The present invention is related to an electromagnetic contactor including an electromagnet including either one of an alternating current (AC) electromagnet including a movable core or a direct current (DC) electromagnet including an armature, and a contact support configured to hold plural movable contacts in alignment to be coupled with and driven by the electromagnet.
As the electromagnetic contactor of this type, there are proposals for an electromagnetic contactor in which a contact support is driven by an AC electromagnet disclosed in, for example, Patent Literature 1, and another electromagnetic contactor in which the contact support is driven by a DC electromagnet disclosed in, for example, Patent Literature 2.
In addition, as disclosed in patent Literature 3, there is a proposal for yet another electromagnetic contactor that enables a configuration of the DC operated electromagnetic contactor with both of the AC and DC operated electromagnetic contactors used as a base.
Regarding the above known electromagnetic contactors, however, in comparing a case where the AC electromagnet is applied with a case where the DC electromagnet is applied, as an electromagnet for driving the contact support, the DC electromagnet is higher in height than the AC electromagnet. Hence, as illustrated in patent Literature 3, an intermediate frame has to be additionally arranged between the top and bottom frames.
Thus, when the AC electromagnet is coupled with an identical contact support, or when the DC electromagnet is coupled with the identical contact support, they cannot be accommodated in an identical frame and an intermediate frame for the DC electromagnet has to be used. Hence, there is an unsolved problem that the AC electromagnet and the DC electromagnet cannot commonly use the frame itself.
Therefore, the present invention has been made in view of the above unsolved problem of the known examples, and has an object of providing an electromagnetic contactor capable of coupling the AC electromagnet or the DC electromagnet with an identical contact support.
In order to achieve the above object, an electromagnetic contactor according to one aspect of the present invention includes an electromagnet including either one of an alternating current (AC) electromagnet including a movable core or a direct current (DC) electromagnet including an armature, and a contact support configured to hold a plurality of movable contacts in alignment to be coupled with the electromagnet and driven by the electromagnet.
The contact support includes a coupling portion including, at a coupling face of the electromagnet: a movable core contact portion extending in a direction crossing an alignment direction of the plurality of movable contacts with which a mounting face of the movable core of the AC electromagnet is in contact, coupling spring edge accommodation portions arranged on both sides of the movable core contact portion, and at least the movable core contact portion and one of end parts in an extension direction of the movable core contact portion being opened; and armature contact portions arranged on opposite sides with respect to the movable core contact portion of the coupling spring edge accommodation portion, with which the armature of the DC electromagnet is in contact. In addition, the AC electromagnet includes an AC electromagnet coupling spring to be inserted into a through hole arranged on the mounting face of the movable core, and the DC electromagnet includes a DC electromagnet coupling spring arranged at a contact face of the armature to be in contact with the armature contact portion.
According to the present invention, either one of the AC electromagnet coupling spring arranged at the movable core of the AC electromagnet or the DC electromagnet coupling spring arranged at the armature of the DC electromagnet is configured to be accommodated at the coupling portion arranged at the contact support, so that the identical contact support can be commonly used in applying the AC electromagnet and in applying the DC electromagnet. Accordingly, this configuration eliminates the need of individually forming the contact supports for both of the AC electromagnet and the DC electromagnet, and the cost of the electromagnetic contactor can be reduced by commonly using the parts.
Hereinafter, embodiments of the present invention will be described with reference to the accompanied drawings.
Referring to
In the first frame 11A, as illustrated in
Referring to
The operated electromagnet 12 is configured with an AC electromagnet 12AC including a stationary core 12F, a movable core 12M capable of advancing or receding with respect to the stationary core 12F, and a spool 12S around which an excitation coil 12c is wound.
Referring now to
The movable core 12M is formed to have a letter E shape when viewed from the right side face, as illustrated in
The spool 12S is arranged around a central protrusion portion 14c protruding on the front side of the stationary core 12F, as illustrated in
In addition, as illustrated in
Further, mounting plate portions 28 each having a mounting hole are respectively formed at four corners of the bottom of the bottomed square tubular portion 21 of the first frame 11A.
The second frame 11B includes a square tubular portion 30 having an opened front end opposing the bottomed square tubular portion 21 of the first frame 11A, as illustrated in
The front face side of the square tubular portion 30 includes a power supply side terminal portion 31a and an auxiliary terminal portion 32a that are formed on the upper side, and a load side terminal portion 31b and an auxiliary terminal portion 32b that are formed on the lower side. The contact mechanism 13 is arranged in the square tubular portion 30. Moreover, as illustrated in
As illustrated in
In addition, the contact mechanism. 13 includes a contact support 36 configured to support four sets of movable contacts 35 to oppose from the front side with a predetermined space being apart from both end parts of the movable contacts 35 to the stationary contacts 34a and 34b.
