Electromagnetic Relay With Triumvirate Spring Assembly
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Solution Overview
Problem
Existing electromagnetic relay assemblies face challenges in damping contact vibration and enhancing contact pressure, which can lead to reduced reliability and efficiency in switching operations.
Innovation Solution
The electromagnetic relay assembly incorporates a C-shaped yoke assembly, a rotatable armature bridge assembly, and a switch assembly with a triumvirate spring assembly, which includes C-shaped apertures for enhanced overtravel and contact pressure, as well as a magnetic field diversion mechanism to induce torque for actuating the switch actuator, thereby improving contact wiping and vibration damping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electromagnetic relay assemblies are used, then the basic switching function is achieved, but contact vibration and bounce occur leading to reduced reliability
Solution Approach 1:
The patent incorporates a vibration damping mechanism with elastomeric material positioned between the armature and the contact assembly. This damping element is pre-installed to absorb and reduce contact bounce and vibration before they can cause harmful effects to the switching contacts, thereby improving reliability by preventing vibration-related failures.
2Reliability
If conventional spring assemblies are used, then basic contact pressure is maintained, but contact pressure is insufficient leading to poor contact wiping and residue accumulation
Solution Approach 1:
The patent employs a triumvirate spring assembly consisting of three springs arranged in a triangular configuration, each spring providing contact pressure through C-shaped apertures. This configuration changes the force parameter by distributing and amplifying the contact pressure across multiple contact points, enabling effective contact wiping and preventing residue accumulation that would otherwise occur with conventional single-spring assemblies.
3Power
If high current capacity (120 amps) is achieved, then power handling capability is improved, but contact vibration and bounce are exacerbated
Solution Approach 1:
The vibration damping mechanism with elastomeric material is specifically designed to handle high current applications. The damping element is positioned to absorb the increased mechanical stress and vibration generated by high current switching (120 amps), cushioning the armature movement before it translates into harmful contact bounce, thereby maintaining reliable switching even at high power levels.
Solution Approach 2:
The patent utilizes a combination of elastomeric damping material and metallic spring components in the triumvirate spring assembly. This composite construction allows the elastomeric portion to absorb vibration and shock from high current switching while the metallic springs maintain the necessary contact pressure, resolving the contradiction between handling high power and suppressing contact bounce.
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 solution effectively reduces contact bounce and vibration, enhances contact pressure, and maintains a residue-free interface, ensuring reliable and efficient switching operations, even at high current capacities like 120 amps.
Implementation Method 1
the coil receives current and creates or imparts a magnetic field, which magnetic field is directable through the bridge assembly via the yoke termini for imparting bridge rotation about the bridge axis of rotation via magnetically induced torque
Implementation Method 2
The C-shaped aperture triumvirate spring assembly provides contact pressure intermediate the first and second contacts and provides contact bounce damping
Data Source
AI summary
An electromagnetic relay enables current to pass through switch termini and comprises a coil assembly, a rotor or bridge assembly, and a switch assembly. The coil assembly comprises a coil and a C-shaped core. The coil is wound round a coil axis extending through the core. The core comprises core termini parallel to the coil axis. The bridge assembly comprises a bridge and an actuator. The bridge comprises medial, lateral, and transverse field pathways. The actuator extends laterally from the lateral field pathway. The core termini are coplanar with the axis of rotation and received intermediate the medial and lateral field pathways. The actuator is cooperable with the switch assembly. The coil creates a magnetic field directable through the bridge assembly via the core termini for imparting bridge rotation about the axis of rotation. The bridge rotation displaces the actuator for opening and closing the switch assembly.