Compact Button System for Industrial AC/DC Relays
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Solution Overview
Problem
Traditional industrial AC/DC relays have a bulky button system that is not suitable for small-sized applications, making it difficult to integrate into modern machines without increasing installation area or costs.
Innovation Solution
A compact button system for industrial AC/DC relays featuring a casing with a rotatable button, a driving block, an indicator board, and a core propelling block, which allows for efficient switching of relay contacts without altering the installation area, using a cover board and housing configuration that enhances manufacturing ease and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional button system with cylindrical button and restoring arm is used, then the relay contact can be switched, but the volume becomes too large for small-sized AC/DC relays
Solution Approach 1:
The button system is divided into separate functional modules: the button assembly (with pressing portion and rotating portion), the driving block, the restoring arm, and the indicator board. Each module performs a specific function and can be independently optimized for size and manufacturing, allowing the overall system to be compact while maintaining reliable contact switching functionality
Solution Approach 2:
The button is pivoted on the casing by a rotatable cross shaft that passes through the casing, creating a nested structure where the button rotates within the confined space of the casing. The driving block is installed within the casing, and the restoring arm is incorporated on both sides of the driving block, maximizing space utilization and reducing overall system volume
2Ease of manufacture
If the button system structure is simplified, then manufacturing becomes easier, but the installation area increases
Solution Approach 1:
The button serves multiple functions: it acts as both the pressing element and the rotating element, while also serving as the indicator mechanism when combined with the indicator board. The driving block integrates the driving arm and restoring arm connections, consolidating multiple components into fewer parts, which simplifies manufacturing while maintaining a compact footprint suitable for small-sized relays
Solution Approach 2:
The button system utilizes vertical space within the casing by arranging components in the vertical dimension rather than spreading them out horizontally. The button rotates vertically, the driving block moves vertically, and the indicator board displays status vertically, allowing the system to be compact in the horizontal installation area while providing full functionality
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 enables the integration of a compact button system into modern AC/DC relays, reducing manufacturing costs and maintaining the same installation area as the original relay core, while providing a reliable and efficient switching mechanism with an optional LED indicator for status monitoring.
Implementation Method 1
the casing having two U-shaped restoring arms incorporated on both sides of the end of the strip driving arm, the outer end of said restoring arms fixed to the casing
Data Source
AI summary
A button system for industrial AC/DC relays comprising a casing (10), a button (5), a driving block (7), an indication board (8) and a core propelling block (6), wherein the cover board (1) and the housing (2) fixed with each other, and at least an opening (11) for pulling the button (5) is arranged on the cover board; the button (5) is pivoted on the top of the casing (10) by the transverse shaft (51); the driving block (7) mounted in the casing (10), the end of the driving block (7) abut against the toughing portion (53) of the button (5); the indicator board (8) is pivoted in the casing (10), the upper portion of the indicator board (8) abut against the front end of the strip driving arm (71) of the driving block (7), and the lower portion is match with the core propelling block (6).