T-Shaped Armature Head and Pushing Block Relay Connection
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Solution Overview
Problem
The existing electromagnetic relay's interference fit assembly between the armature and pushing block leads to plastic waste and dysfunction, making assembly and disassembly difficult, and causing damage to the pushing block during assembly.
Innovation Solution
A T-shaped armature head with a vertical arm and cross arm, combined with a bar-shaped through hole, bar-shaped blind hole, and central through groove in the pushing block, allowing for metal fit assembly without external force, enabling easy assembly and disassembly, and preventing damage during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If interference fit assembly is used between the armature and pushing block, then the connection is stable and reliable, but the assembly process causes plastic waste and can damage the pushing block
Solution Approach 1:
The connection structure is divided into separate components: the armature with protrusion and the pushing block with through hole. The protrusion fits through the through hole to form a pin joint connection, separating the fitting element from the base structure. This segmentation allows easy assembly and disassembly without causing damage or waste, while maintaining connection stability during operation.
Solution Approach 2:
The protrusion acts as an intermediary element that mediates the connection between the armature and pushing block. Instead of direct interference fit between large surfaces, the protrusion serves as a dedicated connecting element that passes through the pushing block, enabling reliable transmission of motion while allowing easy assembly and disassembly.
2Strength
If interference fit assembly is used between the armature and pushing block, then the connection is strong, but disassembly is difficult and may damage components
Solution Approach 1:
The connection is segmented into a removable protrusion element that passes through the pushing block. This allows the armature to be easily separated from the pushing block by simply removing the protrusion, enabling disassembly and repair without damaging components, while maintaining strong connection during operation.
Solution Approach 2:
Instead of using interference fit to create a permanent or difficult-to-disassemble connection, the design inverts the approach by using a through-hole configuration that naturally allows easy removal. The protrusion passes through rather than being pressed into place, reversing the traditional interference fit logic to achieve easy disassembly while maintaining operational strength.
3Ease of operation
If the bump thickness is less than the hole width to enable rotation, then the pin joint function is achieved, but the connection stability is reduced
Solution Approach 1:
The connection transitions from a static interference fit to a dynamic pin joint configuration. The protrusion fits through the hole with clearance, allowing the armature to rotate relative to the pushing block within certain angle ranges. This dynamic connection maintains stability during rotation while enabling the required operational movement.
Solution Approach 2:
The design copies the functional characteristics of a traditional pin joint connection, where a protruding element passes through a hole to create a pivot point. This replicated pin joint mechanism provides both rotation capability and connection stability, solving the contradiction between operational flexibility and connection reliability.
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 allows for efficient movement of the armature to drive the pushing block, maintaining contact connections without plastic waste, reducing production costs, and enabling mass production with a simple and cost-effective structure.
Implementation Method 1
With the electromagnetic force of the powered coil, it maintains that the closed static contact is cut off and the normally-open fixed contact set is connected.
Data Source
AI summary
A connection structure of an armature and a pushing mechanism of a relay has an armature and a pushing block. The head of the armature is T-shaped and connected by a vertical arm and a cross arm. One end of the pushing block has a bar-shaped through hole and a bar-shaped blind hole, disposed alongside and vertical to the motion direction of the pushing block. A through groove to connect the bar-shaped trough hole and the blind hole is disposed at the centre of the bar-shaped through hole and the blind hole. With the through groove, the T-shaped armature head can move along the through groove when the T-shaped armature head is shoved into the bar-shaped through hole. The cross arm of the T-shaped armature head is dropped into the bar-shaped blind hole to cooperate with the bar-shaped blind hole to drive the pushing block when the armature swings.