Relay Clamping Spring Nesting in Armature Depression
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Solution Overview
Problem
Existing relays with mechanical switching contacts face challenges in reducing size due to the need for a minimum switching force and the increased installation space required by retaining springs and armature-yoke arrangements.
Innovation Solution
A relay design featuring a depressed clamping spring arrangement that allows for spring-loaded mounting of the armature on the yoke with a wave-shaped bracket, reducing installation space while maintaining efficient electromagnetic coupling, allowing for a narrow design that does not exceed a terminal width of 3.5 mm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional retaining spring is used to spring-load the armature on the yoke, then the armature can be reset after electromagnetic deflection, but the installation space of the armature-yoke arrangement is disadvantageously increased
Solution Approach 1:
The clamping spring is arranged in a receiving depression in the armature, utilizing the depth dimension rather than enclosing the armature and yoke laterally. This dimensional reconfiguration allows the spring to provide reset force while maintaining a compact overall height of the armature, thereby reducing installation space while preserving the armature reset function
Solution Approach 2:
The clamping spring is nested within the receiving depression of the armature, with the spring's first clamping limb arranged inside the depression and engaging with a recess in the armature. This nesting arrangement allows the spring to be integrated into the armature structure without increasing the overall dimensions of the armature-yoke assembly
2Volume of moving object
If the armature is made smaller to reduce relay size, then the installation space is reduced, but the magnetic force between the yoke and armature is reduced since it is proportional to the armature size
Solution Approach 1:
The clamping spring is designed with optimized geometric parameters including the angle and positioning of its clamping limbs, and is arranged in a receiving depression at a specific distance from the yoke. These parameter optimizations ensure that sufficient magnetic force is generated even with a reduced armature size, maintaining the switching function while enabling compact relay dimensions suitable for terminal blocks with grid dimensions of 3.5 mm or less
3Reliability
If fastening devices are provided on the armature and/or yoke to fasten the retaining spring, then the spring can be secured, but the installation space of the armature-yoke arrangement is further increased
Solution Approach 1:
The fastening function is merged into the structural components themselves: the receiving depression in the armature and the recess in the armature work together to secure the clamping spring. This eliminates the need for separate fastening devices, as the spring is retained by the elastic engagement of its angled tab in the recess, thereby avoiding additional installation space requirements
Solution Approach 2:
The dedicated fastening devices are extracted from the design, replacing them with an integrated retention mechanism where the clamping spring's angled tab elastically engages in the recess formed in the receiving depression. This extraction of separate fastening components reduces the overall installation space while maintaining reliable spring fastening
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 enables a compact relay form that maintains efficient electromagnetic operation, allowing for reduced dimensions and improved power efficiency by optimizing the magnetic field strength and spring force distribution, preventing bouncing between electrical contacts.
Implementation Method 1
an electromagnetic coil (401) arranged on the yoke (103), wherein the yoke (103) can form a coil core
Implementation Method 2
The armature (101) can be ferromagnetic or paramagnetic, wherein a power efficiency of an electromagnetically induced relative movement of the armature with respect to the yoke can be proportional to the magnetic permeability of the armature
Implementation Method 3
a bracket-shaped clamping spring (107) which surrounds the armature (101) and the yoke (103) on the end face in order to fix the armature (101) on the yoke (103)... a tension force can be transmitted to the yoke and to the armature via resilient clamping limbs
Data Source
AI summary
A relay includes an armature, a yoke configured to be electromagnetically coupled to the armature, and a bracket-shaped clamping spring. The armature lies at least partially flat on the yoke, and a receiving depression is partly formed in the armature. The bracket-shaped clamping spring surrounds the armature and the yoke on an end face such that the armature is fixed on the yoke. The bracket-shaped clamping spring has a first clamping limb arranged in the receiving depression of the armature, and a second clamping limb lying on the yoke. The first clamping limb has an angled tab which engages elastically into a recess formed in the receiving depression of the armature.