Vehicle Battery Relay Assembly with Rotating Cam Switch
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Solution Overview
Problem
Existing battery relays for vehicles face challenges in reliably switching high currents while minimizing wear and increasing life cycle, often resulting in slow operation and arcing due to rotary contact type relays and solenoid-operated relays with traditional ratchet and pawl assemblies that increase friction and force on small surfaces.
Innovation Solution
A vehicle battery relay assembly featuring a solenoid-activated switch with a rotatable ratchet gear and pawl mechanism, which converts linear motion into rotary motion to quickly connect and disconnect high currents, reducing arcing and wear by distributing force over a larger surface area and using a contact washer with projecting points for efficient electrical switching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If traditional ratchet and pawl assemblies with pointed teeth or gears are used, then motion is achieved, but friction, wear, and force on small surfaces increase
Solution Approach 1:
The patent applies curvature by replacing traditional pointed teeth with rounded cam surfaces. The cam lobes have curved profiles that guide the follower through controlled rotational motion, eliminating the sharp edges and points that cause high stress concentration and wear. This curved surface interaction distributes force more evenly across larger contact areas, reducing friction and extending component life while maintaining reliable switching operation.
2Reliability
If rotary contact type relays are used, then battery relay function is achieved, but operation speed is slow and arcing occurs
Solution Approach 1:
The patent replaces the traditional multi-component mechanical relay system with a streamlined cam-follower mechanism. This simplified mechanical system eliminates complex rotary contacts and multiple moving parts, reducing inertial delays and mechanical play. The direct cam-driven contact closure achieves faster switching speeds while maintaining reliable electrical connection through the optimized contact geometry and reduced mechanical compliance.
3Reliability
If solenoid operated relays with linear contact movement are used, then switching function is achieved, but arcing and wear occur due to linear motion
Solution Approach 1:
The patent transitions from linear contact movement to rotational cam-driven contact closure. The curved cam surfaces guide the contacts through an arc-shaped approach and separation, allowing the electrical arc to follow a curved path rather than a straight line. This curved arc trajectory reduces the intensity and duration of arcing at the contact points, thereby minimizing wear and extending the life of the switching contacts while maintaining reliable switching function.
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
The solution effectively reduces the size and cost of the relay, increases reliability and life cycle, and minimizes arcing and wear by enabling quick and efficient switching of high currents, while maintaining consistent contact pressure and reducing the force required for operation.
Implementation Method 1
The solenoid has a solenoid coil
Implementation Method 2
A rotatable ratchet gear rotates by engagement with a pawl, the pawl being connected to a plunger of the solenoid
Data Source
AI summary
In a vehicle battery relay assembly for disconnecting or isolating a vehicle battery from a connection line, a housing is provided having a solenoid and a switch activated by the solenoid. The switch electrically connects and disconnects a first contact terminal for connection to the vehicle battery and a second contact terminal for connection to the connection line. The solenoid has a solenoid coil. A rotatable ratchet gear rotates by engagement with a pawl, the pawl being connected to a plunger of the solenoid. The switch comprises a contact element coupled to the ratchet gear, the contact element having at least first and second projecting contact points. The contact element is positioned relative to a contact surface of the first and second contact terminals such that given a first rotation of the contact element the first and second contact terminals are electrically connected and given a subsequent second rotation the first and second contact terminals are electrically disconnected.