Contact Device with Nested Auxiliary Yoke for Magnetic Efficiency
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Solution Overview
Problem
Conventional contact devices face challenges in reducing power consumption while maintaining magnetic efficiency and minimizing floor area, as increasing the thickness of the auxiliary yoke either leads to magnetic saturation or reduces the winding space.
Innovation Solution
The contact device features a spool wound with a coil between U-shaped yokes, with a movable iron core inserted into the spool's center hole, and an annular auxiliary yoke fitted to the lower surface of the first yoke, reducing magnetic resistance and allowing for a wider winding space, thus achieving a smaller floor area and lower power consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the thickness of the auxiliary yoke is increased to reduce magnetic resistance, then magnetic efficiency is improved, but the floor area increases and the device enlarges
Solution Approach 1:
The auxiliary yoke is nested within the first yoke structure, with the auxiliary yoke's outer circumference fitted into the first yoke. This nesting arrangement allows the auxiliary yoke to reduce magnetic resistance while occupying minimal additional floor area, as it utilizes the existing spatial envelope of the first yoke rather than extending outward.
Solution Approach 2:
Instead of increasing the auxiliary yoke thickness in the horizontal plane (which would increase floor area), the invention positions the auxiliary yoke in a vertical or depth dimension within the first yoke's structure. This dimensional repositioning allows the auxiliary yoke to provide its magnetic resistance-reducing function without expanding the device's footprint.
2Loss of energy
If the thickness of the auxiliary yoke is increased without increasing floor area, then magnetic resistance is reduced, but the winding space cannot be ensured
Solution Approach 1:
The auxiliary yoke is positioned locally at specific critical positions within the magnetic circuit (fitted to the lower surface of the first yoke) where it provides the most effective magnetic flux path improvement. This localized placement optimizes magnetic resistance reduction while minimizing interference with the coil winding space, as the auxiliary yoke is placed only where most needed rather than uniformly throughout the structure.
3Area of stationary object
If the thickness of the auxiliary yoke is reduced, then the floor area decreases, but the magnetic resistance becomes large and magnetic saturation easily occurs
Solution Approach 1:
The auxiliary yoke is nested within the first yoke's structural envelope, allowing it to provide enhanced magnetic flux conduction without increasing the overall device footprint. The auxiliary yoke fits into the existing spatial configuration of the first yoke, maintaining a compact floor area while still providing sufficient thickness to prevent magnetic saturation at critical flux paths.
4Loss of energy
If a conventional auxiliary yoke configuration is used, then the magnetic circuit is improved, but the device complexity and assembly difficulty increase
Solution Approach 1:
The auxiliary yoke is designed to be fitted into the first yoke in a nested configuration, creating a integrated assembly where the auxiliary yoke becomes part of the first yoke's structure. This nested design simplifies assembly compared to separate, complex auxiliary yoke arrangements, as the auxiliary yoke can be directly fitted or pressed into the first yoke's designated space, reducing the number of separate assembly steps and fastening operations required.
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
This configuration enhances magnetic efficiency, reduces power consumption, and ensures a predetermined attractive force while maintaining a compact design, facilitating assembly and productivity.
Implementation Method 1
a movable iron core is inserted to a center hole of the spool in a reciprocating manner, and a contact mechanism unit formed above the second yoke is driven with a drive shaft having a lower end fixed to the movable iron core, which reciprocates based on excitation and demagnetization of the coil
Implementation Method 2
an annular auxiliary yoke including an insertion hole communicating to the insertion hole of the first yoke and through which the movable iron core reciprocates is provided at a lower surface of the first yoke
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
This invention provides a contact device having a small floor area and capable of reducing power consumption. A spool wound with a coil is disposed between a first yoke and a second yoke, a movable iron core is inserted to a center hole of the spool in a reciprocating manner, and a contact mechanism unit formed above the second yoke is driven with a drive shaft having a lower end fixed to the movable iron core, and an upper end projecting out from an upper surface of the second yoke. An insertion hole communicating to the center hole of the spool and through which the movable iron core reciprocates is formed in the first yoke. An auxiliary yoke including an insertion hole communicating to the insertion hole of the first yoke and through which the movable iron core reciprocates is provided at a lower surface of the first yoke.