Solenoid device

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Applications No. 2012-44055 filed on Feb. 29, 2012, and No. 2012-253654 filed on Nov. 19, 2012, the disclosures of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a solenoid device having an electromagnetic coil and a plurality of plungers.

BACKGROUND

A solenoid device having an electromagnetic coil which generates magnetic flux when current is passed, a plurality of plungers, and a fixed core made of soft magnetic material is known (refer to Japanese Unexamined Patent Application Publication No. 2005-222871).

The solenoid device is constructed to generate magnetic force by passing current to the electromagnetic coil so that the plungers are attracted by the fixed core. A spring member is disposed between the plungers and the fixed core. When passage of current to the electromagnetic coil is stopped, the magnetic force decreases, and the plungers are apart from the fixed core by the elastic force of the spring member. In such a manner, the plungers are moved forward/backward. By the forward/backward operation of the plungers, for example, the solenoid device is used for turning on/off a switch or opening/closing a valve.

There is a solenoid device in which a plurality of plungers is attracted in predetermined order. Such a solenoid device is used for, for example, a circuit which turns on a plurality of switches in predetermined order. The solenoid device is provided with a plurality of electromagnetic coils, and a plunger is disposed in the center of each of the electromagnetic coils. By passing current to each of the electromagnetic coils, the plurality of plungers is attracted separately. The order of attracting the plungers is controlled by a control circuit connected to the electromagnetic coils.

In the conventional solenoid device, however, the electromagnetic coils of the same number as that of the plungers are necessary to attract the plurality of plungers in order, so that the number of the electromagnetic coils increases. It causes a problem that the manufacture cost of the solenoid device tends to be high. Consequently, a solenoid device in which a plurality of plungers can be attracted in predetermined order and whose manufacture cost is low is demanded.

SUMMARY

It is an object of the present disclosure to provide a low-manufacture-cost solenoid device in which a plurality of plungers can be attracted in predetermined order.

According to an example aspect of the present disclosure, a solenoid device includes: a first electromagnetic coil for generating magnetic flux when current passes through the first electromagnetic coil; a first plunger and a second plunger, each of which moves backward and forward according to energization to the first electromagnetic coil; a first fixed core facing the first plunger in a backward-forward movement direction of the first plunger; a second fixed core facing the second plunger in a backward-forward movement direction of the second plunger; and a yoke. The yoke, the first plunger, the first fixed core, the second plunger, and the second fixed core provide a magnetic circuit, in which the magnetic flux flows. When the first electromagnetic coil is not energized in a unenergization state, a first gap is formed between the first plunger and the first fixed core, and a second gap is formed between the second plunger and the second fixed core. When the first electromagnetic coil is energized in a energization state, the magnetic flux flows in a first magnetic circuit, provided by the first plunger, the first fixed core and the yoke, and a second magnetic circuit, provided by the first plunger, the first fixed core, the second plunger, the second fixed core and the yoke. When the first electromagnetic coil is energized in the energization state, the first plunger is attracted toward the first fixed core by magnetic force, which is generated by a flow of the magnetic flux in the first magnetic circuit, and the second plunger is attracted toward the second fixed core by magnetic force, which is generated by a flow of the magnetic flux in the second magnetic circuit. While switching from the unenergization state to the energization state, the magnetic flux flowing in the first magnetic circuit passes through the first gap, and the magnetic flux flowing in the second magnetic circuit passes through the first gap and the second gap.

In the solenoid device, at the time of switching the first electromagnetic coil from the no-current passage state to the current passage state, the magnetic flux flowing in the first magnetic circuit passes through one gap (first gap), and the magnetic flux flowing in the second magnetic circuit passes two gaps (first and second gaps). Since the gaps are large magnetic resistance as compared with the yoke, the magnetic resistance of the first magnetic circuit having only one gap is low, and that of the second magnetic circuit having two gaps is high. Consequently, a large amount of the magnetic flux flows in the first magnetic circuit, and strong magnetic force for attracting the first plunger is generated. On the other hand, the amount of the magnetic flux flowing in the second magnetic circuit is small, and the magnetic force sufficient to attract the second plunger is not generated. Therefore, the first plunger is attracted before the second plunger.

