Electromechanical Switch Dampener for Noise Reduction
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Solution Overview
Problem
Electromechanical switches, such as contactors or relays, in applications like electric vehicles experience audible noise due to oscillations and vibrations at contact interfaces when handling high electrical currents, which can be distracting and annoying.
Innovation Solution
An electromechanical switch design incorporating a carrier sub-assembly with a support rod, contact spring, and a dampener, where the dampener, made of elastomeric material, surrounds the support rod and engages with the contact spring to absorb vibrations and oscillations, reducing noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high electrical current flows through the contacts to enable quick acceleration, then the power delivery is improved, but the movable contact oscillates and vibrates generating audible noise
Solution Approach 1:
A dampener is introduced as an intermediary element between the movable contact and the stationary contacts. The dampener absorbs vibrations and oscillations generated during high current flow, preventing these vibrations from propagating through the contact interfaces and generating audible noise, while allowing the full current to pass through the electrical circuit.
Solution Approach 2:
The dampener converts the harmful vibrational energy generated during high current operation into a beneficial damping effect. By absorbing the oscillation energy that would otherwise create noise, the dampener transforms the harmful vibration into a controlled energy dissipation mechanism that protects the contact system from excessive vibration while maintaining full power delivery capability.
2Reliability
If the movable contact is designed to engage stationary contacts firmly to ensure reliable electrical connection, then the reliability is improved, but the contact oscillation and vibration increase generating noise
Solution Approach 1:
The dampener serves as a mediator between the firmly engaged movable and stationary contacts. It allows the contacts to maintain firm engagement for reliable electrical connection while simultaneously absorbing the oscillations and vibrations that occur during engagement and operation, preventing these vibrations from manifesting as audible noise.
3Stability of the object's composition
If the contact spring is designed with high stiffness to maintain stable contact pressure, then the contact stability is improved, but the vibration absorption capability decreases
Solution Approach 1:
The dampener is integrated with the contact spring system, merging the functions of maintaining contact pressure stability and absorbing vibrations into a single combined structure. This allows the contact spring to provide stable contact pressure while the integrated dampener simultaneously absorbs the vibrations that would otherwise be generated, achieving both stability and vibration reduction.
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 reduces or eliminates the audible noise generated by contact oscillations, providing a quieter operation even under high current conditions.
Implementation Method 1
The dampener is configured to absorb vibration along one or more of the contact spring or the movable contact
Implementation Method 2
The carrier sub-assembly includes a contact spring surrounding the support rod between the divider wall and the movable contact
Data Source
AI summary
An electromechanical switch includes a housing, first and second stationary contacts mounted to the housing, a movable contact, and a carrier sub-assembly. The housing has a divider wall. The carrier sub-assembly includes a support rod that extends through an aperture in the divider wall and is coupled to the movable contact. The carrier sub-assembly is configured to move the movable contact relative to the first and second stationary contacts. The carrier sub-assembly includes a contact spring surrounding the support rod between the divider wall and the movable contact. The carrier sub-assembly also includes a dampener in engagement with the contact spring. The dampener is configured to absorb vibration along one or more of the contact spring or the movable contact.