Magnetic Switch Movable Distance Limiting Unit
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Solution Overview
Problem
In magnetic switches used in electric vehicles, deviations in assembly tolerances of the movable core, shaft, and stationary contact affect the contact pressure distance, leading to performance deviations, as the contact pressure distance is sensitive to changes in movable and contact distances.
Innovation Solution
A magnetic switch design that includes a movable distance limiting unit, a coil assembly, a contact spring, and a return spring to maintain a consistent contact pressure distance by limiting the movable distance and using a guide portion and anti-rotation features to prevent rotation and ensure precise movement of the movable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If assembly tolerance is relaxed for easier manufacturing, then ease of manufacture is improved, but contact pressure distance precision deteriorates
Solution Approach 1:
The patent introduces a movable distance limiting unit as an intermediary component between the movable core and the stationary contact. This limiting unit includes a limiting portion that physically restricts the movable distance of the movable core, thereby decoupling the contact pressure distance from direct dependence on assembly tolerances of the movable core and stationary contact. The intermediary structure allows manufacturing with relaxed tolerances while maintaining precise contact pressure distance control.
2Ease of manufacture
If assembly tolerance is relaxed for easier manufacturing, then ease of manufacture is improved, but magnetic switch performance stability deteriorates
Solution Approach 1:
The movable distance limiting unit serves as a mediator that isolates the contact pressure distance from variations in assembly tolerances. By introducing this intermediate structure, the system can be manufactured with relaxed tolerances while the limiting unit ensures consistent movable distance and contact pressure distance, thereby maintaining performance stability despite easier manufacturing conditions.
3Measurement precision
If contact pressure distance is made sensitive to assembly tolerances for precise control, then measurement precision is improved, but device complexity increases
Solution Approach 1:
Rather than implementing complex measurement and adjustment systems to achieve precise contact pressure distance control, the patent uses a simple mechanical intermediary - the movable distance limiting unit with its limiting portion. This structure passively enforces precise movable distance control through its geometry alone, avoiding the need for active measurement systems or complex adjustment mechanisms, thus achieving precision without increasing device complexity.
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 design minimizes factors affecting the contact pressure distance, thereby stabilizing the performance of the magnetic switch and reducing deviations caused by assembly tolerance issues.
Implementation Method 1
a coil to generate a magnetic force in accordance with a flow of an electric current on the coil
Implementation Method 2
a contact spring to apply an elastic force to the movable contact in a direction that the movable contact moves toward the stationary contact
Implementation Method 3
a return spring to apply an elastic force to the movable unit in a direction that the movable contact is separated from the stationary contact
Data Source
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AI summary
A magnetic switch comprises a first frame (110) and a second frame (120), a stationary contact (130) to face the second frame, a movable contact (140) contactable with or separated from the stationary contact, a coil assembly that generates a magnetic force in accordance with a flow of an electric current, a movable unit that makes the movable contact to be contactable with or separated from the stationary contact, a contact spring (165) that applies an elastic force to the movable contact in a direction that the movable contact moves toward the stationary contact, a movable distance limiting unit (170) limiting a movable distance of the movable unit to determine a contact pressure distance that the movable contact contacts the stationary contact and the contact spring is pressed, and a return spring to apply an elastic force to the movable unit in a direction that the movable contact is separated from the stationary contact.