Patent Grant
10665406
The disclosure relates to a contact mechanism, and an electromagnetic relay provided therewith.
Among electromagnetic relays, there has hitherto been an electromagnetic relay described in Patent Document 1, for example. This electromagnetic relay is provided with an electromagnetic device including an electric magnet that is excited by electric conduction, and a contact mechanism that brings two fixed contacts and two movable contacts into contact with each other or separate those contacts from each other in association with excitation and demagnetization of the electric magnet.
Patent Document 1: Japanese Unexamined Patent Publication No. 2009-289678
However, in the conventional electromagnetic relay described above, since the movable contacts are respectively provided at free ends of movable touch pieces in a forked shape, the two movable contacts form respective conduction paths independent of each other. Accordingly, for example when a foreign matter is mixed between one set of the contacts and a contact failure then occurs, a current concentrates on the other set of the contacts, to cause abnormal heat generation only in the other conduction path of the movable touch piece. This may result in damage on the movable touch piece and a significant decrease in life of the electromagnetic relay.
In view of the foregoing problem, one or more embodiments may provide a contact mechanism capable of avoiding abnormal heat generation even if a contact failure occurs between one set of contacts, and provide an electromagnetic relay provided with this contact mechanism.
In order to solve the above problem, a contact mechanism according to one or more embodiments is provided with: a movable touch piece that includes a fixed portion, a pair of arms forked from the fixed portion and respectively having free ends, first and second movable contacts provided at the respective free ends of the pair of arms, and a coupler configured to couple the free ends of the pair of arms; and first and second fixed contacts disposed respectively facing the first and second movable contacts contactably to or separably from the first and second movable contacts.
According to the contact mechanism in one or more embodiments, the free ends of the forked arms in the movable touch piece are coupled by the coupler. Thus, even if a contact failure occurs in one movable contact and one fixed contact, it is possible to avoid concentration of a current on the other movable contact and the other fixed contact, and to thereby avoid abnormal heat generation of the movable touch piece.
As one or more embodiments, it may be configured such that the coupler is elastically deformed by a smaller force than the arm.
According to one or more embodiments, for example, even if a foreign matter is mixed between one movable contact and one fixed contact and a gap is then formed between these contacts, the contact state between the other movable contact and the fixed contact can be kept to improve contact reliability
As one or more embodiments, it may be configured such that an intersection of a straight line and a peripheral edge of the fixed portion is taken as a first fixed portion, the straight line connecting between a center of the first movable contact and a center of the fixed portion disposed at a position with the shortest direct distance to the first movable contact, an intersection of a straight line and a peripheral edge of the fixed portion is taken as a second fixed portion, the straight line connecting between a center of the second movable contact and a center of the fixed portion disposed at a position with the shortest direct distance to the second movable contact, and when the center of the first movable contact, the center of the second movable contact, the first fixed portion, and the second fixed portion are located at respective apexes of a quadrangle and the center of the first movable contact and the second fixed portion are disposed at opposite corners of the quadrangle, a spring constant of the movable touch piece between the first movable contact and the first fixed portion and a spring constant of the movable touch piece between the second movable contact and the second fixed portion are larger than a spring contact of the movable touch piece between the first and second movable contacts, and the direct distance between the first movable contact and the first fixed portion and the direct distance between the second movable contact and the second fixed portion are longer than a direct distance between the first and second fixed portions.
According to one or more embodiments, for example, even if a foreign matter is mixed between one movable contact and one fixed contact and a gap is then formed between these contacts, the state of contact between the other movable contact and the other fixed contact can be kept reliably. This can result in improvement in contact reliability.
Note that in this specification, the center of the fixed portion means the center of the fixed portion projected to the surface of the movable touch piece. Further, the centers of the first and second movable contacts mean the centers of the first and second movable contacts projected to the surface of the movable touch piece.
As one or more embodiments, it may be configured such that the arm and the coupler are members different from each other.
According to one or more embodiments, it is possible to increase the range of design of the contact mechanism.
The electromagnetic relay according to one or more embodiments may include the contact mechanism.
According to the electromagnetic relay of one or more embodiments, the contact mechanism allows avoidance of abnormal heat generation in the movable touch piece.
Hereinafter, embodiments will be described with reference to the accompanying drawings. In the following description, in describing configurations represented in the drawings, terms showing directions such as “up”, “down”, “left”, and “right”, and other terms including those, will be used. It is noted that the purpose for using those terms is to facilitate understanding of embodiments through the drawings. Accordingly, those terms do not necessarily show directions used at the time of actually using one or more embodiments. A technical scope of the invention recited in the claims shall not be restrictively interpreted by using those terms.
