Electromagnetic Relay Spring Structure Against Armature Impact Deformation
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Solution Overview
Problem
Conventional electromagnetic relays are prone to deformation and malfunction due to unintended movement of the armature, especially during falls or impacts, which can lead to spring deformation and loss of functionality.
Innovation Solution
The electromagnet device incorporates a spring design with a first arm portion contacting the yoke, a second arm portion contacting the armature, and a protruding portion positioned above the armature, which minimizes upward movement and deformation by distributing the force across a larger area and providing additional rigidity, thereby reducing the likelihood of spring deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional hinge spring is used in the electromagnetic relay, then the device structure is simple, but the spring deforms and malfunctions during falls or impacts due to unintended armature movement
Solution Approach 1:
The spring structure transitions from a conventional two-dimensional planar configuration to a three-dimensional structure with a protruding portion extending upward from the first arm portion. This dimensional addition creates a protective configuration where the protruding portion positions itself above the armature, forming a spatial arrangement that prevents direct impact forces from deforming the spring during falls or impacts.
Solution Approach 2:
The protruding portion of the spring acts as a preemptive protective element positioned above the armature before any fall or impact occurs. This structure provides beforehand cushioning by being the first element to encounter and absorb impact forces, preventing these forces from being transmitted to the critical spring mechanism that would otherwise deform during unexpected movements.
2Strength
If the spring is designed with additional protruding portions for protection, then the spring resistance to deformation improves, but the manufacturing complexity increases
Solution Approach 1:
The spring is segmented into distinct functional portions: a first arm portion that contacts the yoke, a second arm portion that contacts the armature, and a protruding portion that extends upward for protection. This segmentation allows each portion to be optimized for its specific function while maintaining manufacturability through standard spring forming processes.
Solution Approach 2:
The protruding portion is strategically positioned and dimensioned to provide localized protection exactly where needed - above the armature. This local quality approach ensures that the additional structural element provides maximum protective benefit with minimal additional material and manufacturing complexity, rather than reinforcing the entire spring uniformly.
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 enhanced spring design effectively reduces the likelihood of deformation during falls or impacts, ensuring the electromagnet device maintains functionality and reliability by distributing forces and providing additional structural support.
Implementation Method 1
an electromagnet device (2) that drives an armature (25) and includes a coil (21), an iron core (22)
Implementation Method 2
a spring (26) configured to cause the armature (25) in contact with the upper surface (22a) of the iron core (22) to move apart from the upper surface (22a) of the iron core (22)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An electromagnet device includes: a coil; an iron core extending along a central axis of the coil and being disposed inside the coil; a coil bobbin on which the coil is wound; a yoke held on the coil bobbin and including a portion extending along the central axis of the coil; an armature coupled to the yoke and configured to come into contact with or move apart from an upper surface of the iron core; and a spring configured to cause the armature in contact with the upper surface of the iron core to move apart from the upper surface of the iron core. The spring includes: a first arm portion contacting the yoke and extending along the central axis of the coil; a second arm portion contacting the armature and extending from an upper end of the first arm portion to be directed away from the iron core; and a protruding portion protruding from at least one of the first arm portion and the second arm portion so as to be at least partially positioned above an upper surface of the armature.