Relay Carrier Sub-Assembly Direct Shaft Coupling
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Solution Overview
Problem
Existing electrical relay devices face issues due to the use of separate fasteners, such as retaining rings, which can loosen or fall off, causing the shaft to uncouple from the ferromagnetic element and movable contact, leading to device malfunction under vibrations and improper assembly.
Innovation Solution
The electrical relay device employs a carrier sub-assembly with a plunger and shaft directly secured without discrete components, using an interference fit and deflectable prongs to securely attach the shaft to the movable contact, eliminating the need for separate fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fasteners (retaining rings) are used to couple the shaft to the ferromagnetic element and movable contact, then the device can be assembled with discrete parts, but the fasteners are prone to moving out of position or falling off due to vibrations and improper installation
Solution Approach 1:
The shaft is designed as a single integrated piece that directly couples the ferromagnetic element and movable contact without separate fasteners. The shaft includes a first end that directly couples to the ferromagnetic element and a second end that directly couples to the movable contact, eliminating the need for retaining rings and other discrete fastening components.
2Strength
If retaining rings are used as fasteners, then the shaft can be coupled to components, but the retaining rings may loosen or fall off under vibrational forces
Solution Approach 1:
The shaft integrates the coupling function into a single continuous component that directly connects the ferromagnetic element and movable contact. This eliminates weak points where separate fasteners could loosen or detach under vibrational forces, providing continuous mechanical strength throughout the assembly.
Solution Approach 2:
The shaft itself acts as the intermediary element between the ferromagnetic element and movable contact, providing a continuous mechanical connection that transfers force and motion reliably without requiring separate fastening components that could fail under vibration.
3Reliability
If multiple discrete fasteners are used, then the shaft can be secured to components, but the device complexity increases and assembly becomes more difficult
Solution Approach 1:
The shaft is designed as a single integrated component that performs multiple coupling functions simultaneously - connecting the ferromagnetic element at one end and the movable contact at the other end. This reduces the total number of parts and simplifies the overall device structure while maintaining reliable shaft coupling.
Solution Approach 2:
The shaft serves multiple functions within a single component: it acts as a mechanical connector between the ferromagnetic element and movable contact, provides structural support, and enables the transfer of magnetic force to the contact mechanism. This multi-functionality reduces device complexity by eliminating the need for separate fasteners and support structures.
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 the reliability and durability of the electrical relay device by preventing the shaft from uncoupling, ensuring consistent operation even under vibrational forces and improper assembly, thus maintaining the functionality of the device.
Implementation Method 1
The coil of wire is within the housing and is electrically connected to a relay power source. The actuator assembly is configured to move along an actuation axis between a first position and a second position based on a presence or absence of a magnetic field induced by current through the coil of wire.
Implementation Method 2
At least some electrical relay devices include a ferromagnetic element that is disposed at least proximate to the electromagnet such that an induced magnetic field applies a magnetic force upon the ferromagnetic element that translates the ferromagnetic element relative to the electromagnet.
Data Source
AI summary
A carrier sub-assembly for an electrical relay device includes a plunger and a shaft. The plunger is formed of a ferromagnetic material. The plunger has a generally cylindrical shape extending between a top side and a bottom side of the plunger. The shaft extends between a contact end and an opposite plunger end. The shaft is directly secured to the plunger without a discrete component between the shaft and the plunger securing the shaft to the plunger. The shaft and the plunger are configured to move together within the electrical relay device. A segment of the shaft including the contact end protrudes from the top side of the plunger for securing to a movable contact of the electrical relay device.