As illustrated in
The base 10 has a square shape in a top surface view, as illustrated in
As illustrated in
The spool 21 is made up of: first and second guard portions 22, 23 respectively provided at both ends; a third guard portion 24 provided between the first and second guard portions 22, 23; and a body 211 that couples the first to third guard portions 22, 23, 24 together.
As illustrated in
As illustrated in
The third guard portion 24 is disposed substantially parallel to the first guard portion 22 and the second guard portion 23.
Notches 241 are provided at both lower ends of the third guard portion 24. Each of these notches 241 is provided with a press-fit groove (not illustrated) for press-fitting of the coil terminal 28. The body 211 is provided in substantially centers of the first to third guard portions 22, 23, 24, and has a through hole 212 for insertion of the iron core 26.
The coil 25 is wound around the body 211 between the first guard portion 22 and the third guard portion 24 of the spool 21, and the body 211 between the second guard portion 23 and the third guard portion 24.
The iron core 26 has a substantially cylindrical shape and is formed of a magnetic material. Both ends of the iron core 26 are provided respectively with a magnetic pole portion 261 for attraction of the movable iron piece 30, and a caulking portion 262 for caulking and fixing to the yoke 27.
The yoke 27 is a substantially L-shaped platy body made of a magnetic material, and made up of a vertical portion 271 and a horizontal portion 272. Terminal portions 273 are provided on both lower ends of the vertical portion 271. In this yoke 27, the vertical portion 271 is in contact with the first guard portion 22 of the spool 21, and a projection 221 of the first guard portion 22 is positioned between the terminal portions 273. Further, each corner portion of the horizontal portion 272 is provided with a protrusion 274 for caulking and fixing of the movable touch piece 46.
The coil terminal 28 includes a binding piece 281 formed by bending and raising, and is press-fitted into a press-fit groove of the third guard portion 24. The binding piece 281 extends along the wall 13 of the base 10 from the notch 241 of the third guard portion 24 of the spool 21. A lead wire of the coil 25 is wound around the binding piece 281.
As illustrated in
As illustrated in
The fixed contact terminal 41 is a rectangular platy body having conductivity. The fixed contact terminal 41 includes the first and second fixed contacts 42, 43 which are respectively caulked and fixed to both longitudinal ends, and includes the fixed terminals 44 respectively corresponding to the first and second fixed contacts 42, 43. Further, the longitudinal outer sides of the first and second fixed contacts 42, 43 are provided with press-fit portions 45 for press-fitting of the fixed contact terminal 41 to the attachment 231 of the second guard portion 23.
The movable touch piece 46 is a substantially L-shaped platy body having elasticity and conductivity, and made up of a first planner portion 60 and a second planner portion 70.
First and second movable contacts 61, 62 are provided at free end of the first planner portion 60. The first movable contact 61 is disposed facing the first fixed contact 42 contactably to or separably from the first fixed contact 42. The second movable contact 62 is disposed facing the second fixed contact 43 contactably to or separably from the second fixed contact 43. Further, the first planner portion 60 is provided with a through hole 63 for caulking and fixing of the movable touch piece 46 to the movable iron piece 30.
Each corner portion of the second planner portion 70 is provided with a first through hole 71 for caulking and fixing of the movable touch piece 46 to the yoke 27 of the electric magnet device 20. Moreover, the substantially center of the free end of the second planner portion 70 is provided with a second through hole 72 for provisional holding of the movable touch piece 46 at the time when the movable touch piece 46 is caulked and fixed to the yoke 27.
As illustrated in
Next, the operation of the electromagnetic relay 100 will be described.
In the electromagnetic relay 100 before application of a voltage to the coil 25 and excitation of the electric magnet device 20, as illustrated in
When a voltage is applied to the coil 25 to excite the electric magnet device 20, the iron core 26 is magnetized, and the movable iron piece 30 is attracted to the magnetic pole portion 261. With this, the movable touch piece 46 moves toward the fixed contact terminal 41 along with the movable iron piece 30, whereby the first movable contact 61 and the first fixed contact 42 come into contact with each other, and the second movable contact 62 and the second fixed contact 43 come into contact with each other.
Subsequently, when the application of the voltage to the coil 25 is stopped, the attractive force by the magnetic pole portion 261 of the iron core 26 disappears. With this, the movable touch piece 46 moves by its own spring force in a direction separated from the fixed contact terminal 41, whereby the first movable contact 61 and the first fixed contact 42 are separated from each other, and the second movable contact 62 and the second fixed contact 43 are separated from each other. The movable touch piece 46 then moves until coming into contact with the position regulating member 29.
Subsequently, the first planner portion 60 of the movable touch piece 46 will be described in detail.
