Patent Grant
9324524
This application, filed under 35 U.S.C. 371, is the U.S. national phase of International Patent Application Number PCT/JP2012/063778 filed on 29 May 2012 which claims priority to Japanese Patent Application Number 2011-122041 filed on 31 May 2011, all of which said applications are herein incorporated by reference in their entirety.
The present invention relates to an electromagnetic relay and more particularly to an electromagnetic relay excellent in impact resistance.
In a conventional electromagnetic relay, there is a contact device including a fixed terminal provided with a fixed contact, a movable terminal provided with a movable contact configured to attach to and detach from the fixed contact, a cylindrical movable shaft having an end to which the movable contact is fixed, a movable iron core fixed to the other end of the movable shaft, a fixed iron core which is externally inserted into the movable shaft and faces the movable contact and the movable iron core, an electromagnet device which generates magnetic attraction force between the fixed iron core and the movable iron core, thus causing the movable iron core to move and reach the fixed iron core, and a return spring which is interposed between the movable iron core and the fixed iron core and elastically biases the movable iron core so as to be separated from the fixed iron core. In the contact device, the electromagnetic device includes, inside a cylindrical shaft portion thereof, the movable shaft, the fixed iron core, a coil bobbin into which the movable iron core is inserted, a coil which is wound around a shaft portion of the coil bobbin, and a yoke configured to accommodate the coil and the coil bobbin inside thereof and provided with a through hole which is formed in a center of a bottom surface and configured to communicate with a hole of the shaft portion of the coil bobbin. In the contact device, a rising piece which rises toward an inside of the shaft portion from a circumferential edge of the through hole is provided in the yoke. In the contact device, the movable iron core includes a larger diameter portion which faces the fixed iron core along a moving direction and a smaller diameter portion which has a smaller diameter than the larger diameter portion and faces the rising piece in a direction orthogonal to the moving direction. Such a conventional contact device is, for example, disclosed in Japanese Unexamined Patent Publication No. 2006-310249.
However, in the contact device, when impact force is externally applied in an axial direction of the cylindrical movable shaft during non-excitation, for example, there is a possibility that the movable contact comes into contact with the fixed contact due to the force of inertia of the whole movable parts and thus the contact device malfunctions. For this reason, in order to increase an impact resistance, a measure of increasing biasing force with an increase in spring constant of the return spring is considered. However, in terms of securing smooth operation property, it is necessary to increase an attraction force of the electromagnet device rather than the increase of the biasing force of the return spring. For this reason, there is a problem that a high application voltage needs to be applied to drive the movable parts and thus power consumption increases.
The present invention is made in view of the above problems and the invention provides an energy-saving electromagnetic relay excellent in impact resistance.
An electromagnetic relay is provided including a movable iron core arranged to move up and down in an axial center hole of a solenoid formed by winding a coil, a contact switch where an upper end surface of the movable iron core attaches to and detaches from a lower end surface of a fixed iron core arranged in the axial center hole according to magnetization and demagnetization of the solenoid, and a movable contact attaches to and detaches from a fixed contact by a movable shaft which reciprocates along with the movable iron core, and a sliding portion arranged at a lower side of an annular groove portion formed in an exterior circumferential surface of the movable iron core, where the sliding portion is disposed in an auxiliary yoke having a cylindrical shape which is provided in a yoke, wherein the sliding portion always abuts the auxiliary yoke during the up and down movement of the movable iron core, and where a height dimension of the sliding portion is at least equal to or larger than a plate thickness dimension of the yoke.
An electromagnetic relay is further provided as including a movable iron core arranged to move up and down within an axial center hole of a solenoid formed by winding a coil, a contact switch wherein an upper end surface of the movable iron core attaches to and detaches from a lower end surface of a fixed iron core arranged in the axial center hole according to magnetization and demagnetization of the solenoid, and a movable contact attaches to and detaches from a fixed contact by a movable shaft which reciprocates along with the movable iron core, a bored portion provided in an opening edge portion of a lower end surface of the movable iron core; and a sliding portion comprising an exterior circumferential surface of the movable iron core, the sliding portion disposed in an auxiliary yoke having a cylindrical shape which is provided in a yoke, where the sliding portion always abuts the auxiliary yoke during the up and down movement; and where a height dimension of the sliding portion is at least equal to or larger than a plate thickness dimension of the yoke.
Embodiments of an electromagnetic relay according to the present invention are described with reference to the accompanying drawings of
Although terms expressing specific directions and positions, such as “upper”, “lower”, “side”, and “end”, are used in the following description if necessary, those terms are used to make an understanding of the invention easier with reference to the drawings, and the technical scope of the present invention is not limited by definitions of the terms. Furthermore, the following description is basically only for illustration and is not intended to restrict the present invention, and application or use of the present invention.
