Relay manufacturing method

Abstract

To provide a method for manufacturing an electromagnetic relay 10 capable of removing a foreign object 70 from contacts 31, 32 of the electromagnetic relay 10.SOLUTION: A manufacturing method of an electromagnetic relay 10 includes preparing an electromagnetic relay 10A having a fixed contact 32 and a movable contact 31. A manufacturing method of an electromagnetic relay 10 includes causing a high voltage generator 60 to generate discharge between the contacts 31 and 32 when a foreign object 70 attaches to the contacts 31, 32 of the electromagnetic relay 10A due to an attractive force caused by the Coulomb force generated between the contacts 31, 32 and the foreign object 70. The foreign object 70 is separated from the contacts 31, 32 by impact force caused by the discharge. During the discharge, an air flow is generated from an electric blower 61 to blow away the separated foreign object 70 and remove the foreign object 70 from the contacts 31, 32.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a relay. [Background technology]

[0002] Conventionally, some relays include a fixed contact, a movable contact that is configured so that it can be displaced to contact or separate from the fixed contact, and an electromagnetic coil that generates an electromagnetic force that displaces the movable contact (see, for example, Patent Document 1).

[0003] The electromagnetic coil generates an attractive force that attracts the movable contact to the fixed contact by electromagnetic force so that the movable contact comes into contact with the fixed contact. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-147197 Summary of the Invention [Problem to be solved by the invention]

[0005] Generally, glass fibers are used as a reinforcing material in resin materials. When resin products containing glass fibers are used in the manufacturing of products in factories, frictional charging may occur when the glass fibers contained in the resin products come into contact with other components for some reason, and the charged glass fibers may separate from the resin products and float in the air.

[0006] The contacts of the electromagnetic relay are made of a conductive material, so when a charged glass fiber floating in the air approaches the contacts, the charge on the glass fiber induces a charge of a polarity opposite to that of the glass fiber on the surface of the contacts.

[0007] Therefore, an attractive force due to Coulomb force occurs between the charges generated in the glass fiber and the charges generated on the surface of the contact, which may cause the glass fiber to adhere to the surface of the contact as foreign matter.

[0008] The contact area of ​​a glass fiber with the contact surface is very large compared to its volume, and a large Coulomb force is generated between the glass fiber and the contact surface, so the glass fiber cannot be removed from the contact surface by simply blowing air onto the contact surface.

[0009] SUMMARY OF THE INVENTION In view of the above, it is an object of the present invention to provide a method for manufacturing a relay that can remove foreign matter adhering to the contacts of the relay from the contacts of the relay by Coulomb force. [Means for solving the problem]

[0010] In order to achieve the above object, in the invention of claim 1, a method for manufacturing a relay includes providing 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 come into contact with or separate from the fixed contact by displacement; A foreign substance attached to at least one of the fixed contact and the movable contact is separated from the at least one contact by an impact force generated by generating a discharge between the fixed contact and the movable contact; When generating the discharge, a blower (61) generates an air flow that blows away the separated foreign matter and removes the foreign matter from at least one of the contact points.

[0011] Therefore, it is possible to provide a method for manufacturing a relay that can remove foreign matter adhering to the contacts of the relay from the contacts of the relay by Coulomb force.

[0012] In the invention described in claim 2, in the manufacturing method of the relay, A relay (10) is provided, which includes 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 voltage is applied between the fixed contact and the movable contact so that one of the fixed contact and the movable contact has the same polarity as the charged polarity of the foreign object, and the other of the fixed contact and the movable contact, excluding the one of the fixed contact and the movable contact, has a polarity different from the charged polarity of the foreign object, thereby reducing the attractive force due to the Coulomb force acting between either of the contacts and the foreign object (70); When a voltage is applied between the fixed contact and the movable contact, an air flow is generated from a blower (61) to blow away the foreign matter in a state where the attractive force due to the Coulomb force is reduced, thereby removing the foreign matter from one of the contacts.

[0013] Therefore, it is possible to provide a method for manufacturing a relay that can remove foreign matter adhering to the contacts of the relay from the contacts of the relay by Coulomb force.

[0014] In the invention described in claim 3, in the manufacturing method of the relay, A relay (10) is provided, which includes a first fixed contact (32) made of a conductive material, a second fixed contact (32A) made of a conductive material and spaced apart from the first fixed contact, and a movable piece (31A) made of a conductive material and configured to be able to come into contact with the first fixed contact and the second fixed contact or move away from the first fixed contact and the second fixed contact by displacement; Separating a foreign substance (70) attached to at least one of the first fixed contact, the second fixed contact, and the movable piece from the at least one member by an impact force generated by generating a discharge between the first fixed contact and the second fixed contact; When a discharge is generated between the first fixed contact and the second fixed contact, an air flow is generated from a blower (61) to blow away the separated foreign matter and remove the foreign matter from at least one of the members.

[0015] Therefore, it is possible to provide a method for manufacturing a relay that can remove foreign matter adhering to the contacts of the relay from the contacts of the relay by Coulomb force.

