Electromagnetic Relay Twin and Single Contact Sets
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Solution Overview
Problem
Conventional relays cannot simultaneously handle high and low loads due to the limitations of twin and single contacts, where twin contacts manage low loads but fail with high loads, and single contacts manage high loads but not low loads.
Innovation Solution
The electromagnetic relay design includes a twin contact set and a single contact set, with the twin contacts on movable and fixed springs handling low loads and single contacts on movable and fixed springs handling high loads, respectively, and a card that moves in response to electromagnet excitation to synchronize the movement of both sets of springs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate relays are used for high and low loads, then load handling capability is improved, but device complexity increases
Solution Approach 1:
Two separate relay functions (twin contact relay for low load and single contact relay for high load) are merged into a single integrated device. Both contact sets share common components including the housing, armature, electromagnet, and actuating cam, reducing overall complexity compared to using two separate relays while maintaining the ability to handle both high and low load circuits.
Solution Approach 2:
The relay housing and actuating mechanism serve multiple functions by supporting both twin contact and single contact configurations within a single device. The common actuating means (armature and cam) enables both contact sets to be controlled simultaneously, providing multi-functionality that handles both low and high load circuits.
2Manufacturing precision
If twin contacts are used, then contact precision for low loads is improved, but contact reliability for high loads deteriorates
Solution Approach 1:
The relay is divided into two separate contact sets: a first contact set with twin contacts for low load circuits and a second contact set with single contacts for high load circuits. This segmentation allows each contact type to be optimized for its specific load range, resolving the contradiction between contact precision and contact reliability.
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 allows the relay to simultaneously manage high and low loads, ensuring reliable contact operation by utilizing twin contacts for low loads and single contacts for high loads, thereby addressing the limitations of conventional relays.
Implementation Method 1
an electromagnet; a card that moves in response to excitation or non-excitation of the electromagnet
Data Source
AI summary
An electromagnetic relay includes: an electromagnet; a twin contact set that includes first twin contacts provided on a first movable spring, and second twin contacts that are provided on a first fixed contact plate and disposed opposite to the first twin contacts; a single contact set that includes a first single contact provided on a second movable spring, and a second single contact that is provided on a second fixed contact plate and disposed opposite to the first single contact; and a card that moves in response to excitation or non-excitation of the electromagnet, and moves the first and the second movable springs simultaneously with the movement of the card.