Shock-Resistant Relay Structure for Armature Jump Control
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Solution Overview
Problem
Relays used in applications susceptible to shock and vibration, such as electric vehicles, face issues with plastic deformation of springs due to impact, leading to loss of contact force and increased complexity and cost when reinforcing members are added.
Innovation Solution
A hinge-type relay design with integrated ribs and posts in the case to guide and limit armature movement, a compact case structure with resin sealing, and a base with integrated arc-extinguishing and magnetic shielding features to prevent deformation and malfunction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reinforcing members are added to prevent spring deformation under impact, then reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The case integrates multiple functions: it houses the armature, provides guiding ribs for movement, incorporates posts for positioning, and includes integrated arc-extinguishing and magnetic shielding features. This consolidation eliminates the need for separate reinforcing members while maintaining reliability under impact and vibration.
Solution Approach 2:
The case serves multiple purposes simultaneously: structural support, armature guidance, positioning, arc extinction, and magnetic shielding. This multi-functionality prevents spring deformation without adding dedicated reinforcing components, thereby reducing device complexity while improving reliability.
2Manufacturing precision
If integrated ribs and posts are added to guide and limit armature movement, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The guiding ribs and positioning posts are integrated directly into the case structure as a unified component rather than separate parts. This merging achieves precise armature movement control while avoiding the complexity of assembling multiple separate guiding and positioning components.
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
Prevents plastic deformation of springs and reduces component count while maintaining contact accuracy and reliability under impact and vibration, enhancing durability and reducing manufacturing costs.
Implementation Method 1
a relay comprising an electromagnet (20)
Implementation Method 2
a movable spring (58) attached to the armature (60)... the other end of the movable spring (58) comes into contact with the front end (84)
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A base of a relay has a leg extending in a contact/separation direction between contacts, and the leg is configured to come into contact with a yoke when the base is incorporated into a case. The leg is spaced away from an upper part of an armature by a distance. This distance is determined so that an upper surface of the armature does not come into contact with the leg in a normal operation of the armature, but the upper surface of the armature comes into contact with a lower surface of the leg when the armature jumps up beyond a movable range thereof due to, for example, a strong impact applied to a vehicle on which the relay is mounted.