Halbach Arc Path Unit for Universal DC Relay Arc Extinction
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Solution Overview
Problem
Existing DC relays face challenges in manufacturing cost and convenience due to the need for different structural designs for large- and small-capacity relays, and lack of effective arc path formation units to manage arc discharge.
Innovation Solution
An arc path formation unit utilizing a Halbach array with specific magnetic block arrangements and spacers to control magnetic field intensity and direction, allowing for a unified design across capacities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the intensity of magnetic fields is increased to improve arc discharge performance, then arc discharge capability is improved, but device complexity and manufacturing cost increase due to different structural designs required for large- and small-capacity relays
Solution Approach 1:
The Halbach array structure with specifically arranged magnetic blocks (first, second, and third blocks with defined polarities) creates a universal arc path formation unit that can be applied to DC relays of various capacities. The standardized configuration allows the same structural design to serve both large-capacity and small-capacity relays, eliminating the need for capacity-specific structural variations while maintaining effective arc discharge performance across different power ratings.
Solution Approach 2:
The patent applies local quality by strategically arranging magnetic blocks with different polarities in specific positions (first block, second block overlapping it, and third block facing the first) to create localized magnetic field zones. This localized magnetic field control enables precise arc path formation without requiring overall structural complexity, as the magnetic field intensity and direction are optimized only in the critical arc discharge region rather than throughout the entire relay structure.
2Reliability
If different structural designs are used for large- and small-capacity DC relays to optimize performance, then arc discharge performance is optimized, but manufacturing cost and convenience deteriorate
Solution Approach 1:
The Halbach array structure with specifically arranged magnetic blocks (first, second, and third blocks with defined polarities) creates a universal arc path formation unit that can be applied to DC relays of various capacities. The standardized configuration allows the same structural design to serve both large-capacity and small-capacity relays, eliminating the need for capacity-specific structural variations while maintaining effective arc discharge performance across different power ratings.
3Speed
If magnetic fields are strengthened to ensure rapid arc discharge, then arc discharge speed is improved, but harmful factors increase due to potential damage to adjacent components
Solution Approach 1:
The patent applies local quality by strategically arranging magnetic blocks with different polarities in specific positions (first block, second block overlapping it, and third block facing the first) to create localized magnetic field zones. This localized magnetic field control enables precise arc path formation without requiring overall structural complexity, as the magnetic field intensity and direction are optimized only in the critical arc discharge region rather than throughout the entire relay structure.
Solution Approach 2:
The Halbach array configuration converts the potentially harmful strong magnetic field into a beneficial controlled arc path formation mechanism. By arranging magnetic blocks with alternating polarities in a specific pattern, the magnetic field is concentrated and directed along a predetermined arc path, transforming what could be a harmful diffuse magnetic field into a useful, controlled arc discharge channel that protects adjacent components while maintaining rapid discharge speed.
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 solution reduces manufacturing costs and improves convenience by enabling a single design for DC relays of varying capacities, while effectively extinguishing arcs and protecting adjacent components.
Implementation Method 1
The plurality of magnetic bodies arranged according to a certain rule and may produce magnetic fields by themselves or with each other
Implementation Method 2
The Halbach array includes two relatively long surfaces and two relatively short surfaces. At this time, magnetic fields which are produced by the magnetic bodies constituting the Halbach array on the outer side of one of the two long surfaces may be stronger
Implementation Method 3
An electromagnetic force generated by the produced magnetic fields and the flow of current forms a discharge path of the arc
Implementation Method 4
When the fixed contact and the movable contact are separated from each other, an arc is generated between the fixed contact and the movable contact. The arc is a flow of high-pressure and high-temperature current
Data Source
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AI summary
The present invention relates to an arc path formation unit which can reduce manufacturing costs and improve manufacturing convenience, and a direct current relay comprising same, and provides the arc path formation unit and the direct current relay comprising same, which comprise a magnet frame and a Halbach array disposed adjacent to an inner circumference of the magnet frame and forming a magnetic field inside the magnet frame, wherein the Halbach array comprises a first block, a second block, and a third block arranged in parallel with each other in one direction, and a surface of each of the first block and the third block facing the second block is magnetized to have a polarity identical to that of a surface of the second block opposite to the stationary contactor.