Electromagnetic Relay Insulating Chamber and Return Loop Contact Spring
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Solution Overview
Problem
Existing electromagnetic relays are limited to low voltage applications due to short insulation distances between contact springs and armature or pole shoes, and lack sufficient closing force to handle short circuits effectively.
Innovation Solution
The design incorporates an electromagnet system with a coil, coil core, and pole pieces, featuring an armature with an insulating block supporting a contact spring forming a return loop, and a second switch with a contact spring that increases electrodynamic forces for enhanced closing force and insulation, allowing for longer creepage distances to prevent leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the insulation distance between contact spring and armature or pole shoe is kept short, then the relay installation space is reduced, but the relay can only be used for low voltages below 60 volts
Solution Approach 1:
The relay is divided into two separate sides: a first side for low voltage load/diagnostic switches and a second side for high voltage diagnostic switches. This segmentation allows each side to be optimized for its specific voltage requirement, with the high voltage side having sufficient insulation distance while the overall relay remains compact.
Solution Approach 2:
The relay utilizes both opposite sides of the electromagnet system (first side and second side) to accommodate different switch types. By arranging switches on opposite sides rather than stacking them vertically, the design achieves high voltage capability without significantly increasing the relay's footprint volume.
2Device complexity
If a standard contact spring design is used, then the relay structure is simple, but the closing force is insufficient to handle short circuits effectively
Solution Approach 1:
The contact spring is designed with a return loop configuration that allows current to flow in opposite directions through different sections. When short circuit current flows, the electrodynamic forces generated by the interaction between the current and the magnetic field dynamically increase the closing force, providing enhanced short circuit capability without requiring a mechanically complex spring structure.
Solution Approach 2:
The design converts the potentially harmful short circuit current into a beneficial force. The high current flowing through the return loop contact spring generates strong electrodynamic forces that press the contacts together more firmly during short circuits, preventing contact damage and ensuring reliable current transfer.
3Reliability
If the relay is designed for high voltage with increased insulation distance, then voltage applicability is improved, but the relay installation space increases
Solution Approach 1:
The relay is divided into two separate sides: a first side for low voltage load/diagnostic switches and a second side for high voltage diagnostic switches. This segmentation allows each side to be optimized for its specific voltage requirement, with the high voltage side having sufficient insulation distance while the overall relay remains compact.
Solution Approach 2:
The relay utilizes both opposite sides of the electromagnet system (first side and second side) to accommodate different switch types. By arranging switches on opposite sides rather than stacking them vertically, the design achieves high voltage capability without significantly increasing the relay's footprint volume.
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
The solution enables the relay to operate at higher voltages while maintaining increased closing force and preventing contact damage during short circuits, ensuring reliable current transfer and protection.
Implementation Method 1
The contact spring is shaped according to a return loop to form reverse current-carrying conductor sections connected on the one hand to a load pin and on the other hand to a movable contact... the resulting electrodynamic forces can be used to increase the closing force of the relay
Implementation Method 2
The contacts of the first switch are located in an insulating chamber surrounded by insulating walls of a support member, a housing cap and the insulating armature block... Electrical currents have to cover long air and creepage distances of more than half the length of the relay before they reach metal parts. This prevents such leakage currents.
Data Source
AI summary
An OFF-load switch (20) has fixed leg (24c) that is connected to a load terminal pin (43), and a contact spring leg (24a) which is connected with a movable contact (23) which cooperates with a fixed contact (21) connected to load connection pin (44). A diagnosis switch (30) determines the setting of armature (12), and includes contact spring (34) having a movable contact (33) for electrical connection between two diagnosis connector pins (45,46). A relay housing combines together with insulating block (13) of armature to form an insulating chamber for OFF-load switch.