Electromagnetic Contactor Snap-Fit Coupling Wear Compensation
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Solution Overview
Problem
Conventional electromagnetic contactors face issues with looseness and durability due to wear in snap-fit sections, particularly when coupling first and second frames made of fiber-reinforced thermoplastic resin, which are prone to vibration and subsequent loosening.
Innovation Solution
The implementation of a snap-fit section comprising a flexible projecting plate section with a fitting section and a hook section, where the flexible projecting plate section provides elasticity to maintain the fitting state even with wear progression, ensuring secure coupling between the first and second frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a bolt or clamp wire spring is used to couple the first frame to the second frame, then the coupling strength is improved, but the number of components increases
Solution Approach 1:
The patent integrates the coupling function directly into the frame structure by forming hook sections and fitting protruding sections as integral parts of the first and second frames. This eliminates the need for separate coupling components like bolts or clamp wire springs, thereby reducing component count while maintaining coupling strength through the snap-fit engagement between the integrated sections.
Solution Approach 2:
The patent applies local reinforcement by forming thickened fitting protruding sections and hook sections with specific geometric features at the coupling locations. These localized structural enhancements provide the necessary coupling strength without requiring additional components throughout the entire assembly, addressing the strength requirement only where needed.
2Device complexity
If a snap-fit section is used to couple the first frame to the second frame, then the number of components is reduced, but wear progresses due to vibration causing looseness
Solution Approach 1:
The patent incorporates a resilient section in the hook that can elastically deform. This dynamic characteristic allows the hook to absorb vibration energy and maintain continuous contact pressure against the fitting protruding section, compensating for wear over time and preventing looseness without requiring additional damping components.
Solution Approach 2:
The patent modifies the physical parameters of the snap-fit section by creating a thickened fitting protruding section with increased dimensional tolerance and a resilient section with specific elasticity. These parameter changes enable the coupling to withstand vibration and wear while maintaining reliability, achieving durability without adding components.
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 design enhances durability by maintaining the fitting state between the hook and fitting sections, reducing the likelihood of looseness and vibration, and decreases the number of components needed, thereby lowering production costs.
Implementation Method 1
The flexible projecting plate section is provided with elasticity that fits the fitting section further to a base side of the fitting protruding section in accordance with progress of wear between the fitting section and the fitting protruding section.
Data Source
AI summary
The electromagnetic contactor includes a first frame in which an operation electromagnet is mounted; a second frame in which a contact mechanism is mounted; and a snap-fit section that is made up of a fitting protruding section and a hook section formed to one and the other of the first and second frame, respectively, the hook section fitting to the fitting protruding section. The hook section has a flexible projecting plate section formed in a projecting manner to an open end of either the first or second frame and a fitting section formed at a tip of the flexible projecting plate section, the fitting section fitting to the fitting protruding section. The flexible projecting plate section is provided with elasticity that fits the fitting section to a base side of the fitting protruding section in accordance with progress of wear between the fitting section and the fitting protruding section.