Electromagnetic Relay Armature Engagement Design
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Solution Overview
Problem
The production of electromagnetic relays often results in defects due to the scraping of connecting cards during assembly, which can lead to poor contact connections and deformation of the armature's fitting parts, causing reliability issues.
Innovation Solution
The electromagnetic relay design incorporates an armature with a chamfered engagement part and cutaway or recessed features that guide and securely engage the connecting card, preventing scraping and deformation by using inclined surfaces and a deforming mechanism to ensure proper alignment and contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the card is fitted into the armature connecting part, then the card is connected to the armature, but the card material is scraped off producing scrapings
Solution Approach 1:
The armature connecting part is pre-formed with a chamfered surface before the card fitting process. This preliminary chamfering action prepares the surface to guide the card insertion smoothly, preventing scraping from occurring during the subsequent card fitting operation.
Solution Approach 2:
The chamfered surface acts as an intermediary between the card and the armature connecting part. This intermediate chamfered surface guides the card into proper alignment and distributes the contact pressure, preventing direct scraping between the card and the hard armature material.
2Ease of manufacture
If the armature connecting part is formed narrow for card fitting, then the card connection is achieved, but the connecting part strength is insufficient causing deformation
Solution Approach 1:
The armature connecting part has different local qualities: a narrow region for card fitting and a chamfered surface region for smooth insertion. The chamfered surface is specifically designed with this local geometric feature to provide both the necessary guidance for card fitting and sufficient structural strength to prevent deformation during the fitting process.
3Productivity
If card scrapings remain inside the case, then the assembly is completed, but the contacts experience poor connection
Solution Approach 1:
The chamfered surface design prevents the generation of card scrapings in the first place by providing a smooth guidance surface during card insertion. This preliminary anti-action approach prevents the harmful effect (scrapings) from occurring, thereby eliminating the risk of contact connection problems before they can arise.
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 effectively suppresses defects in the production process by preventing card scraping and ensuring reliable contact connections, reducing the likelihood of scrapings and deformation, thus enhancing the reliability and performance of the electromagnetic relay.
Implementation Method 1
An electromagnetic relay is provided with an electromagnet which includes a coil, an armature which faces the electromagnet
Data Source
Figure 1
Figure 2~4
Figure 5~6
AI summary
An electromagnetic relay is provided with an armature (31) which is pulled by an electromagnet (12) and a card (16) which transmits operation of the armature to the moving electrode plate. The armature (31) includes an engagement part (31b) which engages with the card (16). The card (16) includes a pedestal part (16b) which extends from the card body, a deforming part (16d) which extends from the card body and can elastically deform, and a tab (16c) which sticks out toward the pedestal part. The deforming part (16d) has a first part which extends from the card body and a second part which extends bent from the first part. The engagement part (31b) is sandwiched between the pedestal part (16b) and the second part. The ends in the width direction of the surface which the tab contacts when the engagement part is pushed between the pedestal part and the tab are formed with inclined parts.