Electromagnetic Relay Core Joint Curvature for Magnetic Efficiency
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Solution Overview
Problem
The existing electromagnetic relay devices suffer from increased distance between the joint portion and the wire winding portion, leading to potential reductions in magnetic efficiency and assembly challenges due to the orthogonal arrangement of the yoke and stationary core, which results in clearance and complicates component arrangement.
Innovation Solution
The electromagnetic relay device integrates a stationary core and plate member, forming a curved surface at the joint portion to minimize the distance between the winding portion and the joint, enhancing magnetic efficiency and assembly ease.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the yoke and stationary core are arranged orthogonally at the joint portion, then the assembly structure is simplified, but the distance between the joint portion and the wire winding portion increases, reducing magnetic efficiency
Solution Approach 1:
The joint portion between the yoke and stationary core is designed with a curved surface instead of an orthogonal arrangement. This curvature allows the joint portion to be positioned closer to the wire winding portion, shortening the magnetic flux path and improving magnetic efficiency while maintaining the simplified assembly structure.
2Ease of operation
If the yoke and stationary core are arranged orthogonally, then assembly is easier, but the clearance between components increases, complicating component arrangement
Solution Approach 1:
The curved surface at the joint portion optimizes the spatial relationship between components, reducing unnecessary clearance while maintaining ease of assembly. The curvature allows for better component arrangement within the available space.
3Manufacturing precision
If the joint portion is positioned farther from the winding portion, then assembly tolerance is more lenient, but magnetic flux path length increases, reducing magnetic efficiency
Solution Approach 1:
The curved surface design at the joint portion enables the joint to be positioned closer to the winding portion, shortening the magnetic flux path and improving magnetic efficiency. The curvature provides natural tolerance accommodation while maintaining optimal magnetic coupling.
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 improves magnetic efficiency, allows for a smaller coil size, ensures better manufacturability, and maintains air-tightness, while facilitating easier assembly and reducing the likelihood of gas leakage.
Implementation Method 1
an electromagnetic coil that includes a winding portion comprised of a wound conductive wire, the winding portion being configured to generate magnetic flux when energized
Implementation Method 2
the stationary core and the movable core constitute a magnetic path of the magnetic flux generated by the energized winding portion
Implementation Method 3
configured to cause a movable member having at least one movable contact to reciprocate based on electromagnetic attractive force generated by an energized electromagnetic coil
Data Source
AI summary
In an electromagnetic relay device, a plunger causes a movable member to reciprocate to cause a movable contact to abut onto or separate from a stationary contact. A solenoid unit includes an electromagnetic coil, a stationary core, and a movable core. The stationary core includes a plate member located in front of the electromagnetic coil. The plate member is arranged to overlap the electromagnetic coil when viewed in a reciprocation direction of the plunger. The stationary core has a stationary inside portion located inside the electromagnetic coil. The plate member and the stationary inside portion are integrated with each other. The stationary core has a joint surface between the outer peripheral surface of the stationary inside portion and the rear-side surface of the plate member. The joint surface is curved convexly with respect to the plunger to constitute a stationary curved surface.