When the first plunger is attracted and comes into contact with the first fixed core, the first gap disappears. Consequently, the magnetic resistance of the second magnetic circuit decreases, and the amount of the magnetic flux flowing in the second magnetic circuit increases. Therefore, the second plunger is attracted by the second fixed core.

As described above, the first plunger is attracted first and, then, the second plunger can be attracted.

Moreover, in the solenoid device, an electromagnetic coil dedicated to attract the second plunger does not have to be provided. Consequently, the manufacture cost of the solenoid device can be reduced, and the solenoid device can be miniaturized.

As described above, according to the present invention, the solenoid device in which a plurality of plungers can be attracted in predetermined order can be provided at low manufacture cost.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features and advantages of the present disclosure will become more apparent from the following detailed description made with reference to the accompanying drawings. In the drawings:

FIG. 1 is a diagram showing a cross section of an electromagnetic relay using a solenoid device, in a first embodiment;

FIG. 2 is a diagram showing a perspective view of the solenoid device of FIG. 1;

FIG. 3 is a diagram for explaining a path of magnetic flux in the case of passing current to a first electromagnetic coil and the order of attraction of plungers, in the first embodiment;

FIG. 4 is a diagram continued from FIG. 3;

FIG. 5 is a diagram continued from FIG. 4;

FIG. 6 is a diagram illustrating an example of a circuit using the electromagnetic relay in the first embodiment;

FIG. 7 is a diagram showing a cross section of an electromagnetic relay using a solenoid device, in a second embodiment;

FIG. 8 is a diagram showing a diagram for explaining the order of operations of the electromagnetic relay and a path of magnetic flux in the second embodiment;

FIG. 9 is a diagram continued from FIG. 8;

FIG. 10 is a diagram continued from FIG. 9;

FIG. 11 is a diagram continued from FIG. 10;

FIG. 12 is a diagram continued from FIG. 11;

FIG. 13 is a diagram illustrating an example of a circuit using the electromagnetic relay in the second embodiment;

FIG. 14 is a diagram showing a cross section of the electromagnetic relay in the case of passing current to a second electromagnetic coil before current is passed to a first electromagnetic coil in the second embodiment;

FIG. 15 is a diagram showing a cross section of an electromagnetic relay in a third embodiment;

FIG. 16 is a diagram showing a cross section of an electromagnetic relay in a fourth embodiment;

FIG. 17 is a diagram showing a cross section of the electromagnetic relay in the case of passing current only to a first part in the first electromagnetic coil in the fourth embodiment;

FIG. 18 is a diagram showing a cross section of the electromagnetic relay in the case of passing current to both of first and second parts in the first electromagnetic coil in the fourth embodiment;

FIG. 19 is a diagram showing a cross section of an electromagnetic relay in a fifth embodiment;

FIG. 20 is a diagram showing a cross section of an electromagnetic relay in a sixth embodiment;

FIG. 21 is a diagram showing a cross section of an electromagnetic relay in a seventh embodiment;

FIG. 22 is a diagram showing an enlarged diagram of a main part of a second plunger in an eighth embodiment;

FIG. 23 is a diagram showing an enlarged diagram of a main part in a state where the second plunger is attracted in the eighth embodiment;

FIG. 24 is a diagram showing a cross section of an electromagnetic relay in an off state in a ninth embodiment;

FIG. 25 is a diagram showing a cross section of an electromagnetic relay in an on state in the ninth embodiment;

FIG. 26 is a diagram showing a cross section of an electromagnetic relay in an off state in a tenth embodiment;

FIG. 27 is a diagram showing a cross section of the electromagnetic relay in a state where current is passed only to a first coil part in the tenth embodiment;

FIG. 28 is a diagram showing a cross section of the electromagnetic relay in a state where current is passed to the first coil part and, after that, passed also to the second coil part in the tenth embodiment;

