Electromagnetic Relay Positioning Accuracy via Merged Spool

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Solution Overview

Problem

Conventional electromagnetic relays suffer from variations in dimensional and positional accuracy due to integration and assembly errors, leading to inconsistencies in operating characteristics.

Innovation Solution

The electromagnetic relay features a vertical pair of turning shaft projections on the moving iron piece, supported by a base and spool, with a shaft hole in the spool for precise positioning, eliminating assembly errors and enhancing the positioning accuracy of the iron core and moving iron piece.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If the shaft hole is formed by combining the base and spool components, then the structural complexity is reduced, but the manufacturing precision and positioning accuracy deteriorate due to integration and assembly errors

Engineering Contradiction:

Improvestructural complexityVSAvoiddimensional accuracy and positional accuracy of shaft hole

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

The shaft hole formation function is merged into the spool component alone, eliminating the need for integration with the base. The spool now independently provides both the shaft hole and the positioning projection, reducing assembly errors while maintaining structural efficiency.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

A positioning projection is introduced as an intermediary feature on the spool to precisely locate the iron core. This mediator element compensates for any remaining dimensional variations and ensures high positioning accuracy without requiring complex integration between base and spool.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If the shaft hole is formed by combining the base and spool components, then the ease of manufacture is improved, but the reliability deteriorates due to variations in operating characteristics

Engineering Contradiction:

Improveease of assemblyVSAvoidconsistency of operating characteristic

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The critical positioning function is merged into the spool component, which is manufactured as a single piece. This eliminates the interface between base and spool that caused assembly errors, thereby improving reliability while maintaining manufacturing simplicity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The positioning projection is pre-formed on the spool during spool manufacturing, before assembly with the base. This preliminary action ensures that the positioning feature is already precisely located, eliminating subsequent assembly variations and improving operating characteristic consistency.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the positioning projection is added to the spool, then the positioning accuracy of the iron core is improved, but the device complexity increases

Engineering Contradiction:

Improvepositioning accuracy of iron coreVSAvoidstructural complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The spool component is designed to perform multiple functions: it provides the shaft hole for supporting the moving iron piece, the positioning projection for locating the iron core, and structural support for the coil assembly. This multi-functionality avoids adding separate positioning components, thereby improving positioning accuracy without significantly increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 significantly reduces variations in operating characteristics by ensuring accurate assembly and positioning, thereby improving the reliability and consistency of the relay's operation.

Implementation Method 1

a moving contact piece is driven to open and close a contact by the moving iron piece turning based on excitation or demagnetization of the electromagnet block

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

based on excitation or demagnetization of the electromagnet block

Methodology Applied

Scientific EffectElectromagnet: Electromagnet

Data Source

PatentEP2226827B1Electromagnetic Relay

Publication Date: 2016.05.25 OMRON CORP

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Figure 3A~3B

AI summary

An embodiment of the invention provides an electromagnetic relay that has high positioning accuracy of a moving iron piece to hardly generate a variation in operating characteristic. In the electromagnetic relay, a vertical pair of turning shaft projections (63, 64) provided on an identical shaft center in one end portion of a moving iron piece (61) is turnably supported by a base (10) and a spool (31) of an electromagnet block (30) assembled in the base (10), a moving contact piece is driven to open and close a contact by the moving iron piece (61) turning based on excitation or demagnetization of the electromagnet block (30). A shaft hole (37) in which a turning shaft projection (63) on an upper side of the moving iron piece (61) can be inserted is provided in one end portion of the spool (31).