DC Relay Coupling Structure Against Electromagnetic Contactor Separation
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Solution Overview
Problem
Existing DC relays face challenges in maintaining a stable coupled state of the movable contactor due to electromagnetic repulsive forces, leading to potential separation and malfunction.
Innovation Solution
The DC relay incorporates a pin member coupled through an upper yoke and a housing, along with a support member and a lower yoke, to effectively cancel electromagnetic repulsive forces and prevent arbitrary separation of the movable contactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the movable contactor is designed to be freely movable for operational flexibility, then ease of operation is improved, but stability of coupling between the movable contactor, housing and upper yoke deteriorates due to electromagnetic repulsive force
Solution Approach 1:
The patent introduces a lower yoke that generates electromagnetic attractive force to counterbalance the electromagnetic repulsive force acting on the movable contactor. The lower yoke is coupled to the movable contactor via a support member, creating a counteracting force system that maintains coupling stability while preserving the movable contactor's operational freedom.
Solution Approach 2:
The support member acts as an intermediary component between the lower yoke and the movable contactor. It transmits the electromagnetic attractive force from the lower yoke to the movable contactor, enabling the counterbalancing of repulsive forces while maintaining the structural integrity and stability of the coupled state.
2Speed
If electromagnetic repulsive force is increased for faster contactor actuation, then speed of operation is improved, but reliability of electrical connection deteriorates due to contactor separation
Solution Approach 1:
The lower yoke generates electromagnetic attractive force that counterbalances the repulsive force during actuation. This allows the system to utilize high repulsive forces for fast actuation while the counteracting attractive force prevents contactor separation, ensuring reliable electrical connection maintenance throughout the operation cycle.
Solution Approach 2:
The patent changes the magnetic field configuration by introducing the lower yoke, which alters the distribution and direction of electromagnetic forces. This parameter change enables the system to achieve both high-speed actuation and reliable connection by creating a balanced force system where attractive and repulsive forces work in coordination.
3Ease of operation
If the movable contactor is elastically supported for smooth movement, then ease of operation is improved, but stability of coupled state deteriorates due to insufficient resistance against repulsive force
Solution Approach 1:
The lower yoke provides a counterbalancing electromagnetic attractive force that compensates for the insufficient resistance of elastic support alone. This allows the elastic support to continue providing smooth movement while the lower yoke's attractive force prevents separation, achieving both ease of operation and coupled state stability.
Solution Approach 2:
The patent merges two support mechanisms: the elastic support member that provides smooth movement and the lower yoke that provides counterbalancing force. By combining these two systems, the patent achieves both ease of operation through elastic support and stability against separation through electromagnetic attraction.
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 coupling and prevents separation of the movable contactor, maintaining reliable electrical connection despite electromagnetic forces.
Implementation Method 1
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
Implementation Method 2
electromagnetic attractive force attractive force is generated between the fixed core and the movable core
Implementation Method 3
electromagnetic repulsive force is generated as current flows
Implementation Method 4
upper yoke and a lower yoke, to effectively cancel electromagnetic repulsive forces
Data Source
AI summary
A direct current relay is disclosed comprising a pin member and a support member. The support member allows a housing for receiving a movable contactor and an upper yoke for attenuating electromagnetic repulsive power to be coupled to each other. The pin member passes through and is coupled to the support member and the movable contactor to prevent the movable contactor from being unintendedly separated. The support member passes through and is coupled to the housing and the upper yoke, and then extends toward the radial outside by receiving applied pressure which faces the radial outside. The pin member passes through and is coupled to the support member, and then extends toward the radial outside when the pressure is released. Therefore, a separate fastening member for coupling the pin member and the support member to the housing, the upper yoke, the movable contactor, and the like is not required.