Electromagnetic Relay Flange for Magnetic Gap Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electromagnetic relays face challenges in accurately adjusting separation distances and facing areas within magnetic gaps, which affects operational voltage and design flexibility.
Innovation Solution
Incorporating a flange portion on the movable portion that protrudes radially to define separation distances and/or facing areas by abutting against the non-movable portion during coil energization, allowing for precise adjustment of magnetic gaps without additional spacers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional electromagnetic relay structures are used without integrated flange portions, then manufacturing is simpler, but adjustment precision of separation distances and facing areas deteriorates
Solution Approach 1:
The flange portion is integrated directly into the movable portion (such as the movable core or its supporting structure), merging the adjustment function into the existing component rather than using a separate adjustment mechanism. This integration achieves precise control of separation distances and facing areas while avoiding additional complex adjustment devices.
2Adaptability or versatility
If additional spacers are used to define magnetic gaps, then adjustment flexibility is reduced, but manufacturing precision may be maintained
Solution Approach 1:
The adjustment function traditionally performed by separate spacers is extracted and integrated into the movable portion itself through the flange portion. This eliminates the need for additional spacer components while maintaining the ability to precisely define magnetic gap dimensions.
Solution Approach 2:
The flange portion serves multiple functions: it provides structural support for the movable portion, defines the separation distance from the fixed magnetic path, and establishes the facing area geometry. This multi-functionality replaces what would traditionally require multiple separate components.
3Manufacturing precision
If the flange portion protrudes significantly in the coil radial direction, then adjustment precision improves, but the device volume increases
Solution Approach 1:
The flange portion protrudes only in the specific radial direction where adjustment is needed, rather than increasing the movable portion's volume uniformly in all directions. This localized protrusion achieves precise separation distance control while minimizing overall volume increase.
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
Enables excellent adjustment of separation distances and facing areas, improving operational voltage control and design freedom by integrating the flange portion seamlessly with the movable portion.
Implementation Method 1
a coil disposed to develop a magnetic field by energization
Implementation Method 2
a movable core disposed to face the fixed core along the center axis line to be attracted by the fixed core by the magnetic field during the energization of the coil
Data Source
AI summary
An electromagnetic relay includes: a coil; a housing that supports the coil; a non-movable portion supported by the housing and including a fixed core and a fixed magnetic path defining member; and a movable portion provided to be reciprocally movable along a center axis line of the coil according to an energization state of the coil. The movable portion includes a movable core disposed to face the fixed core along the center axis line. The movable portion integrally has a flange portion protruding in a coil radial direction perpendicular to the center axis line to define a separation distance and/or a facing area in a magnetic gap between the fixed magnetic path defining member and the movable core by abutting against the non-movable portion.