External Magnetic Tool for Switching Encapsulated Electromagnetic Relays
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Solution Overview
Problem
Electromagnetic relays without lock-down door and test button assemblies, such as slim relays, lack a means to switch states without energizing the coil, posing challenges during debugging and commissioning, especially when relays are encapsulated and internal components are inaccessible.
Innovation Solution
A tool with a switching member comprising a magnet that moves between defined positions to exert a magnetic force on the armature, switching the relay's state from normally open to normally closed without energizing the relay, using a detachable member with a predefined path that corresponds to the relay's configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lock-down door and test button assembly is integrated into the relay, then manual switching capability is provided, but the cost and device complexity increase
Solution Approach 1:
The patent introduces an external tool as an intermediary device that provides manual switching capability without modifying the relay structure. The tool uses a magnet to interact with the relay's armature through the encapsulation, enabling manual operation while keeping the relay itself simple and cost-effective.
Solution Approach 2:
The patent replaces the mechanical lock-down door and test button assembly with a magnetic field-based switching mechanism. Instead of physical mechanical components integrated into the relay, an external magnet is used to actuate the armature through magnetic attraction, eliminating the need for complex mechanical assemblies.
2Reliability
If the relay is encapsulated for protection, then reliability is improved, but accessibility to internal components for switching is lost
Solution Approach 1:
The external tool acts as a mediator that bridges the gap between the user and the encapsulated relay. The magnet in the tool can transmit force through the encapsulation material to actuate the armature internally, allowing operation without physical access to internal components while maintaining the protective encapsulation.
Solution Approach 2:
The patent replaces direct mechanical access to internal components with magnetic field interaction. The magnetic force can penetrate the encapsulation material to actuate the armature, eliminating the need to open or access the encapsulated relay while maintaining both protection and operability.
3Ease of operation
If the relay is energized to switch state, then switching capability is provided, but the risk of damage and cost increase
Solution Approach 1:
The external magnet serves as an intermediary that provides switching capability without requiring electrical energization of the relay coil. By using magnetic attraction directly on the armature, the tool enables state switching while avoiding the risks associated with applying power to potentially faulty or high-voltage relays.
Solution Approach 2:
The patent replaces electrical actuation (energizing the coil) with direct magnetic actuation. Instead of using electromagnetic induction through the coil to move the armature, an external permanent magnet provides the magnetic force directly, eliminating the need for electrical energy and associated risks of damage from improper energization.
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
Enables switching of electromagnetic relay states externally, allowing for debugging and commissioning without energizing the relay, thereby overcoming the limitations of encapsulated relays and cost constraints associated with additional assemblies.
Implementation Method 1
a magnet capable of moving between a first position and a second position along a path oriented to the relay; wherein movement of the switching member from the first position to the second position is capable of switching a switch state of the electromagnetic relay via a magnetic force exerted by the switching member
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
A tool and method for switching an electromagnetic relay may be provided, whereby the tool comprises a switching member capable of moving between a first position and a second position along a path oriented to the relay; wherein movement of the switching member from the first position to the second position is capable of switching a switch state of the electromagnetic relay via a magnetic force exerted by the switching member.