FIG. 29 is a diagram showing a cross section of the electromagnetic relay in a state where current is passed only to the second coil part in the tenth embodiment;

FIG. 30 is a diagram showing a cross section of the electromagnetic relay in a state where current is passed to the second coil part and, after that, passed also to the first coil part in the tenth embodiment;

FIG. 31 is a diagram showing a cross section of the electromagnetic relay in which the orientation of a second plunger is made opposite, in the tenth embodiment;

FIG. 32 is a diagram showing a cross section of an electromagnetic relay in an eleventh embodiment;

FIG. 33 is a diagram showing a cross section of an electromagnetic relay in an off state in a twelfth embodiment;

FIG. 34 is a diagram showing a diagram for explaining the order of operations of the electromagnetic relay and a path of magnetic flux in the twelfth embodiment;

FIG. 35 is a diagram showing a diagram continued from FIG. 34;

FIG. 36 is a diagram showing a diagram continued from FIG. 35;

FIG. 37 is a diagram showing a diagram continued from FIG. 36;

FIG. 38 is a diagram showing a diagram continued from FIG. 37;

FIG. 39 is a diagram showing a cross section of an electromagnetic relay in an off state in a thirteenth embodiment;

FIG. 40 is a diagram for explaining the order of operations of the electromagnetic relay and a path of magnetic flux in the thirteenth embodiment;

FIG. 41 is a diagram continued from FIG. 40;

FIG. 42 is a diagram continued from FIG. 41;

FIG. 43 is a diagram showing a cross section taken along line XLII-XLII of FIG. 39;

FIG. 44 is a diagram showing a perspective view of a yoke and a fixed core in a fourteenth embodiment;

FIG. 45 is a diagram showing an enlarged cross section of a main part of the electromagnetic relay in the fourteenth embodiment;

FIG. 46 is a diagram for explaining the order of operations of the electromagnetic relay and a path of magnetic flux in the fourteenth embodiment;

FIG. 47 is a diagram continued from FIG. 46;

FIG. 48 is a diagram continued from FIG. 47;

FIG. 49 is a diagram showing a cross section of an electromagnetic relay in a fifteenth embodiment;

FIG. 50 is a diagram showing a cross section of an electromagnetic relay in a sixteenth embodiment; and

FIG. 51 is a diagram showing a cross section of an electromagnetic relay in a seventeenth embodiment.

DETAILED DESCRIPTION

The solenoid device can be used for, for example, an electromagnetic relay. For example, an electromagnetic relay is provided with two switches, one of the switches is turned on/off by a first plunger, and the other switch can be turned on/off by a second plunger.

A magnetic saturation part in which magnetic saturation locally occurs is formed in the yoke existing in the first magnetic circuit, and the amount of the magnetic flux flowing in the first magnetic circuit is regulated by the magnetic saturation part.

In this case, at the time of passing the magnetic flux, the two plungers can be attracted reliably. Specifically, if the amount of the magnetic flux flowing in the first magnetic circuit becomes too large when the first plunger is attracted, the amount of the magnetic flux flowing in the second magnetic circuit becomes small, and a problem occurs that the second plunger is not easily attracted. However, by forming the magnetic saturation part, the amount of the magnetic flux flowing in the first magnetic circuit can be regulated. Consequently, after the first plunger is attracted, the magnetic flux can be sufficiently passed also to the second magnetic circuit. Thus, both of the first and second plungers can be attracted reliably.

If the magnetic saturation part is not formed, magnetic saturation may occur in the first plunger and the first fixed core, and the amount of the magnetic flux flowing in the second magnetic circuit easily decreases. However, by forming the magnetic saturation part, magnetic saturation occurs in the magnetic saturation part before the first plunger and the first fixed core, so that such an inconvenience can be prevented.