An electromagnetic relay according to a first embodiment roughly includes a contact mechanism unit 1 and an electromagnet unit 2 as illustrated in
As illustrated in
As illustrated in
The flange member 20 is prepared by performing press processing on a metallic plate material which is almost rectangular in a plan view, thus forming a rectangular cylinder portion 21 which is approximately rectangular in a plan view in a center portion of the metallic plate material. Next, the rectangular cylinder portion 21 is brazed in a state in which an upper end edge portion of the rectangular cylinder portion 21 is in contact with a lower opening end surface of the ceramic case 10.
The first yoke 22 is prepared by performing press processing on a metallic plate material which is electrically conductive and is almost rectangular in a plan view, and has a circular opening 23 at a center portion. An upper end portion of the fixed iron core 40 described below is caulked and fixed to the opening 23. As illustrated in
The closed-end barrel 30 has a guard portion 31 formed around an upper side opening. Aside from an impact absorber 32 and a thin plate 33 made of stainless steel, the movable iron core 34, return spring 35, and fixed iron core 40 are accommodated in the closed-end barrel 30. In addition, in the closed-end barrel 30, the guard portion 31 is air-tightly, integrally joined to the lower surface edge portion of the opening 23 of the first yoke 22.
Particularly, as illustrated in
The lower end surface of the movable iron core 34 in a state where the movable iron core 34 is detached from and positioned to be farthest from the fixed iron core 40 may be flush with a lower surface of the auxiliary yoke 74 or may be shifted toward the fixed iron core 40 from the lower surface of the auxiliary yoke 74. Accordingly, when the movable iron core 34 is situated in a lowest position, a stable attraction force can be obtained without a reduction in magnetic flux flows to the movable iron core.
The fixed iron core 40 has a cylindrical shape. The fixed iron core 40 has a center hole 41 which penetrates through upper and lower surfaces thereof. Although not illustrated in detail in the drawings, the center hole 41 is a stepped hole including a larger diameter hole at a lower end side and a smaller diameter hole at an upper end side, and a step portion in the boundary between the larger diameter portion and the smaller diameter portion serves as a contact surface of a return spring 35. In addition, an upper end portion of the fixed iron core 40 is slightly smaller in an outer diameter than the other portion, so that the upper end portion is fitted into the opening 23 of the first yoke 22 so as to be caulked and fixed to the opening 23.
The movable shaft 45 has the stepped portion 46 having a smaller outer diameter in an exterior circumferential surface of an upper end portion thereof, and an annular groove portion 47 which is positioned below the stepped portion 46 and distanced by a predetermined length from the stepped portion 46. A locking ring 50 is caulked and fixed to the stepped portion 46, and an E ring 51 can be attached to the annular groove portion 47. After the movable shaft 45 in which the locking ring 50 is caulked and fixed to the stepped portion 46 is inserted into a through hole 56 of the movable contact piece 55 described below, and a contact spring 52 is mounted, the E ring 51 is attached to the annular groove portion 47. Therefore, the movable contact piece 55 is biased toward the locking ring 50 by the contact spring 52.
The movable contact piece 55 is a strip-shaped plate member made of a nonmagnetic material, for example, pure copper: C1020, and the through hole 56 is formed in a center portion. Respective ends of the movable contact piece 55 have a slightly smaller width, and are provided with disk-shaped movable contacts 57 and 57 which are formed to protrude upward through press processing.
The electromagnet unit 2 is configured such that a spool 61 around which a coil 60 is wound is fitted into and unified with the auxiliary yoke 74 provided in the second yoke 70.
The spool 61 is configured such that an upper guard portion 62 and a lower guard portion 63 are connected by a cylindrical drum section 64 and the closed-end barrel 30 is inserted into a center hole 65 of the drum section 64. The upper guard portion 62 has a disk shape having a larger outer diameter than an exterior circumferential surface of the coil 60 which is wound. In addition, coil terminals 66 and 66 are press-fitted into and unified with the upper guard portion 62. On the other hand, the lower guard portion 63 is almost the same in shape as a bottom surface portion of the second yoke, and is formed in a disk shape which conforms the exterior circumferential surface of the coil 60 which is wound.
The second yoke 70 includes a bottom surface portion 71 and a pair of side surface portions 72 and 72 orthogonally extending from respective edges of the bottom surface portion 71. In this manner, the second yoke 70 has an almost C-shaped cross section. And the bottom surface portion 71 of the second yoke 70 has an opening 73 in the center. In addition, a cylindrical auxiliary yoke 74 extends upward from a lower opening edge portion of the opening 73. Further, the engagement protrusions 75 to engage with the notches 24 of the first yoke 20 are formed at upper end portions of the side surface portions 72 of the second yoke 70, respectively.
Next, a method of assembling a sealed electromagnetic relay having the above-described configuration is described.