Referring to
As illustrated in
Referring to an enlarged view of
As illustrated in
The coupling spring edge accommodation portions 46 are arranged along both left and right sides of the movable core contact portion 41, respectively, as illustrated in
The armature contact portions 51 respectively include plate portions 52 that extend on both of left and right outer sides from the partition 48 sides of the spring support plate portions 49 of the coupling spring edge accommodation portions 46, and plate portions 53 that bend backward from both of left and right ends of the plate portions 52 and then extend. Then, the rear faces of the plate portions 52 including rear faces of the spring support plate portions 49 correspond to armature contact faces 54.
In this manner, the contact support 36 is capable of coupling either one of the above-described AC electromagnet 12AC or the polarized DC electromagnet 12DC, as will be described later, since in the contact support 36, there are provided the electromagnet coupling portion 40 includes the movable core contact portion 41 with which the movable core 12M of the AC electromagnet 12AC comes into contact, and the armature contact portion 51 with which a first armature 123 of the polarized DC electromagnet 12DC, as will be described later, comes into contact.
In this situation, when the movable core 12M of the AC electromagnet 12AC is coupled with the contact support 36, as illustrated in
Then, the AC electromagnet coupling spring 56 includes, as illustrated in
The flat plate portion 56a includes a central curved bulge portion 56d that protrudes downward at the central portion in the longer direction and that extends in a direction that is perpendicular to the longer direction. The length in the longer direction of the flat plate portion 56a is set to be substantially equal to a width of the movable core 12M, as illustrated in
Then, in order to couple the contact support 36 and the movable core 12M of the AC electromagnet 12AC, the flat plate portion 56a of the AC electromagnet coupling spring 56 is inserted into the spring insertion hole 55 arranged to be penetrated in the movable core 12M, so that the central curved bulge portion 56d is arranged on a reverse side to a contact face 12a side of the movable core 12M, the contact face 12a being in contact with the movable core contact face 43 of the contact support 36. In this situation, the curved bulge portions 56b and the edge curved bulge portions 56c respectively protrude from left and right side faces of the movable core 12M.
In this state, firstly, the contact face 12a of the movable core 12M is brought into contact with the movable core contact projections 45a on the edge side in the movable core contact portion 41 of the electromagnet coupling portion 40 of the contact support 36. In this state, the curved bulge portions 56b and the edge curved bulge portions 56c of the AC electromagnet coupling spring 56 oppose the coupling spring edge accommodation portion 46 of the contact support 36 from the upper end side.
Subsequently, while sliding the movable core 12M downward, the curved bulge portions 56b of the AC electromagnet coupling spring 56 are respectively opposed to the inclined faces 47a of the partitions 47, and in addition, the edge curved bulge portions 56c are engaged with the inner faces of the spring support plate portions 49. In this situation, since the movable core contact projections 45a are arranged only at the central part in the left-right direction of the board portion 42, the movable core 12M can be inclined when the movable core 12M is brought into contact with the movable core contact projections 45a. Therefore, by inclining the movable core 12M alternately, the curved bulge portions 56b and the edge curved bulge portions 56c of the AC electromagnet coupling spring 56 can be alternately inserted into the left and right coupling spring edge accommodation portions 46. Thus, it is possible to easily insert the AC electromagnet coupling spring 56 into the coupling spring edge accommodation portion 46.
Further, the movable core 12M is made to slide further downward, the contact face 12a of the movable core 12M comes into contact with the movable core contact projections 45b. Furthermore, sliding of the movable core 12M is stopped at a position that abuts the stopper portion 45c of the movable core contact portion 41. Accordingly, as illustrated in
Then, the second frame 11B is coupled to the first frame 11A in which the stationary core 12F and the spool 12S are included with the contact support 36 coupled with the movable core 12M being movably supported in the second frame 11B. For coupling the first frame 11A and the second frame 11B in this case, by engaging the hook portions 27 arranged at the first frame 11A with engagement projections 30a arranged at the second frame 11B, respectively, the snap-fit configuration is achieved and the electromagnetic contactor 10 is formed.
On the other hand, the identical contact support 36 is capable of coupling either one of a polarized DC electromagnet 12DC or a polarized AC electromagnet 12AC.
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
As illustrated in
The thickness “to” of the yoke half bodies 132A and 132B of the outer yoke 131 is set at, for example, 3.2 mm, and the thickness “ti” of the yoke half bodies 142A and 142B of the inner yoke 141 is set at, for example, 1 mm. Thus, each of the yoke half bodies 132A and 132B included in the outer yoke 131 is formed so that the thickness “to” becomes approximately three times the thickness “ti” of each of the yoke half bodies 142A and 142B included in the inner yoke 141.
