Electromagnetic Relay Insulation via Segmented Moving Member

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Solution Overview

Problem

Existing electromagnetic relays face challenges in providing a large insulation distance between the movable contact piece and the movable iron core, which affects the reliability and accuracy of spring load characteristic measurements.

Innovation Solution

The electromagnetic relay incorporates a moving member made of resin with electrical insulation, connecting the movable contact piece to the movable iron core, and utilizes a snap fitting mechanism between two members to simplify the structure while allowing for accurate measurement of spring load characteristics through an inspection hole and convex portion configuration.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a metal shaft is used to connect the movable contact piece to the movable iron core, then the structural strength and connectivity are improved, but the insulation distance between the movable contact piece and the movable iron core becomes insufficient

Engineering Contradiction:

Improveinsulation distanceVSAvoidstructure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The moving member is divided into a first member (metal portion) and a second member (resin portion) that are separate bodies connected by snap fitting. The first member provides mechanical strength and connectivity, while the second member provides electrical insulation. This segmentation allows both metal and resin portions to coexist in the same component, resolving the contradiction between structural strength and insulation distance.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The moving member combines metal and resin materials in a single component. The first member is made of metal for strength, while the second member is made of resin for insulation. This composite structure allows the component to simultaneously achieve both mechanical strength and adequate insulation distance without requiring separate components.

Inventive Principle:

Principle #40Composite materials

2Reliability

If the moving member is made as a single integrated component, then the manufacturing process is simplified, but the ability to provide both metal (for strength) and resin (for insulation) portions is limited

Engineering Contradiction:

Improveinsulation distanceVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The moving member is segmented into two separate members that are assembled together through snap fitting. This allows each member to be manufactured from appropriate materials (metal and resin) using suitable processes, and then assembled into a complete component that provides both strength and insulation functions.

Inventive Principle:

Principle #1Segmentation

3Measurement precision

If the moving member structure is simplified, then the manufacturing is easier, but the accuracy of spring load characteristic measurement may be affected by bending influences

Engineering Contradiction:

Improvespring load characteristic measurement accuracyVSAvoidmoving member structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The convex portion acts as an intermediary measurement point that can be accessed through the inspection hole. This allows measurement forces to be applied directly to the first member without transmitting bending influences through the entire moving member structure, thereby improving measurement accuracy while maintaining a relatively simple overall structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 achieves a larger insulation distance and simplifies the structure, enabling precise measurement of spring load characteristics with reduced influence from bending, thereby enhancing the reliability and accuracy of the electromagnetic relay's operation.

Implementation Method 1

An electromagnetic force acts on the movable iron core due to a magnetic field generated from a coil, and the movable iron core moves due to the electromagnetic force

Methodology Applied

Scientific EffectElectromagnetic force: Electromagnetic Induction

Implementation Method 2

The moving member is made of a resin having electrical insulation

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 3

The first member and the second member of the moving member are connected to each other by snap fitting

Methodology Applied

Scientific EffectSnap fitting: Mechanical Fastener

Data Source

PatentUS11735389B2Electromagnetic relay

Publication Date: 2023.08.22 OMRON CORP

AI summary

An electromagnetic relay includes a first movable contact piece, a first movable contact, a second movable contact, a moving member, a coil, and a movable iron core. The moving member holds the first movable contact piece. The moving member is made of a resin having electrical insulation. The moving member includes a first member and a second member. The first member is connected to a movable iron core. The second member is a separate body from the first member. The second member is connected to the first member by snap fitting. The first member includes a convex portion. The convex portion projects toward the second member in a moving direction of the moving member. The second member includes an inspection hole. The inspection hole faces the convex portion in the moving direction and extends in the moving direction.