[0016] The reference symbols in parentheses attached to each component indicate an example of the correspondence between the component and the specific components described in the embodiments described below. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a perspective view of an electromagnetic relay according to a first embodiment. [Figure 2] 2 is a cross-sectional view taken along line II-II in FIG. 1, and is a diagram for assisting in explaining the configuration of the core, yoke, movable contact, fixed contact, armature plate, leaf spring, etc. of the electromagnetic relay in the first embodiment. FIG. [Figure 3] 4 is a flowchart showing details of a manufacturing process for the electromagnetic relay according to the first embodiment. [Figure 4] FIG. 2 is a diagram for assisting in the detailed description of the manufacturing process of the electromagnetic relay according to the first embodiment, showing a state in which a high-voltage generator is connected to a first load terminal and a second load terminal of the electromagnetic relay. [Figure 5] 1A and 1B are diagrams showing a state in which foreign matter has adhered to the movable contacts and fixed contacts of the electromagnetic relay in the first embodiment, and are diagrams for assisting in the explanation of the mechanism by which foreign matter adheres to the movable contacts and fixed contacts. [Figure 6] 4A and 4B are diagrams for assisting in explaining the operation of separating foreign matter from the movable contact and the fixed contact by the impact force of discharge generated between the movable contact and the fixed contact of the electromagnetic relay in the first embodiment. [Figure 7] 10 is a flowchart showing details of a manufacturing process for an electromagnetic relay according to a second embodiment. [Figure 8] 10A and 10B are diagrams for assisting in explaining the operation of separating the foreign matter from the movable contact by reducing the attractive force due to the Coulomb force acting between the movable contact and the foreign matter in the electromagnetic relay of the second embodiment. [Figure 9]10 is a diagram showing a state in which foreign matter is attached to a fixed contact of an electromagnetic relay in a second embodiment. FIG. [Figure 10] 10A and 10B are diagrams for assisting in explaining the operation of separating the foreign object from the fixed contact by reducing the attractive force due to the Coulomb force acting between the fixed contact and the foreign object in the electromagnetic relay of the second embodiment. [Figure 11] FIG. 10 is a diagram for assisting in the detailed description of the manufacturing process of the electromagnetic relay according to the third embodiment, showing a state in which a high-voltage generator is connected to the first load terminal and the second load terminal of the electromagnetic relay. DETAILED DESCRIPTION OF THE INVENTION

[0018] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the following embodiments, identical or equivalent parts are denoted by the same reference numerals in the drawings to simplify the description.

[0019] (First embodiment) The electromagnetic relay 10 of this embodiment is an electromagnetic relay device that is mounted on, for example, a vehicle and that opens or closes an electric circuit. As shown in Figures 1 and 2, the electromagnetic relay 10 is a relay that includes 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. For ease of explanation, the first load terminal 41, the second load terminal 42, the first coil terminal 46, and the second coil terminal 47 will be collectively referred to as terminals 41, 42, 46, and 47. Furthermore, the movable contact 31 and the fixed contact 32 will be collectively referred to as contacts 31 and 32.

[0021] The base 51 of the electromagnetic relay 10 forms 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. The base 51 is made of a resin material.

[0022] The base 51 is formed to cover the spool 21, the coil winding 26, the core 27, etc. from the side where the terminals 41, 42, 46, and 47 are provided. For example, the spool 21, the yoke 28, etc. are fixed to the base 51.

[0023] The terminals 41, 42, 46, and 47 each protrude outward from the base 51. Note that the fixed contact 32, the second load terminal 42, and the base 51 are not shown in FIG.

[0024] The spool 21 is made of, for example, an electrically insulating resin material. The spool 21 has a spool shaft 22, a first spool base 23, and an opposite spool base 24. The spool shaft 22, the first spool base 23, and the opposite spool base 24 are integrated together.

[0025] The spool shaft portion 22 has a cylindrical shape that extends in the axial direction Da of the coil winding 26. The spool shaft portion 22 is a bobbin portion of the spool 21 around which the coil winding 26 is wound.

[0026] The coil winding 26 and the spool shaft 22 are formed in a cylindrical shape with a common axis CL as the center line. Hereinafter, the axis CL will also be referred to as the coil axis CL. In the description of this embodiment, the axial direction Da of the coil winding 26 will also be referred to as the coil axis Da, and the radial direction DL of the coil winding 26 will also be referred to as the coil radial direction DL.

[0027] The first spool base 23 is provided on one side in the coil axis direction Da with respect to the coil winding 26 and the spool shaft 22. The first spool base 23 is formed to extend from the spool shaft 22 in both a first intersecting direction D1 and a second intersecting direction D2 that intersects with the first intersecting direction D1. Therefore, the first spool base 23 is formed to extend from the spool shaft 22 in the coil radial direction DL.

[0028] The other spool base 24 is provided on the other side of the coil axis direction Da, opposite to the one side with respect to the coil winding 26 and the spool shaft 22. The other spool base 24 is formed so as to extend from the spool shaft 22 in both the first intersecting direction D1 and the second intersecting direction D2. Therefore, the other spool base 24 is formed so as to extend from the spool shaft 22 in the coil radial direction DL.

[0029] The spool 21 has a spool through-hole 21a formed therein, which passes through the inside of the spool shaft 22 and penetrates through the one spool base 23 and the other spool base 24. The spool through-hole 21a extends in the coil axial direction Da, centered on the coil axis CL.

[0030] As will be described later, the coil winding 26 is an electromagnetic coil that generates magnetic flux when energized. The coil winding 26 is configured by winding a wire along the outer peripheral wall surface of the spool shaft portion 22. The coil winding 26 has a coil one end surface 261 provided on one side in the coil axis direction Da and a coil other end surface 262 provided on the other side in the coil axis direction Da.

[0031] The coil one end surface 261 is in contact with the spool base 23 on one side. The coil other end surface 262 is in contact with the spool base 24 on the other side.

