Relay Test Button Mechanism for External Contact Verification
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Solution Overview
Problem
Existing electromechanical relays face challenges in testing without energizing the electromagnetic actuator assembly while maintaining compact dimensions, especially for slim net relays that need to fit into standardized small spaces.
Innovation Solution
A rotatable test button with a cam protrusion engages with the actuator arm to manually operate the movable contact from outside the housing, allowing for testing without energizing the coil, with minimal modifications to the relay's inner components and no significant increase in overall dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a manual actuating means is added to test the contact assembly without energizing the coil, then the relay can be tested externally, but the package dimensions significantly increase
Solution Approach 1:
The test button mechanism is nested within the existing relay housing structure. The button is received in a recess of the housing and integrates with the actuator arm assembly, allowing the testing function to be embedded without adding external volume to the relay package.
Solution Approach 2:
The actuator arm serves dual functions: it acts as the electromagnetic actuator connected to the coil assembly for normal operation, and simultaneously serves as the mechanical linkage for the test button mechanism. This multi-functionality allows testing without adding separate actuating components that would increase package size.
2Ease of operation
If a test button mechanism is integrated into the relay housing, then external testing is enabled, but the housing structure becomes more complex
Solution Approach 1:
The test button mechanism is designed as a separate, modular assembly that can be independently installed within the housing. The button, its spring, and the actuator arm linkage are distinct components that integrate into the existing housing without requiring complete redesign of the housing structure.
Solution Approach 2:
The spring-loaded test button mechanism is self-actuating. When the button is pressed, the spring provides the necessary force to move the actuator arm and operate the contacts. The spring also automatically returns the button to its original position, eliminating the need for complex return mechanisms or additional actuators.
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 easy and efficient testing of the relay and connected circuitry without altering the relay's dimensions, ensuring reliable operation and economic fabrication.
Implementation Method 1
An electromagnetic actuator assembly comprises a coil assembly for generating a magnetic field and a movable armature that is attracted towards a core when the coil is energized
Data Source
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AI summary
The present invention relates to an electromechanical relay and to a method of testing such an electromechanical relay. An electromechanical relay according to the present invention comprises a contact assembly (106) comprising at least one stationary contact (102) and at least one movable contact (104), an electromagnetic actuator assembly (116) for actuating the at least one movable contact (104), wherein the electromagnetic actuator assembly (116) comprises a coil assembly (116, 120, 122) for generating a magnetic field and a movable actuator arm (110) that engages with the movable contact (104) for actuating the movable contact (104) in response to said magnetic field, wherein said actuator arm (110) is slidable in a direction across to a longitudinal axis of the movable contact (104), and a housing (134) that encases the contact assembly (106) and the electromagnetic actuator assembly (116). The electromechanical relay (100) further comprises a rotatable test button (128) with operating means (130) that can engage with the actuator arm (110) for manually operating the at least one movable contact (104) from outside the housing (134) by rotating said test button (128).