Partitioned Electromagnetic Relay Structure for Arc Isolation
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Solution Overview
Problem
Electromagnetic relays for multiphase circuits face issues with arc separation plate occupying space, leading to reduced opening distance between contacts, arcing erosion, increased costs due to separate molds, and insufficient resistance from U-shaped movable elastic pieces, resulting in potential rebound and disconnection of movable contacts.
Innovation Solution
The design includes a housing with partitioned chambers and a rib on the inner wall to enhance electrical isolation, and a movable elastic piece with a bent cantilever portion to increase effective length and electrical force, ensuring reliable contact maintenance without rebound.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electric arc isolation plates are installed in the insulator to divide the inner cavity into chambers, then arc isolation is improved, but the opening distance between movable contact and static contact is reduced
Solution Approach 1:
The patent merges the electric arc isolation plate with the insulator into a single integrated component. The insulator itself is designed with internal partition structures that create isolated chambers, eliminating the need for separate isolation plates. This integration maintains effective arc isolation while maximizing the opening distance between contacts by removing the space occupied by separate plates.
Solution Approach 2:
The insulator is designed to perform multiple functions simultaneously: it provides electrical insulation, creates isolated chambers for arc containment through internal partitions, and maximizes contact opening distance. This multi-functional design eliminates the need for dedicated arc isolation plates, resolving the contradiction between arc isolation and opening distance.
2Reliability
If separate molds are used to manufacture electric arc isolation plates, then arc isolation function is achieved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The patent combines the arc isolation function with the insulator manufacturing process. The insulator is produced as a single integrated piece with internal partition structures formed during the same molding process, eliminating the need for separate molds and assembly steps for isolation plates. This reduces manufacturing cost and simplifies assembly while maintaining arc isolation functionality.
3Ease of operation
If the spacing between movable elastic piece and fixed terminal is increased, then assembly is easier, but electrical force generated is reduced and resistance to Holm force becomes insufficient
Solution Approach 1:
The patent changes the geometric parameters of the movable elastic piece, specifically increasing its effective length and optimizing its cross-sectional dimensions. This increases the electrical force generated during current flow and improves resistance to Holm force, while the design maintains appropriate spacing for easy assembly. The parameter optimization resolves the contradiction between assembly ease and force generation.
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 configuration reduces arcing erosion, lowers manufacturing costs, and enhances the resistance to Holm force, preventing disconnection and improving the reliability of the movable contact in multiphase circuits.
Implementation Method 1
When a short circuit current passes through the cantilever portion of the movable elastic piece and the body portion of the fixed terminal, the current directions on the fixed terminal and the movable elastic piece are opposite, which generates electrical force between the fixed terminal and the movable elastic piece
Implementation Method 2
When a short circuit current passes through a closed movable contact, a strong current contraction produces a large Holm force that drives the movable contact to separate from the static contact
Data Source
AI summary
An electromagnetic relay includes a housing, an insulator, static terminals, and movable terminals. The housing has a top wall and a bottom opening that are opposite in a height direction, a front sidewall and a rear sidewall that are opposite in a front and rear direction, and a left sidewall and a right sidewall that are opposite in a left-right direction. The insulator is arranged in the housing and is formed with a plurality of chambers which are opened towards the front sidewall and are arranged in a row along the left-right direction. The insulator includes a partition plate located between two adjacent chambers. The static terminals are fixedly arranged in respective ones of the plurality of chambers. The movable terminals are arranged in respective ones of the plurality of chambers and are adapted to electrically contact the static terminals.