[0032] Core 27 is made of a magnetic material and is formed in a generally cylindrical shape with its center at coil axis CL. Core 27 forms a magnetic path through which magnetic flux generated from coil winding 26 passes. Core 27 is inserted into spool through-hole 21a.

[0033] As a result, the core 27 generates an electromagnetic force as an attractive force that attracts the armature plate 29 due to the magnetic flux generated from the coil winding 26, as will be described later.

[0034] The yoke 28 is configured in a substantially L-shape using a plate-like member made of a magnetic material. Specifically, the yoke 28 has a first yoke plate portion 281 and a second yoke plate portion 282.

[0035] First yoke plate portion 281 is formed in a plate shape with its thickness direction aligned with second intersecting direction D2. First yoke plate portion 281 is formed to extend in coil axis direction Da. First yoke plate portion 281 is disposed on one side of coil winding 26 in second intersecting direction D2, spaced apart from coil winding 26.

[0036] Second yoke plate portion 282 is formed in a plate shape with its thickness direction aligned with the coil axis direction Da. Second yoke plate portion 282 is formed to extend from the other end of first yoke plate portion 281 in the coil axis direction Da to the other side in second intersecting direction D2.

[0037] The second yoke plate portion 282 is disposed on the other side of the coil winding 26 in the coil axis direction Da, with the other spool base portion 24 sandwiched between the second yoke plate portion 282 and the coil winding 26. The other end of the core 27 in the coil axis direction Da is fixed to the second yoke plate portion 282 by crimping.

[0038] The armature plate 29 forms a magnetic path between the core 27 and the first yoke plate portion 281, allowing magnetic flux to pass through.

[0039] The armature plate 29 is made of a magnetic material and has a plate shape. The armature plate 29 has one end 291 provided on one side in the second intersecting direction D2. The one end 291 of the armature plate 29 is held by one end of the first yoke plate portion 281 on one side in the coil axis direction Da.

[0040] The armature plate 29 is swingable about one end 291. The armature plate 29 has an opposing surface 29a that is located on the other side in the second intersecting direction D2 of the one end 291. The opposing surface 29a faces one end surface 27a of the core 27 on one side in the coil axis direction Da.

[0041] With this configuration, the armature plate 29 is magnetized by the magnetic flux generated by the coil winding 26 passing through it, and an electromagnetic force acts on the armature plate 29 as an attractive force that attracts it to the core 27. As a result, the armature plate 29 swings around one end 291 due to the electromagnetic force, and the opposing surface 29a approaches the core 27.

[0042] The leaf spring 30 is configured as a plate-shaped member made of a conductive metal material 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.

[0043] The leaf spring 30 is fixed to the armature plate 29 by crimping at a portion along the armature plate 29. The leaf spring 30 is fixed to the first yoke plate portion 281 by crimping at a portion along the first yoke plate portion 281.

[0044] The leaf spring 30, by its elastic force, biases the armature plate 29 in a direction that moves the opposing surface 29a of the armature plate 29 away from the one end surface 27a of the core 27. The leaf spring 30 has a free end provided on the other side in the second intersecting direction D2.

[0045] A movable contact 31 is fixed to the free end of the leaf spring 30. The movable contact 31 is connected to a first load terminal 41 via the leaf spring 30. The leaf spring 30 constitutes a conductive member that electrically connects the movable contact 31 and the first load terminal 41.

[0046] The first load terminal 41 is made of a conductive metal material. The movable contact 31 is made of a conductive material (for example, a metal material). The fixed contact 32 is connected to the second load terminal 42. The second load terminal 42 is fixed to the other spool base 24.

[0047] The second load terminal 42 is made of a conductive metal material. The fixed contact 32 is disposed on the other side in the coil axis direction Da of the movable contact 31. The fixed contact 32 is made of a conductive material (for example, a metal material).

[0048] 1 and 2, the first load terminal 41, the second load terminal 42, the first coil terminal 46, and the second coil terminal 47 each protrude from the base 51 to the other side in the coil axis direction Da. In this embodiment, the terminals 41, 42, 46, and 47 are fixed to the other spool base 24.

[0049] 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. The coil winding 26 is connected between the first coil terminal 46 and the second coil terminal 47.

[0050] The first coil terminal 46 and the second coil terminal 47 are made of a metal material such as a copper alloy that has high conductivity.

[0051] As described above, the first coil terminal 46 and the second coil terminal 47 are fixed to the other spool base portion 24 of the spool 21. The first coil terminal 46 and the second coil terminal 47 are aligned in the first intersecting direction D1.

[0052] That is, the first intersecting direction D1 is the arrangement direction of the coil terminals 46, 47. Specifically, the first coil terminal 46 is arranged on one side of the coil axis CL in the first intersecting direction D1, and the second coil terminal 47 is arranged on the other side of the coil axis CL in the first intersecting direction D1.

[0053] Next, the operation of the electromagnetic relay 10 of this embodiment will be described.

[0054] 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 due to the current flowing through the coil winding 26. This magnetic flux passes through a magnetic path that is a closed circuit formed by the core 27, the yoke 28, and the armature plate 29.

[0055] At this time, the armature plate 29 and the core 27 are magnetized by the magnetic flux, and therefore an electromagnetic force acts on the armature plate 29 as an attractive force that attracts the core 27 to the armature plate 29.

[0056] Accordingly, the leaf spring 30 is elastically deformed, and the armature plate 29 swings about the one end 291. As a result, the opposing surface 29a of the armature plate 29 approaches one end surface 27a of the core 27 on one side in the coil axis direction Da.

