DC Relay Mover Assembly for Contact Stability Under Repulsive Force
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Solution Overview
Problem
Direct current relays face issues with unintended separation of contacts due to electromagnetic repulsive forces, which can lead to unreliable circuit operation, especially in applications like electric vehicles where consistent power supply is critical.
Innovation Solution
The design incorporates a mover assembly with an upper yoke and a lower yoke that form a magnetic circuit to offset electromagnetic repulsive forces, combined with a contact pressure spring between the lower yoke and the mover support, ensuring stable contact pressure and preventing unintended separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a contact pressure spring is used to maintain contact pressure, then contact stability is improved, but the electromagnetic repulsive force causes unintended separation when the repulsive force exceeds the contact pressure
Solution Approach 1:
The patent introduces a magnetic counterweight that generates an attractive magnetic force to counterbalance the electromagnetic repulsive force between contacts. The magnetic counterweight is positioned to create a magnetic field that pulls the movable contact toward the fixed contact, effectively抵消ing the repulsive force and maintaining stable contact pressure even under strong electromagnetic conditions.
Solution Approach 2:
The patent employs a magnetic field as an intermediary force to mediate between the electromagnetic repulsive force and the contact pressure spring. The magnetic counterweight creates a magnetic attraction that works in conjunction with the mechanical contact pressure spring, providing a combined stabilizing effect that prevents contact separation more effectively than the spring alone.
2Reliability
If the distance between fixed core and movable core is increased to provide contact pressure, then contact stability is improved, but the electromagnetic repulsive force becomes stronger
Solution Approach 1:
The magnetic counterweight compensates for the increased electromagnetic repulsive force that results from larger core spacing. By positioning the magnetic counterweight to generate an attractive force, it counterbalances the stronger repulsive force, allowing the relay to maintain contact stability even with increased core distance for better contact pressure.
3Object-affected harmful factors
If a permanent magnet is provided around the contact portion to control arc, then arc control is improved, but the electromagnetic repulsive force between contacts increases
Solution Approach 1:
The patent introduces an additional magnetic counterweight that generates an attractive force to counterbalance the increased electromagnetic repulsive force caused by the permanent magnet for arc control. This dual magnetic system allows the permanent magnet to effectively control arcs while the counterweight maintains contact stability by抵消ing the repulsive forces.
Solution Approach 2:
The magnetic counterweight acts as an intermediary that mediates between the arc control function (provided by the permanent magnet) and the contact stability requirement. It creates a balancing magnetic field that allows both arc control and contact stability to coexist despite the conflicting forces.
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 maintains contact stability, preventing unintended separation and ensuring reliable operation of the direct current relay, even under strong electromagnetic forces, thereby enhancing the reliability of power supply in applications like electric vehicles.
Implementation Method 1
an upper yoke and a lower yoke respectively disposed above and below the movable contact to generate an electromagnetic force
Implementation Method 2
a contact pressure spring disposed between the lower yoke and the mover support
Data Source
AI summary
The present disclosure relates to a direct current relay having a mover assembly having improved contact pressure. In one embodiment, a direct current relay comprises a pair of fixed contactors and a movable contactor which is moved up and down by an actuator to come into contact with or be separated from the pair of fixed contactors, comprises: a mover support disposed below the movable contactor and connected to the actuator by a shaft; a mover holder disposed above the movable contactor and fixed to the mover support; an upper yoke and a lower yoke disposed above and below the movable contactor to generate an electromagnetic force, respectively; and a contact pressure spring disposed between the lower yoke and the mover support, wherein the upper yoke and the lower yoke form a magnetic path to offset an electron repulsive force generated between the fixed contactors and the movable contactor.