Multi-Phase Relay Terminal Layout to Cut Copper and Crossing
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Solution Overview
Problem
Existing multi-phase electromagnetic relays face issues with high copper consumption, high cost, complex copper molding, and safety hazards due to crossed lead-out structures and the use of static and movable contact pieces forming a Z-shaped structure, leading to complicated assembly and spot-welding processes.
Innovation Solution
A multi-phase electromagnetic relay design featuring non-crossed and spaced input and output terminals with a cuboid base, where input terminals are led out from one side wall and output terminals from the opposite side wall, connected by an electrical connecting piece, and utilizing a movable-static contact matching structure with parallel components to reduce copper consumption and simplify assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If input terminals and output terminals are led out adjacent to each other from the base, then wiring arrangement is simplified, but lead-out structures cross each other causing high copper consumption and safety hazards
Solution Approach 1:
The patent changes the spatial arrangement of terminals by leading input terminals from the first side wall and output terminals from the opposite second side wall of the cuboid base, utilizing the three-dimensional space of the base to prevent crossing while maintaining compact wiring
2Reliability
If static contact piece and movable contact piece form a Z-shaped structure, then electrical connectivity is achieved, but copper consumption increases and cost rises
Solution Approach 1:
The patent extracts the unnecessary Z-shaped configuration and replaces it with a simplified linear arrangement where the movable contact piece directly connects to the static contact piece through a straight lead-out structure, eliminating redundant copper material while maintaining electrical connectivity
Solution Approach 2:
Instead of forming a Z-shaped structure that requires multiple bends and connections, the patent inverts the approach by using a direct linear connection between contacts, fundamentally changing the structural paradigm to reduce copper consumption
3Reliability
If lead-out structures are arranged with crossed paths, then terminal connectivity is achieved, but assembly and spot-welding processes become complicated
Solution Approach 1:
The patent segments the lead-out structures into distinct non-crossing paths, with input terminals exiting from one side wall and output terminals from the opposite side wall, creating modular, easily manufacturable sections that simplify assembly and welding operations
4Reliability
If lead-out structures are crossed to achieve terminal connections, then electrical pathways are formed, but safe distance between strong electricity is compromised
Solution Approach 1:
The patent employs asymmetric arrangement where input terminals and output terminals are led out from opposite side walls of the cuboid base, creating inherent spatial separation that maintains safe distances between high-voltage pathways while establishing reliable electrical connections
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 design reduces copper consumption, lowers costs, simplifies the assembly and spot-welding processes, and ensures safe distance between high-voltage components, while maintaining effective electrical connectivity.
Implementation Method 1
When current passes through the coil, a magnetic field is generated to drive the armature to move, thereby achieving the closing or opening of the circuit through the cooperation of the push rod and the movable contact
Data Source
AI summary
A multi-phase electromagnetic relay includes a base, lead-out structures and movable-static contact matching structures. Each of lead-out structures includes an input terminal and an output terminal. One movable-static contact matching structure is provided between the input and the output terminals in each of the plurality of lead-out structures. The input and output terminals are respectively led out from the first and second side walls of the base. The input and output terminals bent to the outside of the third side wall of the base, and in a non-crossed and spaced manner. The external connection ends of the input and output terminals are outside the third side wall and are arranged a row parallel to the third side wall. The input and output terminals are respectively arranged at corresponding positions on two sides of the same row. The third side wall is connected between the first and second side walls.