Integrated Control Circuit in Electromagnetic Relay

Solution Overview

Problem

The existing electromagnetic relays for motor starters require separate control circuits, leading to increased points of connection, complexity in wiring, and vulnerability to environmental factors such as vibrations and moisture, which compromises reliability and environmental resistance.

Innovation Solution

Incorporating a control circuit within the electromagnetic relay, utilizing an IC for improved heat resistance and compactness, and integrating it with the relay coil and resistor to reduce activation current and prevent 'short break' phenomena, while also providing protection functions like temperature and overcurrent protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a separate control circuit is provided outside the electromagnetic relay, then the control function can be achieved, but the number of connection points and wiring complexity increases

Engineering Contradiction:

Improvecontrol functionVSAvoidwiring complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control circuit is integrated into the electromagnetic relay housing, merging two previously separate components (electromagnetic relay and control circuit) into a single unit. This eliminates the need for separate wiring connections between the control circuit and relay, reducing connection points and wiring complexity while maintaining the control function.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a separate control circuit is provided outside the electromagnetic relay, then the control function can be achieved, but the number of connection points and wiring complexity increases

Engineering Contradiction:

Improvecontrol functionVSAvoidnumber of connection points

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The control circuit is integrated into the electromagnetic relay housing, merging two previously separate components (electromagnetic relay and control circuit) into a single unit. This eliminates the need for separate wiring connections between the control circuit and relay, reducing connection points and wiring complexity while maintaining the control function.

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If the control circuit is provided at the vehicle exterior, then installation flexibility is improved, but environmental resistance deteriorates due to exposure to rainwater and vibrations

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidenvironmental resistance

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The control circuit is integrated into the electromagnetic relay housing, which is designed to be mounted within the starter assembly. This protected location shields the control circuit from environmental factors such as rainwater and vibrations, improving environmental resistance while maintaining installation flexibility through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

4Ease of operation

If the control circuit is provided at the vehicle exterior, then installation flexibility is improved, but environmental resistance deteriorates due to exposure to rainwater and vibrations

Engineering Contradiction:

Improveinstallation flexibilityVSAvoidprotection from rainwater

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The control circuit is integrated into the electromagnetic relay housing, which is designed to be mounted within the starter assembly. This protected location shields the control circuit from environmental factors such as rainwater and vibrations, improving environmental resistance while maintaining installation flexibility through the integrated design.

Inventive Principle:

Principle #5Merging (Combining)

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 simplifies wiring, enhances reliability and installability, improves environmental resistance, and ensures the electromagnetic relay operates effectively under harsh conditions by reducing the need for external wiring and protecting against overheating and overcurrents.

Implementation Method 1

a relay coil that forms an electromagnet when excited by energization

Methodology Applied

Scientific EffectElectromagnet: Electromagnet

Implementation Method 2

a resistor to reduce an activation current that flows through the motor from a battery

Methodology Applied

Scientific EffectElectrical Resistance: Electrical Resistance

Data Source

PatentUS9562508B2Electromagnetic relay

Publication Date: 2017.02.07 DENSO CORP

AI summary

An electromagnetic relay for starting a motor of a starter includes a resistor to reduce an activation current that flows through the motor from a battery for activation of the motor, a relay contact that causes the starting current to flow while bypassing the resistor, a relay coil that forms an electromagnet when excited by energization, and a control circuit that controls an excited state of the relay coil for activation of the motor to open or close the relay contact, thus controlling energization of the motor from the battery via the resistor. The electromagnetic relay incorporates therein the control circuit.