42 are electrically connected.

[0043] Conversely, when the current to the coil winding 26 is cut off, that is, when the coil winding 26 is de-energized, the biasing force of the leaf spring 30 causes the armature plate 29 to separate from the core 27. As a result, the movable contact 32 separates from the fixed contact 31 to one side in the first direction D1. That is, the movable contact surface 321 separates from the fixed contact surface 311, and at the same time, the movable contact 32 comes into contact with the stopper 33. This disconnects the electrical connection between the first load terminal 41 and the second load terminal 42.

[0044] In this way, the coil winding 26 causes the movable contact 32 to move toward and away from the fixed contact 31 in accordance with the switching between energizing and de-energizing the coil winding 26. The armature plate 29, the first plate portion 301 of the leaf spring 30, and the movable contact 32 are displaced as the armature plate 29 is attracted to the core 27, but the fixed contact 31 and the stopper 33 are not displaced. Figure 2 shows the state in which the coil winding 26 is not energized and the movable contact 32 is away from the fixed contact 31 and in contact with the stopper 33.

[0045] The stopper 33 defines the range of movement of the movable contact 32, which is fixed to the contact coupling portion 301a of the leaf spring 30, to one side in the first direction D1. In other words, the stopper 33 defines the range of movement of the contact coupling portion 301a and the movable contact 32 of the leaf spring 30 when the coil winding 26 is not energized. Specifically, when the coil winding 26 is not energized, the contact coupling portion 301a or the movable contact 32 of the leaf spring 30 comes into contact with the stopper 33 from the other side in the first direction D1 due to the biasing force of the leaf spring 30.

[0046] The stopper 33 is fixed to the base 51 via a stopper extension 34 that extends from the stopper 33. The stopper 33 and the stopper extension 34 constitute a single metal part obtained by press-forming a metal material such as brass.

[0047] As shown in Figures 1 and 2, the first load terminal 41, the second load terminal 42, and the pair of coil terminals 46 each protrude from the base 51 to the other side in the first direction D1. These terminals 41, 42, and 46 are electrically connected by soldering to, for example, a wiring pattern on an electrical circuit board (not shown). In this embodiment, these terminals 41, 42, and 46 are fixed to the base 51.

[0048] The pair of coil terminals 46 are terminals for electrically connecting the coil winding 26 to the circuit board. Therefore, the pair of lead wires extending from the coil winding 26 are each electrically connected to the pair of coil terminals 46. In short, each of the pair of coil terminals 46 is electrically connected to the coil winding 26.

[0049] Next, we will describe a cleaning process in which foreign matter adhering to the fixed contact 31 and the movable contact 32 is removed before the relay 10 is completed, as part of the manufacturing process for the relay 10 of this embodiment.

[0050] In the cleaning process, as shown in Figure 3, first, in step S010 as a preparation step, a semi-finished product 60 of the relay 10, which is in a state before completion, is prepared. As shown in Figure 4, the semi-finished product 60 is in a state before the case 50 is assembled to the relay 10. That is, the semi-finished product 60 is in an exposed state in which the fixed contact 31 and movable contact 32 of the relay 10 are exposed, and it has all the components of the relay 10 except for the case 50.

[0051] Specifically, the semi-finished product 60 in Figure 4 includes a spool 21, coil windings 26, a core 27, a yoke 28, an armature plate 29, a leaf spring 30, a fixed contact 31, a movable contact 32, a stopper 33, a first load terminal 41, a second load terminal 42, a pair of coil terminals 46, and a base 51. Note that during the cleaning process shown in Figure 3, the coil windings 26 are not energized, so the movable contact 32 is kept away from the fixed contact 31.

[0052] Then, in step S010, the prepared semi-finished product 60 is attached to the foreign matter removal device 70 shown in Figure 4. For example, the foreign matter removal device 70 has a mounting base (not shown), and the semi-finished product 60 is fixed to the mounting base of the foreign matter removal device 70.

[0053] The foreign matter removal device 70 is described below. The foreign matter removal device 70 comprises a blower 71, a vibrator 72, a control device 73, and the aforementioned mounting base. The blower 71 is, for example, an electric blower, and is provided to blow air onto the fixed contact 31 and movable contact 32 of the semi-finished product 60 fixed to the mounting base. The vibrator 72 vibrates the semi-finished product 60 in a first direction D1, for example, by vibrating the mounting base to which the semi-finished product 60 is fixed.

