Electromagnetic Relay Stopper Structure for Shaft Fixation Failure
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Solution Overview
Problem
Existing electromagnetic relays fail to operate when the fixation between the drive shaft and the movable iron core is damaged, leading to a loss of contact functionality.
Innovation Solution
Incorporating a stopper mechanism that restricts the movement of the movable iron core relative to the drive shaft, even if the fixation between the two components is damaged, allowing the drive shaft to move together with the movable iron core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the drive shaft is fixed to the movable iron core using fixing means such as welding, screws, or caulking, then the drive shaft and movable iron core can move together reliably, but the fixation may be broken due to heat or impact, causing the electromagnetic relay to fail
Solution Approach 1:
The shaft hole is divided into two segments: a first hole segment through which the drive shaft extends, and a second hole segment larger than the first that accommodates the stopper. This segmentation allows the stopper to be positioned within the shaft hole to provide backup restriction of the movable iron core's movement, ensuring contact functionality even if the fixation between the drive shaft and movable iron core is broken.
Solution Approach 2:
The stopper is preliminarily positioned within the shaft hole during assembly, before any potential fixation failure occurs. This preliminary placement ensures that if the fixation means (welding, screws, or caulking) breaks due to heat or impact, the stopper is already in position to restrict the movable iron core's movement and maintain contact functionality.
2Reliability
If a stopper is added to restrict the movement of the movable iron core relative to the drive shaft, then the electromagnetic relay can operate even when fixation is damaged, but the device complexity increases
Solution Approach 1:
The shaft hole serves multiple functions: it guides the drive shaft, houses the stopper, and provides structural support for the movable iron core. By making the shaft hole multi-functional, the patent avoids adding a separate complex stopping mechanism, thus maintaining simplicity while improving reliability.
Solution Approach 2:
The stopper is nested within the shaft hole, specifically in the second hole segment. This nesting arrangement allows the stopper to be contained within the existing structural space of the movable iron core, avoiding additional external components and minimizing the increase in device complexity.
3Reliability
If the stopper is made larger than the shaft hole to ensure it restricts movement effectively, then the stopper can be retained in the shaft hole, but the arrangement space for the stopper is reduced
Solution Approach 1:
The shaft hole is segmented into a first hole segment and a second hole segment. The stopper is placed in the second hole segment, which is larger than the first. This segmentation allows the stopper to have sufficient size for effective movement restriction while being contained within the available space of the second hole segment, optimizing the use of arrangement space.
Solution Approach 2:
The shaft hole provides a dimensional space along the axial direction of the drive shaft. By extending the shaft hole to include a second hole segment with sufficient length, the patent creates adequate arrangement space for the stopper without increasing the radial dimensions, thus maintaining a compact overall structure.
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
Enables the electromagnetic relay to maintain contact functionality even when the fixation between the drive shaft and the movable iron core is compromised, ensuring reliable operation.
Implementation Method 1
The coil generates a magnetic force that moves the movable iron core in the moving direction
Data Source
AI summary
An electromagnetic relay includes a fixed contact, a movable contact, a movable contact piece, a movable iron core, a drive shaft, a coil, and a stopper. The movable iron core is movable in a moving direction including a contact direction in which the movable contact approaches the fixed contact and a separation direction in which the movable contact separates from the fixed contact. The movable iron core includes a shaft hole extending in the moving direction. The drive shaft is connected to the movable contact piece. The drive shaft extends through the shaft hole. The drive shaft is fixed to the movable iron core. The coil generates a magnetic force to move the movable iron core in the moving direction. The stopper is connected to the drive shaft. The stopper restricts a movement of the movable iron core with respect to the drive shaft in the moving direction.