As illustrated in
Further, the first planner portion 60 of the movable touch piece 46 includes a pair of arms 66 forked downward in the Y-direction from the caulking portion 80. The first movable contact 61 is provided at the tip of the arm 66 on the left side in the X-direction, and the second movable contact 62 is provided at the tip of the arm 66 on the right side in the X-direction. The tips of the arms 66, which are provided with the first and second movable contacts 61, 62, are respectively free ends, and are coupled to each other by a coupler 67. This coupler 67 is formed integrally with the arms 66, and an opening 68 is provided in a region surrounded by the arms 66 and the coupler 67
Of the plurality of caulking portions 80, the caulking portions 80 having shorter direct distances to the first and second movable contacts 61, 62 are provided with first and second fixed portions 64, 65. In this context, an intersection of a straight line A and a peripheral edge of the caulking portion 80 (i.e., an outer periphery of the through hole 63) is taken as the first fixed portion 64, the straight line A connecting between a center C1 of the first movable contact 61 and a center C3 of the caulking portion 80 (i.e., a center of the through hole 63). An intersection of a straight line B and a peripheral edge of the caulking portion 80 is taken as the second fixed portion 65, the straight line B connecting between a center C2 of the second movable contact 62 and the center C3 of the caulking portion 80.
Note that the center C1, C2 of the first and second movable contacts 61, 62 and the center C3 of the caulking portion 80 are respectively the centers of the first and second movable contacts 61, 62 and the caulking portion 80 projected to the first planner portion 60 of the movable touch piece 46.
The first and second movable contacts 61, 62 and the first and second fixed portions 64, 65 are respectively located at apexes of a quadrangle. The first movable contact 61 and the second fixed portion 65 are disposed at opposite corners, and the second movable contact 62 and the first fixed portion 64 are disposed at opposite corners. Further, the first and second movable contacts 61, 62 and the first and second fixed portions 64, 65 are disposed such that the direct distance between the first movable contact 61 and the first fixed portion 64 is substantially equal to the direct distance between the second movable contact 62 and the second fixed portion 65.
A direct distance L1 between the first movable contact 61 and the first fixed portion 64 is a direct distance from the intersection of the peripheral edge of the first movable contact 61 and the straight line A to the first fixed portion 64. A direct distance L2 between the second movable contact 62 and the second fixed portion 65 is a direct distance from the intersection of the peripheral edge of the second movable contact 62 and the straight line B to the second fixed portion 65.
The first planner portion 60 of the movable touch piece 46 having the above configuration is configured such that the coupler 67, which couples the free ends of the arms 66, is elastically deformed by a smaller force than the arm 66.
That is, a spring constant between the first movable contact 61 and the first fixed portion 64 is referred to as k1, and a spring constant of the first planner portion 60 between the second movable contact 62 and the second fixed portion 65 is referred to as k2. A spring constant of the first planner portion 60 between the first and second movable contacts 61, 62 is referred to as k3, and a direct distance between the first and second fixed portions 64, 65 is referred to as L4. Then, the first planner portion 60 of the movable touch piece 46 is configured such that the spring constants k1, k2 are larger than the spring constant k3, and that the direct distances L1, L2 from the first and second movable contacts 61, 62 to the first and second fixed portions 64, 65 are longer than the direct distance L4.
Note that a spring constant k can be obtained by Formula (1) below. In Formula (1), P is a load, δ is an amount of deflection, b is a width of a movable touch piece, h is a thickness of the movable touch piece, I is a distance from a fixed end to a movable contact, to which the load has been applied, and E is a Young's modulus.
k=P/δ=3EI/I3=Ebh3/4I3 (1)
The spring constant k1 (spring constant k2) is calculated by taking the first fixed portion 64 (second fixed portion 65) as a fixed end and applying a vertical load to the center c1 of the first movable contact 61 (the center C2 of the second movable contact 62). Further, the spring constant k3 is calculated by taking one of the centers C1, C2 of the first and second movable contacts 61, 62 as a fixed end and applying a vertical load to the other center. Note that the vertical direction is a direction in which the first movable contact 61 and the second movable contact 62 come in contact with or are separated from the first fixed contact 42 and the second fixed contact 43.
According to the contact mechanism 40 of the above configuration, the first and second movable contacts 61, 62 are provided at the free ends of the forked arm 66 of the movable touch piece, and the coupler 67 couples the free ends with each other. Thus, even if a contact failure occurs in one movable contact and one fixed contact, it is possible to avoid concentration of a current on the other movable contact and the other fixed contact. This can result in avoidance of abnormal heat generation of the movable touch piece 46.
