Electromagnetic Relay Compact Design via Side Terminal Placement
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Solution Overview
Problem
Conventional electromagnetic relays with arc erasure means have a larger size due to the placement of coil terminals on the lower surface, which prevents them from being compact.
Innovation Solution
The electromagnetic relay design includes coil terminals placed at the side of the arc flow, utilizing dead space on the solenoid's end surface and incorporating a yoke with a side opening portion to reduce size and enhance heat dissipation, while using permanent magnets to erase arcs and prevent contact point failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coil terminals are placed on the lower surface at the opposite side from the operation chamber, then the electromagnetic relay structure is conventional and simple, but the height increases and the size becomes larger
Solution Approach 1:
The coil terminals are repositioned from the lower surface to the side surface of the bobbin, changing the spatial arrangement from vertical stacking to lateral placement. This dimensional change allows the terminals to be positioned within the radial space of the solenoid rather than extending the axial height, thereby reducing overall device height while maintaining structural simplicity.
Solution Approach 2:
The invention utilizes the dead space on the end surface of the solenoid and positions coil terminals dynamically within the available lateral space. By placing terminals at the side of the arc flow rather than fixed on the lower surface, the design adapts to the spatial constraints and achieves compactness without compromising electrical connection functionality.
2Device complexity
If coil terminals are placed on the lower surface, then the structure is conventional, but the dead space on the solenoid end surface is not utilized effectively
Solution Approach 1:
The coil terminals are extracted from their conventional lower surface position and relocated to the side surface of the bobbin. This extraction allows the previously unused dead space on the solenoid end surface to be utilized effectively, as the terminals now occupy the lateral space that was previously available but unused in conventional designs.
Solution Approach 2:
The side surface of the bobbin serves multiple functions: it provides structural support, facilitates heat dissipation through increased surface area, and accommodates the coil terminals within the dead space. This multi-functional use of the side surface improves space utilization while maintaining structural integrity and thermal management.
3Reliability
If a complete yoke is used, then the magnetic circuit is complete, but the bottom area increases and heat dissipation is limited
Solution Approach 1:
The yoke is extracted from a complete enclosed structure to an open structure with side opening portions. This extraction removes unnecessary material that would increase bottom area, while the essential magnetic circuit function is preserved through the remaining yoke structure that provides magnetic flux pathways.
Solution Approach 2:
The yoke is designed with side opening portions that create a porous or open structure. This allows heat to dissipate more effectively through the yoke structure itself, while the magnetic circuit remains functional. The openings provide thermal pathways without significantly compromising the magnetic flux containment.
4Reliability
If the yoke is made with complete enclosure, then the magnetic flux is contained, but heat release characteristics are poor
Solution Approach 1:
The yoke incorporates side opening portions that create a porous structure, enabling heat to escape through the yoke walls. This porous design maintains sufficient magnetic flux containment while providing thermal relief pathways, improving heat release characteristics without compromising magnetic circuit integrity.
Solution Approach 2:
The yoke structure has different properties in different regions: the main body provides magnetic flux containment, while the side opening portions provide heat dissipation. This local differentiation of quality allows the same component to simultaneously achieve magnetic containment and thermal management functions.
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 results in a smaller-sized electromagnetic relay with improved heat release characteristics and extended contact point life by effectively utilizing space and preventing arc-induced dust adhesion.
Implementation Method 1
the arc generated at the time of opening and closing of the contact point is flowed, in a predetermined direction, by the magnetic field of at least a single permanent magnet
Implementation Method 2
a solenoid formed from a wound coil and a movable iron core which is reciprocated upwardly and downwardly in an axial hole of the solenoid
Data Source
AI summary
An electromagnetic relay has a solenoid formed from a wound coil, a movable iron core that is reciprocated upwardly and downwardly in an axial hole of the solenoid, and a movable contact point that reciprocates together with the movable iron core. The movable contact point is contacted and separated with and from a fixed contact point for opening and closing a contact point. An arc generated at a time of opening and closing of the contact point is flowed, in a predetermined direction, by the magnetic field of at least a single permanent magnet placed at a side of the fixed contact point and the movable contact point that are contacted and separated with and from each other. Coil terminals are connected to leader lines of the coil, at least at a single side of the flow of the arc.