Electromagnetic Relay Contact Inclination Angle for Bounce Reduction
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Solution Overview
Problem
Conventional electromagnetic relays experience significant contact bounce during closure, leading to arc currents and potential failure, which is difficult to mitigate without compromising current-carrying capability or increasing component complexity.
Innovation Solution
The electromagnetic relay is designed with a specified inclination angle (0° < θ < 45°) between the movable and normally open fixed contacts, allowing for reduced repulsion and bounce through elastic interaction, thereby extending contact life without affecting current-carrying capacity or component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the fixed contact member is made elastic to reduce contact bounce, then contact bounce is reduced, but current-carrying capability decreases
Solution Approach 1:
The contact system is divided into two independent parts: the movable contact spring (providing elasticity for bounce reduction) and the fixed contact member (maintaining rigid structure for current carrying). This segmentation allows each component to optimize its function without compromising the other.
Solution Approach 2:
The movable contact spring acts as an intermediary element between the actuating force and the contact surfaces. It absorbs the shock of contact closure through its elasticity while the fixed contact member maintains its rigid structure for optimal current carrying capability.
2Reliability
If the fixed contact member is made elastic to reduce contact bounce, then contact bounce is reduced, but component complexity increases
Solution Approach 1:
The movable contact spring serves dual functions: it provides the necessary elasticity to reduce contact bounce and simultaneously acts as the moving contact element itself. This self-service approach eliminates the need for additional damping components or complex mechanisms.
Solution Approach 2:
The invention changes the physical parameter of the movable contact spring (its elasticity and pre-tension) to achieve bounce reduction. By optimizing the spring constant and initial tension of the movable contact spring, the system reduces contact bounce without requiring structural modifications to the fixed contact member.
3Stability of the object's composition
If contacts are made parallel to ensure stable contact, then contact stability is improved, but contact bounce increases
Solution Approach 1:
The movable contact spring introduces dynamic behavior to the contact system. Instead of rigid parallel contacts that cause bounce, the spring provides controlled elastic deformation during contact closure, dynamically absorbing the impact while maintaining stable electrical contact.
Solution Approach 2:
The movable contact spring is pre-tensioned to provide cushioning force before contact closure. This beforehand cushioning absorbs the shock of contact bounce through elastic deformation, protecting the contact surfaces from impact damage while ensuring stable contact.
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 effectively prevents initial contact bounce and ensures a longer electrical life for the relay, with optimal results achieved when the inclination angle is between 5° and 20°, significantly reducing arc currents and contact wear.
Implementation Method 1
when a voltage is applied to the coil 1, the movable contact spring 3 and the movable contact 3a move toward a direction A (Fig. 3)
Implementation Method 2
the movable contact spring 3 bends with attractive forces of magnetic
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electromagnetic relay is provided which is capable of reducing a contact bounce at time of closing a contact. The electromagnetic relay is so configured that an opposed angle θ is 0°<θ< 45°, when viewed from a direction to which a normally open fixed contact (6a) and a movable contact (3a) slide before the normally open fixed contact (6a) comes into surface-contact with the movable contact spring (3). (See Fig. 4)