Relay Coil Pin Assembly for Secure Signal Wire Retention
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Solution Overview
Problem
Existing relays face issues with secure fixation between the magnetic circuit and base, lack of over-travel adjustment, and inadequate detection and monitoring of contact conductivity, leading to reliability concerns, especially in high-current applications.
Innovation Solution
The design includes a coil assembly with a coil pin featuring an inverted hook and slope section for secure signal wire fixation, adjustable over-travel mechanisms using hook members and engagement holes, and signal monitoring through protruding parts on fixed contact pieces for real-time contact state and operation count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If split riveting is used to fix the magnetic circuit to the base, then the magnetic circuit is securely fixed, but the split position rusts and oxidizes affecting relay use
Solution Approach 1:
The patent extracts the problematic metal split rivet and replaces it with a plastic rivet that has anti-corrosion properties. The plastic material eliminates the rust and oxidation issues while maintaining the fixation function through deformation and expansion in the through hole.
Solution Approach 2:
The patent changes the material parameter of the rivet from metal to plastic, which fundamentally alters the corrosion resistance property. This material substitution resolves the oxidation problem while the rivet's deformation characteristics provide secure fixation.
2Strength
If hot riveting is used to fix the bobbin to the base, then the bobbin is securely fixed, but over-travel adjustment cannot be achieved in automated assembly
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism where the bobbin can be moved forward or backward along the magnetic circuit before final fixation. This allows over-travel adjustment to be performed in automated assembly, and the plastic rivet's deformation capability ensures secure fixation after adjustment.
Solution Approach 2:
The patent performs over-travel adjustment as a preliminary action before final fixation. The bobbin position is adjusted along the magnetic circuit, and then the plastic rivet is inserted and deformed to lock the adjusted position, achieving both adjustment and secure fixation.
3Object-affected harmful factors
If the housing is impacted from the upper direction, then the housing deforms to protect internal components, but the armature or moving spring becomes stuck
Solution Approach 1:
The patent introduces a protrusion on the yoke as an intermediary protective element. When impact occurs from the upper direction, the protrusion deforms first to absorb the impact energy, preventing the force from reaching and sticking the armature or moving spring.
Solution Approach 2:
The patent designs the protrusion with beforehand cushioning capability. The protrusion is positioned to be the first element to receive impact force, and its deformable nature provides cushioning that protects the critical armature and moving spring from damage.
Data Source
AI summary
A relay coil assembly includes a bobbin having flanges on two ends, an enameled wire wound around bobbin, a coil pin mounted to the flange and having an insertion portion, an enameled wire fixing portion and a signal wire fixing portion, and a signal wire. The signal wire fixing portion is provided with a first engagement recess with an opening facing downward, in which the signal wire is engaged. An inverted hook is provided at one of two recess sidewalls of the first engagement recess, and a slope section is provided at one of the two recess sidewalls of the first engagement recess. The opening gradually enlarges from inside to outside along the slope section, which is capable of squeezing the signal wire into the first engagement recess and the inverted hook is capable of preventing the signal wire from coming out.