Electromagnetic Relay Spring Mechanism for Uniform Contact Resistance
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Solution Overview
Problem
Traditional electro-magnetic relays face issues with maintaining uniform contact pressure and resistance between two circuits due to positional deviations and uneven force distribution caused by the armature's point of contact.
Innovation Solution
The electro-magnetic relay design incorporates a contact block with a press spring featuring a Z-shaped center and inclined ends, distributing the armature's driving force evenly to two movable springs, ensuring uniform contact force and resistance across both circuits through a guided concavity and insulation sheet configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the armature presses the center of a card block to distribute force to two circuits, then the contact pressure becomes uniform, but positional deviation breaks the uniformity and causes uneven contact resistance
Solution Approach 1:
The press spring is segmented into two separate movable springs, each independently supporting one circuit. This segmentation allows each spring to independently compensate for positional deviations, ensuring that contact pressure uniformity is maintained even when the armature's position varies, thereby preventing uneven contact resistance
Solution Approach 2:
The movable springs are designed to be elastically deformable, allowing them to dynamically adjust and compensate for positional deviations of the armature. This dynamic adaptation ensures that contact pressure remains uniform across both circuits despite manufacturing tolerances or assembly variations
2Device complexity
If the armature drives contacts directly, then the structure is simple, but contact resistance becomes uneven due to force concentration at one point
Solution Approach 1:
The press spring acts as an intermediary between the armature and the movable contacts. It receives the concentrated force from the armature and distributes it evenly to two separate movable springs, which then apply uniform contact pressure to the contacts of both circuits. This intermediary mechanism resolves the force distribution problem while maintaining structural simplicity
3Stability of the object's composition
If the contact surfaces are stationary, then the structure is stable, but oxidation and dust accumulation increase contact resistance over time
Solution Approach 1:
The movable springs are designed to allow the contact surfaces to move relative to each other during operation. This dynamic movement creates a wiping action that continuously cleans the contact surfaces, removing oxidation and dust accumulation. The structural stability is maintained through the spring's elastic support, while the controlled movement ensures reliable contact resistance over time
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 stabilizes contact pressure and resistance, maintaining uniformity even with positional deviations, and provides a wiping action to prevent oxidation and dust accumulation, ensuring consistent and reliable circuit operation.
Implementation Method 1
an electro-magnetic drive block composed of at least a coil, an iron core, a yoke and an armature
Data Source
AI summary
The electro-magnetic relay comprises a contact block which is structured to uniformly maintain the contact resistance between the terminals of two circuits. Fixed contacts are provided for each of the terminals of the two circuits and each of two sets of a pair of movable contacts in positions corresponding to these is supported by two both-end-supported movable springs. An insulation sheet and a press spring are overlapped over the two movable springs and disposed as a bridge. A pair of tongues are formed on the press spring by a Z-character shaped cut and by an armature pressing their tips, the insulation sheet and press spring transforms to an upward concave shape, the two movable springs bend and are taken in inside while inclining and the movable contacts touch the fixed contacts while sliding.