[0054] Furthermore, the control device 73 is an electronic control device that controls the blower 71 and the vibration device 72, and has the configuration of a microcomputer equipped with a CPU, RAM, ROM, and non-volatile rewritable memory (not shown). The control device 73 reads and executes a computer program stored in the ROM or non-volatile rewritable memory, which are non-transitional physical recording media. When this computer program is executed, the method corresponding to the computer program is executed. That is, the control device 73 performs various control processes according to the computer program. After step S010 in Figure 3, the process proceeds to step S020.

[0055] In step S020, which is the removal process, the control device 73 performs the following by controlling the vibration device 72 and the blower 71, respectively. That is, the control device 73 vibrates the semi-finished product 60 fixed to the mounting base with the vibration device 72, while blowing air onto the fixed contact 31 and movable contact 32 of the semi-finished product 60 with the blower 71. As a result, as shown in Figure 5, foreign matter Bx attached to at least one of the fixed contact 31 and the movable contact 32 is removed. In this embodiment, foreign matter Bx attached to each of the fixed contact 31 and the movable contact 32 is removed.

[0056] At this time, the control device 73 controls the vibration device 72 to vibrate the mounting base, thereby vibrating the semi-finished product 60, and as shown in Figure 6, repeatedly changes the vibration frequency FQ of the vibration applied to the semi-finished product 60 (i.e., the vibration frequency FQ of the semi-finished product 60).

[0057] In detail, the vibration device 72 vibrates the semi-finished product 60 by varying the vibration frequency FQ of the semi-finished product 60 between the side higher and the side lower than the resonant frequency FQr of the resin component (e.g., base 51) that makes up the semi-finished product 60. This is because the foreign matter Bx attached to the fixed contact 31 and the movable contact 32 almost always includes filler that has fallen off from the resin component that makes up the semi-finished product 60, and the filler among the foreign matter Bx has a high adhesive force to each contact 31 and 32.

[0058] The resonant frequency FQr of a filler can be experimentally determined beforehand, for example, by placing the filler on a vibration table and vibrating the table while changing the vibration frequency. More specifically, the frequency at which the filler on the vibration table vibrates violently during the change in vibration frequency can be determined as the resonant frequency FQr of the filler.

[0059] Then, once the removal of foreign matter in step S020 is complete, the case 50 is assembled onto the semi-finished product 60 to obtain the completed relay 10.

[0060] Next, we will describe the effects and benefits obtained in this embodiment. (1) According to this embodiment, in step S020 of Figure 3, the control device 73 controls the vibration device 72 and the blower 71 respectively to perform the following actions as shown in Figures 4 and 5. That is, the control device 73 vibrates the semi-finished product 60 with the vibration device 72 and blows air onto the fixed contact 31 and the movable contact 32 with the blower 71 to remove foreign matter Bx adhering to at least one of the fixed contact 31 and the movable contact 32.

[0061] Therefore, the synergistic effect of applying vibration and air blowing makes it possible to improve the removal capability of foreign matter Bx adhering to the fixed contact 31 or movable contact 32 compared to the case of air blowing alone.

[0062] Furthermore, since the vibration and air blow act simultaneously on the foreign matter Bx, it is possible to improve the removal capability compared to when the vibration and air blow are performed separately. For example, glass fibers, which are foreign matter Bx with high adhesion, can be removed from both the fixed contact 31 and the movable contact 32. In addition, it is possible to effectively remove not only the foreign matter Bx attached to the fixed contact 31 and the movable contact 32, but also the foreign matter Bx attached to their surroundings. For these reasons, in this embodiment, it is possible to reduce the occurrence of contact conductivity failures caused by foreign matter Bx such as glass fibers getting stuck between the fixed contact 31 and the movable contact 32.

[0063] (2) In addition, according to this embodiment, in step S020 of Figure 3, the vibration device 72 vibrates the semi-finished product 60 while varying the vibration frequency FQ of the semi-finished product 60 as shown in Figure 6. That is, the vibration device 72 vibrates the semi-finished product 60 while varying the vibration frequency FQ of the semi-finished product 60 between the side higher and the side lower than the resonance frequency FQr of the resin component that constitutes the semi-finished product 60.

