Electromagnetic Relay Integral Base and Spool
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Solution Overview
Problem
Electromagnetic relays have complex structures due to numerous components, leading to low manufacturing efficiency and assembly errors, and the plastic housing for positioning features lacks reliability and stability.
Innovation Solution
The electromagnetic relay design includes a base with a spool and coil, a yoke inserted into the spool, an L-shaped armature with an elastic pressing member for positioning, and a U-shaped yoke forming an annular magnetic loop, with the base and spool formed as a single integral component to reduce complexity and enhance stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electromagnetic relay includes multiple components (base, spool, coil, yoke, armature, contacts, etc.), then the functionality and reliability of the relay are improved, but the structure becomes complex and manufacturing efficiency decreases
Solution Approach 1:
The patent integrates multiple components into a unified structure. The base and spool are formed as a single integral component, reducing assembly steps. The elastic pressing member combines positioning and thrust functions in one element. The armature integrates the movable contact carrier, combining motion transmission and contact functions.
2Reliability
If multiple components are assembled together, then the relay achieves required functionality, but excessive cumulative errors occur during assembly
Solution Approach 1:
By forming the base and spool as a single integral component, the patent eliminates assembly interfaces between these parts, thereby eliminating cumulative errors at the interface. Fewer separate components mean fewer assembly operations and fewer opportunities for error accumulation.
3Ease of operation
If the armature is movably assembled onto the base with positioning features in the plastic housing, then the armature can be positioned, but the positioning reliability and stability are insufficient
Solution Approach 1:
The patent segments the positioning function from the housing structure by introducing a separate elastic pressing member. This dedicated component provides both positioning and stable support for the armature, rather than relying solely on integrated housing features.
Solution Approach 2:
The elastic pressing member utilizes elastic materials to provide both positioning capability and stable support. The elasticity allows for reliable positioning while accommodating manufacturing tolerances and providing continuous contact force.
4Ease of manufacture
If the base and spool are formed as separate components, then manufacturing flexibility is maintained, but the overall structure complexity and assembly time increase
Solution Approach 1:
The base and spool are formed as a single integral component, eliminating the need for separate manufacturing and assembly of these parts. This integration directly reduces assembly time and improves manufacturing efficiency, while the integral design maintains manufacturing flexibility through suitable fabrication methods.
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 simplifies the structure, improves manufacturing efficiency, and enhances the reliability of the armature positioning, reducing assembly errors and increasing the stability of the relay's operation.
Implementation Method 1
an electromagnetic loop is formed among the yoke, the armature and the iron core, and the armature moves under the action of electromagnetic force
Implementation Method 2
an elastic pressing member fixed on the base and pressed against an outer side of the armature so as to position the armature on the base and provide an auxiliary thrust to the armature
Data Source
Figure 1
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AI summary
An electromagnetic relay includes a base, a spool provided on the base, a coil wound on the spool, a yoke inserted into a] hole of the spool, an armature movably provided on the base, a movable contact fixed on the base, a static contact fixed on the base, an driving member adapted to be connected between the armature and the movable contact, and an elastic pressing member fixed on the base and pressed against an outer side of the armature so as to position the armature on the base and provide an auxiliary thrust to the armature. The armature may be reliably positioned on the base by the elastic pressing member to prevent the armature from being detached from the base, and the armature may be provided with an auxiliary thrust by the elastic pressing member.