Silent Electromagnetic Relay Spring Housing Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional silent electromagnetic relays require changes in the armature's bending angle and elastic member shape to maintain silencing effect with customer specifications, complicating parts control and increasing manufacturing costs, and struggle to achieve high silencing due to metal-to-metal contacts.
Innovation Solution
The use of first and second silent springs with fixed shapes, positioned to maintain constant distance between the moving iron and magnetic pole, allowing them to contact non-metallic housing components, reducing noise absorption and simplifying manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the bending angle of the armature is changed to adapt to customer specifications, then the relay can meet different operating voltage and return voltage requirements, but the shape of the elastic member must also be changed to maintain silencing effect, which complicates parts control and increases manufacturing cost
Solution Approach 1:
The armature is separated into two independent components: the main armature body and the elastic member (silent spring). The elastic member is designed as an independent component with a standard shape that can be easily replaced or adjusted without changing the main armature structure. This segmentation allows different armature configurations for different specifications while maintaining a standardized elastic member design, thereby simplifying parts control.
Solution Approach 2:
The elastic member is designed with a universal shape and mounting structure that can be used across different relay specifications. By standardizing the elastic member design (making it universally applicable), the patent enables adaptation to various customer specifications without requiring custom elastic members for each specification, thus reducing parts complexity and manufacturing cost.
2Adaptability or versatility
If the bending angle of the armature is changed to adapt to customer specifications, then the relay can meet different operating voltage and return voltage requirements, but the shape of the elastic member must also be changed to maintain silencing effect, which increases manufacturing cost
Solution Approach 1:
The armature is separated into two independent components: the main armature body and the elastic member (silent spring). The elastic member is designed as an independent component with a standard shape that can be easily replaced or adjusted without changing the main armature structure. This segmentation allows different armature configurations for different specifications while maintaining a standardized elastic member design, thereby simplifying parts control.
Solution Approach 2:
The elastic member is designed with a universal shape and mounting structure that can be used across different relay specifications. By standardizing the elastic member design (making it universally applicable), the patent enables adaptation to various customer specifications without requiring custom elastic members for each specification, thus reducing parts complexity and manufacturing cost.
3Device complexity
If metal armature contacts metal core or metal yoke, then the structure is simple, but it is not easy to obtain high silencing effect
Solution Approach 1:
The patent introduces a resin layer as an intermediary material between the metal armature and the metal core/yoke. This resin layer acts as a mediator that absorbs collision noise while allowing the metal-to-metal structural simplicity to be maintained. The silent spring presses the armature against the resin-coated surface, creating a metal-resin-metal contact sequence that reduces noise without significantly complicating the structure.
Solution Approach 2:
The patent uses a composite structure combining metal and resin materials. The resin layer is applied to the core or yoke surface, creating a composite contact interface (metal armature + resin layer + metal core/yoke). This composite material approach reduces collision noise by utilizing the damping properties of resin while maintaining the structural integrity and simplicity of metal components.
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 approach maintains a predetermined silencing effect across specification changes, reduces manufacturing costs, and achieves a higher silencing effect by using springs with the same shapes and contacting resin molded products, resulting in a quieter electromagnetic relay.
Implementation Method 1
a silent spring, the other end of which is in pressure contact with the magnetic pole portion or the housing
Data Source
Figure 1
Figure 2
Figure 3
AI summary
There is provided a silent electromagnetic relay in which a predetermined degree of silencing effect can be maintained irrespective of a change to the specification, higher silencing effect can be obtained at the time of return, the parts control is easy, and the cost of manufacturing is low. A first silent spring is mounted in a position of an inward face of a moving iron to be attracted to an iron core of an electromagnet portion, an L-shaped moving iron turning based on excitation and demagnetization of the electromagnet portion housed in a housing that is a resin molded product. Furthermore, a second silent spring for coming in contact with an inner face of the housing is mounted to an outward face of the moving iron and on an opposite side to the first silent spring.