Electromagnetic Contactor Buffer Spring Core Collision
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Solution Overview
Problem
Conventional electromagnetic contactors fail to effectively reduce collision velocity between movable and fixed cores, leading to mechanical abrasion and limited buffer effectiveness due to dimensional limitations and insufficient elasticity of buffer members.
Innovation Solution
The electromagnetic contactor incorporates a supporting mechanism with a buffer spring between the fixed core and the coil bobbin, an elastic member between the fixed insulating base and the fixed core, and a void at the contact surface, where the buffer spring load is set lower than the combined load of the retracting and contact springs, allowing the fixed core to move towards the movable core, reducing collision velocity by altering the magnetic drawing force during the alternating-current cycle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a buffer member made of elastic material is inserted into the fixed core to reduce oscillation and collision noise, then oscillation and collision noise are reduced, but the collision velocity of the movable core and fixed core is not reduced, and the buffer effect is insufficient due to dimensional limitations
Solution Approach 1:
A buffer spring is introduced as an intermediary element between the fixed core and the fixed insulating base. This buffer spring serves as a mediator that absorbs collision energy and reduces the impact force between the movable core and fixed core, while also providing a cushioning effect during operation. The buffer spring acts as a separate component that mediates the interaction between the cores and the insulating base, improving the buffer effect without interfering with the electrical contact function.
2Length of moving object
If the dimension of the electromagnetic contactor in the moving direction is limited, then the device size is compact, but sufficient elasticity cannot be obtained from elastic materials, resulting in poor buffer effect
Solution Approach 1:
The buffer spring's parameters (wire diameter, coil diameter, number of coils, free length) are optimized to achieve the desired elasticity within the limited dimensional space. By adjusting these parameters, the buffer spring provides sufficient elastic deformation capacity and buffer effect while maintaining a compact overall device size. The parameter optimization allows the buffer spring to compensate for the limited available space in the moving direction.
3Speed
If the load of the buffer spring is set smaller than the combined load of the retracting spring and contact spring, then the fixed core moves towards the movable core reducing collision velocity, but the configuration becomes more complex
Solution Approach 1:
The buffer spring is pre-loaded with a force smaller than the combined load of the retracting spring and contact spring. This preliminary force configuration causes the fixed core to move towards the movable core during actuation, reducing the relative collision velocity when the cores meet. The pre-set load difference creates a controlled movement that mitigates impact without requiring complex additional mechanisms.
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 decreases the relative collision velocity of the cores, enhancing mechanical endurance by ensuring the fixed core moves towards the movable core, reducing abrasion and improving the buffer effect, thus enhancing the overall mechanical durability.
Implementation Method 1
a bobbin of an electromagnetic coil, and a movable core which is actuated by the electromagnetic coil
Implementation Method 2
a buffer spring, an elastic member is provided between the fixed insulating base and a lower surface of the fixed core
Data Source
AI summary
An electromagnetic contactor includes a fixed core into which a bobbin of an electromagnetic coil is inserted and fitted, a movable core, a movable insulating base, a retracting spring, a fixed insulating base, and a supporting mechanism. The supporting mechanism is inserted into a through-hole formed in a thickness direction of the fixed core, and is configured in such a manner that a buffer spring is arranged between both ends of a supporting member that is arranged so as to protrude from the through-hole and a lower surface of the coil bobbin. An elastic member is provided between the fixed insulating base and a lower surface of the fixed core.