Further, the coupler 67, which couples the free ends of the arms 66, is configured so as to be elastically deformed by a smaller force than the arm 66. That is, the first and second movable contacts 61, 62 and the first and second fixed portions 64, 65 are disposed so as to satisfy: the spring constants k1, k2>the spring constant k3; and the direct distances L1, L2>the direct distance L4. It is thus possible to reduce the deformation of the other movable contact at the time when one movable contact is applied with a load to be deformed. As a result, even if a foreign matter or the like is mixed between one movable contact and one fixed contact and a gap is then formed between the one set of the contacts, the contact state between the other movable contact and the other fixed contact can be kept to improve the contact reliability.
The caulking portion 80 formed by the protrusion 31 of the movable iron piece 30 and the through hole 63 in the first planner portion 60 of the movable touch piece 46 is not restricted to the above embodiments. For example, as illustrated in
As illustrated in
As thus described, the caulking portion may simply fix the movable touch piece to the movable iron piece, and the shape and the size of the caulking portion, the number of caulking portions installed, and the like can be freely selected and changed.
Note that, even when the shape of the caulking portion is different, the intersection of the straight line A and the peripheral edge of the caulking portion becomes the first fixed portion 64, the straight line A connecting between the center C1 of the first movable contact 61 and a center C31 of the caulking portion located the closest to the first movable contact 61, the caulking portion being located the closest to the first movable contact 61. Further, the intersection of the straight line B and the peripheral edge of the caulking portion becomes the second fixed portion 65, the straight line B connecting between the center C2 of the second movable contact 62 and a center C32 of the caulking portion located the closest to the second movable contact 62, the caulking portion being located the closest to the second movable contact 62
The number of caulking portions may be one, or more than one. For example, as illustrated in
Note that the center C3 of each of the caulking portions 80, 81, 82, 83, 84, and 85 illustrated in each of
The coupler 67 of the first planner portion 60 of the movable touch piece 46 is not restricted to the above embodiments. For example, as illustrated in
The movable touch piece 46 may have a pair of arms 66 with different lengths. Even in this case, one or more embodiments can be applied as long as the first and second movable contacts 61, 62 and the first and second fixed portions 64, 65 are disposed so as to satisfy: the spring constants k1, k2>the spring constant k3; and the direct distances L1, L2>the direct distance L4.
The opening 68 is not restricted to have the triangular shape illustrated in
Naturally, the constituents described in the above embodiments may be appropriately combined, or may be appropriately selected, replaced, or deleted.
In a state where a first planner portion 160 of the movable touch piece 145 illustrated in
Specifically, the relation among the following was analyzed: a rate of the spring constant k3 between the first and second movable contacts 161, 162 assuming that the spring constant k1 of the first planner portion 160 between the first movable contact 161 and the first fixed portion 164 is 100%; a rate (L1/L4) of the direct distance L1 from the first movable contact 161 to the first fixed portion 164 with respect to the direct distance L4 between the first and second fixed portions 164, 165; and a change rate (H2/H1) of a displacement amount (H2) of the second movable contact 162 with respect to a displacement amount (H1) of the first movable contact 161 at the time of application of a predetermined load to the first movable contact 161.
Note that the movable touch piece 145 illustrated in
As illustrated in Table 1, it was found that, when the spring constants k1, k2 are larger than the spring constant k3 and the direct distance L1 is longer than the direct distance L4, the change rate H2/H1 is smaller than 50%.
On the other hand, as illustrated in Table 2, it was found that, when the spring constant k3 is larger than the spring constants k1, k2 and the direct distance L1 is shorter than the direct distance L4, the change rate H2/H1 is larger than 50%.
That is, it was found that, by disposing the first and second movable contacts 161, 162 and the first and second fixed portions 164, 165 so as to satisfy: the spring constants k1, k2>the spring constant k3; and the direct distances L1, L2>the direct distance L4, the change rate in displacement of the other movable contact is not larger than 50% at the time when a load is applied to one movable contact. In the case of this change rate being not larger than 50%, even when a foreign matter which could be generated in normal use, such as resin waste generated in manufacturing of an electromagnetic relay, was mixed between one movable contact and one fixed contact and a gap was formed between the one movable contact and the one fixed contact, it was possible to keep the state of contact between the other movable contact and the other fixed contact.
The contact mechanism according to one or more embodiments is not restricted to, for example, the electromagnetic relay of the above embodiments, but can be applied to an electromagnetic relay having another configuration.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2015-058403 | Mar 2015 | JP | national |
This application is a continuation application of International Application No. PCT/JP2016/056628, filed on Mar. 3, 2016, which claims priority based on the Article 8 of Patent Cooperation Treaty from prior Japanese Patent Application No. 2015-058403, filed on Mar. 20, 2015, the entire contents of which are incorporated herein by reference.
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| Entry |
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| Number | Date | Country | |
|---|---|---|---|
| 20170345597 A1 | Nov 2017 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | PCT/JP2016/056628 | Mar 2016 | US |
| Child | 15679378 | US |
