Electrical Relay Slider With Contact Opening Element
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Solution Overview
Problem
Electrical relays with moveable spring contacts often experience impaired functioning due to welding issues, where the restoring force is insufficient to break the weld between the moveable and fixed spring contacts, especially in monostable relays, and the armature's force is not effectively utilized to open the contact in bistable systems.
Innovation Solution
Incorporating a slider with a contact opening element that strikes the moveable spring contact to break any existing weld between it and the fixed spring contact, utilizing the slider's movement to apply a sudden and intense force to tear the weld, and optimizing the design to ensure maximum tearing force by allowing full opening of the slider despite the weld, thereby utilizing the armature's energy for effective contact separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a monostable electrical relay uses a slider to restore the moveable spring contact to the open position, then the relay structure is simple, but the restoring force is insufficient to tear welds between the moveable and fixed spring contacts
Solution Approach 1:
The patent transforms the static slider structure into a dynamic one by introducing a cam mechanism. The cam converts the uniform linear motion of the slider into a dynamic motion pattern with varying force application, creating a force peak that exceeds the weld strength between contacts.
Solution Approach 2:
The patent changes the force application parameters by using a cam profile designed to generate a force peak. This transforms the uniform low restoring force into a time-varying force with a maximum value sufficient to tear welds, while maintaining the simple monostable relay structure.
2Reliability
If a bistable electrical relay applies force to the moveable spring contact during opening, then weld tearing capability is improved, but the armature does not enter the high-force region until the end of armature movement
Solution Approach 1:
The patent applies preliminary action by using the cam mechanism to prepare the force application timing. The cam profile is designed so that the force peak occurs at the optimal moment during armature movement, ensuring weld tearing happens before the armature reaches the end of its travel.
3Ease of manufacture
If the slider is fixedly connected to the moveable spring contact, then the connection is simple, but the uniform low restoring force is insufficient to break welds
Solution Approach 1:
The patent introduces the cam as an intermediary element between the slider and the moveable spring contact. This mediator transforms the uniform low force from the slider into a high peak force applied to the contact, maintaining simple fixed connections while achieving sufficient tearing force.
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 effectively tears welds between the moveable and fixed spring contacts, ensuring reliable operation of the electrical relay by applying sufficient force to break the weld, even in bistable systems, thereby maintaining the relay's functionality and service life.
Implementation Method 1
When a magnetic system of the electrical relay is excited, the moveable spring contact is moved by the slider from an open position toward the fixed spring contact into a closed position, as a result of the armature being drawn toward a coil of the magnetic system.
Implementation Method 2
A restoring force inherent to the moveable spring contact causes it to rapidly return to the open position.
Implementation Method 3
The slider has at least one contact opening element extending there from. The contact opening element strikes the moveable spring contact during movement of the moveable spring contact to the open position to break any existing weld between the moveable spring contact and the fixed spring contact.
Data Source
AI summary
An electrical relay includes a magnetic system, a contact system and a slider. The magnetic system includes an armature. The contact system includes a moveable spring contact and a fixed spring contact. The moveable spring contact is moveable between an open position and a closed position. The moveable spring contact is in electrical contact with the fixed spring contact in the closed position. The slider connects the moveable spring contact to the armature. The slider transfers movement of the armature to the moveable spring contact. The slider has at least one contact opening element extending there from. The contact opening element strikes the moveable spring contact during movement of the moveable spring contact to the open position to break any existing weld between the moveable spring contact and the fixed spring contact.