Magnetic Contactor with Cylindrical Core and Voltage Regulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic contactors face limitations in maintaining reliable operation across varying voltages and temperatures, leading to coil deterioration and increased resistance, which affects contact maintenance and miniaturization due to their fixed rated voltage range and bulky structure.
Innovation Solution
A magnetic contactor design featuring a broad rated voltage range, reduced coil consumption current through an inverting switch and voltage dropping element, and a compact structure utilizing a cylindrical movable core and modularized PCB with integrated inverting switch, allowing for efficient voltage regulation and space optimization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a coil with a fixed rated voltage is used in a magnetic contactor, then the contactor can operate reliably at that specific voltage, but the product cannot adapt to different voltage conditions and requires multiple variants for different voltage ranges
Solution Approach 1:
The patent applies universality by designing a single magnetic contactor model that can operate across multiple voltage ranges (24V to 600V) through optional coil selections. The contactor body and structure remain universal while accommodating different coil specifications, eliminating the need for multiple product variants and simplifying inventory management.
2Reliability
If external source current is continuously applied to the coil, then the contactor maintains its switching function, but the coil temperature exceeds the limited temperature and the resistance increases causing operational failure
Solution Approach 1:
The patent implements periodic action by introducing a duty cycle specification that limits continuous coil operation to specific time intervals (e.g., 10 seconds on, 50 seconds off). This periodic operation pattern prevents the coil temperature from exceeding the limited temperature of 65°C, thereby maintaining reliable contact operation without thermal deterioration.
3Force
If the movable core and fixed core have an E-shape configuration, then the magnetic contactor can provide sufficient magnetic force for contact switching, but the space occupied in the frame becomes large limiting product miniaturization
Solution Approach 1:
The patent applies dimensionality change by transitioning from traditional E-shaped cores to a cylindrical movable core configuration. This geometric transformation optimizes the magnetic circuit in three-dimensional space, providing sufficient magnetic force for contact switching while significantly reducing the frame space occupation and enabling product miniaturization.
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 solution ensures reliable operation within allowable voltage and temperature limits, prevents coil overheating, and enables miniaturization while maintaining contact reliability, broadening the product's useful voltage range and reducing size constraints.
Implementation Method 1
magnetic contactors are devices that switch power (a current) flowing in a main circuit by using the electromagnet principle
Implementation Method 2
When external power is applied to a coil 14a which is wound around an outer surface of the bobbin 14, a magnetic field is generated around the coil 14a
Implementation Method 3
The fixed core 15 changed to the electromagnet absorbs and downward attracts the movable core 12 of a conductor with a magnetic force
Implementation Method 4
the movable core 12 disposed on the backspring 13 is raised to the original position by an elastic restoring force of the backspring 13
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Disclosed is a magnetic contactor. The magnetic contactor includes a frame, a bobbin provided in the frame, and configured to include a hollow part, a movable core movably inserted into the hollow part in an axial direction, a yoke disposed at the outer surface of the bobbin to be separated from the coil and to face each other, and configured to act as a fixed core, and a manipulating circuit part disposed at the outer surface of the bobbin in parallel with a moving direction of the movable core to intersect the yoke. The coil is wound around an outer surface of the bobbin. Accordingly, a coil having a broad rated voltage range is used. Also, a structure of a product is simplified, and a space is broadly used.