Electromagnetic Relay Adjustable Contact Gap
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Solution Overview
Problem
Conventional electromagnetic relays face challenges in adjusting contact gaps to accommodate changes in electric voltage or current while maintaining stable opening and closing operations with minimal design changes, often leading to increased power consumption and heat generation.
Innovation Solution
The electromagnetic relay incorporates a backstop and backstop positioner mechanism that allows for adjustable contact gaps between fixed and movable contacts, enabling the relay to adapt to different voltage or current conditions by setting the backstop at various positions, thereby maintaining a stable contact gap with minimal design modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the contact gap is enlarged to suppress arc discharge in high voltage circuits, then arc discharge is suppressed, but the power consumption of the coil increases and heat generation increases
Solution Approach 1:
The invention changes the geometric parameter of the contact gap to a variable range rather than a fixed value. By providing an adjustable contact gap mechanism, the relay can optimize the contact gap size for different voltage levels, suppressing arc discharge in high voltage applications while allowing smaller gaps for lower voltage applications to reduce coil power consumption and heat generation.
Solution Approach 2:
The invention introduces a dynamic adjustment capability for the contact gap through the backstop positioner mechanism. The contact gap can be dynamically changed between different predetermined positions, allowing the relay to adapt to varying voltage conditions and optimize performance by selecting appropriate gap sizes rather than being locked into a single fixed gap dimension.
2Object-affected harmful factors
If the contact gap is enlarged to suppress arc discharge, then arc discharge is suppressed, but the design complexity increases due to the need for different relay types
Solution Approach 1:
The invention makes a single relay design universal by incorporating an adjustable contact gap mechanism. Instead of requiring multiple relay types with fixed different gap sizes, one relay design can serve multiple voltage applications by adjusting the contact gap to different predetermined positions, thereby reducing design complexity and inventory requirements.
Solution Approach 2:
The invention segments the contact gap adjustment into discrete predetermined positions rather than continuous adjustment. The backstop positioner provides multiple fixed positions, each optimized for specific voltage ranges, allowing the system to handle different voltage conditions with distinct gap configurations while maintaining a unified relay structure.
3Adaptability or versatility
If the contact gap is adjusted to accommodate voltage changes, then adaptability improves, but the device complexity increases due to additional components
Solution Approach 1:
The invention merges the contact gap adjustment function with the existing relay structure by integrating the backstop and backstop positioner into the contact assembly. The adjustment mechanism is combined with the contact support structure, allowing adaptability through integrated components rather than adding separate independent adjustment systems, thereby minimizing the increase in 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 solution allows for stable opening and closing operations across varying electric conditions with reduced power consumption and heat generation, as the adjustable contact gap mechanism ensures reliable performance without significant design changes to the relay components or load circuit.
Implementation Method 1
an electromagnet; a movable contact actuated by the electromagnet
Data Source
AI summary
An electromagnetic relay including an electromagnet, a movable contact actuated by the electromagnet, and a fixed contact disposed opposite to the movable contact and capable of contacting and separating from the movable contact. The electromagnetic relay further includes a backstop for stopping movement of the movable contact in a direction separating from the fixed contact, and a backstop positioner for setting the backstop at a position for defining a predetermined contact gap between the fixed contact and the movable contact. In a state where movement of the movable contact is stopped by the backstop, different-sized contact gaps are defined between the fixed contact and the movable contact, depending on the position of the backstop set by the backstop positioner.