Electromagnetic Relay Layout for Easier Armature Assembly
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Solution Overview
Problem
Existing electromagnetic relays face challenges in assembly efficiency and productivity due to complex configurations and arrangements of components.
Innovation Solution
The electromagnetic relay is designed with a configuration that allows sequential assembly of contact units and armature units along a single direction, incorporating a holder with a separator to simplify the magnetic gap and improve assembly workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If all components (fixed contacts, movable contacts, yokes, and armature) are arranged in one direction on the base, then the electromagnetic relay structure is simplified, but the assembly operation becomes complex and productivity decreases
Solution Approach 1:
The electromagnetic relay is divided into separate modules: a contact mechanism unit containing all contact components (fixed contacts, movable contacts, movable springs) and an electromagnet unit containing the armature, yokes, and coil. These modules are manufactured independently and then assembled together, allowing parallel production and simplifying the assembly process while maintaining structural simplicity.
Solution Approach 2:
The patent transitions from arranging all components in a single direction (one-dimensional layout) to a multi-dimensional arrangement where contact units and electromagnet units are positioned at different locations on the base and connected through magnetic fields. This spatial reorganization enables more efficient assembly operations while preserving the simplified structural arrangement.
2Ease of operation
If the magnetic gap is simplified by incorporating a holder with separator, then assembly workability is improved, but the precision of magnetic field control may be affected
Solution Approach 1:
A holder with an integrated separator is introduced as an intermediary component between the armature and the magnetic circuit. The separator portion creates a controlled magnetic gap without requiring complex adjustment mechanisms, thereby improving assembly workability while maintaining sufficient magnetic field control precision through the designed gap structure.
Solution Approach 2:
The holder combines multiple functions into a single component: it supports the armature, provides mechanical separation, and incorporates a separator to establish the magnetic gap. This integration simplifies the assembly process by reducing the number of separate components while maintaining the necessary magnetic field control through the built-in separator structure.
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 enhances assembly efficiency and productivity by facilitating easier assembly and reducing component complexity, while maintaining reliable contact switching and detection capabilities.
Implementation Method 1
an electromagnet which includes a coil and a yoke provided so as to protrude from the coil
Implementation Method 2
a permanent magnet held between the pair of yokes
Data Source
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AI summary
An electromagnetic device (3X) includes: an electromagnet (5) including a coil (50) and a yoke (52); an armature (7); a permanent magnet (9) including poles one of which faces the armature (7); and an auxiliary yoke (Y1) including a first surface (Y11) which faces the other of the poles of the permanent magnet (9) and crosses a magnetic pole direction of the permanent magnet (9), and a second surface (Y12) facing the yoke (52), the armature (7) moving toward or away from the yoke (52) when the electromagnet (5) is excited, the second surface (Y12) of the auxiliary yoke (Y1) facing the yoke (52) in a range of at least part of a movable range of the armature (7) moving in response to the excitation.