Electromagnetic Relay Integrated Arc Protector and Spring Support
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Solution Overview
Problem
Conventional electromagnetic relays require a large number of components and man-hours for assembly due to inadequate elastic support from buffering rubber and increased component count, leading to potential gaps and handling difficulties.
Innovation Solution
The electromagnetic relay design incorporates an arc protector with a compression spring support portion that protrudes from the arc shielding portion, featuring a washer and buffer member to stabilize the compression spring, reducing component count and assembly time while preventing gap formation and noise generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If buffering rubber is used to support the compression spring, then elastic support is provided, but gaps may form between the buffering rubber and compression spring leading to inadequate support
Solution Approach 1:
The buffering rubber and arc protector are merged into a single integrated component. The buffering rubber is formed as an integral part of the arc protector, eliminating the interface between separate components and preventing gap formation while maintaining elastic support functionality
Solution Approach 2:
The integrated component combines the arc protector (rigid protective structure) with buffering rubber (elastic material) into a composite structure. This allows the single component to provide both arc protection and elastic support for the compression spring
2Adaptability or versatility
If multiple separate components are used for arc protection and spring support, then functional requirements are met, but the number of components and assembly time increase
Solution Approach 1:
Multiple functional components (arc protector and buffering rubber) are merged into a single integrated component. This reduces the total number of parts and simplifies assembly operations while maintaining all required functions of arc protection and spring support
Solution Approach 2:
The integrated component performs multiple functions simultaneously: it provides arc protection through the arc protector portion and elastic support for the compression spring through the integrated buffering rubber portion, eliminating the need for separate dedicated components
3Reliability
If buffering rubber is used as a separate small component, then elastic support is provided, but handling becomes difficult and assembly requires more man-hours
Solution Approach 1:
The small buffering rubber component is merged with the larger arc protector to form a single integrated component. This eliminates handling difficulties associated with small separate parts while maintaining the elastic support function through the integrated buffering rubber structure
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 reduces the number of components and assembly time by providing stable support for the compression spring and arc protection with a single integrated component, preventing gap formation and noise, thus enhancing the assembly efficiency and reliability of the electromagnetic relay.
Implementation Method 1
a compression spring for applying an elastic force to the movable contact so as to be in contact with the fixed contact
Implementation Method 2
an arc protector including an arc shielding portion for shielding an arc
Implementation Method 3
a coil, a yoke disposed around the coil to form a magnetic path
Data Source
Figure 1
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Figure 3
AI summary
An electromagnetic relay includes a housing; a fixed contact provided within the housing; a movable contact disposed within the housing so as to be contactable to and separable from the fixed contact; a driving unit configured to drive the movable contact, and including a shaft having one end connected to the movable contact and a compression spring for applying an elastic force to the movable contact so as to be in contact with the fixed contact; and an arc protector including an arc shielding portion for shielding an arc, and a compression spring support portion formed to protrude from the arc shielding portion to support the compression spring, the compression spring support portion comprising a shaft accommodating portion for accommodating the shaft therein. Under such configuration, the number of required components can be reduced and generation of a gap can be prevented.