[0057] 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.

[0058] Furthermore, when the application of voltage between the first coil terminal 46 and the second coil terminal 47 is stopped, current stops flowing through the coil winding 26. In this case, magnetic flux stops being generated from the coil winding 26.

[0059] At this time, the magnetization of the core 27 and the armature plate 29 disappears, and the electromagnetic force acting as the above-mentioned attractive force no longer acts on the armature plate 29. Accordingly, the elastic deformation of the leaf spring 30 returns to normal.

[0060] As a result, the elastic force of the leaf spring 30 causes the armature plate 29 to swing about the one end 291 as a fulcrum so that the opposing surface 29a moves away from the one end surface 27a of the core 27. As a result, the opposing surface 29a of the armature plate 29 moves away from the one end surface 27a of the core 27 on one side.

[0061] Accordingly, 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. As a result, the first load terminal 41 and the second load terminal 42 are disconnected by the movable contact 31 and the fixed contact 32.

[0062] In this way, depending on whether or not the coil winding 26 is energized, the movable contact 31 comes into contact with the fixed contact 32 or separates from the fixed contact 32. Accordingly, the first load terminal 41 and the second load terminal 42 are connected or disconnected.

[0063] Next, a manufacturing process for the electromagnetic relay 10 of this embodiment will be described with reference to Figures 3, 4, 5, and 6. Figure 3 is a flowchart showing the manufacturing process for the electromagnetic relay 10 of this embodiment.

[0064] FIG. 4 is a diagram showing a state in which a high-voltage generator 60 as a 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 jig is installed near the electromagnetic relay 10.

[0065] Fig. 5 is a diagram showing a state in which foreign matter 70 is attached to each of the movable contact 31 and the fixed contact 32 before a discharge is generated between the movable contact 31 and the fixed contact 32. Fig. 6 is a diagram showing a state in which the foreign matter 70 separates the movable contact 31 and the fixed contact 32 due to an impact force caused by a discharge between the movable contact 31 and the fixed contact 32.

[0066] First, in the first process of step 100, the electromagnetic relay 10 is prepared, to which the spool 21, coil winding 26, core 27, yoke 28, armature plate 29, leaf spring 30, contacts 31, 32, terminals 41, 42, 46, 47, and base 51 are assembled.

[0067] Here, a case will be described in which a foreign substance 70 that has been charged to, for example, a positive polarity by frictional charging is attached to the contacts 31 and 32 as shown in FIG.

[0068] First, before a discharge occurs between the contacts 31 and 32 of the electromagnetic relay 10, a negative charge is induced on the surface of the fixed contact 32 by the positive charge generated on the foreign object 70. Therefore, an attractive force due to the Coulomb force occurs between the positive charge generated on the foreign object 70 and the negative charge generated on the surface of the fixed contact 32.

[0069] Therefore, the foreign object 70 is attracted to the fixed contact 32 by the Coulomb force. Similarly, a negative charge is induced on the surface of the movable contact 31 of the electromagnetic relay 10 by the positive charge generated on the foreign object 70.

[0070] Therefore, an attractive force due to the Coulomb force occurs between the positive charge generated on the foreign matter 70 and the negative charge generated on the surface of the movable contact 31. Therefore, the foreign matter 70 is attached to the movable contact 31 by the attractive force due to the Coulomb force.

[0071] In contrast to this, in the second process of step 110, air is blown toward the contacts 31 and 32 from the electric blower 61 (ie, the blower).

[0072] Furthermore, when no electromagnetic force is generated from the core 27 and the movable contact 31 is separated from the fixed contact 32, a high voltage is output from the high voltage generator 60 between the first load terminal 41 and the second load terminal 42.

[0073] As a result, a high voltage is applied between the contacts 31 and 32. As a result, a discharge occurs between the contacts 31 and 32. In this embodiment, the discharge may be, for example, a spark discharge or an arc discharge. At this time, the impact force of the discharge separates the foreign matter 70 from the surfaces of the contacts 31 and 32 of the electromagnetic relay 10.

[0074] Specifically, as the discharge occurs between the contacts 31 and 32, a rapid air flow is generated around the discharge path between the contacts 31 and 32. As a result, the air flow separates the foreign matter 70 from the surfaces of the contacts 31 and 32, as shown in FIG.

[0075] At this time, the airflow blown out from the electric blower 61 is blown onto the contacts 31, 32. Accordingly, the foreign matter 70 that has been separated from the contacts 31, 32 by the impact force of the discharge is blown away from the contacts 31, 32 by the airflow.

[0076] Similarly, even if foreign matter 70 negatively charged by frictional electrification adheres to the contacts 31 and 32, the foreign matter 70 is removed from the contacts 31 and 32.

[0077] In this case, before a discharge occurs between the contacts 31 and 32, a positive charge is induced on the surface of each of the contacts 31 and 32 by the negative charge generated on the foreign object 70. Therefore, an attractive force due to the Coulomb force is generated between the negative charge generated on the foreign object 70 and the positive charge generated on the surface of the fixed contact 32.

[0078] In contrast, when a discharge is generated between the contacts 31 and 32, the impact force of the discharge between the contacts 31 and 32 separates the foreign matter 70 from the surfaces of the contacts 31 and 32. At this time, the foreign matter 70 is blown away from the contacts 31 and 32 by the airflow blown onto the contacts 31 and 32 from the electric blower 61.

