Electromagnetic Relay Drive Shaft Insulation Design
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Solution Overview
Problem
Conventional electromagnetic relays face challenges in ensuring insulation between the movable contact piece and the movable iron core without increasing the number of components, which limits design freedom and complicates assembly.
Innovation Solution
Incorporating an insulating portion made from insulating material into the drive shaft, which contacts both the movable contact piece and the movable iron core, thereby eliminating the need for additional insulation components and allowing for increased design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conductive drive shaft is used to couple the movable contact piece and movable iron core, then mechanical strength and conductivity are improved, but insulation between the movable contact piece and movable iron core deteriorates
Solution Approach 1:
The drive shaft is segmented into a conductive portion (for mechanical strength and movement transmission) and an insulating portion (for electrical insulation). The insulating portion is inserted into a groove of the movable contact piece, creating distinct functional zones within the drive shaft assembly that simultaneously provide mechanical strength and electrical insulation.
Solution Approach 2:
The insulating portion acts as an intermediary element between the conductive drive shaft and the movable contact piece. This intermediary component provides the necessary electrical insulation while allowing mechanical coupling and movement transmission, resolving the contradiction between conductivity and insulation requirements.
2Reliability
If additional insulation components are provided to ensure insulation between movable contact piece and movable iron core, then insulation reliability is improved, but device complexity and number of components increase
Solution Approach 1:
The insulating portion is merged with the drive shaft assembly by inserting it into a groove of the movable contact piece. This integration combines the insulation function with the existing drive shaft structure, eliminating the need for separate insulation components and reducing overall device complexity while maintaining insulation reliability.
Solution Approach 2:
The drive shaft assembly is designed to serve multiple functions: mechanical coupling, movement transmission, and electrical insulation. The insulating portion integrated into the drive shaft structure provides insulation while the drive shaft itself maintains its mechanical functions, creating a multi-functional component that reduces the total number of parts needed.
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 solution effectively reduces the number of components and assembly steps while ensuring insulation between the movable contact piece and the movable iron core, enhancing the electromagnetic relay's design freedom and operational efficiency.
Implementation Method 1
When a voltage is applied to the coil of the electromagnetic drive device, the movable iron core is attracted to the fixed iron core and moves upward together with the drive shaft
Data Source
AI summary
An electromagnetic relay includes a fixed contact, a movable contact piece, a drive shaft, and a movable iron core. The movable contact piece is movable in a first direction and in a second direction. The drive shaft that extends in the first direction and the second direction and that is coupled to the movable contact piece. The movable iron core is coupled to the drive shaft so as to be integrally movable at a position beyond the movable contact piece in the first direction or at a position beyond the movable contact piece in the second direction. The drive shaft includes a first contact portion configured to contact the movable contact piece, a second contact portion configured to contact the movable iron core, and an insulating portion made from an insulating material and configured to insulate the movable contact piece and the movable iron core from each other.