Electromagnetic Switch Buffer for Impact Noise Reduction
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Solution Overview
Problem
Electromagnetic switches in electric vehicles generate noise due to the impact of the movable core contacting the stationary core, degrading the perceived quality of the product, and existing solutions lack effective long-term durability and simplified assembly processes.
Innovation Solution
A noise-decreasing electromagnetic switch design featuring a buffer with a fixing recess on the stationary core to elastically support the shaft and core, reducing impact noise through a buffering space and improved assembly, using a bowl-shaped buffer with a fixing step to prevent separation and enhance durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the movable core contacts the stationary core directly, then the electromagnetic switch can be结构简单 (simple structure), but impact noise is generated degrading product quality
Solution Approach 1:
A buffer is introduced as an intermediary component between the movable core and the stationary core. The buffer absorbs impact energy during contact, preventing direct impact noise while maintaining the simple overall structure of the electromagnetic switch.
Solution Approach 2:
The buffer is pre-installed between the movable core and stationary core to provide cushioning before impact occurs. This beforehand cushioning prevents impact noise during operation without requiring complex active control systems.
2Object-affected harmful factors
If a buffer is added between the stationary core and contact spring, then noise and vibration are reduced, but the device complexity increases
Solution Approach 1:
The buffer serves as a mediator that reduces noise and vibration between the movable core and stationary core. While it adds a component, the buffer is a simple elastic element that does not significantly complicate the device.
Solution Approach 2:
The buffer changes the mechanical parameters (elasticity, damping) of the contact interface, transforming the rigid impact into a controlled elastic deformation, thereby reducing noise and vibration without complex mechanisms.
3Reliability
If the buffer is securely fixed to prevent separation, then long-term durability is improved, but the assembly process becomes more complex
Solution Approach 1:
The buffer is designed with a segmented structure featuring a fixing step and fixing recess. This segmentation allows the buffer to be securely anchored to the stationary core through a simple snap-fit or insertion mechanism, ensuring durability while maintaining ease of assembly.
Solution Approach 2:
The buffer's fixing step automatically engages with the fixing recess during assembly, creating a self-securing mechanism that prevents separation without requiring additional fasteners or complex assembly steps, thus maintaining ease of manufacture while ensuring 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 solution effectively minimizes noise and vibration, maintains long-term durability, and simplifies the assembly process by using a buffer to absorb impact and provide elastic support, thereby enhancing the overall performance and reliability of the electromagnetic switch.
Implementation Method 1
a buffer is disposed between the stationary core and the contact spring to elastically support the shaft and the stationary core
Implementation Method 2
when a magnetic field is formed in response to power being applied to the coil, the movable core is attracted toward the stationary core
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A noise decreasing type electromagnetic switch includes a buffer (300) disposed between a stationary core (140) and a contact spring (230) to electrically support a shaft and the stationary core. The buffer includes a buffering space therein. Accordingly, impact caused at the stationary core and the shaft can be effectively absorbed even by the buffering space as well as an elastic force of the buffer. The buffer is inserted in the stationary core for coupling so as to be prevented from being separated during operations, resulting in maintaining long-term durability. Also, the buffer may support the stationary core and a metal plate, whereby an assembly process can be simplified.