High-Voltage DC Relay Layout for Arc Isolation and Auxiliary Contacts
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Solution Overview
Problem
High-voltage DC relays with auxiliary contacts suffer from contamination and damage due to electric arcs generated during contact separation, affecting the auxiliary contact structure and failing to provide insulation between strong and weak currents.
Innovation Solution
A high-voltage DC relay design featuring a plastic body with blocking walls to prevent contamination from electric arcs, and a novel arrangement of auxiliary and main contact leading-out terminals to ensure insulation and proper assembly alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If auxiliary contact leading-out terminals are fixed on the top wall of the ceramic cover and symmetrically arranged between main fixed contacts, then the relay can provide auxiliary contact function, but electric arc generated during contact separation contaminates and damages the auxiliary contact structure
Solution Approach 1:
The auxiliary contact leading-out terminals are extracted from the top wall of the ceramic cover and repositioned to the bottom end of the relay body, removing them from the harmful electric arc zone generated during main contact separation. This spatial extraction prevents contamination and damage to the auxiliary contact structure.
Solution Approach 2:
The arrangement of auxiliary contact leading-out terminals changes from a two-dimensional symmetric arrangement on the top wall to a three-dimensional configuration at the bottom end, utilizing vertical space dimension to separate auxiliary contacts from the electric arc generation zone of main contacts.
2Volume of stationary object
If auxiliary contact leading-out terminals are arranged on the top wall, then the relay structure is compact, but insulation between strong and weak currents cannot be ensured
Solution Approach 1:
The relay body is segmented into distinct functional zones: main contact terminals at the top end and auxiliary contact terminals at the bottom end. This spatial segmentation separates strong current paths from weak current paths, ensuring electrical insulation between them while maintaining a compact overall structure.
Solution Approach 2:
The relay housing structure acts as an intermediary barrier between main contact terminals and auxiliary contact terminals, providing physical and electrical isolation. The housing material and internal structure serve as the mediating element that ensures insulation between strong and weak current circuits.
3Ease of manufacture
If auxiliary movable contact piece is exposed during assembly turnover process, then assembly is simple, but the auxiliary movable contact piece gets contaminated or deformed
Solution Approach 1:
A protective cover structure is provided that acts as a flexible barrier, enclosing the auxiliary movable contact piece during assembly and turnover processes. This cover protects the contact piece from contamination and deformation while allowing for simple assembly operations.
Solution Approach 2:
The protective cover is pre-installed on the relay body before assembly operations, creating a protected environment for the auxiliary movable contact piece during the turnover and assembly processes. This preliminary protective action prevents contamination and deformation before they can occur.
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
Prevents contamination and deformation of auxiliary contacts, ensures reliable insulation between strong and weak currents, and facilitates proper assembly alignment of the relay components.
Implementation Method 1
an electric arc is generated, so that metal particles with larger heat are irregularly scattered in the ceramic inner cavity after the electric arc is broken
Data Source
AI summary
The present disclosure discloses a high-voltage DC relay comprising a cover, a main contact leading-out terminal, a coil bobbin, an auxiliary contact leading-out terminal and a coil leading-out terminal, wherein the cover and the coil bobbin are arranged up and down; two main contact leading-out terminals and two auxiliary contact leading-out terminals are respectively fixed on a top wall of the cover and their bottom ends respectively extend into a cavity of the cover; a winding shaft of the coil bobbin is vertically arranged; the coil leading-out terminal is mounted in a flange of the coil bobbin; the high-voltage DC relay also comprises a first connecting assembly and a second connecting assembly, wherein the first connecting assembly is composed of a first plastic element and a first conductive element, the second connecting assembly is composed of a second plastic element and a second conductive element.