High-Voltage DC Relay Terminal Layout for Rapid Welding Assembly
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Solution Overview
Problem
Existing DC relays face challenges in assembly efficiency, reliability of electrical connections, and structural integrity due to conventional pin-type leading-out terminals, which are prone to breakage and require complex assembly methods.
Innovation Solution
The DC relay features load, coil, and auxiliary leading-out terminals with welding planes for quick assembly, U-shaped connections reinforced by injection molding, and a ceramic cover design with injection pieces for insulation and glue management, enhancing structural strength and assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional pin-type leading-out terminals are used, then the relay can be assembled, but the assembly efficiency is low and the electrical connection reliability is poor
Solution Approach 1:
The patent changes the connection interface parameter from pin-type to welding plane type. The welding planes provide a flat, stable surface for welding that is inherently more reliable than pin-type connections, while also enabling faster assembly through automated welding processes compared to manual pin insertion and soldering.
Solution Approach 2:
The patent replaces the mechanical pin insertion and soldering system with a welding-based connection system. The welding planes allow for direct metallurgical bonding between the relay terminals and external components, eliminating the need for separate soldering operations and improving both reliability and assembly efficiency.
2Ease of manufacture
If conventional pin-type leading-out terminals are used, then the relay structure is simple, but the terminals are prone to breakage and require complex assembly methods
Solution Approach 1:
The patent changes the terminal geometry parameter from pin-shaped to flat welding plane shape. This geometric modification eliminates the stress concentration points that exist in pin-type terminals, making them resistant to breakage during handling and assembly while maintaining structural simplicity.
Solution Approach 2:
The welding plane design inherently cushions against mechanical stress and breakage by distributing loads across a larger surface area. The flat geometry provides built-in mechanical strength that prevents the terminal from breaking during assembly operations, eliminating the need for complex protective measures.
3Productivity
If auxiliary leading-out terminals are provided on the ceramic cover, then the relay can be assembled, but the assembly process is complex and time-consuming
Solution Approach 1:
The patent segments the assembly process by providing dedicated welding planes on the ceramic cover for auxiliary terminals. This segmentation allows the auxiliary terminals to be independently positioned and welded without interfering with the assembly of other components, thereby simplifying the overall assembly process and increasing assembly speed.
Solution Approach 2:
The welding planes for auxiliary terminals are pre-formed on the ceramic cover during manufacturing. This preliminary action eliminates the need for post-assembly modification or complex routing of auxiliary terminals, allowing for rapid assembly by simply positioning and welding the terminals to their predetermined locations.
Data Source
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AI summary
A high-voltage DC relay convenient for quick assembly includes a housing, and load leading-out terminals, coil leading-out terminals and auxiliary leading-out terminals being provided with a connecting part for electrical connection with an external component. The connecting parts are respectively exposed to the housing; the connecting part of the load leading-out terminal is arranged at a top end of the housing; and the connecting parts of the coil leading-out terminal and the auxiliary leading-out terminal is arranged at a bottom end of the housing. Each connecting part has a welding plane for electrical connection with a corresponding one of the external components through quick welding. The present disclosure can realize the rapid welding assembly of products, maximize production efficiency of assembly and welding, and has characteristics of simple structure, low manufacturing cost and reliable electrical connection.