Electromagnetic Relay Contact Layout to Reduce Arc Interference

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Solution Overview

Problem

Existing electromagnetic relays have complex structures that complicate manufacturing and increase the likelihood of electric arcs affecting each other's contacts, leading to reliability issues.

Innovation Solution

The electromagnetic relay design simplifies the structure by using a coil, bobbin, core, armature, first and second movable springs, and a card that adjusts contact positions based on coil excitation, increasing insulation distance and reducing arc interference between first and second movable contacts.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a complex structure with multiple contact devices is used, then the relay can achieve multiple switching functions, but the structure becomes complicated and manufacturing difficulty increases

Engineering Contradiction:

Improveswitching functionsVSAvoidstructure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple contact devices into a single integrated structure where the first and second contact devices share common components (coil, bobbin, core, armature). The movable contacts are positioned on the same armature, and the fixed contacts are arranged in a compact configuration, reducing the overall number of independent components while maintaining multiple switching functions.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single armature serves multiple functions by carrying both the first movable contact and the second movable contact. The coil and magnetic circuit components generate electromagnetic force that simultaneously controls both contact devices. This multi-functional design allows one set of electromagnetic components to control multiple switching operations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Volume of moving object

If contact devices are positioned closer together, then the relay size is reduced, but electric arcs from one contact may affect the other contact

Engineering Contradiction:

Improverelay sizeVSAvoidelectric arc interference

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an insulating structure (insulating member or insulating housing) as an intermediary element between the first and second contact devices. This insulating barrier physically separates the contact regions, preventing electric arcs from one contact from affecting the other contact, while still allowing the overall relay size to remain compact.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If traditional electromagnetic relay structure is used, then reliable contact switching is achieved, but manufacturing complexity and assembly difficulty increase

Engineering Contradiction:

Improvecontact switchingVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent divides the relay into distinct modular segments: the electromagnetic actuator module (coil, bobbin, core, armature) and the contact modules (first contact device with first movable and first fixed contacts, second contact device with second movable and second fixed contacts). This segmentation allows each module to be manufactured and tested independently, then assembled together, simplifying the overall manufacturing process while maintaining reliable contact switching.

Inventive Principle:

Principle #1Segmentation

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 manufacturing simplicity and reduces the likelihood of electric arcs affecting contacts, improving reliability and contact pressure between movable and fixed contacts.

Implementation Method 1

The electromagnet generates electromagnetic force for driving the armature to move the movable terminal and the auxiliary movable terminal

Methodology Applied

Scientific EffectElectromagnetic force: Electromagnetic Induction

Implementation Method 2

When the electromagnet stops generating electromagnetic force, the armature is returned to the original position by the return force of the return spring

Methodology Applied

Scientific EffectElastic force: Elasticity

Data Source

PatentUS20240379311A1Electromagnetic relay

Publication Date: 2024.11.14 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An electromagnetic relay includes: a coil; a bobbin; a core inserted into the bobbin; an armature; a first fixed contact; a first movable spring including a first movable contact configured to cause the first movable contact to move into and out of contact with the first fixed contact; a second fixed contact; a second movable spring including a second movable contact configured to cause the second movable contact to move into and out of contact with the second fixed contact; and a card configured to cause the second movable contact to move into or out of contact with the second fixed contact according to switching of the coil between an excited state and a non-excited state. The first movable spring includes a first end portion near the first end of the armature and a second end portion farther from the first end of the armature.