[0079] Furthermore, even if foreign matter 70 made of a resin material, a metal material, or the like, rather than glass fiber, adheres to the surfaces of contacts 31 and 32 in a state of being charged by friction, the foreign matter 70 can be removed from contacts 31 and 32 by discharge and the airflow from electric blower 61.

[0080] In this manner, the foreign matter 70 is removed from the contacts 31 and 32 of the electromagnetic relay 10. This completes the manufacturing process of the electromagnetic relay 10 of this embodiment.

[0081] In the first step of the manufacturing process for the electromagnetic relay 10 of this embodiment described above, an electromagnetic relay 10 is prepared that includes a fixed contact 32 made of a conductive material and a movable contact 31 made of a conductive material.

[0082] The movable contact 31 is configured so that it can come into contact with the fixed contact 32 or move away from the fixed contact 32 by its displacement.

[0083] In the second step of the manufacturing process of the electromagnetic relay 10, when the foreign object 70 is attached to the contacts 31, 32 of the electromagnetic relay 10 due to the attractive force caused by the Coulomb force generated between the contacts 31, 32 and the foreign object 70, the high-voltage generator 60 generates a discharge between the contacts 31, 32.

[0084] Therefore, when discharge occurs between the contacts 31 and 32, the foreign object 70 can be separated from the contacts 31 and 32 by the impact force that accompanies the discharge between the contacts 31 and 32.

[0085] In this second step, the electric blower 61 generates an airflow that blows away the foreign matter 70 that has been separated from the contacts 31, 32 by the discharge between the contacts 31, 32, thereby removing the foreign matter 70 from the contacts 31, 32.

[0086] As described above, it is possible to provide a method for manufacturing the electromagnetic relay 10 that can remove the foreign matter 70 from the contacts 31 and 32 of the electromagnetic relay 10.

[0087] (Second embodiment) In the first embodiment, an example has been described in which the foreign object 70 is separated from the contacts 31, 32 of the electromagnetic relay 10 by discharging between the contacts 31, 32.

[0088] However, instead, a second embodiment will be described in which the attractive force due to the Coulomb force generated between the contact 31 of the electromagnetic relay 10 and the foreign object 70 is reduced to separate the foreign object 70 from the contact 31.

[0089] This embodiment differs from the first embodiment in the manufacturing process of the electromagnetic relay 10. Therefore, the manufacturing process of the electromagnetic relay 10 will be described below with reference to FIGS.

[0090] Fig. 7 is a flowchart showing the manufacturing process of the electromagnetic relay 10 of this embodiment. Fig. 8 is a diagram showing a state in which the foreign object 70 has been separated from the movable contact 31 of the electromagnetic relay 10.

[0091] Fig. 9 is a diagram showing a state in which foreign matter 70 is attached to fixed contact 32 before a high voltage is applied between contacts 31 and 32. Fig. 10 is a diagram showing a state in which foreign matter 70 has separated from fixed contact 32 of electromagnetic relay 10.

[0092] First, in the first manufacturing process of step 100, the electromagnetic relay 10 is prepared in the same manner as in the first embodiment.

[0093] 5, in the same manner as in the first embodiment, a negative charge is induced on the surface of the fixed contact 32 of the electromagnetic relay 10A 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 fixed contact 32.

[0094] Similarly, a negative charge is induced on the surface of the movable contact 31 of the electromagnetic relay 10 by the positive charge generated on the foreign object 70. Therefore, an attractive force due to the Coulomb force occurs between the positive charge generated on the foreign object 70 and the negative charge generated on the surface of the movable contact 31.

[0095] Therefore, the foreign matter 70 is attached to each of the contacts 31 and 32 by the attractive force of Coulomb force.

[0096] In contrast, in the second manufacturing process of step 110A, air is blown from the electric blower 61 toward the movable contact 31.

[0097] At this time, with no electromagnetic force being generated from core 27 and movable contact 31 separated from fixed contact 32, high voltage generator 60 outputs a high voltage between first load terminal 41 and second load terminal 42. At this time, with no discharge occurring between contacts 31 and 32, movable contact 31 becomes positive polarity and fixed contact 32 becomes negative polarity.

[0098] That is, the movable contact 31 has the same polarity as the charge polarity of the foreign object 70, and the fixed contact 32 has a polarity different from the charge polarity of the foreign object 70. As a result, a Coulomb force acts as a repulsive force between the foreign object 70 and the movable contact 31, which repels the foreign object 70 away from the movable contact 31.

[0099] That is, the Coulomb force acting as an attractive force that attracts foreign matter 70 to movable contact 31 is reduced. Therefore, as shown in Fig. 8, foreign matter 70 is separated from movable contact 31. As a result, the airflow blown out from electric blower 61 is blown onto movable contact 31, and foreign matter 70 that has separated from movable contact 31 is blown away from movable contact 31 by the airflow.

[0100] At this time, if foreign matter 70 is attached to the fixed contact 32 by Coulomb force, as shown in Figure 9, in the third step of the manufacturing process in the next step 110B, a high voltage is output from the high voltage generator 60 between the first load terminal 41 and the second load terminal 42.

[0101] At this time, no electromagnetic force is generated from core 27, movable contact 31 is separated from fixed contact 32, and no discharge occurs between contacts 31 and 32. At this time, movable contact 31 has a negative polarity and fixed contact 32 has a positive polarity. Therefore, movable contact 31 has a polarity different from the polarity of charge of foreign object 70, and fixed contact 32 has a polarity the same as the polarity of charge of foreign object 70.

