Relay Apparatus with Shared Yoke for Power Reduction
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Solution Overview
Problem
Existing relay apparatuses face challenges in reducing power consumption and external dimensions while maintaining efficient relay operation, with prior art limited to a 50% reduction in power consumption and resulting in unbalanced relay characteristics due to uneven magnetic flux distribution.
Innovation Solution
A relay apparatus with a common yoke configuration that allows magnetic flux from multiple coils to flow through a shared magnetic circuit, reinforcing the magnetic flux to reduce power consumption and prevent accidental activation of relays, achieved by using a magnetic flux restriction section and controlling current flow through the coils to ensure sequential activation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a single electromagnetic coil is used to activate multiple relays through shared magnetic flux, then power consumption is reduced by 50%, but the external dimensions and manufacturing cost increase due to larger coil aperture requirements
Solution Approach 1:
The invention divides the magnetic flux path into multiple independent circuits, each with its own electromagnetic coil. Instead of using a single large coil to generate all magnetic flux, multiple smaller coils generate flux that flows through separate magnetic circuits. This segmentation allows each coil to have a smaller aperture while collectively activating multiple relays, thus reducing overall dimensions while maintaining low power consumption.
Solution Approach 2:
The invention introduces a new spatial dimension by creating a three-dimensional magnetic flux distribution pattern. Magnetic flux from different coils flows through different paths in space, utilizing the third dimension (depth/vertical direction) to route flux through the yoke structure. This allows multiple coils with small apertures to effectively cover the activation of multiple relays without increasing the footprint area.
2Device complexity
If all magnetic flux is concentrated in a single electromagnetic coil, then relay activation is simplified, but the cross-sectional area of the coil aperture must be large, increasing overall size
Solution Approach 1:
The magnetic flux is segmented into multiple independent circuits, each handled by a separate electromagnetic coil. Instead of concentrating all flux through one large coil aperture, each coil generates flux through its own smaller aperture. The yoke structure guides these segmented flux paths to their respective relays, simplifying the activation mechanism for each individual relay while keeping coil dimensions small.
Solution Approach 2:
The yoke serves as an intermediary magnetic conductor that receives flux from multiple electromagnetic coils and distributes it to the appropriate relays. This intermediary structure allows the decoupling of coil aperture size from the number of relays activated, as the yoke efficiently routes the segmented flux paths without requiring large coil apertures.
3Adaptability or versatility
If a single electromagnetic coil serves multiple relays, then manufacturing cost increases due to large copper usage, but relay functionality is maintained
Solution Approach 1:
The single large electromagnetic coil is segmented into multiple smaller coils, each serving one or more relays. While there are now multiple coils instead of one, the total copper volume is reduced because each small coil has a much smaller aperture and requires less wire length. The segmented approach optimizes the copper-to-functionality ratio by matching coil size to the specific activation requirements of each relay group.
Solution Approach 2:
The invention changes the parameters of the electromagnetic coils from one large coil with high current requirements to multiple smaller coils with lower individual current requirements. This parameter change reduces the total copper material needed, as the smaller coils have shorter mean lengths per turn and can use thinner wire gauges while achieving the same overall activation capability across multiple relays.
4Use of energy by moving object
If magnetic flux from multiple coils flows through a common yoke, then power consumption is reduced, but accidental relay activation may occur due to unbalanced magnetic flux distribution
Solution Approach 1:
The yoke is designed with different local magnetic circuit paths for each relay, creating local quality variations in magnetic flux distribution. Each relay has its own optimized flux path through the yoke, ensuring that magnetic flux from one coil primarily affects its intended relay rather than accidentally activating others. This local optimization maintains reliable control while allowing the system to operate at lower power levels.
Solution Approach 2:
The yoke acts as a controlled intermediary that manages magnetic flux distribution between multiple coils and relays. By designing the yoke with specific magnetic circuit characteristics for each path, it mediates the flux flow to ensure that each relay receives the appropriate amount of flux from its designated coil while being isolated from flux generated by other coils, thus preventing accidental activation.
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 achieves a significant 75% reduction in power consumption when relays are activated for extended periods and ensures balanced relay operation by optimizing magnetic flux distribution, thereby reducing overall size and manufacturing costs.
Implementation Method 1
a first magnetic flux flows via a first magnetic circuit around the first coil, extending through the first movable magnetic member and the yoke
Implementation Method 2
when respective currents are passed concurrently through the first and second coils, a third magnetic flux flows via a third magnetic circuit, extending successively through the first movable magnetic member, the yoke, the second movable member, and back through the yoke
Data Source
AI summary
A relay apparatus incorporates at least first and second relays having respective first and second electromagnetic coils, with a single yoke partially surrounding each of the coils. When current is passed through only the first electromagnetic coil, to activate the first relay, resultant magnetic flux acting on the armature of the second relay is attenuated by passing a current through the second electromagnetic coil to produce opposing-direction magnetic flux. When current is passed in the opposite direction through the second coil, to activate the second relay, the magnetic fluxes produced by the first and second electromagnetic coils become mutually reinforced, thereby reducing the power consumption required to activate both of the relays and to maintain that activated state.