Electromagnetic Relay Compact Design via Coil Spring Repositioning
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Solution Overview
Problem
The existing electromagnetic relay designs face challenges in reducing size due to the requirement for insulation between fixed-contact insulating base-plates and movable contacts, which limits further miniaturization.
Innovation Solution
The design incorporates a housing with separate compartments and an insulating wall, where the coil spring is positioned between the movable contact and the insulating wall, allowing the movable contact to move closer to the housing without the need for additional space for the coil spring, thus enabling a more compact structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fixed contacts are secured to the fixed-contact insulating base-plate located in the contact separation direction relative to the movable contact, then the insulation between the fixed-contact insulating base-plate and the movable contact is maintained, but additional space is required above the upper portion of the fixed contacts, making it difficult to further reduce the size of the electromagnetic relay
Solution Approach 1:
The patent repositions the coil spring from being located above the fixed contacts (in the contact separation direction) to being located beside the movable contact (in a direction perpendicular to the contact separation direction). This dimensional repositioning allows the spring to occupy space that does not interfere with the insulation requirements between the fixed-contact insulating base-plate and the movable contact, thereby maintaining reliability while reducing the overall volume of the electromagnetic relay.
2Ease of operation
If space is allocated for contact and separation of the movable contact relative to the pair of fixed contacts, then the contact operation is enabled, but the size reduction of the electromagnetic relay is limited
Solution Approach 1:
The patent employs a coil spring with dynamic characteristics that can compress and expand to provide the necessary contact pressure during the contact and separation operation. By positioning the spring beside the movable contact rather than above the fixed contacts, the design optimizes the dynamic movement space, allowing the movable contact to operate freely while minimizing the overall size of the relay housing.
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 configuration allows for a more compact electromagnetic relay by eliminating the need for additional space between the movable contact and the housing, enhancing the relay's size reduction capabilities.
Implementation Method 1
a coil spring provided in the first compartment between the movable contact and the insulating wall in the contact movement direction with the movable shaft passing therethrough, the coil spring configured to create a force biasing the first and second movable contact points toward the opposing first and second fixed contact points
Implementation Method 2
a solenoid in the second compartment configured to drive the movable shaft in the contact movement direction
Data Source
AI summary
An electromagnetic relay is provided with a housing; a first fixed contact terminal and a second fixed contact terminal; a movable contact, a movable shaft with one end connected to the movable contact, and a coil spring placed between the movable contact and an insulating wall in a chamber in the housing. The coil spring configured to bias movable contact points toward the opposing fixed contact points. The movable contact includes a contact body which includes a connection hole configured to receive the movable shaft and allow the movable shaft to travel relatively in the contact movement direction. The movable shaft includes a second holder that together with the first holder retains the coil spring.