Rocker Armature High-Voltage Relay for Mechanical Shock Stability
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Solution Overview
Problem
High-voltage relays in electric vehicles face challenges in maintaining reliable circuit closure under high electrical stress and mechanical shocks, particularly during driving or accidents, which can lead to unintended opening or closing of circuits.
Innovation Solution
A high-voltage relay design featuring a magnetic drive assembly with a rocker armature that tilts between open and switching positions, utilizing a rocker configuration to equalize the moments of inertia of its arms, and incorporating locking devices to prevent unintended motion, ensuring stable contact engagement under high mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high voltages and currents are used in electric vehicle drive and charging circuits, then power transmission capability is improved, but the risk of unintended circuit opening or closing due to mechanical shocks increases
Solution Approach 1:
The rocker armature is designed with two arms of equal length extending from the first yoke, creating equal moments of inertia that counterbalance each other. This counterweight principle ensures that during mechanical shocks or vibrations, the opposing arms experience equal and opposite forces that cancel out, preventing unintended switching of the high-voltage circuit while maintaining high power transmission capability
Solution Approach 2:
The rocker armature employs a symmetric configuration with two arms of equal length, which is a form of controlled symmetry (inverse asymmetry principle). This symmetric design ensures equal distribution of mechanical stresses and moments during shocks, enhancing reliability under high-voltage conditions while maintaining the ability to transmit high currents
2Ease of operation
If the armature is designed to tilt between open and switching positions, then switching functionality is improved, but susceptibility to unintended motion during vibrations or accidents worsens
Solution Approach 1:
The two arms of the rocker armature are designed with equal moments of inertia, creating a counterbalancing effect that resists unintended motion during vibrations or accidents. This allows the armature to perform controlled switching movements while remaining stable against external mechanical disturbances
Solution Approach 2:
The rocker armature combines the switching function and the shock resistance function into a single integrated component. The same rocker structure that enables tilting between open and switching positions also provides mechanical shock tolerance through its equal-moment design, eliminating the need for separate stabilization mechanisms
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 ensures safe operation at high voltages and currents by preventing unintended switching due to mechanical shocks, maintaining circuit integrity even under extreme conditions, and supporting high amperages up to 15 kA for short durations.
Implementation Method 1
a magnetic drive assembly (3) having a first yoke (5) and a second yoke (7) spaced apart from one another, and an armature (17) driven by the magnetic drive assembly
Data Source
AI summary
A high-voltage relay includes a magnetic drive assembly having a first yoke and a second yoke spaced apart from one another, and an armature driven by the magnetic drive assembly. The armature is a rocker having a first arm and a second arm extending away from the first yoke. The armature can be tilted between an open position and a switching position and is mounted on the first yoke. The first arm has a switching contact assembly. A magnetic circuit including the first yoke and the second yoke is closed in the switching position by the second arm.