Electromagnetic Relay Shaft Geometry for Low-Impact Contact Separation
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Solution Overview
Problem
Conventional electromagnetic relays face issues with cutoff performance between fixed and movable contacts due to high impact forces, leading to malfunctions, and existing solutions to absorb vibrations and impacts increase manufacturing costs.
Innovation Solution
Incorporating a positioning portion with a first inclined portion on the drive shaft or movable iron core that collides in a non-perpendicular orientation, reducing axial impact force and integrating this feature with the contact case or housing to minimize manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the movable iron core collides with the auxiliary yoke in a flat surface orthogonal to the drive shaft, then the cutoff position is achieved, but a large impact force is generated in the axial direction causing malfunction
Solution Approach 1:
The invention replaces the flat surface collision interface with an inclined surface (first inclined portion on the movable iron core contacting the positioning portion). This inclined geometry transforms the collision from a perpendicular impact into a glancing contact, reducing the axial impact force component while still achieving reliable positioning at the cutoff position.
2Object-affected harmful factors
If a magnet is disposed around the movable iron core to absorb vibration and impact, then vibration and impact are reduced, but the manufacturing cost increases due to the increase in the number of parts
Solution Approach 1:
The invention extracts the vibration and impact absorption function from separate components (magnets, cushion rubber) and integrates it into the existing movable iron core structure through the inclined surface design. The inclined surface itself provides the cushioning effect by reducing impact force, eliminating the need for additional parts and reducing manufacturing cost.
Solution Approach 2:
The movable iron core serves dual functions: it acts as both the electromagnetic actuator and the impact absorption element. The inclined surface on the movable iron core automatically reduces impact force during collision with the positioning portion, making the system self-regulating without requiring external damping components.
3Object-affected harmful factors
If cushion rubber is used to absorb vibration and impact of the movable iron core, then vibration and impact are reduced, but the manufacturing cost increases due to the increase in the number of parts
Solution Approach 1:
The invention removes the need for separate cushioning components by integrating the impact reduction function directly into the movable iron core's geometry. The inclined surface provides the necessary vibration and impact absorption without requiring additional parts like cushion rubber.
Solution Approach 2:
The invention changes the geometric parameters of the movable iron core by adding an inclined surface instead of using a flat surface. This parameter change (from flat to inclined) fundamentally alters the collision dynamics, reducing impact force while eliminating the need for separate damping materials.
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 enhances cutoff performance by reducing axial impact forces and preventing malfunctions while reducing manufacturing costs by eliminating the need for additional components like magnets or cushion rubber.
Implementation Method 1
When a voltage is applied to the coil, the movable iron core moves from the cutoff position to the operating position
Implementation Method 2
the movable iron core moves from the operating position to the cutoff position due to the elastic force of the urging member
Data Source
AI summary
An electromagnetic relay includes a fixed contact, a movable contact piece having a movable contact, a drive shaft, an electromagnetic drive device, and a positioning portion. The movable contact piece is movable in a first direction contacting the fixed contact and in a second direction separating from the fixed contact. The electromagnetic drive device includes a movable iron core integrally movably connected to the drive shaft. The electromagnetic drive device switches between a contact state in which the movable contact comes into contact with the fixed contact and a separate state in which the movable contact is separated from the fixed contact by moving the drive shaft with the movable iron core. The positioning portion positions the drive shaft or the movable iron core in the separate state. The drive shaft or the movable iron core includes a first inclined portion that contacts the positioning portion in the separate state.