Relay Moving Core Protrusion for Magnetic Force and Assembly
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Solution Overview
Problem
Relays face challenges in achieving strong initial magnetic force between moving and fixed cores, leading to assembly issues and durability problems due to interference between springs and components.
Innovation Solution
A relay design incorporating a protrusion on the moving core that extends towards the fixed core, enhancing the initial magnetic force and minimizing interference between the return spring and other components by using a chamfered protrusion to facilitate elastic deformation and improve assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a planar moving core is used, then the structure is simple, but the initial magnetic force between moving core and fixed core is insufficient
Solution Approach 1:
The moving core transitions from a uniform planar structure to a structure with localized protrusions. These protrusions concentrate the magnetic flux density at specific contact points with the fixed core, thereby enhancing the initial magnetic force without requiring a complete redesign of the entire core structure. This localized modification resolves the contradiction by maintaining overall structural simplicity while improving magnetic force at critical locations.
2Force
If the moving core and fixed core are positioned close together, then the magnetic force is strong, but springs interfere with other components causing assembly issues
Solution Approach 1:
The moving core is segmented into a main body and protruding portions. This segmentation allows the protrusions to extend toward the fixed core to enhance magnetic force, while the main body remains positioned at a distance that prevents spring interference. The segmented structure enables independent optimization of magnetic force (via protrusions) and assembly ease (via main body positioning).
Solution Approach 2:
The solution moves from a two-dimensional planar contact to a three-dimensional structure with protrusions extending in the axial direction. This dimensional change allows the magnetic contact surfaces to be closer (improving magnetic force) while the main bodies remain spaced apart (preventing spring interference), effectively resolving the spatial conflict in multiple dimensions.
3Force
If a protrusion is added to the moving core, then the initial magnetic force is enhanced, but the device complexity increases
Solution Approach 1:
Instead of complicating the entire moving core structure, only localized protrusions are added to specific regions where magnetic contact is needed. This minimal modification approach enhances initial magnetic force while keeping the overall device complexity low, as the protrusions are simple geometric additions rather than complex structural changes.
4Force
If the moving core is designed with a corn-like shape, then the magnetic force is improved, but the assembly property deteriorates due to interference between springs and components
Solution Approach 1:
The corn-like shape is interpreted as segmented protrusions rather than a completely different complex geometry. By using discrete protruding portions that extend axially, the design achieves enhanced magnetic force similar to corn-like structures, while maintaining simpler overall geometry that prevents spring interference and improves assembly property.
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 protrusion enhances the initial magnetic force, improving operation characteristics and reducing assembly interference, thus enhancing the relay's performance and durability.
Implementation Method 1
a coil assembly disposed in the housing and configured to generate a magnetic field when a current is applied
Implementation Method 2
the moving core is brought into contact with a fixed core in response to magnetic force of a coil, which is generated when power is supplied to the coil
Implementation Method 3
the relay uses an arc-extinguishing mechanism that the permanent magnet is appropriately disposed adjacent to the fixed contact and the movable contact generating the arc, and the arc is controlled, cooled and extinguished using a force decided according to strength, and direction of magnetic flux generated in the permanent magnet
Implementation Method 4
a return spring surrounding the movable shaft and located between the fixed core and the moving core
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A relay according to one embodiment of the present invention includes a housing, a cylinder, a fixed contactor coupled to the housing, a movable contactor contactable with or separated from the fixed contactor, a coil assembly disposed in the housing to generate a magnetic field, a movable shaft coupled with the movable contactor at an upper portion thereof, a fixed core inserted into the cylinder, a moving core fixed to the movable shaft to move the movable shaft in a pressing manner, a wipe spring to supply elastic force to the movable shaft, and a return spring located between the fixed core and the moving core. The moving core includes a cylindrical protrusion extending toward the fixed core and surrounding the movable shaft.