Electromagnetic Relay Two-Piece Movable Terminal
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Solution Overview
Problem
The existing electromagnetic relays have a limited permissible current due to the uniform thickness of the movable terminal member, which restricts the thickness of the spring plate and hence the current capacity.
Innovation Solution
The electromagnetic relay features a two-piece structure for the movable terminal member, comprising a spring plate and a leg with specific included angles and thickness ratios, allowing for increased current capacity while maintaining resiliency, and a method of manufacturing this structure using a mold assembly and punch to join the spring plate and leg.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the thickness of the movable terminal member is increased to increase permissible current, then the current capacity is improved, but the resiliency of the spring plate deteriorates
Solution Approach 1:
The movable terminal member is divided into two separate components: a spring plate and a leg, which are then fixedly joined together. This segmentation allows the spring plate to maintain its original thin thickness (0.05mm to 0.15mm) for optimal resiliency, while the leg can be made thicker (0.2mm to 0.5mm) to increase current capacity. The two pieces are joined by stacking the connection portion of the spring plate on the first leg and fixing them together, resolving the contradiction between needing thin plates for elasticity and thick structures for current handling.
2Quantity of substance
If the thickness of the spring plate is increased to handle larger currents, then the current capacity is improved, but the elasticity and resiliency of the spring plate are reduced
Solution Approach 1:
The spring plate and leg are segmented as separate components with different thickness optimizations. The spring plate remains thin (0.05mm to 0.15mm) to preserve elasticity and resiliency for reliable contact making and breaking, while the leg is made thicker (0.2mm to 0.5mm) to increase current carrying capacity. This segmentation resolves the contradiction by allowing each component to be optimized for its specific function without compromising the other.
3Ease of manufacture
If a single-piece uniform thickness structure is used for the movable terminal member, then the manufacturing is simplified, but the permissible current is limited
Solution Approach 1:
While segmentation into two pieces slightly increases manufacturing complexity compared to a single-piece structure, it enables significantly higher permissible current (up to 25A). The manufacturing process includes preparing a mold assembly with a punch having stamping heads, positioning the spring plate and first leg on the mold, and stamping them together to fix them. This controlled increase in manufacturing steps is justified by the substantial improvement in current capacity.
Solution Approach 2:
The invention changes the thickness parameter distribution from uniform to non-uniform by using two pieces with different thicknesses. The spring plate has thickness of 0.05mm to 0.15mm while the leg has thickness of 0.2mm to 0.5mm. This parameter change allows the overall structure to handle higher currents while maintaining the resiliency needed for reliable operation.
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 increases the permissible current from 10 A to 25 A, enhancing the relay's sensitivity and current handling capability while maintaining the spring plate's elasticity.
Implementation Method 1
The electromagnet unit includes an electromagnet disposed on the base
Implementation Method 2
a magnetically attractive member magnetically attractable by the electromagnet
Implementation Method 3
the spring plate resiliently moves toward the stationary terminal member
Data Source
AI summary
An electromagnetic relay includes a base, an electromagnet disposed on the base, an armature unit having a magnetically attractive member magnetically attractable by the electromagnet, a movable terminal unit mounted on the armature unit and including a first terminal member and a first contact, and a stationary terminal member mounted on the base. The first terminal member is a two-piece structure composed of a spring plate and a first leg. A ratio of the thickness of the first leg to the thickness of the spring plate ranges from 2 to 4. When the electromagnet is energized and de-energized, the first contact contacts and moves away from the second contact, respectively. A method of making the electromagnetic relay is also disclosed.