Electromechanical Switch Assembly to Minimize Magnetic Air Gaps
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Solution Overview
Problem
The formation of air gaps during assembly of electromechanical switching devices, such as contactors and relays, compromises magnetic circuit performance and reliability due to variations in manufacturing and assembly, leading to reduced magnetic force and increased contact resistance.
Innovation Solution
A method involving precise component integration by partially inserting a lower static core into a core cavity and applying external forces to coil yoke arms with a predetermined outward bend, ensuring seamless assembly and minimizing air gaps in magnetic circuit pathways.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple components are assembled to form magnetic circuitry, then manufacturing cost is reduced through looser tolerances, but air gaps are introduced that degrade magnetic performance
Solution Approach 1:
The patent combines multiple magnetic circuit components (coil yoke, plunger assembly enclosure, coil enclosure, and lower static core) into a single integrated assembly where the external sides of the coil yoke arms are bent outward at predetermined angles. This merging eliminates air gaps between components while maintaining manufacturability through the bending process rather than requiring precision machining of multiple separate parts.
Solution Approach 2:
The coil yoke arms are bent outward at predetermined angles during manufacturing before final assembly. This preliminary action ensures that when the components are assembled, the magnetic circuit pathways are already optimally positioned with minimal air gaps, eliminating the need for post-assembly adjustments or tolerance compensation.
2Ease of manufacture
If components are assembled with standard tolerances, then manufacturing is easier and less costly, but air gaps form between components reducing magnetic force
Solution Approach 1:
The patent changes the geometric parameter of the coil yoke arms by bending them outward at predetermined angles (e.g., 5 to 15 degrees). This parameter change compensates for standard manufacturing tolerances and ensures that when components are assembled with normal tolerances, the magnetic circuit pathways remain in optimal contact with minimal air gaps, maintaining strong magnetic force.
3Reliability
If air gaps are minimized through precision assembly, then magnetic performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The optimal geometric configuration is built into the coil yoke arms during manufacturing through predetermined outward bends. This preliminary action simplifies the final assembly process, as components can be assembled using standard procedures without requiring complex alignment tools or techniques to minimize air gaps.
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
Enhances magnetic force generation and reliability by eliminating or reducing air gaps, maintaining consistent power consumption and improving device performance.
Implementation Method 1
Central to their functionality are magnetic circuits, integrated to guide and harness the electromagnetic fields generated by the device's coils
Implementation Method 2
magnetic flux lines strongly prefer flowing through steel rather than air, with a preference factor ranging from 100 to over 10,000 depending on the steel grade
Data Source
AI summary
In a particular embodiment, a method of assembling an electromechanical switching device is disclosed that includes partially inserting a lower static core into a core cavity of a coil assembly having a plurality of components including a plunger assembly enclosure and a coil enclosure. In this embodiment, the core cavity is formed by the plunger assembly enclosure and the coil enclosure. The method also includes positioning the coil assembly within a coil yoke and pushing the coil assembly into the coil yoke such that the lower static core is fully inserted in the core cavity.