Relay Flag Structure Pivoting Without Deformation

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Solution Overview

Problem

Conventional relays face issues with permanent deformation of flag structures during assembly, leading to inefficient engagement with support structures, reduced accuracy in indicating switch states, and increased costs due to the need for deformation forces and complex tooling, which complicates the assembly process and reduces manufacturing efficiency.

Innovation Solution

A relay design featuring a non-deformable flag structure with projections that slot into an open-ended slot on the base plate, allowing for pivoting without substantial deformation, coupled with a card structure that changes the flag's orientation, and a housing to prevent dislodgment, simplifying assembly and enhancing mechanical sensitivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a compressive or tensile force is applied to deform the flag structure during assembly, then the flag structure can engage with the support structure, but the flag structure sustains permanent deformation and cannot return to its original state

Engineering Contradiction:

Improveengagement of flag structure with support structureVSAvoidoriginal state of flag structure

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Instead of deforming the flag structure to achieve engagement, the patent inverts the approach by designing the flag structure with pre-formed projections that naturally fit into corresponding recesses on the support structure. This eliminates the need for deformation during assembly, allowing the flag to maintain its original state while achieving reliable engagement.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The flag structure is segmented into distinct functional elements: the flag body and separate projections. These projections are specifically shaped and positioned to mate with complementary features on the support structure, enabling engagement without requiring deformation of the entire flag structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If a compressive or tensile force is applied to the flag structure during assembly, then the flag structure can be fitted to the support structure, but the assembly process becomes slower and less efficient

Engineering Contradiction:

Improvefit of flag structure to support structureVSAvoidassembly speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The projections are pre-formed as integral parts of the flag structure during manufacturing, rather than being created during assembly. This preliminary action eliminates the need for deformation forces during assembly, significantly speeding up the process while ensuring proper fit.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flag structure's projections are designed to self-align and self-fit into the support structure's recesses through simple insertion movements. The geometry of the projections and recesses guides proper positioning automatically, eliminating the need for complex deformation operations and external tooling.

Inventive Principle:

Principle #25Self-service

3Reliability

If excessive force is applied to the flag structure during assembly, then the flag structure can engage with the support structure, but the flag structure can be broken

Engineering Contradiction:

Improveengagement of flag structureVSAvoidintegrity of flag structure

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

Rather than using excessive force to achieve engagement, the patent inverts the approach by designing complementary geometries where projections naturally fit into recesses. This allows engagement through gentle insertion forces, eliminating the risk of breaking the flag structure while ensuring reliable connection.

Inventive Principle:

Principle #13The other way round (Inversion)

4Ease of manufacture

If complicated tooling is used to insert components due to the positioning of the flag structure, then components can be assembled, but the efficiency of the assembly process is reduced and manufacturing cost increases

Engineering Contradiction:

Improveassembly of relay componentsVSAvoidtooling complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The flag structure's projections are designed to self-align and self-position within the relay assembly. When the flag is inserted, the projections automatically find their correct positions in the recesses without requiring complex alignment tooling. This self-positioning capability eliminates the need for complicated fixtures and jigs, simplifying the assembly process and reducing manufacturing costs.

Inventive Principle:

Principle #25Self-service

Data Source

PatentEP2874166B1A relay, a flag structure and a flag assembly

Publication Date: 2017.11.01 SCHNEIDER ELECTRIC LOGISTICS ASIA PTE LTD

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AI summary

A relay (100) and a method of assembling a relay (100) are provided. The relay (100) comprising: a relay switch (120) configured to operate in a first switch mode and a second switch mode; a flag structure (200) for indicating an operative status of the relay switch (120), the flag structure (200) capable of being orientated in a first position for indicating the relay switch (120) being in the first switch mode and in a second position for indicating the relay switch being in the second switch mode; a card structure (300) coupled to the flag structure (200) for changing the orientation of the flag structure (200) from the first position to the second position or from the second position to the first position; and a base plate (110) coupled to the flag structure (200) and the card structure (300), the base plate (110) comprising an open ended slot (116) for allowing part of the flag structure (200) to be received therein.