Relay Armature Segmentation for High Current Stability
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Solution Overview
Problem
Conventional relays face limitations in armature flexibility and space due to welding, leading to potential overflow and burning when controlling large currents, as the armature's range is restricted within a limited space.
Innovation Solution
The design includes a longer main section with a bent portion and a connection section that increases the conductive area and flexibility, allowing the armature to pivot more accurately and stably under high currents, comprising a case with a coil unit, multiple legs, and an armature with an upright and transverse section, enhancing the armature's ability to control large currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the armature is welded to the leg of the relay to fix its position, then the armature structure is simple and easy to manufacture, but the range of motion of the armature is limited and flexibility is reduced
Solution Approach 1:
The armature is divided into multiple sections (connection section, main section, bent portion) that can pivot relative to each other, allowing the armature to be segmented into flexible segments while maintaining ease of manufacture through modular construction
Solution Approach 2:
The armature transitions from a fixed welded structure to a dynamic pivoting structure where the connection section can rotate relative to the leg, enabling the armature to adapt its position dynamically while maintaining simple manufacturing processes
2Volume of moving object
If a shorter armature is used to fit within limited relay space, then the relay size is compact, but the armature may cause overflow and burning when controlling larger currents
Solution Approach 1:
The armature extends in multiple dimensions with the connection section extending beyond the case and the main section positioned beneath the contact, utilizing three-dimensional space efficiently to provide sufficient current control capability within a compact relay volume
Solution Approach 2:
The multi-section armature structure nests within the limited relay space by positioning the main section beneath the contact and extending the connection section strategically, allowing a longer effective armature length to fit within compact relay dimensions
3Reliability
If the main section of the armature is extended to control larger currents, then the current control capability is improved, but the space required within the relay case increases
Solution Approach 1:
The armature utilizes vertical space by extending the connection section beyond the case and positioning the main section beneath the contact, allowing increased current control capability without proportionally increasing the horizontal footprint of the relay case
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
The solution provides increased flexibility and stability for the armature, enabling it to accurately turn on or off circuits under high currents, while maintaining a compact relay design by extending the armature's range and enhancing heat dissipation.
Implementation Method 1
The first end of the conductive plate is located between the coils seat and the armature. The second end of the conductive plate is resiliently contact the coils seat, or is removed from the coils seat. The driving member is connected to the first end of the conductive plate. The conductive plate pivots when the conductive plate is magnetically attracted by the coil seat
Data Source
AI summary
A relay includes a case and a coil unit is located in the case. Multiple first legs each have the first end thereof connected to the coil unit, and the second end thereof extending beyond the case. A second leg has the first end thereof located in the case and forms a contact, and the second end of the second leg extends beyond the case. A third leg includes an upright section and a transverse section which extends from the upright section and located in the case. The upright section has one end thereof extending beyond the case. An armature has a connection section connected to the transverse section, and a main section located beneath the contact. The connection section increases conductive area and flexibility of the armature in the case.