Electromagnetic Relay Contact Device Vertical Stacking
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Solution Overview
Problem
Electromagnetic relays face challenges in handling large current loads due to Joule heat-induced deformation of moving contact springs, leading to reduced contact pressure and current carrying capacity, and existing solutions with braided wires are difficult to automate and have increased size.
Innovation Solution
A contact device with a moving contact assembly featuring a leaf spring and multiple moving members, arranged to reduce overall size while maintaining high contact pressure, eliminates the need for braided wires and facilitates automatic assembly by using a hinged relay design with a coil to move the contacts based on energization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple moving contacts and fixed contacts are provided in the rightward/leftward direction to enable large current supply, then the current carrying capacity is improved, but the outer dimension in the rightward/leftward direction increases
Solution Approach 1:
The patent transitions from arranging contacts horizontally (rightward/leftward direction) to arranging them vertically (upward/downward direction). The moving contacts are positioned above the fixed contacts in the upward direction, allowing current paths to be stacked vertically rather than spread horizontally. This dimensional change enables large current carrying capacity while reducing the device's footprint in the horizontal plane.
2Quantity of substance
If braided wires are used to handle large current loads, then the current carrying capacity is improved, but the device complexity and difficulty of automated assembly increase
Solution Approach 1:
The patent extracts and eliminates the braided wire component from the design. Instead of using complex braided wire structures to handle large currents, the invention uses simple rigid contact members (moving contacts and fixed contacts) arranged in multiple vertical paths. This extraction of the problematic component simplifies the overall device structure and enables automated assembly while maintaining the required current carrying capacity.
3Quantity of substance
If the moving contact spring is subjected to Joule heat from large current loads, then the current carrying capacity is improved, but the contact pressure decreases due to deformation
Solution Approach 1:
The patent segments the current path into multiple separate vertical paths, each with its own moving contact and fixed contact pair. By dividing the total current load across multiple segmented paths (arranged in the upward/downward direction), the Joule heat generated in each individual contact spring is reduced. This segmentation prevents excessive thermal deformation and maintains adequate contact pressure in each path while still achieving overall high current carrying capacity.
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 enables the electromagnetic relay to handle large current loads efficiently with reduced size, maintaining high contact pressure and current carrying capacity without the need for braided wires, and allows for automated assembly and reduced thickness.
Implementation Method 1
an electromagnetic device. The electromagnetic device includes a coil and configured to move the moving contact assembly depending on whether the coil is energized or not
Implementation Method 2
The first moving member is implemented as a leaf spring and is provided with the first moving contact
Implementation Method 3
Joule heat-induced deformation of moving contact springs
Data Source
AI summary
A contact device according to an embodiment includes: a fixed contact assembly including a first fixed contact and a second fixed contact; and a moving contact assembly including a first moving contact and a second moving contact. The moving contact assembly includes: a first moving member; and a second moving member. The second moving member is arranged, in a first direction, between the first moving member and the fixed contact assembly and fixed to the first moving member at one end in a second direction intersecting with the first direction. The first moving contact and the second moving contact move as the first moving member moves. A first distance from the one end in the second direction to the first moving contact is longer than a second distance from the one end in the second direction to the second moving contact.