Polarized Relay Magnetization via Segmented Assembly
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Solution Overview
Problem
Existing polarized electromagnetic relays face challenges in magnetizing permanent magnets without damaging other components, particularly the coil, due to strong induced currents and forces from rare earth magnets, making it difficult to produce small, sensitive relays with high magnetic resistance.
Innovation Solution
The design separates components to allow for the magnetization of a ferromagnetic alloy precursor within a carrier component, using soft iron magnetic flux parts that are not damaged by high magnetic field strengths, and assembling the coil assembly after magnetization to avoid risk to the electromagnet coil.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the permanent magnet is magnetized in the installed state within the base body, then the relay structure is simplified, but the coil is damaged by excessively strong induced currents
Solution Approach 1:
The relay is divided into two separate parts: a base body containing the permanent magnet precursor and magnetic flux parts, and a separate coil assembly. This segmentation allows the permanent magnet to be magnetized in the base body without the coil present, avoiding induced current damage while maintaining structural simplicity.
Solution Approach 2:
The permanent magnet precursor is magnetized in advance within the base body before the coil assembly is installed. This preliminary magnetization action eliminates the need for post-installation magnetization, thereby preventing induced current damage to the coil while achieving the desired magnetic field configuration.
2Volume of moving object
If strong permanent magnets with rare earths are used to achieve small relay size, then the relay sensitivity is improved, but handling and assembly become difficult due to strong attractive forces
Solution Approach 1:
The permanent magnet precursor is magnetized in advance within the base body before final assembly. This preliminary magnetization allows the use of strong rare earth magnets to achieve compact relay size and high sensitivity, while the magnetization process itself is performed when the magnet is still in the base body, facilitating easier handling during assembly.
Solution Approach 2:
The base body acts as an intermediary that holds the permanent magnet precursor in a controlled environment during magnetization. This intermediary structure allows strong magnets to be magnetized and handled safely before final assembly, reducing the difficulty of handling strong attractive forces during the assembly process.
3Reliability
If the permanent magnet is placed close to the coil to reduce magnetic resistance, then the magnetic flux path is improved, but the coil is exposed to strong induced voltages and currents during magnetization
Solution Approach 1:
The relay is segmented into a base body with the permanent magnet precursor and a separate coil assembly. This segmentation allows the permanent magnet to be positioned close to the coil in the final assembly to reduce magnetic resistance, while the magnetization process occurs separately when the coil is not present, avoiding induced voltage and current damage.
Solution Approach 2:
The permanent magnet precursor is magnetized in advance in the base body before the coil assembly is installed. This preliminary action enables the permanent magnet to be positioned optimally close to the coil for low magnetic resistance, while the magnetization itself is performed safely without the coil present to avoid induced electromagnetic effects.
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 method enables the production of small, sensitive polarized relays with reduced magnetic resistance and allows for various relay functions by modifying component parameters, while avoiding damage to the coil during magnetization.
Implementation Method 1
magnetizing the permanent magnet precursor in the carrier component (40), which results in the permanent magnet (11)
Implementation Method 2
an electromagnet with a coil (1)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Polarised relay with an electromagnet, two-pole or three-pole permanent magnet (11), armature (12) and switch (20; 30) mounted in and on a stack-like support component (40). The support component (40) receives magnetic flux parts (7, 8, 9) and the permanent magnet (11) in an upper chamber (41), said permanent magnet being magnetised while the electromagnet is still located outside the support component (40). The electromagnet is then pushed into a drawer (42) in the support component (40) and the remaining parts of the relay are mounted.