Electromagnetic Relay Resilient Plate Segmentation for Current Capacity
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Solution Overview
Problem
Existing electromagnetic relays have limited allowable current due to the sensitivity constraints imposed by the resiliency of the resilient plate, which cannot be enhanced simply by increasing the size or thickness of the plate.
Innovation Solution
The electromagnetic relay design includes a conductive resilient plate with a movable portion of increased length and a first flexible conductive member, such as a copper braided wire, to enhance the conductive cross-sectional area and maintain resiliency, allowing for higher allowable current and sensitivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the size or thickness of the resilient plate is increased to enhance allowable current, then the allowable current increases, but the sensitivity of the relay deteriorates
Solution Approach 1:
The resilient plate is divided into two separate components: a resilient plate and a flexible conductive member. The resilient plate maintains thin dimensions for high sensitivity, while the flexible conductive member (with larger cross-sectional area) handles current conduction. This segmentation allows each component to be optimized for its specific function without compromise.
Solution Approach 2:
The flexible conductive member serves dual functions: it provides electrical connection between the resilient plate and terminal, and simultaneously enhances the allowable current capacity. This multi-functionality eliminates the need to increase the resilient plate's thickness for current handling, preserving sensitivity while improving current capacity.
2Strength
If a thicker resilient plate is used to increase allowable current, then the allowable current increases, but the resiliency of the plate deteriorates
Solution Approach 1:
The resilient plate is segmented from the current conduction path by introducing a separate flexible conductive member. This allows the resilient plate to remain thin and maintain its resiliency characteristics, while the flexible conductive member provides the necessary current conduction capacity without compromising the plate's mechanical properties.
Solution Approach 2:
Different parts of the system have different properties optimized for their specific functions: the resilient plate has thin dimensions and high resiliency for sensitive actuation, while the flexible conductive member has larger cross-sectional area for current conduction. Each component's local quality is optimized independently.
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 increases the allowable current while maintaining high sensitivity and enabling smooth transition between circuit states with reduced moving resistance, outperforming prior art under the same induction current conditions.
Implementation Method 1
The electromagnet 12 is mounted to the base 11 along a longitudinal direction (L), and is used to generate an electromagnetic force when energized
Implementation Method 2
the resilient plate 172 has a straight segment 173 fixed to the fixing plate 13, a resilient segment 174 fixed to the magnetic attractive member 14
Data Source
AI summary
An electromagnetic relay includes a magnetic attractive member magnetically attractable by an electromagnet unit, and a conductive resilient plate connected to the magnetic attractive member and having a movable portion fixed to the magnetic attractive member, and a movable contact being urged to contact with a first stationary contact. A flexible conductive member is connected to the conductive resilient plate. When the electromagnetic unit is energized and attracts the magnetically attractive member to move the conductive resilient plate therealong, the movable contact contacts with a second stationary contact. When the electromagnetic unit is de-energized, the movable contact contacts with the first stationary contact.