Relay Overtravel Adjustment via Rotary Dial Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic relays face challenges in achieving a reliable and precise overtravel adjustment for contact springs due to the mechanical properties of metallic contact springs, making it difficult to set a uniform overtravel position.
Innovation Solution
A rotary adjustment mechanism is integrated into the pusher assembly, allowing for precise adjustment of the gap between contact system components through a graduated dial with a screwdriver-accessible slot, enabling uniform overtravel setting for all contact springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If contact springs are manually bent, turned, or twisted to set overtravel position, then overtravel adjustment is achieved, but manufacturing precision and reliability are poor due to mechanical properties of metallic contact springs
Solution Approach 1:
The invention replaces static manual manipulation of contact springs with a dynamic adjustment mechanism. A threaded rod with a rotating head allows the pusher to be positioned at different distances from the armature by rotating the head, which moves the pusher along the threaded rod. This dynamic adjustment mechanism provides precise control over the overtravel position without requiring manual bending or twisting of the contact springs.
Solution Approach 2:
The invention substitutes the manual mechanical manipulation of contact springs (bending, turning, twisting) with a threaded adjustment mechanism. The threaded rod converts rotational motion of the head into linear displacement of the pusher, providing a more precise and controllable method for setting the overtravel position compared to direct manual manipulation of the springs.
2Reliability
If contact springs are manipulated to achieve overtravel setting, then overtravel adjustment is provided, but the adjustment is difficult to replicate precisely due to mechanical properties of the springs
Solution Approach 1:
The threaded adjustment mechanism allows for dynamic and precise positioning of the pusher relative to the armature. By rotating the head on the threaded rod, the pusher can be accurately positioned to achieve the desired overtravel setting, ensuring uniformity across multiple relays during manufacturing.
Solution Approach 2:
The invention changes the parameter control method from manual spring manipulation to a threaded mechanical adjustment. The threaded rod provides a direct relationship between rotational input and linear displacement, allowing for precise control of the pusher-to-armature distance and ensuring consistent overtravel settings.
3Manufacturing precision
If a rotary adjustment mechanism is added to the pusher assembly, then precise and uniform overtravel adjustment is achieved, but device complexity increases
Solution Approach 1:
The threaded rod with rotating head serves multiple functions: it provides the overtravel adjustment mechanism, acts as a positioning element for the pusher, and includes a head for tool engagement. This multi-functional design achieves precise adjustment without adding excessive complexity to the overall assembly.
Solution Approach 2:
The threaded rod acts as an intermediary element between the rotating head and the pusher. It converts the rotational motion of the head into precise linear positioning of the pusher, enabling accurate overtravel adjustment while maintaining a relatively simple overall 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 solution provides a simplified, precise, and easily replicable mechanism for overtravel adjustment, ensuring consistent wear and extended cycle life of the contact tips by allowing for incremental and uniform adjustment of the contact spacing.
Implementation Method 1
The relay coil has a coil and a magnetically permeable core connected to the tilting armature to move the armature
Implementation Method 2
The coil is a cylindrical hollow member with a rectangular internal cross section corresponding to a cross section of the core, and is spring loaded to return to a specified position when the coil is de-energized
Data Source
AI summary
An electromagnetic relay has an overtravel adjustment to set the gap in the contact arrangement. The armature is actuated by a relay coil and linked to a pusher to drive the pusher to operate the contact system. The pusher includes a rotary dial disposed in a slot on the pusher adjacent to the armature. The rotary adjustment increases or decreases a gap of the contacts to provide an over-travel adjustment. The pusher includes bifurcated tines defining the slot for receiving an armature linkage and the rotary adjustment. The rotary adjustment includes a head and a post depending from the head. The post is disposed within the slot and the head portion in contact with the armature linkage portion. The rotary adjustment sets the distance between the forward edge and the armature to achieve the desired overtravel for the contact arrangement.