Electromagnetic Relay Yoke Insulation for Arc Extinction
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Solution Overview
Problem
Electromagnetic relays used in high voltage applications face challenges in reliably extinguishing arcs between contacts, especially when the direction of electric current reverses, and existing solutions that use insulating adhesives increase manufacturing costs and complexity.
Innovation Solution
The electromagnetic relay design incorporates a permanent magnet for magnetic arc extinction, a hinge spring, and a bottom plate formed of an insulator to cover the yoke, allowing for effective arc extinction in both directions without the need for extensive adhesive use, thus reducing manufacturing costs and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating adhesives are used to cover the yoke for arc extinction, then arc extinction reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent replaces expensive and complex insulating adhesive application with a simple insulating plate that can be easily manufactured and installed. The insulating plate serves as a disposable-like component that provides reliable arc extinction without requiring complex manufacturing processes or expensive materials.
Solution Approach 2:
The patent changes the physical state and form of the insulating material from a liquid adhesive requiring application and drying processes to a solid plate that can be directly installed. This parameter change simplifies the manufacturing process while maintaining the insulating function for arc extinction.
2Reliability
If insulating adhesives are used to cover the yoke for arc extinction, then arc extinction reliability is improved, but manufacturing cost increases
Solution Approach 1:
The insulating plate is designed as a simple, inexpensive component that replaces costly insulating adhesives. The plate can be manufactured from common insulating materials and installed through simple mechanical means, significantly reducing manufacturing costs while maintaining arc extinction reliability.
Solution Approach 2:
The patent replaces the chemical bonding process of adhesives with a mechanical installation system using an insulating plate. This substitution eliminates the need for adhesive application, drying, and curing processes, reducing both time and cost while providing reliable arc extinction.
3Ease of manufacture
If the yoke is exposed without insulation, then manufacturing is simpler, but arc extinction in high voltage applications becomes unreliable
Solution Approach 1:
The insulating plate provides a simple, inexpensive solution to the reliability problem of exposed yokes. Rather than complicating the manufacturing process with adhesives, the plate offers a straightforward mechanical installation that ensures reliable arc extinction in high voltage applications.
Solution Approach 2:
The insulating plate acts as an intermediary component between the exposed yoke and the surrounding environment. It provides the necessary insulation for reliable arc extinction without requiring complex manufacturing processes, thus resolving the contradiction between simplicity and 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
The design effectively extinguishes arcs irrespective of current direction, simplifies manufacturing by reducing adhesive use, and enhances reliability and weatherability, making it suitable for high voltage applications like electric vehicle battery precharge.
Implementation Method 1
an electromagnet that generates a magnetic field when an electric current flows through a coil wrapped around an iron core
Implementation Method 2
The electromagnetic relay design incorporates a permanent magnet for magnetic arc extinction
Implementation Method 3
a hinge spring
Data Source
AI summary
An electromagnetic relay includes a base, a fixed contact terminal including a fixed contact, and fixed to the base, a movable contact terminal including a movable contact that contacts the fixed contact, an electromagnet that generates a magnetic field when an electric current flows through a coil wrapped around an iron core, an armature connected to the movable contact terminal, and moved by a magnetic force generated in the electromagnet, a yoke including a vertical part, and a horizontal part connected to the iron core, and a bottom plate formed of an insulator, and covering a surface of the horizontal part facing away from the iron core. The bottom plate includes a yoke insertion part into which the horizontal part is inserted in a direction parallel to the horizontal part.