The connection ring 12 is arranged in a metal layer formed in an upper surface of the ceramic case 10. In addition, a shaft portion of the fixed contact terminal 13 is inserted into the connection ring 12 and is brought into contact with the upper opening edge portion of the connection ring 12. In addition, the rectangular cylinder portion 21 of the flange member 20 is arranged in the lower opening end surface of the ceramic case 10. In addition, these members in this state are brazed and unified. Of course, the fixed contact 14 is arranged on the lower end surface of the fixed contact terminal 13 in advance.
An air-venting pipe 25 illustrated in
The movable shaft 45 is inserted into the center hole 41 of the fixed iron core 40 which is caulked and fixed to the first yoke 22 from above the first yoke 22. Then, the flange member 20 unified with the ceramic case 10 or the like is arranged on the upper surface of the first yoke 22, and the first yoke 22 and the flange member 20 are air-tightly joined to each other through laser welding. Subsequently, the return spring 35 is inserted into the center hole 41 of the fixed iron core 40. In addition, the first yoke 22 and the flange member 20 are joined through laser welding in a state in which the movable shaft 45 is inserted in the center hole 36 of the movable iron core 34. On the other hand, the impact absorber 32 and the thin plate 33 are inserted into the closed-end barrel 30. Then, the guard portion 31 of the closed-end barrel 30 is air-tightly joined to a periphery portion of the opening 23 of the bottom surface of the first yoke 22 through laser welding. Subsequently, after an insulating gas is jetted into an interior space of the ceramic case 10 which is air-tightly sealed via the air-venting pipe 25, the air-venting pipe 25 is subjected to cold-rolling so as to be sealed.
Thus, in the contact mechanism unit 1 formed in this manner, the movable iron core 34 is arranged under the fixed iron core 40 via the return spring 35, and the lower end surface of the movable iron core 34 comes into tight contact with the thin plate 33 arranged on the bottom surface of the closed-end barrel 30 and thus is positioned in an initial state. When the electromagnet unit 2 is magnetized and the movable iron core 34 is moved upward as described above, the spring force of the return spring 35 which acts on the movable iron core 34 increases. Therefore, when the electromagnet unit 2 is not excited, the movable iron core 34 can be automatically returned to the initial state.
Next, the coil 60 is wound around the drum section 64 of the spool 61, and an insulating seal, which is not illustrated, is pasted thereon. After lead wires of the coil 60 are tangled and soldered to coil terminals 66 and 66 press-fitted into the upper guard portion 62 of the spool 61, respectively and the coil terminals 66 and 66 are bent and hung down. Subsequently, the auxiliary yoke 74 which protrudes upward from the bottom surface of the second yoke 70 is press-fitted into the center hole 65 of the spool 61, and the electromagnet unit 2 is completed.
The contact mechanism unit 1 and the electromagnet unit 2 are assembled by inserting the closed-end barrel 30 of the contact mechanism unit 1 into the center hole 65 of the spool 61 and engaging the engagement protrusions 75 of the second yoke 70 with the notches 24 of the first yoke 22. The sealed electromagnetic relay is completed by attaching the pair of permanent magnets 16 and 16 to the front and back surfaces of the ceramic case 10 via the holders 15.
A second embodiment, illustrated in
In order to secure an insulation distance between a coil terminal fitted into a lower guard portion 63 of a spool 61 and the second yoke 70, an insulating member of a thin body which has a through hole in a center and has a sectional cup shape is clamped between the lower guard portion 63 and a bottom surface portion 71 of the second yoke 70.
Portions the same as those of the first embodiment are represented by the same reference signs, and a description thereof is omitted.
As illustrated in
According to the present example, since an exterior circumferential surface is flat-tapped and there is no level difference in a sliding portion 39, there is an advantage that magnetic resistance is small and magnetic efficiency is not likely to be lowered.
Since other features of the embodiment of
Next, operation of the sealed electromagnetic relay having the configuration described above is described.
In a state where an electromagnet unit 2 is not excited, i.e., where no voltage is applied to a coil 60, as shown in
When a voltage is applied to the coil 60 and the electromagnet unit 2 is magnetized, magnetic flux will flow into a magnetic circuit configured by a fixed iron core 40, the movable iron core 34, an auxiliary yoke 74, a second yoke 70, and a first yoke 22. At this time, a gap exists between the movable iron core 34 and the fixed iron core 40, and the movable iron core 34 is arranged to be movable up and down. Therefore, as illustrated in
When the electromagnet unit 2 is demagnetized, the movable iron core 34 will be detached from the fixed iron core 40 based on the spring force of the contact spring 52 and the return spring 35. For this reason, after the movable shaft 45 slides down and the movable contact 57 is switched to open with respect to the fixed contact 14, the movable iron core 34 comes into contact with an impact absorber 32 via a thin plate 33 made from stainless steel, and returns to an original state.
