Force-Guided Relay with Coil Between Contacts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing safety relays are not compact enough for miniaturization in safety-related applications, leading to a need for a more compact and cost-effective design.
Innovation Solution
A relay with forcibly guided contacts where the armature acts as a spring contact carrier, allowing the movable contact elements to be directly fastened to the armature and the actuator to be moved perpendicularly to the coil's longitudinal axis, with a compact design achieved by arranging the coil between the opener and make contact elements and positioning the actuator on the coil's end face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional relay designs with separate armature and contact spring assemblies are used, then the relay structure is simple and easy to manufacture, but the relay size is large and not compact enough for miniaturization
Solution Approach 1:
The patent combines the armature and contact spring assembly into a single integrated component. The contact springs are directly attached to the armature, eliminating the need for separate contact spring assemblies and reducing the overall relay volume while maintaining structural simplicity
Solution Approach 2:
The armature serves multiple functions: it acts as both the magnetic actuation component and the contact spring carrier. This multi-functionality reduces the number of separate components needed, enabling miniaturization without significantly increasing structural complexity
2Length of stationary object
If the coil is arranged between the movable opener contact element and the movable make contact element with the actuator on the coil's end face, then the overall height of the relay is minimized for compact design, but the magnetic field distribution and contact actuation precision become more challenging
Solution Approach 1:
The patent positions the actuator on the end face of the coil (perpendicular to the coil axis) rather than along the coil axis, utilizing a different spatial dimension for actuator placement. This arrangement minimizes the overall height of the relay while the magnetic field lines still effectively actuate the contacts through the armature's rotational movement
Solution Approach 2:
The armature is designed to rotate about an axis perpendicular to the coil axis, dynamically converting the linear magnetic force into rotational motion that actuates both normally open and normally closed contacts. This dynamic mechanism ensures precise contact actuation despite the compact coil arrangement
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 design results in a compact and robust relay with a low overall height, defined by the actuator's length, while maintaining the necessary electrical insulation and stability for safe operation.
Implementation Method 1
a magnet system with coil, core and armature
Implementation Method 2
In a switching state, the longitudinal axis of the armature runs essentially parallel to the longitudinal axis of the coil
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The relay (5) has an opener that is provided with movable break contact elements (40,44,46) and normally closed fixed contact elements (20,27). The movable break contact elements are attached to armature (50) whose longitudinal axis is extended parallel to longitudinal axis of coil (80). The movable normally-open contact elements (140,150,160) are extended partially parallel to longitudinal axis of coil. The open extremity (42) of the movable break contact elements and open extremity (158) of movable normally-open contact element (150) are coupled to the actuator (30). USE : Relay with forcibly guided contacts, used for switching electric loads. ADVANTAGE : The operability of the relay can be improved with small size and reduced installation space. The number to components of relay can be reduced. Compact structure of the relay can be ensured with reduced cost, by arranging the coil between movable break contact elements and movable normally-open contact elements. Overall height of the relay can be adjusted corresponding to the length of the actuator. DESCRIPTION OF DRAWINGS : The drawing shows an exploded perspective view of the relay. 5 : Relay 20,27 : Normally closed fixed contact elements 30 : Actuator 40,44,46 : Movable break contact elements 42,158 : Open extremities 50 : Armature 80 : Coil 140,150,160 : Movable normally-open contact elements.