Electromagnetic Relay with Integrated Armature and V-Shaped Spring
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Solution Overview
Problem
Electromagnetic relays used for high voltage direct current applications face challenges in reducing manufacturing costs and size due to the need for additional components to manage electromagnetic repulsion forces and arc extinction across contacts, leading to increased complexity and cost.
Innovation Solution
The design incorporates a samarium-cobalt permanent magnet, a hinge spring, and a V-shaped armature with a movable contact spring featuring cut projection portions to manage arc direction and repulsion forces without additional components, allowing for efficient arc extinction and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional components (such as iron pieces) are attached to generate contact force between movable contact and fixed contact, then the electromagnetic repulsion force is managed, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The patent combines the armature and movable contact spring into a single integrated component. The armature serves dual functions: as the magnetic actuator that moves in response to the electromagnetic field, and as the support structure for the movable contact spring. This integration eliminates the need for separate iron pieces or additional components to generate contact force, thereby reducing component count while maintaining reliable contact force generation during overcurrent energization.
2Reliability
If current paths are formed around the fixed contact and movable contact, then the electromagnetic repulsion force is managed, but the relay size increases
Solution Approach 1:
Instead of forming current paths around the contacts to manage electromagnetic repulsion, the patent inverts the approach by using the armature's magnetic properties and the movable contact spring's elasticity to directly counteract repulsion forces. The armature, being magnetic, is attracted to the electromagnetic coil, and this attraction force is transmitted through the integrated structure to maintain contact pressure, eliminating the need for peripheral current paths and reducing overall relay size.
3Reliability
If additional components are added to handle high voltage direct current arc extinction, then arc extinction is achieved, but manufacturing cost increases
Solution Approach 1:
The patent employs a permanent magnet arranged in opposition to the electromagnetic coil, creating a magnetic field that interacts with the arc current. This configuration generates a magnetic force that naturally directs and extinguishes arcs without requiring additional arc extinction components. The system uses its existing magnetic components (electromagnetic coil and permanent magnet) to perform the arc extinction function, making the system self-sufficient and avoiding increased manufacturing costs.
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 effectively extinguishes arcs and reduces the electromagnetic repulsion force, enabling a compact and cost-effective electromagnetic relay capable of handling high voltage direct current without the need for additional components, thus lowering manufacturing costs and simplifying the design.
Implementation Method 1
an electromagnetic coil and a permanent magnet arranged in opposition to each other
Implementation Method 2
a samarium-cobalt permanent magnet
Implementation Method 3
a hinge spring
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
An electromagnetic relay (I) includes: a pair of fixed contact terminals (22), each of which has a fixed contact (38); a movable contact spring (18) that has a pair of movable pieces (18a, 18b) and a coupler (18c) that couples the pair of movable pieces, each of the pair of movable pieces having a movable contact (36) that contacts and is separated from the fixed contact; an armature (16) that has a flat plate (16a) to be adsorbed to an iron core (24) and a hanging portion (16b) bent from the flat plate and extending downward, and moves the movable contact spring by a rotation operation; and an electromagnetic device (31) that drives the armature, wherein the hanging portion has a projection (16f) to fix the movable contact spring on a face thereof facing the electromagnetic device and a pulling portion (16b2) that extends downward more than the projection and pulls the movable contact spring when a current flows between the fixed contact and the movable contact.