Relay Stationary Contact Fuse Integration
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Solution Overview
Problem
Relays lack overload protection and arc-extinguishing mechanisms, leading to safety hazards such as fires and reduced product lifespan due to potential short circuits and excessive current.
Innovation Solution
A relay design incorporating a fuse for overload and short circuit protection, combined with an insulating ceramic ring filled with quartz sand and a magnetic arc extinguishing mechanism, to ensure safe electrical conduction and disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If no overload protection device is provided in the relay, then the device complexity is reduced, but safety hazards such as fire occur due to current overload or short circuit
Solution Approach 1:
The fuse is integrated into the stationary contact structure, merging the overload protection function with the existing contact system. The fuse is disposed inside the insulating ring that is already part of the stationary contact assembly, combining multiple functions into a unified structure rather than adding a separate protection device.
Solution Approach 2:
The insulating ring serves multiple functions: it provides electrical insulation between the upper terminal and lower contact, houses the fuse for overload protection, and contains the arc-extinguishing material. This multi-functional design achieves safety without proportionally increasing device complexity.
2Duration of action of stationary object
If no arc-extinguishing device is provided in the relay, then the device complexity is reduced, but the arcing time increases and product lifetime decreases
Solution Approach 1:
The arc-extinguishing material (quartz sand or sodium chloride) is integrated within the insulating ring structure, merging the arc-extinguishing function with the existing insulating component. This eliminates the need for a separate arc-extinguishing device while extending product lifetime.
Solution Approach 2:
The fuse and arc-extinguishing material convert the harmful effects of overcurrent and arcing into beneficial protection mechanisms. The fuse melts to interrupt excessive current, while the arc-extinguishing material quickly suppresses arcs, transforming potential damage sources into protective features.
3Reliability
If the fuse is placed inside the insulating ring, then the overload protection function is achieved, but the manufacturing precision requirements increase
Solution Approach 1:
The stationary contact assembly is segmented into distinct functional zones: the insulating ring housing, the fuse element, the arc-extinguishing material, and the contact terminals. This segmentation allows each component to be manufactured and assembled separately, reducing overall manufacturing precision requirements while achieving reliable overload protection.
Solution Approach 2:
The insulating ring acts as an intermediary structure that houses the fuse and arc-extinguishing material, providing a pre-formed cavity that simplifies the placement and positioning of these components. This intermediary structure reduces the precision requirements for directly positioning the fuse and extinguishing material.
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
The solution effectively prevents fires and extends product lifespan by providing reliable overload and short circuit protection, while the arc extinguishing mechanism reduces arcing time and enhances safety.
Implementation Method 1
the fuse has the effects of overload protection and short circuit protection
Implementation Method 2
the fuse has the effects of overload protection and short circuit protection
Implementation Method 3
an insulating ring is connected between the upper terminal and the lower contact
Implementation Method 4
the insulating ring is filled with quartz sand
Implementation Method 5
a magnetic arc extinguishing mechanism
Data Source
AI summary
A relay includes: a housing, a base plate, and a driving device, connected to the base. At least one stationary contact group is provided on the housing. The stationary contact group includes two stationary contacts insulated from each other. At least one stationary contact in the stationary contact group includes an upper terminal and a lower contact are included. The upper terminal and the lower contact are isolated from each other and electrically connected by a fuse. The base plate is provided in the housing and can switch between on and off positions. The base plate, when being in the on position, contacts the stationary contact group for the electrical conduction of the two stationary contacts in the stationary contact group, and, when being in the off position, is isolated from the stationary contact group for disconnecting the electrical conduction of the two stationary contacts in the stationary contact group.