Electromagnetic Relay Hinge Cutouts for Stress Dispersion
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Solution Overview
Problem
In existing electromagnetic relays, stress concentration at the hinge portion leads to a high likelihood of cracks, reducing the device's lifespan.
Innovation Solution
The electromagnetic relay features a movable block with hinge portions that include first and second cutout portions, dispersing stress along the boundary between the connection and welded portions, preventing concentration and thus minimizing crack occurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the connection portions are merely connected to common contact terminals without cutout portions, then the structure is simple and easy to manufacture, but stress concentration occurs at the boundary between connection portion and welded portion, causing cracks to occur frequently
Solution Approach 1:
The patent applies local quality by introducing cutout portions at specific locations on the connection portion of the hinge. These cutout portions are strategically positioned to disperse stress concentration at the boundary between the connection portion and welded portion, while leaving other areas of the hinge structure intact. This localized modification improves crack resistance without requiring a complete redesign of the entire hinge structure.
Solution Approach 2:
The cutout portions effectively segment the continuous connection portion into distinct regions, creating stress distribution zones that prevent stress concentration. By dividing the connection area through these cutouts, the stress path is redistributed away from the critical boundary area, reducing the likelihood of crack initiation and propagation.
2Productivity
If the movable block is rotated based on electromagnetic block excitation, then the relay performs its switching function, but stress concentrates at the basal portion of the shaft portion, leading to hinge portion cracking
Solution Approach 1:
The cutout portions are specifically positioned on the connection portion to address the stress concentration issue at the boundary area, while maintaining the rotational functionality of the shaft portion. This localized structural modification allows the hinge to maintain its switching operation capability while improving its resistance to stress-induced cracking.
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 design significantly reduces stress concentration, resulting in a longer-lasting electromagnetic relay with improved mechanical durability.
Implementation Method 1
The wide connection portions are welded so as to be integrated with the common contact terminals to provide welded portions
Data Source
AI summary
Provided is an electromagnetic relay, which hardly cracks at the hinge portion of a movable block so that it can have a longer life. In this electromagnetic relay, a wider connecting portion (52) of a pair of hinge portions (50 and 50) protruding on a common axis from the both sides of a movable block (40) is integrally welded to the common contact terminal (30) of a base block (20), thereby to form welded portions (59), and the movable block (40) is turned on the pin portion (51) of the hinged portions (50) as the turning axis in response to the magnetization and demagnetization of an electromagnet block (10) mounted on the base block (20), thereby to turn on and off the contacts. Moreover, a reference line (57), which joins an action point (58) positioned between the welded portion (59) disposed on the inner side edge of the connecting portion (52) of the hinge portion (50) and the turning axis and the center of the welded portion (59), crosses the boundary between the connecting portion (52) and the welded portion (59) integrally welded.