Electrical Relay Carrier Sub-Assembly with Direct Shaft Plunger Integration
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Solution Overview
Problem
Existing electrical relay devices face issues due to the use of separate fasteners, such as retaining rings, which can loosen or fall off, causing the shaft to uncouple from the ferromagnetic element and movable contact, leading to device malfunction.
Innovation Solution
The electrical relay device employs a carrier sub-assembly where the shaft is directly secured to the plunger without intervening fasteners, using an interference fit and flanges to mechanically lock the shaft in place, ensuring stable coupling throughout the device's operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate fasteners (retaining rings) are used to couple the shaft to the ferromagnetic element and movable contact, then the device can be assembled with simple components, but the fasteners are prone to loosening and falling off due to vibrations and forces during use
Solution Approach 1:
The shaft and ferromagnetic element are merged into a single integral component, eliminating the need for separate fasteners. The shaft is directly formed with a head portion that engages the ferromagnetic element, creating a unified structure that cannot loosen or disassemble during operation.
Solution Approach 2:
The shaft is inserted through the ferromagnetic element, with the head portion of the shaft nested within a cavity of the ferromagnetic element. This nesting arrangement provides secure retention without requiring external fasteners, as the shaft is physically contained within the ferromagnetic element structure.
2Ease of operation
If retaining rings are used to secure the shaft, then initial assembly is straightforward, but the retaining rings can dislodge under vibration and force, causing device malfunction
Solution Approach 1:
The shaft and ferromagnetic element are combined into one integral piece, removing the retaining ring component entirely. This merger ensures that the structural connection cannot deteriorate over time, as there are no separate parts that can wear, loosen, or fail.
Solution Approach 2:
The problematic retaining ring is extracted from the design. By removing this vulnerable component, the patent eliminates the source of reliability issues while maintaining assembly simplicity through the integral shaft design.
3Ease of manufacture
If multiple separate fasteners are used to secure the shaft to both the ferromagnetic element and movable contact, then the coupling can be easily installed, but the multiple fasteners increase the complexity of potential failure points
Solution Approach 1:
The shaft is designed as a single component that simultaneously secures both the ferromagnetic element and movable contact without requiring separate fasteners for each connection. This reduces the total component count while maintaining secure coupling.
Solution Approach 2:
The shaft serves multiple functions: it acts as the actuating mechanism, secures the ferromagnetic element via its head portion, and connects to the movable contact. This multi-functionality eliminates the need for separate fasteners for each connection point.
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 solution eliminates the risk of fastener dislodgment, providing a reliable and stable connection between the shaft, plunger, and movable contact, ensuring consistent operation of the electrical relay device even under vibrations and varying forces.
Implementation Method 1
a coil (110) surrounded by the plunger... When the relay power source (112) applies a current to the coil (110), the current through the coil (110) induces a magnetic field that acts on the plunger (132), causing the plunger (132) to translate
Implementation Method 2
a ferromagnetic element that is disposed at least proximate to the electromagnet such that an induced magnetic field applies a magnetic force upon the ferromagnetic element that translates the ferromagnetic element relative to the electromagnet
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
A carrier sub-assembly (126) for an electrical relay device includes a plunger (132) and a shaft (134). The plunger is formed of a ferromagnetic material. The plunger has a generally cylindrical shape extending between a top side (138) and a bottom side (140) of the plunger. The shaft extends between a contact end (142) and an opposite plunger end (144). The shaft is directly secured to the plunger without a discrete component between the shaft and the plunger securing the shaft to the plunger. The shaft and the plunger are configured to move together within the electrical relay device. A segment of the shaft including the contact end protrudes from the top side of the plunger for securing to a movable contact of the electrical relay device.