Electromagnetic Contactor DC to AC Conversion Groove
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Solution Overview
Problem
Existing electromagnetic contactors face increased costs and poor workability when converting from DC to AC operation type, particularly in hermetically sealed capsule structures, due to the need for significant configuration changes and dedicated terminal plates or resin casting.
Innovation Solution
An electromagnetic contactor design that includes a substrate with a rectifier circuit inserted between the electromagnet and external coil terminals, held by a groove in the case, allowing easy conversion from DC to AC operation without altering the capsule structure or using resin casting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a dedicated terminal plate is disposed in the substrate or the substrate is fixed by the resin casting agent to convert DC operation type to AC operation type, then the conversion can be achieved, but the cost increases and workability deteriorates
Solution Approach 1:
The substrate is designed with a universal groove structure that can accommodate different operation types (DC or AC) without requiring dedicated terminal plates or resin casting. The same substrate structure serves multiple functions by simply inserting or removing the rectifier circuit substrate, eliminating the need for operation-type-specific modifications.
Solution Approach 2:
The rectifier circuit is segmented as a separate removable substrate that can be independently inserted into the groove. This segmentation allows the conversion between DC and AC operation types by simply adding or removing this modular component, without affecting the rest of the contactor structure.
2Adaptability or versatility
If the DC operation type is changed to the AC operation type by using a rectifier circuit with dedicated terminal plate and resin casting, then the operation type conversion is achieved, but the basic configuration including the capsule structure must be significantly changed
Solution Approach 1:
The rectifier circuit is extracted as a separate removable substrate that can be independently added or removed. This extraction allows the conversion between operation types without modifying the capsule structure or other basic configurations, as the rectifier function is taken out as a standalone module.
Solution Approach 2:
The groove in the substrate acts as an intermediary structure that mediates between the fixed capsule structure and the variable rectifier circuit. This intermediary groove allows the rectifier substrate to be inserted or removed without interfering with the hermetically sealed capsule structure, enabling operation type conversion while preserving the basic configuration.
3Stability of the object's composition
If the rectifier circuit substrate is held by resin casting agent, then the substrate is fixed in position, but the workability decreases and cost increases
Solution Approach 1:
The substrate fixing structure is segmented into a groove and corresponding protrusion, eliminating the need for resin casting. This mechanical segmentation provides stable positioning through simple geometric interlocking, improving workability and reducing cost while maintaining positioning stability.
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
Enables cost-effective and efficient conversion from DC to AC operation without changing the basic configuration, including the hermetically sealed capsule structure, while maintaining workability and preventing increased costs.
Implementation Method 1
a substrate (33) having a rectifier circuit whose input side is connected to the external coil terminal and whose output side is connected to the coil so as to output a DC after converting an input AC into the DC
Implementation Method 2
an electromagnet that opens and closes the contact by using DC excitation of a coil
Data Source
Figure 1
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Figure 3
AI summary
There is provided an electromagnetic contactor which can easily and inexpensively change the DC operation type to the AC operation type. The electromagnetic contactor includes an electromagnet 32 that opens and closes a contact by using DC excitation of a coil, a lower case 13 that accommodates the electromagnet 32, external coil terminals 21 and 22 that are disposed in the lower case 13 beside the electromagnet 32, and a substrate 33 that is accommodated in the lower case 13, and that has a rectifier circuit whose input side is connected to the external coil terminals 21 and 22 and whose output side is connected to the coil so as to output a DC after converting an input AC to the DC. An inner surface of the lower case 13 has a groove 47 between the electromagnet 32 and the external coil terminals 21 and 22. The substrate 33 is held by being inserted into the groove 47.