DC Relay Contact Assembly to Prevent Electromagnetic Separation
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Solution Overview
Problem
Existing DC relays face challenges in preventing arbitrary separation of the movable contactor due to incomplete cancellation of electromagnetic repulsive force, leading to malfunction or failure.
Innovation Solution
The DC relay incorporates a structure with a lower yoke and an upper yoke that generate electromagnetic attractive force to cancel repulsive force between the movable and fixed contacts, along with a coupling protrusion and pin member for stable coupling without additional members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate damping magnet is provided adjacent to a fixed contact to cancel electromagnetic repulsive force, then electromagnetic repulsive force is canceled, but the device complexity increases due to additional components
Solution Approach 1:
The damping magnet is integrated into the movable contactor body, merging the damping function with the movable contactor structure. This eliminates the need for separate damping magnets adjacent to fixed contacts, reducing device complexity while maintaining the electromagnetic repulsive force cancellation capability that prevents contact separation
Solution Approach 2:
The movable contactor is designed to serve multiple functions: it acts as both the contact element and the damping magnet carrier. By incorporating the damping function into the movable contactor itself, the structure achieves multi-functionality, reducing the total component count while ensuring reliable contact operation through electromagnetic repulsive force cancellation
2Device complexity
If the movable contactor is only elastically supported by an elastic portion, then the structure is simple, but the movable contactor may be arbitrarily separated from the fixed contact due to incomplete cancellation of electromagnetic repulsive force
Solution Approach 1:
The damping magnet is merged with the movable contactor body, creating an integrated structure that provides both elastic support through the elastic portion and electromagnetic repulsive force cancellation through the damping magnet. This combination maintains structural simplicity while preventing arbitrary contact separation
Solution Approach 2:
The damping magnet is positioned and configured to generate electromagnetic repulsive force that counteracts the attractive force attempting to separate the movable and fixed contacts. This preliminary anti-action prevents contact separation before it can occur, ensuring reliable contact maintenance during operation
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 effectively prevents arbitrary separation of the movable contactor, maintains stable contact between the movable and fixed contacts, and allows for coupling without separate coupling members, enhancing the reliability and operational stability of the DC relay.
Implementation Method 1
a lower yoke and an upper yoke that generate electromagnetic attractive force to cancel repulsive force between the movable and fixed contacts
Implementation Method 2
When control power is applied, the plurality of coils generate an electromagnetic field. The fixed core and the movable core are magnetized by the electromagnetic field
Data Source
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AI summary
Disclosed are a direct current relay and a manufacturing method therefor. A movable contact part provided in a direct current relay according to an embodiment of the present invention comprises a movable contact and a lower yoke positioned below the movable contact. The lower yoke is configured to attenuate an electromagnetic repulsive force generated by contact between the movable contact and a fixed contact. The movable contact is provided with a coupling protrusion portion that protrudes downward. The lower yoke is provided with a movable contact coupling portion into which the coupling protrusion portion is inserted. The coupling protrusion portion can receive pressure directed radially outward after being inserted into the movable contact coupling portion. The coupling protrusion portion is expanded radially outward by the pressure. Accordingly, the outer circumferential surface of the coupling protrusion portion can be inserted into and coupled to the inner circumferential surface of the lower yoke that forms the movable contact coupling portion. Thus, a separate fastening member for coupling the movable contact and the lower yoke is not required. Accordingly, a method for manufacturing the direct current relay can be simplified.