Insulating Separation Component for Relay Galvanic Isolation
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Solution Overview
Problem
Relays face challenges in preventing the transmission of high-frequency interferences from the load circuit to the control circuit due to conductive connections between the armature and the switching bridge.
Innovation Solution
A component group using an electrically insulating separation component with a receptacle for the armature and connection elements for the switching bridge carrier, providing a galvanic separation through a combination of form-fit and force-fitting mechanisms, including a cover for enhanced insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal elements are used to connect the armature and switching bridge, then electrical conductivity is improved, but high-frequency interference transmission increases
Solution Approach 1:
An insulating element is introduced as an intermediary component between the armature and switching bridge carrier. This mediator provides mechanical connection while blocking electrical interference, thus resolving the contradiction between maintaining electrical connectivity and preventing high-frequency interference transmission.
Solution Approach 2:
The electrical conductivity parameter is changed by replacing metal connection elements with insulating material. This parameter change eliminates the harmful effect of high-frequency interference transmission while maintaining the necessary mechanical and electrical functions through alternative means.
2Object-affected harmful factors
If an insulating element is used to separate the armature and switching bridge, then high-frequency interference transmission is reduced, but assembly complexity increases
Solution Approach 1:
Multiple functions are merged into the insulating element: it serves as both the insulation barrier and the mechanical mounting structure with integrated connection elements. The insulating element combines the functions of electrical isolation, mechanical support, and assembly features, thereby reducing overall device complexity despite adding insulation functionality.
Solution Approach 2:
The insulating element is designed with multi-functionality, serving simultaneously as an electrical insulator, mechanical connector, and structural support component. This universal design approach allows a single component to fulfill multiple roles, simplifying the overall assembly process despite the added insulation requirement.
3Ease of operation
If the insulating element has integrated connection elements, then ease of assembly is improved, but manufacturing precision requirements increase
Solution Approach 1:
Connection elements are pre-integrated into the insulating element during manufacturing, allowing for preliminary positioning and alignment features to be built-in. This preliminary action enables easier assembly by providing built-in guidance and alignment mechanisms that reduce the need for high-precision manual adjustment during assembly.
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
Effectively reduces or eliminates high-frequency interference transmission while allowing for simple and secure assembly and operation of the relay.
Implementation Method 1
separation component made from an electrically insulating substance
Data Source
Figure 1
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AI summary
Shown is a component group (1) for galvanically separating an armature (2) and a switching bridge (18) of a relay (100), the switching bridge (18) being arranged on a switching bridge carrier (8), with a separation component (10) made from an electrically insulating substance, wherein the separation component (10) has a receptacle (15) for inserting the armature (2) and connection elements (20) for plugging together with the switching bridge carrier (8). Further shown is a relay (100) comprising such a component group (1).