DC Relay Movable Contact Holder Assembly for Stable Coupling
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Solution Overview
Problem
Existing direct current relays face challenges in manufacturing the movable contact holder due to complex assembly processes, assembly errors, and instability in maintaining the coupled state of the housing components, which are made from different materials and assembled through insert injection.
Innovation Solution
A movable contact part design featuring an upper and lower holder with coupling protrusions and grooves, allowing for easy assembly in a vertical direction, multiple coupling points, and stable maintenance, enhanced by elastic materials and cushioning parts for improved design freedom and vibration absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional movable contact part is used, then the structure is simple, but contact noise occurs and contact reliability deteriorates due to inclined contact and adhesion
Solution Approach 1:
The movable contact part is designed to rotate about a pivot point during engagement, transitioning from an inclined contact state to a substantially perpendicular contact state. This dynamic movement eliminates adhesion and contact noise while maintaining structural simplicity through the single-pivot mechanism
Solution Approach 2:
The movable contact part is divided into distinct functional zones: a contact portion with first contact surface, a second contact surface, and a pivot point. This segmentation allows the contact surfaces to be positioned at different orientations, enabling the perpendicular contact configuration that prevents adhesion while maintaining structural simplicity
2Object-affected harmful factors
If the contact surfaces are positioned at specific locations, then contact noise is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The movable contact part automatically adjusts its own orientation during engagement through rotation about the pivot point. The geometry of the contact surfaces and pivot point configuration causes the contact to naturally transition to a perpendicular state, eliminating the need for high-precision fixed positioning while still achieving noise reduction
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
Facilitates easy and stable assembly of the movable contact part and housing components, improving assembly accuracy and maintaining the coupling state, while allowing for customizable design based on operating environments.
Implementation Method 1
a coil that generates a magnetic field
Data Source
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AI summary
Disclosed are a movable contact part and a direct current relay including the same. The movable contact part according to an embodiment of the present invention includes an upper holder and a lower holder. One holder among the upper holder and the lower holder has a coupling protrusion that protrudes toward the other holder. The other holder among the upper holder and the lower holder has a coupling groove into which the coupling protrusion is inserted and coupled. The lower holder is coupled to the inside of a housing, and the upper holder is coupled to each of the lower holder and the housing. Accordingly, the coupling between the upper holder and the lower holder is facilitated, and the coupled state can be stably maintained.