[0102] As a result, a Coulomb force acting as a repulsive force that separates the foreign object 70 from the fixed contact 32 is generated between the foreign object 70 and the fixed contact 32. In other words, the Coulomb force acting as an attractive force that attracts the foreign object 70 to the fixed contact 32 is reduced.

[0103] 10, foreign matter 70 is separated from fixed contact 32. At this time, the airflow blown out from electric blower 61 is blown onto fixed contact 32, so that foreign matter 70 separated from fixed contact 32 is blown away from fixed contact 32.

[0104] Furthermore, when a foreign object 70 having a negative charge on its surface due to frictional electrification adheres to the movable contact 31 by the attractive force of Coulomb force, a high voltage is output from the high voltage generator 60 between the contacts 31 and 32 so that the movable contact 31 becomes negative and the fixed contact 32 becomes positive.

[0105] In this case, when the movable contact 31 is separated from the fixed contact 32 and no discharge occurs between the contacts 31 and 32, the movable contact 31 has the same polarity as the charged polarity of the foreign object 70, and the fixed contact 32 has a polarity different from the charged polarity of the foreign object 70.

[0106] Therefore, a Coulomb force acting as a repulsive force that separates the foreign object 70 from the movable contact 31 is generated between the foreign object 70 and the movable contact 31. In other words, the Coulomb force acting as an attractive force that attracts the foreign object 70 to the movable contact 31 is reduced.

[0107] As a result, the foreign matter 70 is separated from the movable contact 31. At this time, the airflow blown out from the electric blower 61 is blown onto the movable contact 31, so that the foreign matter 70 separated from the movable contact 31 is blown away from the movable contact 31 by the airflow.

[0108] When a foreign object 70 having a negative charge on its surface due to frictional electrification adheres to the fixed contact 32 by the attractive force of Coulomb force, a high voltage is output from the high voltage generator 60 between the contacts 31 and 32 so that the movable contact 31 becomes positive and the fixed contact 32 becomes negative.

[0109] In this case, when the movable contact 31 is separated from the fixed contact 32 and no discharge occurs between the contacts 31 and 32, the fixed contact 32 has the same polarity as the charged polarity of the foreign object 70, and the movable contact 31 has a polarity different from the charged polarity of the foreign object 70.

[0110] Therefore, a Coulomb force acting as a repulsive force that separates the foreign matter 70 from the fixed contact 32 is generated between the foreign matter 70 and the fixed contact 32. In other words, the Coulomb force acting as an attractive force that attracts the foreign matter 70 to the fixed contact 32 is reduced.

[0111] As a result, the foreign matter 70 is separated from the fixed contact 32. At this time, the airflow blown out from the electric blower 61 is blown onto the fixed contact 32, so that the foreign matter 70 separated from the fixed contact 32 is blown away from the fixed contact 32.

[0112] As a result of the above, the foreign matter 70 that has been attached to the contacts 32 and 31 by the attractive force of Coulomb force can be separated from the contacts 32 and 31 and removed.

[0113] In this manner, the foreign matter 70 is removed from the contacts 31 and 32 of the electromagnetic relay 10. This completes the manufacturing process of the electromagnetic relay 10 of this embodiment.

[0114] In the first step of the manufacturing process for the electromagnetic relay 10 of this embodiment described above, an electromagnetic relay 10 is prepared that includes a fixed contact 32 made of a conductive material and a movable contact 31 made of a conductive material.

[0115] The movable contact 31 is configured so that it can come into contact with the fixed contact 32 or move away from the fixed contact 32 by its displacement.

[0116] In the second step of the manufacturing process for the electromagnetic relay 10, when a frictionally charged foreign object 70 is attached to the movable contact 31, a high voltage is applied between the contacts 31 and 32. At this time, when no discharge occurs between the contacts 31 and 32, the movable contact 31 has the same charged polarity as the foreign object 70, and the fixed contact 32 has a polarity opposite to the charged polarity of the foreign object 70.

[0117] This reduces the attractive force due to the Coulomb force generated between the movable contact 31 and the foreign object 70. Therefore, the foreign object 70 is separated from the movable contact 31. At this time, the airflow blown out from the electric blower 61 blows the foreign object 70 separated from the movable contact 31 away from the movable contact 31.

[0118] In the third step of the manufacturing process for the electromagnetic relay 10, when a frictionally charged foreign object 70 is attached to the fixed contact 32, a high voltage is applied between the contacts 31 and 32. At this time, when no discharge occurs between the contacts 31 and 32, the movable contact 31 has a polarity different from the charged polarity of the foreign object 70, and the fixed contact 32 has a polarity identical to the charged polarity of the foreign object 70.

[0119] This reduces the attractive force due to the Coulomb force generated between the fixed contact 32 and the foreign object 70. Therefore, the foreign object 70 is separated from the fixed contact 32. At this time, the airflow blown out from the electric blower 61 blows the foreign object 70 separated from the fixed contact 32 away from the fixed contact 32.

[0120] As described above, it is possible to provide a method for manufacturing the electromagnetic relay 10 that can remove the foreign matter 70 from the contacts 31 and 32 of the electromagnetic relay 10.

[0121] (Third embodiment) In the first embodiment, an example has been described in which the relay from which the foreign object 70 is removed is the electromagnetic relay 10 including the movable contact 31 and the fixed contact 32.

[0122] However, instead, a third embodiment will be described in which the electromagnetic relay 10 includes a movable piece 31A and fixed contacts 32, 32A.

