Rotary Slider Relay for High Pole Density and Compact Volume
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Solution Overview
Problem
Existing relays face challenges in increasing the number of contact poles without significantly increasing size and ensuring high contact reliability, due to variations in part dimensions affecting contact pressure and requiring more manufacturing steps.
Innovation Solution
A relay design featuring a movable block with sliders that rotate over a base substrate with contactors, maintaining constant contact pressure and reliability, allowing for a higher number of contact pairs in a compact space by using a coil block to generate electromagnetic force and switch continuity between sliders and contactors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of movable contact segments is increased to increase the number of poles, then the number of contact poles increases, but the structure becomes larger and the relay becomes bulkier
Solution Approach 1:
The patent transitions from a linear arrangement of contact segments to a radial arrangement where movable contact segments are positioned around a rotational axis. This dimensional change allows multiple contact poles to be packed in a compact circular pattern rather than requiring linear extension, thereby increasing the number of poles without proportionally increasing the relay volume.
Solution Approach 2:
The relay is divided into distinct functional modules: a stationary base substrate with fixed contactors, a rotatable movable block with multiple movable contact segments, and a coil assembly. This segmentation allows the contact segments to be independently arranged radially and rotated to establish different contact combinations, enabling high pole count in a compact structure.
2Quantity of substance
If the number of movable contact segments is increased, then the number of contact poles increases, but the structure used to support the movable contact segments becomes larger
Solution Approach 1:
The movable block serves multiple functions: it provides structural support for all movable contact segments, acts as a rotational mechanism to establish different contact combinations, and functions as a common mounting platform. This multi-functionality eliminates the need for separate support structures for each contact segment, reducing overall structural complexity despite the high number of poles.
3Reliability
If contact pressure is increased to improve contact reliability, then contact reliability improves, but variance in dimensions of constituent parts affects contact pressure consistency
Solution Approach 1:
The patent replaces the traditional coil-actuated armature mechanism with a rotational slider mechanism. The coil generates rotational motion that drives sliders to move radially, establishing contact with fixed contactors. This substitution provides more consistent contact pressure because the rotational motion can be precisely controlled and the radial movement of sliders ensures uniform force distribution across multiple contact points.
Solution Approach 2:
The patent changes the operational parameter from linear displacement to rotational angle. By controlling the rotation angle of the movable block, the system can precisely control the position and contact pressure of multiple sliders simultaneously. This parameter change enables consistent contact pressure across all contact poles while maintaining high reliability.
4Quantity of substance
If multiple relays are combined into a relay module to increase the number of poles, then the number of contact poles increases, but the overall size of the relay module increases and the number of manufacturing steps increases
Solution Approach 1:
The patent merges multiple relay functions into a single integrated device. The movable block with multiple contact segments and the base substrate with multiple contactors are combined into one assembly, eliminating the need for separate relay modules. This integration reduces the number of manufacturing steps by consolidating what would otherwise require multiple discrete components and assembly operations.
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 effectively increases the number of contact poles while minimizing size and enhancing contact reliability, allowing for efficient switching with reduced manufacturing complexity and improved contact pressure consistency.
Implementation Method 1
The coil block includes a coil. The coil is configured to generate electromagnetic force by electric conduction to rotate the movable block with respect to the base substrate.
Data Source
AI summary
A relay includes a movable block, a base substrate, and a coil block. The movable block is provided rotatably around a rotational axis of the movable block. The movable block includes a plurality of sliders. The base substrate is disposed opposite the movable block in the rotational axis direction of the movable block, and contacts the sliders. The base substrate includes a plurality of contactors that come into contact with the sliders. The coil block includes a coil that generates electromagnetic force by electric conduction to rotate the movable block with respect to the base substrate. As the movable block rotates, continuity is switched between the sliders and the contactors.