Electromagnetic Switch Deformable Force Transfer Element
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Solution Overview
Problem
Electromagnetic switches, such as relays, face damage from temporary welding of contacts due to high currents, leading to potential plastic deformation of contact springs when manually actuated.
Innovation Solution
Incorporating a deformable force transfer element between the slider and armature to limit the forces applied during manual actuation, preventing plastic deformation by deforming and capping the press force at a threshold value that avoids damage to contact springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual actuation force is increased to separate welded contacts, then contact separation may be achieved, but plastic deformation of contact springs occurs causing permanent damage
Solution Approach 1:
A deformable force transfer element is introduced as an intermediary between the manual actuator and the armature. This element deforms under excessive force to limit the maximum force transmitted to the contact springs, preventing permanent damage while still allowing contact separation when welding occurs.
Solution Approach 2:
The deformable force transfer element is pre-configured with specific mechanical properties (elastic modulus, geometry) to deform at a predetermined force threshold. This beforehand cushioning protects the contact springs from sudden force spikes during fault conditions while maintaining normal switching operation.
2Object-affected harmful factors
If contact areas are increased to reduce welding probability, then welding prevention improves, but device complexity and size increase
Solution Approach 1:
Instead of increasing contact area, the invention changes the mechanical parameter of the force transfer system by introducing a deformable element with specific force-threshold characteristics. This alternative approach addresses welding prevention through force limitation rather than geometric modification, avoiding increased device complexity.
3Strength
If force transfer element is made more deformable to limit force better, then contact spring protection improves, but switching force adequacy may be compromised
Solution Approach 1:
The force transfer element exhibits different mechanical responses at different force levels: it remains relatively rigid at normal switching forces to ensure adequate force transmission, but becomes highly deformable when force exceeds the threshold to protect contact springs. This local quality differentiation resolves the contradiction between protection and switching adequacy.
Solution Approach 2:
The force transfer element's effective stiffness is dynamic rather than static - it maintains high stiffness for normal operation and transitions to low stiffness under excessive force conditions. This dynamic behavior ensures both adequate switching force transmission and contact spring protection without compromising either function.
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
Prevents permanent damage to contact springs and ensures reliable operation by limiting forces to prevent welding and ensure contact opening and closing without causing irreversible deformation.
Implementation Method 1
The deformable force transfer element (105) is deformed by the press force on exceeding a press force threshold value
Implementation Method 2
The threshold value can for example be so selected that it corresponds to the force that a magnetic system of the electromagnetic switch, also taking an excitation into account, would also exert on the armature
Data Source
AI summary
The disclosure relates to an electromagnetic switch, comprising: an armature; a slider configured to manually move to actuate the armature; and a deformable force transfer element positioned between the slider and the armature, wherein the slider is configured to be pressed against the deformable force transfer element to actuate the armature with a press force, and wherein the deformable force transfer element is configured to deform when a press force threshold value is exceeded to limit a transferable force from the slider onto the armature.