DC Relay Contact Assembly Anti-Rotation for Friction Control
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Solution Overview
Problem
High-voltage DC relays experience unstable contact resistance and metal noise due to friction between the movable contact assembly and the push rod assembly, leading to potential failure from metal particles accumulating on the contact surface.
Innovation Solution
Incorporation of an anti-rotation structure with flexible or elastic anti-rotation pieces that provide elastic forces to the movable contact assembly, preventing rotation and reducing friction, and an elastic assembly for contact pressure, along with magnetizers to manage electric repulsion forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the movable contact assembly is allowed to rotate around the push rod axis, then the relay structure is simpler, but friction between the movable contact assembly and contact bracket increases causing metal noise and unstable contact resistance
Solution Approach 1:
The patent introduces an anti-rotation structure that changes the rotational parameter from free rotation to constrained rotation. The anti-rotation piece with elastic deformation capability modifies the mechanical parameters of the system, allowing controlled rotation while preventing excessive deflection that would cause instability in contact resistance.
Solution Approach 2:
The anti-rotation piece acts as an intermediary element between the movable contact assembly and the contact bracket. It mediates the interaction by providing elastic deformation to absorb rotational forces, thereby reducing direct friction between metal surfaces while maintaining structural connection.
2Object-generated harmful factors
If friction between movable contact assembly and contact bracket is reduced, then metal noise and particle generation decrease, but the anti-rotation structure adds device complexity
Solution Approach 1:
The anti-rotation piece is designed as a flexible elastic component that can deform to accommodate rotational movements. This flexible element reduces friction and metal-to-metal contact by allowing controlled deformation, thereby decreasing metal noise and particle generation while adding minimal structural complexity.
Solution Approach 2:
The patent converts the harmful friction force into beneficial elastic deformation of the anti-rotation piece. The friction that would normally cause wear and noise is transformed into elastic energy storage and release in the anti-rotation piece, reducing direct metal-to-metal contact while maintaining the necessary mechanical interaction.
3Stability of the object's composition
If the movable contact assembly deflection angle is controlled, then contact position stability improves, but additional anti-rotation constraints increase structural complexity
Solution Approach 1:
The anti-rotation structure modifies the deflection angle parameter by introducing elastic constraints. The anti-rotation piece can deform within a controlled range to allow necessary movement while preventing excessive deflection, thereby maintaining contact position stability without requiring complex rigid constraints.
Solution Approach 2:
The patent employs a dynamic anti-rotation solution where the anti-rotation piece can elastically deform during operation. This dynamic capability allows the structure to adapt to operational requirements while maintaining controlled deflection angles, providing stability without the need for complex fixed constraints.
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
Stabilizes contact resistance, reduces metal noise and particle generation, and enhances the reliability of the relay by minimizing friction and maintaining consistent contact position.
Implementation Method 1
an anti-rotation structure, including a first anti-rotation piece and a second anti-rotation piece, the first anti-rotation piece is located between the first side wall and the first side surface, the second anti-rotation piece is located between the second side wall and the second side surface
Implementation Method 2
When the coil unit is energized, the static iron core can generate magnetic attraction force and attract the movable iron core to move, thereby driving the push rod assembly together with the movable contact assembly to move
Data Source
AI summary
A relay includes a pair of static contact leading-out terminals; a movable contact assembly including a movable contact piece are configured to contact with or separate from the pair of static contact leading-out terminals along a first direction; the movable contact assembly has a first and a second side surfaces along a third direction; wherein a moving direction of the movable contact piece, the first direction, and the third direction are perpendicular with each other; a push rod assembly including a contact bracket; the contact bracket has a first side wall corresponding to the first side surface and a second side wall corresponding to the second side surface along the third direction; and an anti-rotation structure including a first anti-rotation piece located between the first side wall and the first side surface and a second anti-rotation piece located between the second side wall and the second side surface.