As described above, by setting the thickness “to” of the yoke half bodies 132A and 132B of the outer yoke 131 to approximately three times the thickness “ti” of the yoke half bodies 142A and 142B of the inner yoke 141, it is possible to reduce the magnetic resistances of the yoke half bodies 132A and 132B of the outer yoke 131 to be smaller than the magnetic resistances of the yoke half bodies 142A and 142B. Thus, as will be described later, when the excitation coil 116 is energized to form the magnetic flux in a direction opposite to the magnetization direction of each permanent magnet 151, it is possible to suppress a reverse magnetic flux, which is magnetic flux passing in the direction opposite to the magnetization direction of each permanent magnet 151.
The minimum width of each of the yoke half bodies 132A and 132B of the outer yoke 131, that is, the width of one of constricted portions 137 that are formed at connection positions between the central plate portion 133 and the opposite plate portions 134 and 135 disposed at the front and rear end portions thereof, is set at 16 mm, and the cross-sectional area of one of the constricted portions 137, which has the minimum width, is set at 51.2 mm2. The cross-sectional area at the minimum width is 1.7 times a cross-sectional area of 30.1 mm2 at a minimum width of the outside yoke 101 having an identical thickness in the above-described conventional example.
As described above, by adjusting the thickness and width of the yoke half bodies 132A and 132B of the outer yoke 131 to set the cross-sectional area at a minimum width larger than that in the conventional example, it is possible to reduce the magnet resistances of the respective yoke half bodies 132A and 132B to be smaller than those in the conventional example illustrated in
Further, the magnet resistances of the yoke half bodies 132A and 132B of the outer yoke 131 can be further reduced by applying a magnetic material having a sufficiently large relative permeability to the relative permeability of, for example, SPCC, which is a typical iron material having a relative permeability of approximately 200,000, such as a pure iron, and having a small magnetic resistance.
As described above, the magnetic resistance of the respective yoke half bodies 132A and 132B of the outer yoke 131 are reduced, so that the convergent magnetic flux formed at the plunger 121 can be diverged into the yoke half bodies 132A and 132B of the outer yoke 131 when the excitation coil 16 is energized, as will be described later. In addition, the balance of magnetic flux density between the plunger 121 and the yoke half bodies 132A and 132B of the outer yoke 131 can be optimized.
Accordingly, the electromagnet efficiency will be improved. When an identical operation force is tried to be available at the plunger 121, it is possible to reduce the number of windings of the excitation coil 116 to be wound around the spool 111. Thus, the polarized DC electromagnet 12DC can be downsized, and the cost reduction can be achieved, by setting a configuration of acquiring an operation force same as the AC electromagnet 12AC to have the same size as the AC electromagnet 12AC.
In addition, since areas, in the opposite plate portions 134 and 135 of the yoke half bodies 132A and 132B of the outer yoke 131, opposing the first armature 123 and the second armature 124 of the plungers 121 are set larger than the central plate portion 133, the magnetic resistance is made smaller and the magnetic flux between both of the yoke half bodies can be transmitted well.
Further, the thickness “to” of the outer yoke 131 is set to approximately three times the thickness “ti” of the inner yoke 141, and the magnetic resistance of the outer yoke 131 is set smaller than the magnetic resistance of the inner yoke 141. Hence, the magnetic flux of the reverse polarity of the permanent magnet 151, when the excitation coil 116 is made to be in an excitation state, can be prevented from flowing backward across the permanent magnet 151.
In addition, since the magnetic resistance of a magnetic body included in the outer yoke 131 is set smaller than the magnetic resistance of a magnetic body included in the inner yoke 141, the magnetic flux of the reverse polarity to the permanent magnet 151 can be prevented from flowing backward across the permanent magnet 151, as described above.
Then, at the first armature 123 of the polarized DC electromagnet 12DC, as illustrated in
The flat plate portion 162 includes an insertion hole 162a that permits the insertion of an attachment projection 122a projecting from the central part of the first armature 123 that is arranged at an end part of the plunger 121.
The curved plate portion 163 includes a curved bulge portion 164 that bulges to be away from the front face of each of the first armatures 123 respectively arranged at both end parts in the longer direction of the flat plate portion 162, and an edge curved bulge portion 165 that curves in an opposite direction to each of the curved bulge portions 164 respectively arranged at the outer sides of the curved bulge portions 164. Here, each of the bottom faces of the edge curved bulge portions 165 is spaced apart from the surface of the first armature 123 at a predetermined distance, and can be accommodated in a coupling spring edge accommodation portion of the above-described contact support 36 with given elasticity.