[0064] Therefore, by utilizing the resonance phenomenon of the filler, the filler as foreign matter Bx can be peeled off from the fixed contact 31 and the movable contact 32, thereby facilitating the removal of foreign matter Bx adhering to the fixed contact 31 or the movable contact 32.

[0065] (Second Embodiment) Next, a second embodiment will be described. In this embodiment, the differences from the first embodiment described above will be mainly explained. Furthermore, parts that are the same as or equivalent to the above embodiment will be omitted or simplified in their description. The same applies to the descriptions of the embodiments described later.

[0066] In this embodiment, in step S020 of Figure 3, the wind velocity Va of the air blown from the blower 71 onto the fixed contact 31 and movable contact 32 of the semi-finished product 60 is varied. Specifically, in step S020, the control device 73 vibrates the semi-finished product 60, which is fixed to the mounting base, with the vibration device 72, while varying the wind velocity Va of the air blown by the blower 71 onto the fixed contact 31 and movable contact 32 of the semi-finished product 60, as shown in Figure 7. For example, the control device 73 repeatedly varies the wind velocity Va of the air blown onto the fixed contact 31 and movable contact 32 over a wind velocity adjustment range from the lower limit wind velocity to the upper limit wind velocity allowed by the blower 71.

[0067] As described above, in this embodiment, the air velocity Va blown onto the fixed contact 31 and the movable contact 32 is varied during the vibration of the semi-finished product 60. Therefore, compared to, for example, the case where the air velocity Va is constant, it is possible to enhance the effect of blowing away foreign matter Bx from the fixed contact 31 or the movable contact 32.

[0068] Except as described above, this embodiment is the same as the first embodiment. In this embodiment, the effects obtained from the configuration common to the first embodiment can be obtained in the same way as in the first embodiment.

[0069] (Third embodiment) Next, a third embodiment will be described. This embodiment will primarily describe the differences from the first embodiment described above.

[0070] In this embodiment, in step S020 of Figure 3, the direction of the air blown onto the fixed contact 31 and movable contact 32 of the semi-finished product 60 is changed. Specifically, in step S020, the control device 73 vibrates the semi-finished product 60, which is fixed to the mounting base, with a vibration device 72, and changes the direction of the air blown onto the fixed contact 31 and movable contact 32 of the semi-finished product 60 with respect to the fixed contact 31 and movable contact 32.

[0071] To this end, the foreign matter removal device 70 of this embodiment is equipped with a plurality of blowers 711, 712, and 713 as shown in Figure 8, instead of the blower 71 shown in Figure 4. Specifically, these plurality of blowers 711, 712, and 713 are the first blower 711, the second blower 712, and the third blower 713, and the first to third blowers 711, 712, and 713 are all the same devices as the blower 71 of the first embodiment. The first to third blowers 711, 712, and 713 are each controlled by a control device 73. However, the arrangement and orientation of the fixed contact 31 and the movable contact 32 are different for the first to third blowers 711, 712, and 713.

[0072] In detail, the first to third blowers 711, 712, and 713 surround the fixed contact 31 and the movable contact 32 when viewed along the first direction D1, and are all positioned in a direction that allows them to blow air onto the fixed contact 31 and the movable contact 32. Therefore, the direction of the air blown onto the fixed contact 31 and the movable contact 32 differs among the first to third blowers 711, 712, and 713.

[0073] Then, in step S020 of Figure 3, when the control device 73 blows air onto the fixed contact 31 and the movable contact 32 using the first to third blowers 711, 712, and 713, it turns on the first to third blowers 711, 712, and 713 one by one in sequence, as shown in the time chart of Figure 9.

[0074] For example, as shown in Figure 9, the control device 73 first turns on the first blower 711 and turns off the second and third blowers 712 and 713. Then, at the next timing after a predetermined time has elapsed, the control device 73 turns on the second blower 712 and turns off the first and third blowers 711 and 713. Furthermore, at the next timing after a predetermined time has elapsed, the control device 73 turns on the third blower 713 and turns off the first and second blowers 711 and 712. Furthermore, at the next timing after a predetermined time has elapsed, the control device 73 again turns on the first blower 711 and turns off the second and third blowers 712 and 713. In this embodiment, the ON periods for each of the blowers 711, 712, and 713 are repeated at staggered timings, thereby repeatedly changing the direction of the air blown onto the fixed contact 31 and the movable contact 32.

