Multi-Phase Relay Terminal Layout for Lower Copper Use
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Solution Overview
Problem
Existing multi-phase electromagnetic relays face issues of high copper consumption, complex assembly, and high cost due to crossed lead-out structures and Z-shaped movable-static contact piece assemblies, leading to complications in insulation, spot-welding, and safety concerns.
Innovation Solution
The design includes input and output terminals led out from opposite sides of the base in a non-crossed and spaced manner, with parallel arrangement and external connection ends, and a novel movable-static contact matching structure with parallel components, reducing copper consumption and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the input terminal and output terminal are led out adjacent to each other from the base, then the wiring arrangement is compact, but the lead-out structures cross each other causing high copper consumption and complex assembly
Solution Approach 1:
The patent changes the spatial arrangement dimension by leading input terminals from the first side wall and output terminals from the opposite second side wall of the base, rather than adjacent walls. This dimensional reconfiguration prevents crossing of lead-out structures and reduces copper consumption while maintaining compact footprint.
2Loss of substance
If the lead-out structures are arranged to avoid crossing, then copper consumption is reduced, but the terminals require more space outside the base
Solution Approach 1:
The patent segments the terminal arrangement by separating input terminals on one side wall from output terminals on the opposite side wall, allowing each to have its own dedicated lead-out path without crossing. This segmentation reduces total copper length while the bending arrangement manages the external terminal positioning efficiently.
3Reliability
If the movable-static contact piece assembly forms a Z-shaped structure, then the contact switching function is achieved, but the copper consumption and cost increase
Solution Approach 1:
The patent extracts the essential function of the Z-shaped movable-static contact piece assembly and replaces it with a simplified parallel arrangement where movable contact pieces directly connect to static contact pieces. This extraction removes the unnecessary Z-shaped copper routing while preserving the contact switching reliability through direct parallel connections.
4Area of stationary object
If the lead-out structures cross inside the base, then the terminal arrangement is compact, but the insulation and spot-welding processes become complicated
Solution Approach 1:
The patent resolves the manufacturing complexity by changing the spatial dimension of lead-out structure arrangement. By leading input terminals from one side wall and output terminals from the opposite side wall, the lead-out structures run parallel without crossing, eliminating insulation and spot-welding complications while maintaining compact base area utilization.
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 reduces copper consumption, lowers costs, simplifies assembly, and ensures safe electrical insulation, while maintaining effective operation in high-voltage environments.
Implementation Method 1
a multi-phase electromagnetic relay includes a base, a plurality of lead-out structures led out from the inside out of the base and a plurality of movable-static contact matching structures installed inside the base
Data Source
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AI summary
A multi-phase electromagnetic relay, comprising a plurality of paths of lead-out terminals and a plurality of movable and stationary contact matching structures (61, 62, 63), wherein each lead-out terminal separately comprises a wire inlet terminal (21, 22, 23) and a wire outlet terminal (31, 32, 33); a movable and stationary contact matching structure is matched between the wire inlet terminal and the wire outlet terminal in the same path; a plurality of wire inlet terminals are arranged at one side of the movable and stationary contact matching structure, and a plurality of wire outlet terminals are arranged at the other side of the movable and stationary contact matching structure; The plurality of wire inlet terminals are spaced apart from each other but are not staggered, the plurality of wire outlet terminals are spaced apart from each other but are not staggered, and the plurality of wire inlet terminals and the plurality of wire outlet terminals are spaced apart from each other but are not staggered; The external connection ends (211, 221, 231) of the plurality of wire inlet terminals and the external connection ends (311, 321, 331) of the plurality of wire outlet terminals all extend towards the same direction; and the external connection end of the wire inlet terminal and the external connection end of the wire outlet terminal in the same path are oppositely arranged at the two sides of the movable and stationary contact matching structure. According to the multi-phase electromagnetic relay, the lead-out terminals can be prevented from being arranged in a staggered mode, so that the problems of complex insulation and spot-welding are solved, and copper consumption can be reduced; moreover, the copper consumption of movable and stationary spring components in the relay can be reduced, so that the cost is reduced.