[0123] In the electromagnetic relay 10 of this embodiment, the fixed contact 32 is a first fixed contact connected to the second load terminal 42. The fixed contact 32A is a second fixed contact connected to the first load terminal 41. The fixed contact 32A is disposed apart from the fixed contact 32A. The fixed contacts 32A, 32A are each made of a conductive material (for example, a metal material).

[0124] The movable piece 31A includes a conductive portion 31a and movable contacts 31b and 31c. The conductive portion 31a electrically connects the movable contacts 31b and 31c. The conductive portion 31a and the movable contacts 31b and 31c are each made of a conductive material (e.g., a metal material).

[0125] The movable piece 31A in this embodiment is supported by a leaf spring (not shown).

[0126] In this embodiment configured as described above, the movable piece 31A is displaced by the electromagnetic force generated by the coil winding 26, elastically deforming the leaf spring, so that the movable contact 31b comes into contact with the fixed contact 32A and the movable contact 31c comes into contact with the fixed contact 32A.

[0127] That is, the movable piece 31A is brought into contact with each of the fixed contacts 32A, 32 by the electromagnetic force generated by the coil winding 26. Therefore, the movable piece 31A can bring the fixed contacts 32A, 32 into an electrically connected state.

[0128] Furthermore, when no electromagnetic force is generated from the coil winding 26, the elastic deformation of the leaf spring returns to its original state, so that the movable contact 31b of the movable piece 31A separates from the fixed contact 32A, and the movable contact 31c separates from the fixed contact 32A.

[0129] That is, due to the elastic deformation of the leaf spring, the movable piece 31A is separated from each of the fixed contacts 32A and 32. Therefore, the movable piece 31A can put the fixed contacts 32A and 32 into an open state.

[0130] Next, the manufacturing process of the electromagnetic relay 10 of this embodiment will be described with reference to Fig. 3 and Fig. 11. Fig. 3 is a flowchart showing the manufacturing process of the electromagnetic relay 10 of this embodiment. Fig. 11 is a diagram showing a state in which a high-voltage generator 60, which serves as a jig used in the manufacturing process of the electromagnetic relay 10, is connected to the electromagnetic relay 10, and an electric blower 61, which serves as a jig, is installed near the electromagnetic relay 10.

[0131] First, in the first manufacturing process of step 100, the electromagnetic relay 10 is prepared, to which the first load terminal 41, the second load terminal 42, the fixed contacts 32, 32A, the movable contact 31b, etc. are assembled.

[0132] In the second manufacturing process step 110, air is blown from the electric blower 61 toward the fixed contacts 32, 32A and the movable contact 31b.

[0133] At this time, with the movable piece 31A separated from the fixed contacts 32, 32A, a high voltage is applied between the fixed contacts 32, 32A from the high voltage generator 60. As a result, a discharge occurs between the fixed contacts 32, 32A.

[0134] Specifically, a discharge occurs between the fixed contact 32A and the movable contact 31c, and a current flows between the movable contacts 31b and 31c through the conductive portion 31a. In addition, a discharge occurs between the fixed contact 32A and the movable contact 31b.

[0135] That is, a discharge occurs between the fixed contact 32 and the movable piece 31A, a current flows through the movable piece 31A, and a discharge also occurs between the fixed contact 32A and the movable piece 31A.

[0136] At this time, the impact force of the discharge between the fixed contact 32 and the movable contact 31c and the impact force of the discharge between the fixed contact 32A and the movable contact 31b separates the foreign matter 70 from the surfaces of the movable piece 31A and the fixed contacts 32 and 32A of the electromagnetic relay 10.

[0137] Specifically, when a discharge occurs between the fixed contact 32 and the movable contact 31c, a rapid air flow is generated from the discharge path between the fixed contact 32 and the movable contact 31c toward the surrounding area.

[0138] In addition, as the discharge occurs between the fixed contact 32A and the movable contact 31b, a rapid air flow is generated from the discharge path between the fixed contact 32A and the movable contact 31b toward the surrounding area. Therefore, the foreign matter 70 is separated from the surfaces of the movable piece 31A and the fixed contacts 32 and 32A by the air flow caused by such discharge.

[0139] At this time, when the airflow blown out from the electric blower 61 is blown against the foreign matter 70, the foreign matter 70 is blown away away from the movable piece 31A and the fixed contacts 32, 32A.

[0140] As a result, when foreign matter 70 charged by frictional charging adheres to the movable piece 31A and the fixed contacts 32 and 32A, the foreign matter 70 can be removed from the movable piece 31A and the fixed contacts 32 and 32A by discharge and air blowing.

[0141] In this manner, the foreign matter 70 is removed from the movable piece 31A and the fixed contacts 32, 32A of the electromagnetic relay 10. This completes the manufacturing process of the electromagnetic relay 10 of this embodiment.

[0142] In the first step of the manufacturing process for the electromagnetic relay 10 of this embodiment described above, an electromagnetic relay 10 is prepared that includes a fixed contact 32 made of a conductive material and a fixed contact 32A made of a conductive material and positioned away from the fixed contact 32.

[0143] The electromagnetic relay 10 is provided with a movable piece 31A made of a conductive material. The movable piece 31A is configured so that it can be brought into contact with the fixed contacts 32, 32A or separated from the fixed contacts 32, 32A by its displacement.

[0144] In the second step of the manufacturing process for the electromagnetic relay 10, when a foreign object 70 is attached to at least one of the fixed contacts 32, 32A and the movable piece 31A by an attractive force due to Coulomb force, a discharge is generated as follows.

