Electromagnetic Relay Positioning Member for Alignment
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Solution Overview
Problem
Conventional electromagnetic relays face reliability issues due to deformation of synthetic resin-based components during molding, which can alter the positional relationship between parts, affecting their performance and durability.
Innovation Solution
The contact device incorporates a separate positioning member made of a less deformable synthetic resin material, which holds and positions critical components like the armature, driver, and terminals within a case made of a more affordable, easily deformable synthetic resin, ensuring consistent part alignment and reducing the impact of case deformation on the device's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the case is made of synthetic resin material for cost-effective production, then manufacturing cost is reduced and ease of manufacture is improved, but the case deforms during molding which alters the positional relationship between parts and decreases reliability
Solution Approach 1:
The device is divided into two functional parts: the case (base) made of inexpensive synthetic resin for cost-effective manufacturing, and a separate positioning member made of highly rigid material to maintain precise positional relationships. This segmentation allows each component to fulfill its specific function without compromise.
Solution Approach 2:
The positioning member acts as an intermediary element between the electromagnetic block and the contact block, compensating for the deformation of the synthetic resin case. It serves as a stable reference framework that ensures accurate positioning despite case deformation.
2Productivity
If a single synthetic resin material is used for the case to simplify manufacturing, then device complexity is reduced and productivity is improved, but manufacturing precision deteriorates due to deformation during molding
Solution Approach 1:
The manufacturing system is segmented into two material systems: the case made of easily moldable synthetic resin for high productivity, and the positioning member made of highly rigid material (such as metal or rigid plastic) that maintains dimensional stability and manufacturing precision.
Solution Approach 2:
The material parameter (rigidity) is changed for the positioning member compared to the case. By selecting a material with significantly higher rigidity for the positioning member, the system achieves both the ease of manufacturing the case and the precision required for component positioning.
3Device complexity
If the positioning member is integrated into the case to reduce part count, then device complexity is reduced and ease of manufacture is improved, but the case must be made of less deformable material which increases manufacturing cost
Solution Approach 1:
The positioning function is segmented into a separate component (positioning member) rather than being integrated into the case. This allows the case to be made of inexpensive, easily manufactured synthetic resin while the positioning member is made of the required rigid material.
Solution Approach 2:
The positioning member serves multiple functions: it provides precise positioning for the electromagnetic block and contact block, acts as a rigid reference framework, and compensates for case deformation. This multi-functionality justifies the additional component.
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 configuration enhances the reliability and durability of the electromagnetic relay by maintaining consistent part alignment and reducing operational noise, while allowing for cost-effective production by using different resin materials for the case and positioning member.
Implementation Method 1
a driver and an armature driven by the driver. The driver includes a bobbin, a coil formed by winding a wire around the bobbin
Implementation Method 2
Since a strong magnetic field in generated by the concentration of electric current in the narrowed portion, and an electric arc generated across the contacts is subjected to a corresponding electromagnetic force according to Fleming's left-hand rule
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The contact device includes a driving block, a contact block, a case, and a positioning member. The driving block includes a driver and an amature driven by the driver. The driver includes a bobbin, a coil formed by winding a wire around the bobbin, and a heel piece. The contact block includes a fixed contact, a movable contact to be in contact with and separate from the fixed contact by the armature, a first terminal holding the fixed contact, and a second terminal holding the movable contact. The case accommodates the driving block and the contact block. The positioning member is provided as a separate part from the case and the bobbin, and accommodated in the case. The positioning member holds the first terminal, the second terminal, and the heel piece.