The polarized DC electromagnet 12DC having the above configuration is coupled with the contact support 36. The polarized DC electromagnet 12DC is coupled with the contact support 36 by bringing the front face of the first armature 123 into contact with the armature contact portion of the contact support 36, and in addition, by attaching to bring the curved bulge portions 165 of the curved plate portions 163 of the DC electromagnet coupling spring 161 into contact, in a frontward bending manner, with the inner faces of the spring support plate portions in the coupling spring edge accommodation portions.
Then, in a state where the polarized DC electromagnet 12DC and the contact support 36 are integrated with the DC electromagnet coupling spring 161, as illustrated in
Thus, according to the present embodiment, since the edge curved bulge portion 165 of the DC electromagnet coupling spring 161 is supported by the spring support plate portion of the coupling spring edge accommodation portion of the contact support 36, the contact support 36 and the plunger 121 of the DC electromagnet coupling spring 161 can be integrated with the spring support plate portion of the contact support 36 being held by the elasticity of the DC electromagnet coupling spring 161.
Thus, according to the above-described embodiment, the movable core of the AC electromagnet can be integrally coupled with the contact support 36 by the AC electromagnet coupling spring, and in addition, the first armature 123 of the polarized DC electromagnet 12DC can be integrally coupled with the contact support 36 by the DC electromagnet coupling spring 161.
Therefore, the contact support 36 for the AC electromagnet and the contact supports 36 for the DC electromagnet do not have to be provided separately, the identical contact support 36 is capable of coupling either one of the AC electromagnet or the DC electromagnet, and it is possible to reduce the number of parts and to reduce the manufacturing cost of the electromagnetic contactor.
In addition, as described above, the number of windings of the excitation coil is reduced by improving the electromagnet efficiency of the polarized DC electromagnet 12DC, and the polarized DC electromagnet 12DC is further downsized to have an identical size to the AC electromagnet 12AC, so that an outer shape of the first frame 171A that accommodates the polarized DC electromagnet 12DC can be formed to have an outer shape identical to that of the first frame that accommodates the above-described AC electromagnet 12AC. Therefore, the second frame 11B can be commonly used, too, and it is possible to provide the electromagnetic contactor, the manufacturing cost of which can be further reduced.
It is to be noted that in the above embodiments, the description has been given of the case where the movable core contact portion 41 of the electromagnet coupling portion 40 is arranged in the direction that is perpendicular to the alignment direction of the moveable contacts 35. However, the present invention is not limited to this. The movable core contact portions 41 may be arranged in a direction crossing the alignment direction of the moveable contacts.
In addition, in the above embodiments, the description has been given of the case where the widths of the opposite plate portions 134 and 135 of the respective yoke half bodies 132A and 132B of the outer yoke 131 in the polarized DC electromagnet 12DC are configured to be larger than the width of the central plate portion 133. However, the present invention is not limited to this. In other words, in the present invention, the widths of the central plate portion 133 can be identical to those of the opposite plate portions 134 and 135, and the point may be keeping a large cross-sectional area in the smallest width.
In addition, in the above embodiments, the description has been given of the case where the thickness “to” of the outer yoke 131 is set to 3.2 mm and the thickness “ti” of the inner yoke 141 is set to 1 mm in the polarized DC electromagnet 12DC. However, the present invention is not limited to this. In other words, the thickness “to” of the outer yoke 131 and the thickness “ti” of the inner yoke 141 can be set arbitrarily. The point may be setting the thickness “to” of the outer yoke 131 to be larger than the thickness “ti” of the inner yoke 141, so that the balance of the magnetic flux density between the plunger 121 and the outer yoke 131 can be optimized.
In addition, in the above embodiments, the description has been given of the case where the first frame 11A that accommodates the AC electromagnet 12AC and the first frame 171A that accommodates the polarized DC electromagnet 12DC are formed to have identical outer shapes. However, the present invention is not limited to this. The first frame 11A and the first frame 171A may be formed to have different shapes.
Number | Date | Country | Kind |
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2014-104746 | May 2014 | JP | national |
This application is a continuation application filed under 35 U.S.C. §111(a) of International Patent Application No. PCT/JP2015/001944, filed Apr. 7, 2015, which claims the foreign priority benefit under 35 U.S.C. §119 of Japanese Patent Application No. 2014-104746, filed May 20, 2014, the contents of which are incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2015/001944 | Apr 2015 | US |
Child | 15066365 | US |