Electromagnetic Relay Parallel-Series Coil Switching
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Solution Overview
Problem
Electromagnetic relays face heating issues due to high coil currents required to pull the armature into contact position, with existing solutions like PWM being unsuitable for complex applications due to the need for complex microelectronic components and switching architectures.
Innovation Solution
An electromagnetic relay design that increases the total resistance of the excitation coils by switching from a parallel to a series connection, reducing coil current and magnetic flux to minimize heat dissipation, using capacitors and a switching element to manage the magnetic field for attracting and holding the armature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If high coil current is used to pull the armature into contact position, then the magnetic field strength is sufficient to close the relay, but the coil power consumption and heat generation increase
Solution Approach 1:
The patent applies dynamics by making the circuit configuration changeable from static to dynamic. The switching element transitions the excitation coils between parallel and series connections based on the armature position, allowing the total resistance and current to vary dynamically. This resolves the contradiction by providing high current (low resistance) during armature closure and low current (high resistance) during holding, thus achieving sufficient magnetic field strength only when needed while reducing continuous power consumption and heat generation.
Solution Approach 2:
The patent implements periodic action through two distinct operational phases: a pull-in phase with parallel connection providing high current for armature closure, and a holding phase with series connection providing reduced current. This periodic switching between high-power and low-power states allows the system to achieve the necessary magnetic field strength transiently while minimizing continuous energy loss and heat generation.
2Reliability
If high coil current is used to pull the armature into contact position, then the relay closes reliably, but the heat loss power increases
Solution Approach 1:
The dynamic switching between parallel and series connections allows the system to provide high current transiently for reliable armature closure, then transition to low current for holding. This temporal separation ensures reliable closing while minimizing continuous heat generation, as the high-current state exists only briefly during the pull-in phase.
Solution Approach 2:
The switching element is configured to preemptively transition from parallel to series connection as soon as the armature reaches the contact position. This preliminary action prevents the sustained high current that would cause excessive heat loss, while still ensuring reliable closure has been achieved. The system anticipates the end of the closure phase and switches to energy-saving mode before unnecessary heating can occur.
3Loss of energy
If PWM control is used to reduce coil current, then power consumption decreases, but the device complexity increases
Solution Approach 1:
The patent extracts the current control function from complex PWM electronics and implements it through a simple switching element that reconfigures the existing excitation coil circuitry. By taking out the need for microelectronic PWM controllers and replacing it with a basic switching component, the solution reduces power consumption while avoiding the device complexity that would accompany electronic PWM implementation.
Solution Approach 2:
The switching element acts as an intermediary that provides simple on/off control between the power source and the excitation coils, transitioning them between parallel and series configurations. This intermediary component achieves current reduction without requiring complex PWM electronics, thus lowering both power consumption and device complexity compared to electronic control solutions.
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 coil power and heat generation, particularly beneficial for components with low heat capacity, while maintaining precise switching accuracy and reliability.
Implementation Method 1
the first excitation coil and the second excitation coil are configured to provide the magnetic field for attracting and holding the armature
Implementation Method 2
which is configured to be attracted from the open position to the contact position by a magnetic field
Implementation Method 3
a first circuit branch comprising a first capacitor and a first excitation coil connected in series therewith, a second circuit branch comprising a second capacitor and a second excitation coil connected in series therewith
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
The invention relates to an electromagnetic relay (100), wherein the relay (100) comprises a yoke (601) and an armature (602) which is swivellably arranged on the yoke (601) and having has an open position and a contact position in relation to the yoke (601), and which is designed to be attracted by a magnetic field out of the open position into the contact position and retained in the contact position, comprising a first branch circuit (101) having a first capacitor (101-2) and a first exciter coil (101-1) connected in series with same, a second branch circuit (102) having a second capacitor (102-2) and a second exciter coil (102-1) connected in series with same, wherein the first exciter coil (101-1) and the second exciter coil (102-1) are designed to provide the magnetic field for attracting and retaining the armature (602), and comprising a switch element (103) arranged between the first branch circuit (101) and the second branch circuit (102) and having a first switch state and a second switch state, wherein the first branch circuit (101) and the second branch circuit (102) are arranged in a parallel connection in the first switch state of the switch element (103), and wherein the first exciter coil (101-1) and the second exciter coil (102-1) are arranged in a series connection in the second switch state of the switch element (103), and wherein the switch element (103) is designed to switch from the first switch state into the second switch state if the armature (602) is attracted into the contact position by the magnetic field of the first and second coils.