The expression “occurrence of magnetic saturation” denotes that magnetic flux density enters a magnetic saturation region of a BH curve. The magnetic saturation region can be defined as a region in which the magnetic flux density is equal to or higher than 50% of the saturation magnetic flux density. The saturation magnetic flux density is magnetic flux density in a state where the magnetic field is applied to a magnetic member from the outside and the strength of magnetization does not increase even when the magnetic field is further applied from the outside.

The first electromagnetic coil has first and second coil parts to which current can be passed separately. The first coil part is disposed in a position closer to the first fixed core than the second coil part in a forward/backward movement direction of the first plunger. The yoke includes an intermediate yoke disposed between the first and second coil parts and a sliding-contact yoke provided in a position farther from the first fixed core than the intermediate yoke in the forward/backward movement direction of the first plunger and with which the first and second plungers come into slide-contact. When current is passed only to the first coil part as one of the first and second coil parts, the first plunger is attracted by the first fixed core by magnetic force generated by magnetic flux flowing in the intermediate yoke, the first plunger, and the first fixed core. When current is passed only to the second coil part as one of the first and second coil parts, the first plunger is attracted and moved apart from the first fixed core by the sliding-contact yoke by magnetic force generated by magnetic flux flowing in the intermediate yoke, the first plunger, and the sliding-contact yoke.

In this case, by passing current only to the first coil part in the first electromagnetic coil, the first plunger can be attracted by the first fixed core. By passing current only to the second coil part, the first plunger can be attracted by the slide-contact yoke. That is, the first plunger can be moved close to the first fixed core or apart from the first fixed core. Consequently, when the first plunger should not be attracted by the first fixed core, the first plunger can be forcedly moved apart from the first fixed core. Thus, the first plunger can be prevented from being erroneously attracted by the first fixed core.

In the first plunger, a flange whose diameter is enlarged in the radial direction is formed. In the no-current passage state, length from the flange to the sliding-contact yoke in the forward/backward movement direction of the first plunger is shorter than length from the intermediate yoke to the flange.

In this case, in the no-current passage state, the flange of the first plunger is in a position closer to the slide-contact yoke more than the intermediate yoke. Therefore, when current is passed only to the second coil part, strong magnetic force is generated between the flange and the slide-contact yoke. Consequently, the first plunger can be reliably attracted by the slide-contact yoke, and the first plunger can be prevented from being attracted by the intermediate yoke.

Each of the two plungers, the first and second plungers, is formed in a plate shape, the plungers move forward/backward in the plate thickness direction, and the plungers come into contact with/separate from the surface of the yoke in association with the forward/backward movement operation of the plungers.

In this case, the plunger does not come into slide-contact with the yoke even when it performs the forward/backward moving operation. Therefore, abrasion of the plungers can be suppressed. In the case where the plunger does not come into slide-contact with the yoke, to prevent abrasion of the plungers, in many cases, a thin film made of solid lubricant is formed on the surface. However, by preventing the plungers from coming into slide contact with the yoke as described above, it is unnecessary to form a thin film of solid lubricant. Thus, the manufacture cost of the plungers can be reduced.

A pillar-shaped core in which the first and second fixed cores are integrated is inserted in the center of the first electromagnetic coil, the first plunger is provided on one side in the axial direction of the pillar-shaped core with respect to the first electromagnetic coil, and the second plunger is provided on the other side in the axial direction with respect to the first electromagnetic coil.

In this case, since the first and second fixed cores are integrated, as compared with the case of forming the first and second fixed cores separately, the cores can be miniaturized. In addition, the number of components can be decreases, so that the manufacture cost of the solenoid device can be decreased.

In the no-current passage state, a third gap is formed between the first plunger and the yoke and a fourth gap is formed between the second plunger and the yoke. At the time of switch from the no-current passage state to the current passage state, the magnetic flux flowing in the first magnetic circuit passes through the first gap and the third gap, and the magnetic flux flowing in the second magnetic circuit passes through the first gap, the third gap, the fourth gap, and the second gap.

