DC Relay Mover Assembly With Supporting Pin for Contact Stability
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Solution Overview
Problem
The existing direct current relays face issues with the movable contact escaping due to weak support force from the contact pressure spring or under strong external forces, which can lead to unreliable operation.
Innovation Solution
A direct current relay design that incorporates a supporting pin extending through the movable contact and mover holder, with a 'C' shape cross-section acting as a leaf spring, providing additional stability and preventing escape by connecting the movable contact and mover holder securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only a contact pressure spring is used to support the movable contact, then the device complexity is reduced, but the reliability deteriorates due to the movable contact escaping under weak support force or strong external forces
Solution Approach 1:
The supporting pin is integrated with the mover holder as a unified structure, where the pin extends through both the movable contact and mover holder to provide mechanical connection. This merging approach enhances reliability by preventing movable contact escape while avoiding the need for separate fastening components, thus not increasing device complexity.
Solution Approach 2:
The supporting pin is pre-installed in the mover holder before assembly, creating a predetermined mechanical constraint path. This preliminary action ensures that when the movable contact is assembled onto the pin, the support structure is already in place to prevent escaping, thereby improving reliability without requiring complex real-time adjustment mechanisms.
2Reliability
If a supporting pin is added to connect the movable contact and mover holder, then the reliability is improved by preventing escape, but the device complexity increases
Solution Approach 1:
The supporting pin serves multiple functions simultaneously: it acts as a mechanical connector between the movable contact and mover holder, provides structural support to prevent escaping, and guides the movable contact during operation. This multi-functionality improves reliability while minimizing the increase in device complexity by using a single component for multiple purposes.
Solution Approach 2:
The supporting pin is strategically positioned at the critical location where the movable contact interfaces with the mover holder. By concentrating the support function at this specific local area rather than distributing it throughout the entire assembly, the design improves reliability at the point of need without unnecessarily complicating the overall device structure.
3Reliability
If the contact pressure spring force is increased to prevent movable contact escape, then the reliability is improved, but the ease of operation deteriorates due to increased contact pressure
Solution Approach 1:
The design replaces the reliance on high contact pressure spring force with a mechanical constraint system using the supporting pin. Instead of using elastic force (spring) to prevent escaping, the system uses rigid mechanical guidance through the pin, which maintains reliability without requiring high contact pressure, thus preserving ease of operation.
Solution Approach 2:
The supporting pin establishes a predetermined mechanical constraint before operation begins, creating a physical guide path for the movable contact. This preliminary structural arrangement eliminates the need for high contact pressure during operation, as the pin itself provides the necessary support and prevention of escaping, thereby maintaining ease of operation while ensuring reliability.
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
The supporting pin effectively prevents the movable contact from escaping, ensuring stable operation even under external forces and enhancing the assembly process with easy insertion into the mover holder and movable contact.
Implementation Method 1
a contact pressure spring (55) disposed between the movable contact (50) and the mover support (40) to provide a contact pressure to the movable contact (50)
Implementation Method 2
a supporting pin (35) installed to extend through the movable contact (50) and the mover holder (45)... a 'C' shape cross-section acting as a leaf spring, providing additional stability
Implementation Method 3
The actuator is operated using the principles of electromagnet and includes a fixed core 7a, a movable core 7b... when a control power is applied, an electromagnetic force is generated around the cylinder 7e
Implementation Method 4
The return spring 7d provides an elastic force to the movable core 7b to allow the movable core 7b to return to its initial position when the control power of the coil is cut off
Data Source
AI summary
The present disclosure relates to a direct current relay and, more particularly, to a direct current relay including a mover assembly having improved support force with respect to a movable contactor. The direct current relay according to an embodiment of the present disclosure 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; a contact pressure spring disposed between the movable contactor and the mover support to provide a contact pressure to the movable contactor; and a supporting pin installed to extend through the movable contactor and the mover holder.