Authenticated Electromagnetic Relay Power Switching Structure
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Solution Overview
Problem
Existing electromagnetic relays lack security features to prevent unauthorized energization and operation, posing risks in applications like automobile locking/unlocking and engine starting devices.
Innovation Solution
An electromagnetic relay with a control unit that authenticates energization requests, a power source switching unit to ensure power supply, and a communication unit for encrypted communication, along with a latching mechanism to control energization and de-energization, ensuring secure operation only with authorized signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional electromagnetic relay is designed, then it can perform basic switching functions, but it requires many separate components (coil, core, armature, contacts, insulating parts) making the structure complex and the number of parts large
Solution Approach 1:
The patent integrates the coil, core, armature, and contact into a single integrated relay body structure. The coil is formed by winding conductor around the core to create a solenoid, the armature is positioned within the solenoid, and the contact is attached to the armature, all within one molded housing that provides structural support and electrical insulation, eliminating the need for separate assembly of multiple discrete components
Solution Approach 2:
The relay body serves multiple functions simultaneously: it provides the structural framework for mounting all components, acts as an electrical insulator between conductive parts, provides magnetic shielding through its material properties, and establishes electrical connections between terminals. This multi-functionality reduces the overall component count while maintaining reliability
2Loss of energy
If the relay coil is wound around a core with air gaps, then magnetic flux leakage occurs reducing efficiency, but increasing coil winding density to compensate increases inductance and affects switching characteristics
Solution Approach 1:
The patent changes the magnetic circuit parameters by using a continuous ferromagnetic core without air gaps, which fundamentally alters the magnetic flux path. This eliminates magnetic flux leakage that would occur with air-gapped cores, improving magnetic coupling efficiency without requiring increased winding density that would raise inductance
Solution Approach 2:
The relay body is constructed from ferromagnetic material that provides both structural support and magnetic shielding properties. This composite approach combines the mechanical strength of the molded housing with the magnetic properties of the ferromagnetic material, creating an integrated structure that guides magnetic flux efficiently while maintaining low inductance characteristics
3Ease of manufacture
If traditional separate-component relay assembly is used, then manufacturing is complex requiring multiple assembly steps, but achieving high manufacturing precision for contact alignment and electrical insulation becomes difficult
Solution Approach 1:
The relay body is pre-formed as a single molded structure with all mounting features, terminal connections, and insulating barriers already precisely positioned during the injection molding process. This preliminary formation of the structural framework eliminates the need for subsequent assembly operations that would require complex alignment procedures, ensuring consistent manufacturing precision for contact alignment and electrical insulation
Solution Approach 2:
The patent replaces traditional mechanical assembly methods with injection molding technology. The relay body is created as a single integrated piece through mold injection, which automatically ensures precise dimensional tolerances, proper alignment features, and built-in electrical insulation. This substitution of manufacturing processes eliminates the need for multiple assembly steps and achieves high precision consistently
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures secure energization by authenticating external signals, preventing unauthorized operation, reducing power consumption, and maintaining reliable power supply, enhancing security in automotive and other applications.
Implementation Method 1
an electromagnetic relay which comprises a coil 111 and a core 112 integrated into one piece with a solenoid structure formed by winding the coil 111 around the core 112
Implementation Method 2
wherein the relay body 102 is made of a ferromagnetic material and shields and guides magnetic flux
Data Source
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AI summary
Problem: To provide an electromagnetic relay exhibiting security capability that allows energization only upon receiving a relay energization-permitted instruction transmitted from the outside by a remote key or the like. Solution: An electromagnetic relay comprising an electromagnetic unit having an electromagnet, and a contact unit for contacting or separating a movable contact and fixed contacts upon energization of the electromagnet, which electromagnetic relay is configured to comprise a control unit adapted to receive a signal from outside and after analyzing the received signal to determine based on the analysis result whether to energize the electromagnetic unit, and a power source switching unit for supplying power to the control unit by selecting one or the other of, or switching between, power supplied to the electromagnetic unit and power supplied to the contact unit.