Electromagnetic Relay Hinge Spring Noise Reduction
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Solution Overview
Problem
Conventional electromagnetic relays have a complex spring structure, difficulty in accurate processing, and increased height due to the supporting spring's placement, which affects switching lifespan and generates collision noise during pivoting.
Innovation Solution
A hinge spring with an elastic contacting portion and support integrated into the moving iron, allowing for adjustable contact with a card member and yoke, reducing collision noise without affecting the pivoting operation, and maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a supporting spring is arranged at the upper portion of the moving iron to support the moving iron, then the moving iron can be supported, but the height dimension of the entire electromagnetic relay becomes larger
Solution Approach 1:
The hinge spring is repositioned from the upper portion to the lower portion of the moving iron, changing the spatial arrangement from vertical stacking to a configuration that utilizes the width dimension. This allows the supporting spring to be arranged laterally rather than vertically, reducing the height dimension while maintaining the supporting function through the hinge spring's elastic support at the relocated position.
2Reliability
If the supporting spring is arranged at the upper portion of the moving iron, then the moving iron can be supported, but the bent structure of the supporting spring becomes complex and difficult to process accurately
Solution Approach 1:
Instead of positioning the hinge spring at the upper portion of the moving iron as in conventional designs, the invention inverts this arrangement by placing the hinge spring at the lower portion. This inversion simplifies the bending structure and anchoring configuration, making the spring easier to manufacture with accurate dimensions while preserving its elastic support function for the moving iron.
3Object-affected harmful factors
If an operation buffer spring is provided to suppress collision force, then collision noise is reduced, but the contact pressure is suppressed which adversely affects the switching lifespan of the contact
Solution Approach 1:
The invention separates the collision suppression function from the contact pressure maintenance function. By positioning the hinge spring's elastic contacting portion to contact the card member at a specific location, the collision suppression effect is achieved through localized elastic deformation, while the contact pressure between the movable and fixed contacts is maintained independently, thus preserving switching lifespan without being compromised by noise reduction requirements.
4Ease of manufacture
If the hinge spring has a simple configuration, then manufacturing is easier, but adjusting the contact position requires complex deformation of the elastic contacting portion
Solution Approach 1:
The hinge spring is designed with an elastic contacting portion that inherently provides adjustment capability through its elastic deformation properties. The simple configuration of the hinge spring allows it to be manufactured easily, while the elastic contacting portion's natural elasticity enables precise contact position adjustment during assembly or operation, as the elastic deformation automatically compensates for positioning variations without requiring complex external adjustment mechanisms.
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
The solution effectively suppresses collision noise and stabilizes the pivoting operation of the moving iron, ensuring smooth and accurate contact switching without increasing the relay's height or complicating the spring structure.
Implementation Method 1
a hinge spring having a connecting portion to be pressure-contacted to the outer surface of the middle part of the yoke, an elastic contacting portion extending from the connecting portion at a predetermined angle, and an elastic support extending from the connecting portion at a predetermined angle
Implementation Method 2
an elastic support extending from the connecting portion at a predetermined angle so as to elastically support the moving iron plate pivotably at the yoke
Data Source
Figure 1
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Figure 3
AI summary
This invention is provided with an electromagnet block (2), wherein a coil (24) is wound around an iron core (22) with a spool (23) interposed therebetween, and a yoke (41) that has one end thereof anchored to one end section of the iron core (22) is made to extend to a section at the side of a magnet pole section (25) at the other end of the iron core (22). A hinge spring (44) is anchored to the yoke (41), and a moving iron (4) is provided pivotably in a state of being supported by the hinge spring (44), with the other end of the yoke (41) functioning as a fulcrum. The hinge spring (44) is provided with an elastic contacting section (46) that extends from the position where the hinge spring (44) is anchored to the yoke (41), towards a direction opposite the position where the moving iron (4) is supported. The moving iron (4) has integrated therewith, at a side opposite a section (63) to be drawn with respect to the fulcrum, a card member (65) that can come in contact with the elastic contacting section (46) before coming in contact with the yoke (41).