Electromagnetic Relay Mechanical Coupling Assembly
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Solution Overview
Problem
Conventional electromagnetic relays require time-consuming welding of the movable core and shaft, making the assembly process labor-intensive and difficult to inspect for defects, and necessitate additional facilities for maintaining a predetermined gap between components, increasing production costs.
Innovation Solution
The electromagnetic relay design eliminates the welding process by using a coupling mechanism with a shaft and movable core connected via a hook and fixing member, allowing for easy assembly and reduced production costs, with the shaft made of synthetic resin to reduce weight and enhance moving speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the movable core and shaft are coupled by welding, then the connection strength is improved, but the assembly time and production cost increase
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical coupling system consisting of a coupling portion and fixing member. The shaft includes a coupling portion with a hook structure that engages with a fixing member, eliminating the need for welding while providing secure mechanical connection. This substitution reduces assembly complexity and time while maintaining connection integrity.
Solution Approach 2:
The patent divides the coupling system into separate components: the shaft with its coupling portion, the fixing member, and the movable core. This segmentation allows for modular assembly where the coupling portion and fixing member can be independently manufactured and assembled, reducing overall assembly time and enabling parallel production processes.
2Reliability
If welding is used to couple the shaft and movable core, then the connection reliability is improved, but the difficulty of detecting defects increases
Solution Approach 1:
The patent replaces welding with a mechanical coupling system featuring a hook and fixing member structure. This mechanical connection allows for visual inspection and easy detection of assembly defects, whereas welded joints require specialized equipment and expertise to inspect. The mechanical coupling maintains reliability through positive engagement while enabling simple quality control.
3Manufacturing precision
If additional facilities are used to maintain the predetermined gap between fixed core and movable core, then the manufacturing precision is improved, but the device complexity and production cost increase
Solution Approach 1:
The patent incorporates the gap maintenance function directly into the coupling portion and fixing member design. The structural geometry of these components is pre-designed to maintain the predetermined gap between the fixed core and movable core during assembly and operation. This eliminates the need for additional adjustment facilities or complex positioning mechanisms, reducing device complexity while ensuring manufacturing precision.
4Strength
If the shaft is made of metal, then the strength is improved, but the weight increases and moving speed decreases
Solution Approach 1:
The patent employs a composite material strategy by using synthetic resin for the shaft body while incorporating metal or reinforced elements in the coupling portion where strength is critical. This composite approach reduces the overall weight of the shaft for improved moving speed while maintaining sufficient strength through strategic material placement in high-stress areas.
Solution Approach 2:
The patent applies different material properties to different parts of the shaft: the shaft body uses lightweight synthetic resin for reduced weight and improved speed, while the coupling portion uses stronger materials or reinforcement to maintain connection strength. This local differentiation of material quality optimizes both weight and strength requirements.
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
Facilitates a faster and more cost-effective assembly process by eliminating welding and reducing the need for additional equipment, while minimizing the relay's size and weight, and ensuring stable operation with reduced production costs.
Implementation Method 1
a coil (141); a yoke (150) disposed within the coil (141) and having an inner section (162) for forming a magnetic path inside and outside of the coil (141); a movable core (180) disposed within the coil (141) to be attractable by the inner section (162)
Data Source
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AI summary
An electromagnetic relay includes a housing, a fixed contact provided within the housing, a movable contact movable to contact or be separated from the fixed contact, and a driving unit configured to drive the movable contact to be in contact with or separated from the fixed contact, and including a coil, a yoke disposed within the coil and having an inner section for forming a magnetic path inside and outside of the housing, a movable core disposed within the coil to be attractable by the inner section, and a shaft having one end connected to the movable core and another end connected to the movable contact, capable of facilitating an assembling process of a shaft and a movable core by eliminating a welding process.