Electromagnetic Switching Device Tolerance Absorbing Bar
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Solution Overview
Problem
The existing electromagnetic switching devices face a high failure rate due to assembly tolerance issues, where variations in the height of the upper or lower assemblies cause gaps during sealing, allowing epoxy to flow into the housing and compromising the device's reliability.
Innovation Solution
Incorporating an elastically deformable tolerance absorbing bar below the top plate of the housing, which is integrated with the side and bottom plates, and features an inclined surface to absorb assembly tolerance by deforming and preventing the top plate from being lifted, thus maintaining a seal during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the upper or lower assembly height increases due to assembly tolerance, then the assembly is easier to manufacture with standard tolerances, but the top plate is pushed upward creating gaps that compromise sealing reliability
Solution Approach 1:
The elastomeric material is used to create a dynamic, deformable structure between the upper and lower assemblies. This elastomeric structure can dynamically adjust its shape and position to compensate for height variations in the assemblies, maintaining continuous contact with the top plate and preventing gap formation that would compromise sealing reliability.
Solution Approach 2:
The elastomeric material changes its physical parameters (shape, volume, position) in response to height variations in the assemblies. By allowing the elastomeric structure to deform and adjust its parameters, the system compensates for manufacturing tolerances and maintains reliable sealing without requiring tight tolerance control.
2Ease of manufacture
If epoxy is used to seal the housing opening, then the housing is sealed, but assembly tolerance causes gaps that allow epoxy to flow into the housing increasing failure rate
Solution Approach 1:
The elastomeric material serves as a preliminary cushioning element that prevents gap formation before epoxy sealing is applied. By compensating for height variations in advance, the elastomeric structure ensures that epoxy remains contained and does not flow into the housing, thereby preventing the failure mode without requiring rework or additional sealing steps.
Solution Approach 2:
The elastomeric structure acts as an intermediary element between the upper and lower assemblies, mediating the height variations and preventing direct transmission of gaps to the epoxy seal. This intermediary elastomeric layer absorbs the tolerance variations and maintains a continuous barrier that prevents epoxy infiltration.
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 solution effectively reduces the failure rate and improves durability by ensuring a proper seal without gaps, even with slight variations in assembly height, enhancing the overall performance and reliability of the electromagnetic switching device.
Implementation Method 1
a tolerance absorbing bar located below the top plate and elastically deformable
Data Source
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AI summary
Disclosed is an electromagnetic device. The electromagnetic switching device includes a housing (100) having an opening, a top plate (110) ; side plates (130) extending downward from the top plate (110) ; a bottom plate (120) spaced apart from the top plate (110) under the top plate (110) ; an opposite part (130a) which is one of the side plates (130) facing the opening and coupled to the top and bottom plates (110 & 120) , and a tolerance absorbing bar (140) extending toward the opening.