Halbach Arc Path Structure for Outward DC Relay Arc Discharge

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Solution Overview

Problem

Existing DC relays face challenges in effectively controlling the direction of arc discharge paths, leading to potential damage to internal components and reduced durability due to arcs not being immediately discharged to the outside.

Innovation Solution

The proposed arc path generation unit incorporates a Halbach array and a magnet part within a magnetic frame, forming a magnetic field that induces the arc to be discharged externally. The Halbach array enhances the magnetic field strength, ensuring the arc is quickly extinguished and directed away from the center, preventing damage to internal components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a permanent magnet is provided in the space where fixed contact and movable contact are in contact, then a magnetic field is formed to create electromagnetic force for arc discharge, but the electromagnetic force direction varies depending on current flow direction, causing arcs to be discharged inward toward the central portion in some cases

Engineering Contradiction:
Improvearc discharge controlVSAvoidarc damage to internal components
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies asymmetry by configuring permanent magnets with specific polarity arrangements that create a unidirectional magnetic field pattern. The magnets are positioned and oriented asymmetrically relative to the contact points, ensuring that regardless of current direction, the resulting electromagnetic force consistently directs arcs outward away from the central portion. This asymmetric configuration eliminates the bidirectional force problem of conventional symmetric magnet arrangements.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent implements local quality by providing different permanent magnet configurations at different locations within the relay. Each contact point has specifically oriented magnets tailored to its position, creating localized magnetic field patterns that ensure outward arc discharge for each specific contact location. This localized optimization ensures reliable arc control at each point rather than using a uniform magnet arrangement throughout.

Inventive Principle:
Principle #3Local quality

2Reliability

If multiple permanent magnets with different polarities are provided, then electromagnetic force is generated to discharge arcs, but arcs generated at certain contact positions are not immediately discharged to the outside and may damage internal components

Engineering Contradiction:
Improvecontact separation functionVSAvoidarc impact on drive unit components
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary anti-action by pre-configuring the permanent magnets and their polarities to counteract the potential harmful effect of inward-directed arcs before the arc discharge process begins. The magnetic field is pre-established with a pattern that anticipates and prevents arcs from moving toward the central portion, where drive unit components are located. This preventive configuration ensures arcs are always directed outward away from vulnerable components.

Inventive Principle:
Principle #9Preliminary anti-action

Solution Approach 2:

The patent converts the potentially harmful electromagnetic force that could direct arcs inward into a beneficial force by strategically positioning and orienting permanent magnets. The same electromagnetic interaction that could cause damage is reconfigured to reliably propel arcs outward. The magnetic field pattern is designed so that the electromagnetic force, rather than being a harmful factor, becomes a controlled mechanism for safe arc discharge away from internal components.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Reliability

If the space part length in one direction is formed to be longer than in the other direction, then arc discharge path is controlled, but the magnetic field strength may be insufficient without additional magnet structures

Engineering Contradiction:
Improvearc discharge path controlVSAvoidmagnetic field strength
Core Design Contradiction:
ReliabilityVSForce

Solution Approach 1:

The patent merges the functions of multiple permanent magnets into a unified magnetic field pattern that works synergistically. By combining several magnets with specific polarity arrangements, the patent creates a composite magnetic field that is stronger and more controllable than individual magnets could produce alone. This merged configuration enhances magnetic field strength while maintaining the elongated space part geometry for proper arc discharge path control.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a composite magnetic structure using multiple permanent magnets with different polarities arranged in a specific pattern. This composite magnet system creates a magnetic field with both sufficient strength and the desired directional characteristics. The combination of different magnet polarities and orientations produces a composite magnetic field that overcomes the weakness that would result from the elongated space configuration alone.

Inventive Principle:
Principle #40Composite materials

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

The solution effectively directs the arc away from critical components, enhancing the durability of the DC relay by ensuring rapid and controlled arc discharge, thus preventing potential safety accidents and reducing maintenance costs.

Implementation Method 1

The discharge path of arc may be formed by the formed magnetic field and the electromagnetic force generated by the flow of current

Methodology Applied
Scientific EffectElectromagnetic force: Lorentz Force

Implementation Method 2

a Halbach array which is positioned in the space part of the magnetic frame to form a magnetic field in the space part

Methodology Applied
Scientific EffectMagnetic field: Magnetic Field

Data Source

PatentUS12322563B2Arc path generation unit and direct current relay including same
Publication Date: 2025.06.03 LS ELECTRIC CO LTD
  • US12322563B2 patent drawing
  • US12322563B2 patent drawing
  • US12322563B2 patent drawing

AI summary

Disclosed are an arc path generation unit and a direct current relay including the same. An arc path generation unit according to various exemplary embodiments of the present disclosure comprises a Halbach array and a magnet part which form a magnetic field in a space part formed in the arc path generation unit. The magnetic field formed by the Halbach array and the magnet part forms an electromagnetic force, together with the current applied to each of fixed contacts. The electromagnetic force formed near each fixed contact is formed in a direction going away from the center of the space part, or in a direction going away from each fixed contact. Therefore, generated arcs can be rapidly suppressed and discharged through induction by the electromagnetic force.