Latch Relay Coil Spring Contact Force
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Solution Overview
Problem
Existing latch relays experience reduced contact force due to material fatigue and load variations, leading to inconsistent conduction performance and operational distance, resulting in degraded reliability and product variability.
Innovation Solution
A latch relay design incorporating a support member and a compressive coil spring elastic member between the movable contactor and transmission lever, allowing for stable contact and separation in a straight line, maintaining consistent operational performance and reducing deformation variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a leaf spring is used to provide contact force in the latch relay, then the movable contactor can be brought into contact with the fixed contactor, but the contact force decreases over time due to material fatigue and plastic deformation
Solution Approach 1:
The patent replaces the reusable leaf spring with a pre-compressed coil spring that is designed to be replaced after a certain number of operations. This disposable spring maintains consistent elastic force throughout its service life and is replaced once fatigue occurs, eliminating the gradual contact force degradation experienced with leaf springs while keeping the overall system cost-effective
2Ease of operation
If a leaf spring is used to provide contact force, then the movable contactor can operate, but load variations occur during ON/OFF operations due to material characteristic variations
Solution Approach 1:
The patent changes the spring parameter from a leaf spring geometry that is sensitive to material variations to a coil spring with controlled wire diameter, mean diameter, and pitch. These parameters can be precisely controlled during manufacturing, resulting in consistent elastic force and uniform operational characteristics across all latch relay units, eliminating the load variations experienced with leaf springs
3Manufacturing precision
If a leaf spring is used in the latch relay, then contact force can be generated, but large load error by products and load variations regarding deformation occur, resulting in degradation of consistency by products
Solution Approach 1:
The patent changes from a leaf spring with complex geometric parameters to a coil spring with simpler, more controllable parameters (wire diameter, mean diameter, pitch, number of active coils). These parameters can be precisely controlled during coiling, resulting in uniform deformation characteristics and consistent product performance across production batches
Solution Approach 2:
The patent replaces the leaf spring mechanical system with a coil spring mechanical system. The coil spring's helical structure provides more predictable and uniform elastic deformation under load, reducing manufacturing variability and improving product consistency compared to the flat leaf spring geometry
4Reliability
If the operational distance of the movable contactor is reduced due to leaf spring fatigue, then conduction performance degrades, but replacing the leaf spring is complex
Solution Approach 1:
The patent segments the latch relay into modular components, with the coil spring as a separate replaceable element. This allows the spring to be independently replaced without disassembling other components, simplifying maintenance and ensuring consistent conduction performance by replacing fatigue-prone parts without complex repair procedures
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
The design enhances durability and maintains consistent conduction and breaking performance by minimizing load variations and deformation, ensuring stable operation and increased product reliability.
Implementation Method 1
a bobbin installed in the frame and having a coil wound therearound; first and second yokes coupled to both sides of the bobbin and provided as magnetic bodies; a rotary mover formed of a magnetic body and rotating in a clockwise direction or in a counterclockwise direction between head portions of the first and second yokes
Implementation Method 2
an elastic member provided between the support member and the movable contactor and providing contact force such that the movable contactor is brought into contact with the first fixed contactor or separated from the first fixed contactor
Data Source
AI summary
A latch relay includes a frame, a bobbin installed in the frame and having a coil wound therearound, first and second yokes provided as magnetic bodies, a rotary mover rotating in a clockwise direction or in a counterclockwise direction between head portions of the first and second yokes, first and second fixed contactors installed to be spaced apart from one another and parallel to each other within the frame, a movable contactor having one end connected to the second fixed contactor, a transmission lever having one end coupled to one side of the rotary mover to make a vertical movement, a support member fixedly installed on one side of the transmission lever, and an elastic member providing contact force such that the movable contactor is brought into contact with the first fixed contactor or separated from the first fixed contactor, while moving according to a movement of the transmission lever.