Regarding an impact resistance of the electromagnetic relay according to the present invention, a calculated moving distance and a calculated impact resistance value are obtained, and an actually measured impact resistance value is also obtained. The result is shown in
Examples 1 and 2 illustrated in
The calculated moving distance and calculated impact resistance value are calculated using the following formula on the assumption that total energy before a collision occurs and total energy in a state in which a movable part moved to a bottom dead center of a spring are equal to each other.
½·(kx1+F0)x1+½·mv12+mgx1=½·(kx2+F0)x2+½·mv22+mgx2+Rf
In the above formula, k is spring constant, x1 is spring displacement before a collision, x2 is spring displacement after a collision, F0 is spring mounting force, m is total mass of movable parts, v1 is speed before a collision, v2 is speed after a collision, and Rf is sliding-resistance energy.
Further, since collision speed at which an impact load of 60 G is generated by an existing impact test machine was a speed determined by free fall from a height of h=0.12 (m) and the collision speed was v1=(2 gh)1/2, the collision speed was set to v1=1.534 (m/sec).
Furthermore, when the spring constant k and spring mounting force F0 of a comparative example were the same as those of examples 1 and 2 and when the spring displacement before a collision was x1=0 (mm), the displacement x2 of the spring was calculated at the bottom dead center for a case where the speed after a collision was V2=0. At this time, in order to prevent malfunction, the displacement x2 of the spring after a collision needs to be equal to or smaller than a distance-between-contacts xGap.
When it was assumed that the impact load of 60 G was loaded in an axial direction of a movable shaft in the above formula and condition, a moving distance of the whole movable part in the axial direction was calculated as the calculated moving distance. The calculation result is shown in
When it was assumed that the impact load of 60 G was loaded as shown in
On the other hand, the movable contact came into contact with the fixed contact and malfunction occurred in the comparative example because the calculated moving distance of comparative example exceeded the distance-between-contacts xGap.
When the impact load was loaded in the axial direction of the movable shaft, the impact value, i.e., calculated impact resistance value, at which the movable part is displaced as long as the distance-between-contacts xGap and the malfunction occurs was calculated.
Furthermore, in order to confirm whether the calculated result is in compliance with characteristics of an actual electromagnetic relay, as shown in
A calculation result and a measurement result are shown in
As shown in
On the other hand, in the comparative example, since the calculation impact resistance value and actually-measured impact resistance value at which malfunction occurs are equal to or smaller than 60 G and malfunction easily occurs, it was obvious that the comparative example was inferior to examples 1 and 2 in impact resistance.
Therefore, it was confirmed that an impact resistance improves with decrease in weight in the movable iron core.
For examples 1 and 2, the annular groove portion is provided in the exterior circumferential surface of the movable iron core which weighs 0.86 m and 0.64 m, respectively. For the comparative example, the annular groove portion is not provided in the exterior circumferential surface of the movable iron core and weighs m. For the various examples, operation sound and return sound are measured individually. Measurement results are shown below.
It was found from the above measurement results that examples 1 and 2 exhibited decreases of 5.1 dB and 8.5 dB in the operation sound, respectively compared to the comparative example, and decreases of 7.5 dB and 7.9 dB in the return sound, respectively compared to the comparative example.
Accordingly, it was confirmed that the sound is reduced as the weight of the movable iron core is decreased.
The present invention is not limited to the configuration described in the above embodiments, and various changes to the embodiments are possible.
According to the present invention, since the movable iron core is reduced in weight and force of inertia is small, even though an impact force is applied in an axial direction of the movable shaft, the whole movable part becomes difficult to be displaced, and thus an electromagnetic relay which is unlikely to malfunction is obtained. Furthermore, since it is unnecessary to increase an application voltage for prevention of malfunction, there is an advantage that an energy-saving electromagnetic relay which consumes less electric power is obtained.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2011-122041 | May 2011 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2012/063778 | 5/29/2012 | WO | 00 | 12/2/2013 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2012/165433 | 12/6/2012 | WO | A |
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| 20090322453 | Kawaguchi et al. | Dec 2009 | A1 |
| Number | Date | Country |
|---|---|---|
| 2006310249 | Nov 2006 | JP |
| 2010-010058 | Jan 2010 | JP |
| Entry |
|---|
| International Search Report for corresponding application PCT/JP2012/063778 filed May 29, 2012; Mail date Jun. 26, 2012. |
| Japanese Office Action for corresponding application JP 2013-518104; Report Dated Oct. 7, 2014. |
| The Search Report from the corresponding European Patent Application No. 12792427.2 issued on May 13, 2015. |
| Number | Date | Country | |
|---|---|---|---|
| 20150123753 A1 | May 2015 | US |
