Relay Armature Structure to Prevent Spring Deformation
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Solution Overview
Problem
Conventional relays face issues with performance variation and size due to insecure fixation of fixed terminals, deformation of movable springs during caulking, and inefficient use of space, leading to potential malfunctions and increased size.
Innovation Solution
The relay design includes an electromagnet with a recessed armature, fixed terminals inserted at an angle, and an iron core positioned centrally to optimize space usage, along with a movable spring design that prevents distortion during caulking, ensuring secure attachment and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the movable spring is formed from a relatively thin metal plate and caulked to the armature, then the relay size is reduced, but the movable spring may be deformed by the pressing force of the punch during caulking
Solution Approach 1:
The armature is designed with a through-hole positioned at the recessed portion before the caulking process. This preliminary structural preparation allows the movable spring to be inserted and positioned accurately, enabling precise caulking that minimizes deformation while securing the thin metal plate spring to the armature
Solution Approach 2:
The through-hole in the armature acts as an intermediary structure that facilitates the connection between the movable spring and armature. The hole provides a precise location for the spring to engage with the armature, allowing the caulking process to apply force through a controlled path that reduces deformation of the thin metal plate
2Reliability
If the fixed terminals are inserted at an angle to secure fixation, then the terminal fixation is improved, but the space utilization becomes inefficient
Solution Approach 1:
The armature is designed with recessed portions at both ends in the direction perpendicular to the axial direction of the iron core. This asymmetric recessed structure creates optimized engagement surfaces that allow secure terminal fixation while maintaining compact dimensions. The recessed portions provide precise positioning for terminal attachment without requiring excessive insertion angles
Solution Approach 2:
The invention transitions from conventional terminal insertion approaches to utilizing the recessed portions at the ends of the armature. This dimensional approach allows terminals to be secured through the recessed structures, achieving reliable fixation while optimizing space utilization in the horizontal direction rather than requiring angled insertion that would consume vertical space
3Length of stationary object
If the armature is designed with recessed ends to optimize space, then the relay height is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The recessed portions are integrated into the armature design as a preliminary structural feature before assembly. By forming the recesses as part of the armature manufacturing process rather than as separate features, the design simplifies the overall manufacturing workflow and reduces the accumulation of tolerances that would otherwise require极高 precision
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 enhances energization performance, suppresses performance variations, and allows for a compact, reliable relay with reduced height and minimized risk of malfunctions by ensuring secure terminal fixation and efficient space utilization.
Implementation Method 1
an electromagnet having a coil wounded on a winding frame and an iron core positioned in the winding frame
Data Source
AI summary
A relay is described that comprises, for example, an electromagnet having a coil wounded on a winding frame and an iron core positioned in the winding frame, a movable terminal having an armature actuated by activation of the electromagnet, a movable spring attached to the armature and a movable contact attached to the movable spring, and a fixed contact opposed to the movable contact. The armature has a shape in which both ends of the armature in a direction perpendicular to an axial direction of the iron core are recessed relative to a center of the armature, and the armature does not exist in a thickness direction of a site which is cut to form the movable spring.