Relay Cord Shaped for Automated Assembly
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Solution Overview
Problem
Existing relays for switching high load currents face challenges in automated assembly due to the flexibility of cords used, which makes it difficult to position and connect the connection region to the fixed connection without manual intervention.
Innovation Solution
A self-supporting contact arrangement where the cord is resiliently pretensioned and forms a stable structure, allowing it to assume a predetermined position and remain stable without additional retention, enabling automated assembly by forming a self-supporting assembly that can be integrated into the relay.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible cord is used to connect the connection region to the switching contact, then the cord does not significantly inhibit the movement of the switching contact, but the cord cannot be readily positioned and connected without manual intervention
Solution Approach 1:
The cord is pre-formed into a self-supporting structure with predetermined bends and curves before assembly. This preliminary shaping allows the cord to maintain its position without additional retention mechanisms, enabling automated assembly while preserving flexibility for switching contact movement.
Solution Approach 2:
The cord's physical parameters are modified by creating specific bent shapes and curves that provide inherent structural support. By changing the cord's geometry from a straight configuration to a pre-formed curved structure, the cord gains positional stability while maintaining its flexible electrical connection function.
2Extent of automation
If the cord is formed as a self-supporting structure with predetermined position, then automated assembly becomes possible, but the cord must be resiliently pretensioned to maintain stability
Solution Approach 1:
The cord is formed with curved and bent sections rather than straight lines. These curves create a self-supporting structure that inherently maintains the connection region's position. The curvature provides structural stability through the cord's own geometry, eliminating the need for additional retention mechanisms.
Solution Approach 2:
The cord's own resilient properties and pre-formed shape are utilized to maintain its predetermined position. The structure serves itself by using its inherent elasticity and geometric configuration to provide stability, without requiring external retention devices or complex assembly mechanisms.
3Adaptability or versatility
If the cord extends in a curved manner to allow flexibility, then switching contact movement is facilitated, but the connection region cannot be positioned and connected without manual intervention
Solution Approach 1:
The cord is pre-formed into its final curved configuration before assembly. This preliminary action creates a self-supporting structure that maintains its shape during automated assembly, eliminating the need for manual positioning while preserving the flexibility required for switching contact movement.
Solution Approach 2:
The cord's geometric parameters are changed by creating specific bent shapes and curves. These parameter changes transform the cord from a simple flexible connector into a self-supporting structure that combines flexibility with positional stability, enabling automated assembly.
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 self-supporting structure allows for automated assembly of the relay, improving the ease of connection and stability of the cord, reducing the need for manual intervention and enhancing the reliability of the connection between the switching contact and the fixed connection.
Implementation Method 1
the cord is resiliently pretensioned and produces a restoring force, which forms the cord in the inherently stable manner
Data Source
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AI summary
The invention relates to a contact arrangement (1) for a relay for switching high load currents. Furthermore, the invention relates to a relay (43) for switching high load currents having a contact arrangement (1). Finally, the invention relates to a method for assembling a relay. In order to be able to assemble the contact arrangement (1) in the relay in an at least partially automated manner, without additional retention devices being required for a cord (4), there is provision according to the invention for the cord (4) to be retained in an inherently stable manner owing to its shape as a self-supporting structure and for the method to have a method step in which the cord (4) is shaped to form a self-supporting structure with a bent shape.