[0145] That is, by applying a high voltage between the fixed contacts 32 and 32A from the high voltage generator 60, discharges are generated between the fixed contact 32 and the movable contact 31c and between the fixed contact 32A and the movable contact 31b. Therefore, the impact force caused by such discharges can separate the foreign object 70 from at least one of the members.

[0146] In this process, when a discharge is generated between the fixed contacts 32, 32A, an air flow is generated from the electric blower 61 to blow away the separated foreign matter 70 and remove the foreign matter 70 from at least one of the members.

[0147] As described above, it is possible to provide a method for manufacturing the electromagnetic relay 10 that can remove the foreign matter 70 from the fixed contacts 32, 32A and the movable piece 31A of the electromagnetic relay 10.

[0148] (Other embodiments) (1) In the above first and second embodiments, an example was described in which the electromagnetic relay 10 was used as the relay, in which the movable contact 31 was displaced by electromagnetic force to contact the fixed contact 32. Alternatively, the relay may be a manual relay in which the movable contact 31 is manually brought into contact with the fixed contact 32 by an operator.

[0149] (2) In the third embodiment, an example was described in which the electromagnetic relay 10 was used as the relay, in which the movable piece 31A is brought into contact with the fixed contacts 32, 32A by electromagnetic force. Alternatively, the relay may be a manual relay in which the movable piece 31A is brought into contact with the fixed contacts 32, 32A manually by an operator.

[0150] (3) In the above first and second embodiments, an example was described in which the electromagnetic relay 10 was used as the relay, in which the movable contact 31 was brought into contact with the fixed contact 32 by electromagnetic force. Alternatively, the relay may be an electromagnetic relay 10 in which the movable contact 31 is separated from the fixed contact 32 by electromagnetic force.

[0151] (4) In the third embodiment, an example was described in which the electromagnetic relay 10 was used as the relay, in which the movable piece 31A was brought into contact with the fixed contacts 32, 32A by electromagnetic force. Alternatively, the electromagnetic relay 10 may be used as the relay, in which the movable piece 31A is separated from the fixed contacts 32, 32A by electromagnetic force.

[0152] (5) In the above first to third embodiments, an example has been described in which the relay is the electromagnetic relay 10 for a vehicle. However, instead of this, the relay may be an electromagnetic relay 10 used for various purposes other than a vehicle.

[0153] (6) In the first to third embodiments, an axial flow fan is illustrated as the electric blower 61 in Fig. 7 and Fig. 11. However, the electric blower 61 is not limited to this, and various types of fans other than an axial flow fan may be used.

[0154] (7) The present invention is not limited to the above-described embodiments, and can be modified as appropriate within the scope of the claims. Furthermore, the above-described embodiments are not unrelated to each other, and can be combined as appropriate, except in cases where the combination is clearly impossible. Furthermore, in the above-described embodiments, it goes without saying that the elements constituting the embodiments are not necessarily essential, except in cases where they are specifically stated as essential or where they are clearly considered essential in principle.

[0155] Furthermore, in each of the above embodiments, when numerical values ​​such as the number, values, amounts, and ranges of components of the embodiments are mentioned, they are not limited to the specific numbers, except when it is specifically stated that they are essential or when they are clearly limited to a specific number in principle, etc. Furthermore, in each of the above embodiments, when the shape, positional relationship, etc. of components, etc. are mentioned, they are not limited to the shape, positional relationship, etc., except when it is specifically stated or when they are clearly limited to a specific shape, positional relationship, etc. in principle, etc. [Explanation of symbols]

[0156] 10 Electromagnetic relay 31 Movable contact 31A Movable Piece 32 Fixed contacts 32A Fixed Contact 61. Blower 70 Foreign objects

Claims

1. A relay (10) is provided, which includes 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 discharge between the fixed contact and the movable contact, which generates an impact force to separate foreign matter adhering to at least one of the fixed contact and the movable contact from the at least one of the fixed contact and the movable contact; When the discharge is generated, an air flow is generated from a blower (61) to blow away the separated foreign matter and remove the foreign matter from the at least one contact.

2. A relay (10) is provided, which includes 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 voltage is applied between the fixed contact and the movable contact so that one of the fixed contact and the movable contact has the same polarity as the charged polarity of the foreign object (70) and the other of the fixed contact and the movable contact excluding the one of the fixed contact and the movable contact has a polarity different from the charged polarity of the foreign object, thereby reducing the attractive force due to Coulomb force acting between the one of the contacts and the foreign object; When a voltage is applied between the fixed contact and the movable contact, an air flow is generated from a blower (61) to blow away the foreign matter in a state in which the attractive force due to the Coulomb force is reduced, thereby removing the foreign matter from one of the contacts.

3. A relay (10) is provided, which includes a first fixed contact (32) made of a conductive material, a second fixed contact (32A) made of a conductive material and spaced apart from the first fixed contact, and a movable piece (31A) made of a conductive material and configured to be able to come into contact with the first fixed contact and the second fixed contact or move away from the first fixed contact and the second fixed contact by displacement; a foreign substance (70) attached to at least one of the first fixed contact, the second fixed contact, and the movable piece is separated from the at least one member by an impact force generated by generating a discharge between the first fixed contact and the second fixed contact; A method for manufacturing a relay, comprising generating an air flow from a blower (61) that blows away the separated foreign matter and removes the foreign matter from at least one of the members when generating a discharge between the first fixed contact and the second fixed contact.

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