Electromagnetic Contactor Connecting Spring Load Equalization
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Solution Overview
Problem
The existing electromagnetic contactor configuration, where a connecting plate with an arc-shaped central section bulges toward the contact support, struggles to equalize loads on the end sections when the central section is displaced in the width direction, leading to potential distortion of the contact support's attitude relative to the movable core.
Innovation Solution
A connecting spring with a movable core contact plate section inserted into a through hole, featuring a depressed section and paired contact sections on both ends, which allows for equalization of loads even when displaced, ensuring secure connection without attitude distortion by forming contact with the inside of the through hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the connecting plate is formed with an arc-shaped central section that bulges toward the contact support side, then the connection between movable core and contact support is strengthened, but load equalization fails when the central section is displaced in the width direction, causing attitude distortion
Solution Approach 1:
The connecting spring is divided into functionally distinct sections: a movable core contact plate section for precise positioning and load distribution, and a pair of curved plate sections for elastic connection and attitude maintenance. This segmentation allows each section to optimize its specific function, resolving the contradiction between connection strength and attitude precision.
Solution Approach 2:
Different sections of the connecting spring are given different geometric properties: the movable core contact plate section has a flat contact surface with depressed sections for precise load distribution, while the curved plate sections provide elastic compliance. This local differentiation enables simultaneous achievement of strong connection and precise attitude control.
2Reliability
If the connecting spring is designed with a complex arc-shaped structure, then connection reliability is improved, but the device size increases and miniaturization becomes difficult
Solution Approach 1:
The connecting spring incorporates dynamic elastic elements (curved plate sections) that provide compliance and reliability without requiring large static dimensions. The elastic deformation of these sections absorbs misalignment and maintains reliable connection while keeping the overall device compact.
Solution Approach 2:
The connecting spring is designed to be inserted through a through-hole in the movable core, with the curved plate sections nested within housing sections. This nested configuration maximizes connection reliability within minimal space, enabling device miniaturization.
3Ease of manufacture
If the connecting spring uses a simple flat structure, then manufacturing is simplified, but load equalization capability is insufficient when displacement occurs
Solution Approach 1:
The connecting spring features asymmetric geometry with depressed sections on the movable core contact plate section that create specific contact points. This asymmetric design provides load equalization capability while maintaining manufacturing simplicity through stamping or forming processes.
Solution Approach 2:
The geometric parameters of the connecting spring are optimized: the curved plate sections provide elastic compliance through controlled curvature, while the depressed sections create precise contact points. These parameter optimizations achieve load equalization without complex manufacturing.
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 ensures stable connection and attitude maintenance between the movable core and contact support, reducing bending and space requirements, while allowing for miniaturization and standardization of the electromagnetic contactor.
Implementation Method 1
a connecting spring that connects the movable core of the AC electromagnet and the contact support
Data Source
AI summary
An electromagnetic contactor with connecting spring including: a movable core contact plate section that is inserted into a through hole formed in a movable core and comes into contact with a contact support side of the through hole; and a pair of curved plate sections each joined to either end of the movable core contact plate section and housed in connecting spring tip housing sections formed in the contact support, the sides of which opposite to a contact surface of the movable core contact plate section come into contact with the connecting spring tip housing sections. In the movable core contact plate section, a depressed section is formed in a direction crossing a longitudinal direction to bulge out to an opposite side to the contact support side is formed, and contact sections that come into contact with the through hole are formed on both ends of the depressed section.