Double-break relay with synchronous contact bridge
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In DC applications, particularly in vehicles with 24 VDC or 48 VDC, existing relays face challenges in safely and quickly extinguishing the electric arc that occurs when the contact spring is deflected between relay contacts, leading to high electric arc energy.
Innovation Solution
A relay design featuring two contact springs fixed to relay connection contacts with a stationary conductive contact bridge and a solenoid-operated mechanism for synchronous parallel deflection, reducing electric arc energy by halving it through double interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single contact spring is used to close or interrupt the electric circuit, then the relay structure is simple, but the electric arc energy is high and difficult to extinguish
Solution Approach 1:
The patent divides the single contact spring into two separate contact springs (first contact spring and second contact spring) that operate in series. This segmentation creates two separate interruption points for the electric circuit, effectively halving the electric arc energy by splitting the arc into two smaller arcs that occur sequentially rather than simultaneously across a single contact point.
2Object-generated harmful factors
If two contact springs are used in series to reduce electric arc energy, then the electric arc energy is halved, but the relay structure becomes more complex
Solution Approach 1:
The patent merges the actuation mechanism for both contact springs into a single solenoid-operated mechanism. This lifting magnet simultaneously deflects both the first and second contact springs into their closed or open positions, coordinating their motion through a shared magnetic field and common plunger core, thereby reducing overall structural complexity despite having two contact springs.
Solution Approach 2:
The patent introduces a stationary contact bridge as an intermediary element that connects the two contact springs in series. This contact bridge serves as a fixed connection point between the movable contact springs, enabling the series configuration while maintaining a compact and simplified structural arrangement.
3Object-generated harmful factors
If a solenoid-operated mechanism is used for synchronous deflection of two contact springs, then the electric circuit interruption is synchronized and electric arc energy is reduced, but the device complexity increases
Solution Approach 1:
The patent replaces complex mechanical linkage systems with a magnetic field-based solenoid mechanism. The lifting magnet uses electromagnetic forces to simultaneously deflect both contact springs, eliminating the need for complex mechanical gears, linkages, or cam mechanisms that would be required to achieve synchronized motion through purely mechanical means.
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 synchronous double interruption of the electric circuit using two series-connected contact springs effectively reduces electric arc energy, ensuring safe and efficient switching with reduced bounce in both closed and open relay positions.
Implementation Method 1
a single solenoid-operated mechanism for the synchronous, parallel deflection of the two contact springs into the closed or open relay position
Implementation Method 2
The solenoid actuator may be constructed in a mono-stable or bi-stable manner
Implementation Method 3
two contact springs which are each fixed in an electrically conductive manner to the relay connection contacts
Implementation Method 4
the important aspect is to safely and quickly extinguish the electric arc, which occurs temporarily when the contact spring is deflected into the closed relay position, between the relay contact and the contact spring which is approaching
Data Source
AI summary
A relay for closing or interrupting the electric circuit between two relay connection contacts includes two contact springs which are each fixed in an electrically conductive manner to the relay connection contacts with the spring ends thereof facing away from each other and which face each other with the other free, deflectable spring ends thereof. A stationary, electrically conductive contact bridge, against which the free spring ends abut in the closed relay position and from which the free spring ends are lifted in the open relay position, is included. A single solenoid-operated mechanism is for the synchronous, parallel deflection of the two contact springs into the closed or open relay position.