Relay Contact Spring Inclined Edge Rolling Motion
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Solution Overview
Problem
Electrical switching devices, such as relays, generate loud noises during switching due to the contact spring and armature striking each other over a large surface, leading to noise peaks.
Innovation Solution
The edge between the contact spring and armature is formed as a protrusion, extending over the contact spring's width, and inclined relative to its longitudinal direction, allowing for a rolling motion instead of a direct strike, which distributes the impact energy over time, reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the contact spring and armature strike against each other over a large surface during switching, then the switching action is reliable and firm, but the switching noise becomes very loud
Solution Approach 1:
The patent segments the contact surface by providing multiple contact springs instead of a single large contact surface. Each contact spring makes contact separately with the armature, dividing the single large impact into multiple smaller, distributed impacts. This segmentation reduces the noise intensity while maintaining reliable switching through the combined effect of multiple contacts.
Solution Approach 2:
The patent introduces an inclined edge geometry that adds a dimensional aspect to the contact interaction. Instead of direct perpendicular impact, the inclined edge creates a rolling motion that distributes the impact over time and space, transforming the nature of the contact from a sudden strike to a gradual rolling engagement, thereby reducing noise peaks.
2Object-generated harmful factors
If the edge runs in an inclined manner, then the switching noise is reduced through rolling motion, but the switching mechanism becomes more complex
Solution Approach 1:
The patent applies local quality by providing the inclined edge only at specific locations where contact occurs, rather than redesigning the entire armature or contact spring structure. The inclined edge is localized to the contact region, minimizing the overall geometric complexity while achieving noise reduction at the critical contact points.
Solution Approach 2:
The inclined edge introduces a curved or angled surface geometry that enables rolling motion. This curvature element, while adding some complexity, is a simple geometric modification that can be manufactured through standard machining or molding processes, balancing noise reduction benefits with manufacturing feasibility.
3Object-generated harmful factors
If the abutting location moves in the longitudinal direction of the contact spring, then the resilient resistance is altered and noise is reduced, but the control precision becomes more difficult
Solution Approach 1:
The patent employs dynamics by allowing the abutting location to move along the inclined edge during the switching process. This dynamic movement enables the contact point to progress from the upper end to the lower end of the inclined edge, creating a rolling motion that reduces noise. The movement is naturally controlled by the spring force and geometry, reducing the need for precise static positioning.
Solution Approach 2:
The inclined edge creates an asymmetric contact geometry where the abutting location naturally progresses in one direction during switching. This asymmetric design guides the movement of the contact point along a predetermined path, reducing the need for complex control mechanisms while maintaining noise reduction benefits.
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 significantly reduces switching noise by converting the impact energy into a rolling motion, resulting in lower noise peaks and a quieter operation.
Implementation Method 1
The contact spring and the component no longer strike one another, but rather roll on one another. Through the rolling, the conversion of the impact energy into noise is distributed over a larger time-span.
Data Source
Figure 1~3
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AI summary
The invention relates to an arrangement (1) for an electric switching device, in particular a relay such as a hinged-armature relay. The arrangement has at least one contact spring (2), a further component (4), at least two switching states (22, 24) and a transition phase (30) between the two switching states (22, 24). In one switching state (24), the contact spring (2) is moved with respect to the other switching state (22). In the transition phase, the contact spring (2) and the further component (4) abut one another at an edge (42) having an abutting location (56). In order to reduce the arrangement's (1) switching noise which results from the mutual striking action, it is envisaged according to the invention that the edge (42) runs in an inclined manner with respect to a longitudinal direction (46) of the contact spring (2).