Electromagnetic Relay Card Segmentation for Assembly and Insulation
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Solution Overview
Problem
Conventional electromagnetic relays face challenges with low assembly workability, degraded insulating characteristics, and insulation failures due to the need for large-sized rectangular holes for assembly, which compromises the insulating distance and allows abrasion powder to pass through.
Innovation Solution
The design includes a movable iron piece, a contact driving part, and a card with a manipulation hole and projection system, where the card is not integral with the iron piece, allowing for improved assembly workability and insulating characteristics by lengthening the insulating distance and preventing abrasion powder from passing through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a large-sized rectangular hole is made in the base for assembly, then assembly workability is improved, but insulating distance is reduced and insulating characteristics are degraded
Solution Approach 1:
The card is divided into separate sections with the manipulation projection integrated into one portion while the card body remains separate. This segmentation allows the manipulation hole to be smaller and more precisely positioned, improving insulating characteristics while maintaining assembly workability through the integrated projection design.
Solution Approach 2:
The manipulation projection is nested within the card structure, with the projection integrated into the card body. This nesting allows the projection to fit precisely within the manipulation hole, enabling a smaller hole size that maintains insulating distance while still providing adequate assembly workability.
2Ease of manufacture
If a large-sized rectangular hole is made in the base for assembly, then assembly workability is improved, but abrasion powder can pass through causing insulation failure
Solution Approach 1:
The card structure is segmented with the manipulation projection as a separate integrated feature. This allows the manipulation hole to be smaller and more precisely controlled in size, preventing abrasion powder from passing through while the integrated projection maintains assembly workability through its designed geometry.
Solution Approach 2:
The card has different local qualities: the manipulation projection area is designed with specific dimensional characteristics for easy assembly, while the main card body maintains structural integrity and insulating properties. This local differentiation allows the small manipulation hole to prevent powder passage while the overall card structure maintains assembly workability.
3Device complexity
If the card is integral with the movable iron piece, then structural simplicity is improved, but assembly workability is reduced
Solution Approach 1:
The card is segmented from the movable iron piece, with the manipulation projection being an integrated feature of the card rather than the iron piece. This segmentation allows independent optimization of the card's insulating properties while maintaining assembly workability through the projection's integrated design.
Solution Approach 2:
The manipulation projection acts as an intermediary element between the card and the manipulation hole. This intermediary feature facilitates assembly by providing a dedicated engagement point, improving assembly workability while the card itself remains separate from the movable iron piece for better insulating characteristics.
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 assembly workability, maintains desired insulating distances, and reduces the risk of insulation failures, resulting in an electromagnetic relay with improved assembly efficiency and reliability.
Implementation Method 1
an electromagnetic part (20), a movable iron piece (40)
Implementation Method 2
the movable iron piece (40) operable based on excitation and demagnetization of the electromagnetic part (20)
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
An electromagnetic relay includes an electromagnetic part (20), a movable iron piece (40), a contact driving part (60), a contact (63, 72) which is opened and closed by driving the contact driving part (60) with a card (50) disposed between the movable iron piece (40) and the contact driving part (60). Particularly, the card (50) is disposed between the insulating wall (11) and the contact driving part (60), a driving projection (52) projected onto an inward surface side opposed to the insulating wall (11) of the card (50) is inserted in and projected from a manipulation hole (13) made in the insulating wall (11), and the driving projection (52) of the card is pressed by the movable iron piece (40) that is operated based on excitation and demagnetization of the electromagnetic part (20).