Electromagnetic Relay Auxiliary Terminal Malfunction Detection

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Solution Overview

Problem

Conventional electromagnetic relays lack an auxiliary terminal to detect malfunctions such as welding between movable and fixed terminals, which can lead to undetected failures.

Innovation Solution

Incorporating an auxiliary terminal configuration with a distinct auxiliary external input/output terminal and auxiliary external output/input terminal, along with an auxiliary movable terminal and armature, to enable detection of malfunctions by switching between electrical connection and disconnection, supported by an auxiliary driving portion and an electromagnet.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an auxiliary terminal is added to detect malfunctions, then reliability is improved, but device complexity increases

Engineering Contradiction:

Improvedetection capabilityVSAvoidstructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The auxiliary movable terminal is integrated with the main movable terminal structure, both being moved by the same armature. This merging approach allows malfunction detection functionality to be added while sharing common structural elements, thereby improving reliability without proportionally increasing device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The armature serves multiple functions: it moves both the main movable terminal for switching operation and the auxiliary movable terminal for malfunction detection. This multi-functionality allows the detection capability to be added while reusing existing actuation mechanisms, reducing the overall complexity increase

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If partition wall is added to separate terminals, then manufacturing precision is improved, but device complexity increases

Engineering Contradiction:

Improveterminal positioningVSAvoidstructure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The relay body is divided into separate regions by partition walls, with each terminal pair (main and auxiliary) having its own dedicated space. This segmentation prevents manufacturing errors from affecting multiple terminals simultaneously and simplifies assembly, improving manufacturing precision while keeping the partition structure relatively simple

Inventive Principle:

Principle #1Segmentation

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

Enables the detection of malfunctions in movable and fixed terminals, ensuring reliable operation and preventing failures like welding, thereby enhancing the reliability of the electromagnetic relay.

Implementation Method 1

an electromagnet that generates electromagnetic force for driving the armature to move the movable terminal and the auxiliary movable terminal

Methodology Applied

Scientific EffectElectromagnetic force: Electromagnet

Data Source

PatentUSRE49318E1Electromagnetic relay

Publication Date: 2022.11.29 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

The electromagnetic relay comprises an auxiliary fixed terminal that has a configuration different from that of a fixed terminal and includes an auxiliary external input/output terminal and an auxiliary external output/input terminal that can be electrically connected to the auxiliary external input/output terminal. The electromagnetic relay comprises an auxiliary movable terminal that has a configuration different from that of a movable terminal and can electrically connect the auxiliary external input/output terminal and the auxiliary external output/input terminal.