[0075] In Figure 9, "ON" for the blower means that the blower is activated and blows air onto the fixed contact 31 and the movable contact 32. Conversely, "OFF" for the blower means that the blower is stopped. In Figure 8, the positions of the fixed contact 31 and the movable contact 32 are indicated by dashed lines.

[0076] Next, we will describe the effects and benefits obtained in this embodiment. (1) According to this embodiment, in step S020 of Figure 3, during the vibration of the semi-finished product 60, the direction of the air blown onto the fixed contact 31 and the movable contact 32 of the semi-finished product 60 is changed with respect to the fixed contact 31 and the movable contact 32. Therefore, compared to the case where, for example, the direction of the air blown onto the fixed contact 31 and the movable contact 32 is constant, it is possible to enhance the effect of blowing away foreign matter Bx from the fixed contact 31 or the movable contact 32.

[0077] Except as described above, this embodiment is the same as the first embodiment. In this embodiment, the effects obtained from the configuration common to the first embodiment can be obtained in the same way as in the first embodiment.

[0078] Although this embodiment is a modification based on the first embodiment, it is also possible to combine this embodiment with the second embodiment described above.

[0079] (Other embodiments) (1) In each of the embodiments described above, the filler contained in the resin component constituting the relay 10 is specifically glass fiber, but this is just one example. For example, the resin component may contain any or all of the following as filler: glass fiber, silica, talc, etc.

[0080] (2) In the first embodiment described above, Figure 4 shows the blower 71 blowing air onto the fixed contact 31 and the movable contact 32 from the other side of the second direction D2, but this is just one example. The blower 71 may blow air onto the fixed contact 31 and the movable contact 32 in a direction different from the one shown in Figure 4.

[0081] (3) In each of the embodiments described above, the control performed by the control device 73 in Figure 4 is performed according to a computer program, but it may also be implemented in hardware. Furthermore, in step S020 in Figure 3, the operation of the blower 71 and the vibrator 72 under the control of the control device 73 may also be achieved by manual operation of the blower 71 and the vibrator 72 by an operator.

[0082] (4) The present disclosure is not limited to the embodiments described above and can be implemented in various modified forms. Furthermore, the embodiments described above are not unrelated to each other and can be combined as appropriate, except in cases where the combination is clearly impossible.

[0083] Furthermore, it goes without saying that, in each of the above embodiments, the elements constituting the embodiment are not necessarily essential unless explicitly stated to be particularly essential or unless they are clearly considered essential in principle. Also, in each of the above embodiments, when numerical values ​​such as the number, numerical values, quantities, or ranges of the components of the embodiment are mentioned, the embodiment is not limited to those specific numbers unless explicitly stated to be particularly essential or unless it is clearly limited to a specific number in principle. Also, in each of the above embodiments, when the material, shape, positional relationship, etc. of the components are mentioned, the embodiment is not limited to those material, shape, positional relationship, etc. unless explicitly stated or unless it is clearly limited to a specific material, shape, positional relationship, etc. in principle. [Explanation of Symbols]

[0084] 10 Relay 31 Fixed contacts (first contact, second contact) 32 Movable contact (2nd contact, 1st contact) 60 Semi-finished products Bx foreign body

Claims

1. A method for manufacturing a relay (10) comprising conductive first contacts (31, 32) and conductive second contacts (32, 31) that can be moved in and out of contact with the first contacts, (S010) Prepare a semi-finished product (60) of the relay in which the first contact and the second contact are exposed, A method for manufacturing a relay, comprising: vibrating the semi-finished product while blowing air onto the first contact and the second contact to remove foreign matter (Bx) adhering to at least one of the first contact and the second contact (S020).

2. The aforementioned semi-finished product has resin parts (21, 51) containing filler, The method for manufacturing a relay according to claim 1, wherein, in removing the foreign matter, the vibration frequency (FQ) of the vibration applied to the semi-finished product is varied between the side higher and the side lower than the resonant frequency (FQr) of the filler, with the semi-finished product being vibrated.

3. The method for manufacturing a relay according to claim 1 or 2, wherein the removal of the foreign matter involves vibrating the semi-finished product while varying the wind velocity (Va) of the air blown onto the first contact and the second contact.

4. The method for manufacturing a relay according to claim 1 or 2, wherein the removal of the foreign matter involves vibrating the semi-finished product while changing the direction of the air blown onto the first contact and the second contact with respect to the first contact and the second contact.

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