Electromagnetic Relay Pivot Structure for Stable Contact Switching
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Solution Overview
Problem
Conventional electromagnetic relays experience unstable downward movement of the conductive contact due to insufficient electromagnetic force, leading to reliability and sensitivity issues.
Innovation Solution
The electromagnetic relay incorporates a magnetic unit with a magnetic member, a magnetic driven subunit, an arcuate groove, and an arcuate protrusion, which allows the magnetic component to pivot about the fulcrum portion without forming an air gap, thereby reducing magnetoresistance and enhancing the torque generated.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional electromagnetic relay uses a magnetic driven plate with a gap between the magnetic driven plate and magnetic plate, then the structure is simple, but the magnetoresistance increases and the magnetic attraction force is insufficient, leading to unstable contact movement
Solution Approach 1:
The patent applies curvature by designing the arcuate groove and arcuate protrusion that guide the pivot movement of the magnetic component. The arcuate (curved) path ensures continuous contact between the magnetic component and fulcrum portion, eliminating air gaps while maintaining a compact structure. This curved geometry transforms the linear gap problem into a rotational arc movement, resolving the contradiction between reliability and structural simplicity.
Solution Approach 2:
The magnetic driven subunit is designed with nested components where the magnetic component pivots within the arcuate groove of the fulcrum portion. The pushing block, levered portion, and magnetic component are nested together in a compact arrangement that eliminates the need for separate adjustment mechanisms, reducing overall structural complexity while ensuring stable contact through the arcuate guidance system.
2Reliability
If the electromagnetic relay requires strong electromagnetic force to overcome magnetoresistance, then the contact movement becomes stable, but the relay size increases and power consumption increases
Solution Approach 1:
The patent replaces the conventional linear mechanical movement with a rotational pivot mechanism guided by arcuate geometry. This mechanical substitution transforms the high-force linear pull required to close the gap into a lower-force rotational movement along an arc, reducing the electromagnetic force requirement and allowing for a more compact relay design while maintaining stable contact movement.
Solution Approach 2:
The invention introduces a rotational dimension to the previously linear movement. By pivoting the magnetic component along an arcuate path rather than moving linearly across a gap, the system utilizes angular displacement to achieve contact closure. This dimensional change from linear to rotational movement reduces the force requirement and enables a more compact overall relay structure.
3Device complexity
If the electromagnetic relay uses a conventional linear movement mechanism, then the structure is straightforward, but the magnetic force is consumed by overcoming air gap magnetoresistance rather than driving contact movement
Solution Approach 1:
The arcuate groove and arcuate protrusion create a curved pivot path that eliminates air gaps during rotation. This curvature-based mechanism ensures continuous magnetic coupling between the magnetic component and fulcrum portion, preventing energy loss to magnetoresistance while maintaining a relatively simple structural implementation through the arcuate guidance system.
Solution Approach 2:
The patent substitutes the linear mechanical pull mechanism with a rotational pivot mechanism. This mechanical substitution changes the energy utilization from overcoming air gap resistance in linear motion to maintaining continuous magnetic coupling during rotational motion, significantly reducing magnetic force consumption while achieving the same contact closure function.
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 improves the reliability and sensitivity of the relay by ensuring smooth movement of the movable contact between the first and second contacts, even with a smaller electromagnetic force, and reduces the overall size of the relay.
Implementation Method 1
The electromagnetic unit (2) is disposed on the base unit (1) and is operable for generating an electromagnetic force when being energized
Implementation Method 2
the magnetic component (35) is magnetically attracted and driven by the electromagnetic force of the electromagnetic unit (2) to move
Implementation Method 3
enhancing the torque generated
Implementation Method 4
The arcuate groove (33) is formed in one of the fulcrum portion (312) and the magnetic driven portion (351). The arcuate protrusion (34) is formed at another one of the fulcrum portion (312) and the magnetic driven portion (351), is pivotably connected to the arcuate groove
Implementation Method 5
the levered portion (352) of the magnetic component (35) drives the pushing block (36) to push the movable conductive connector (61)
Data Source
AI summary
An electromagnetic relay includes an electromagnetic unit, a magnetic unit, first and second contacts, and a movable conductive terminal. The magnetic unit has a magnetic member having a fulcrum portion, a magnetic driven subunit, an arcuate groove, and an arcuate protrusion. The magnetic driven subunit includes a pushing block for pushing the movable conductive terminal, and a magnetic component magnetically attractable by the electromagnetic unit. The arcuate groove and the arcuate protrusion are respectively and interchangeably formed in the fulcrum portion and the magnetic component, and are pivotably connected to each other such that the magnetic component is pivotable about the fulcrum portion relative to the magnetic member. The movable conductive terminal is driven by the electromagnetic unit to contact one of the first contact and the second contact.