In this case, at the time of switch from the no-current passage state to the current passage state, the magnetic flux flowing in the second magnetic circuit has to pass through the four gaps of the first to fourth gaps, so that the force of attracting the second plunger becomes weak. Due to this, until the first plunger is attracted, the second plunger is not attracted. Therefore, the first plunger is attracted first and, then, the second plunger can be attracted with reliability.

The solenoid device further includes: a second electromagnetic coil which generates magnetic flux when current is passed to the coil; a third plunger which moves forward/backward when current is passed to the second electromagnetic coil; and a third fixed core disposed so as to be opposed to the third plunger in the forward/backward movement direction of the third plunger. The first and second plungers are attracted by passage of current to the first electromagnetic coil and, after that, by passing current to the second electromagnetic coil, the third plunger is attracted by the third fixed core.

In this case, two attraction states; a state where the first and second plungers are attracted by passing current to the first electromagnetic coil (first attraction state) and a state where the first to third plungers are attracted by, after the passage of current to the first electromagnetic coil, passing current also to the second electromagnetic coil (second attraction state) can be obtained by the passage of current/no current to the two electromagnetic coils.

By passing current to the first electromagnetic coil and, after that, passing current to the second electromagnetic coil, the magnetic flux generated by the passage of current to the second electromagnetic coil flows also in the second plunger. By passing current to the second electromagnetic coil and, after that, stopping the passage of current to the first electromagnetic coil, attraction of only the first plunger is cancelled in a state where the second and third plungers are attracted by the magnetic flux of the second electromagnetic coil.

In this case, three attraction states, a state where only the second and third plungers are attracted (third attraction state) and the first and second attraction states, can be obtained by the passage of current/no current to the two electromagnetic coils.

For example, in the case of using the solenoid device for an electromagnetic relay, in a state where switches which are turned on/off by the second and third plungers are on, a switch which is turned on/off by the first plunger can be turned off. Consequently, in the case where sudden surge occurs, adhesion of the switch which is turned on/off by the first plunger can be suppressed.

In the case of passing current to the second electromagnetic coil before passage of current to the first electromagnetic coil, only the third plunger out of the first, second, and third plungers is attracted.

In this case, since only the third plunger can be attracted, for example, in the case of using the solenoid device for an electromagnetic relay, only a switch which is turned on/off by the third plunger can be turned on. In this state, for example, whether another switch is adhered or not can be determined.

The second plunger has a body to be attracted by the second fixed core, a diameter-reduced part which projects from the body to the side opposite to the second fixed core in the forward/backward movement direction, and a diameter-enlarged part which is formed in the diameter-reduced part and has a diameter larger than that of the diameter-reduced part. The body, the diameter-reduced part, and the diameter-enlarged part are made of soft magnetic material. The yoke has a first part with which the body of the second plunger comes into slide-contact and a second part which is apart from the first part and with which the third plunger comes into slide-contact. In an attraction state where the second plunger is attracted by the second fixed core, the diameter-enlarged part comes close to the second part and a gap between the second plunger and the second part becomes relatively small. In a no-attraction state where the second plunger is not attracted by the second fixed core, the diameter-enlarged part is apart from the second part and the diameter-reduced part moves close to the second part, so that the gap between the second plunger and the second part becomes wider than that in the attraction state.

In this case, the gap between the second plunger and the second part is wider than that in the attraction state, so that the magnetic resistance between the second plunger and the second part can be increased. Consequently, flow of the magnetic flux of the first electromagnetic coil to the second part is suppressed. Therefore, the magnetic flux of the first electromagnetic coil flows in the second plunger more easily, and the second plunger can be attracted by the stronger magnetic force.

In the attraction state, the gap between the second plunger and the second part is narrower than that in the no-attraction state. Consequently, the magnetic flux generated by the passage of current to the second electromagnetic coil flows in the second plunger more easily. Therefore, at the time of stopping the passage of current to the first electromagnetic coil, the second plunger can be attracted reliably by the magnetic flux of the second electromagnetic coil.

As described above, with the above configuration, the first and second plungers can be attracted reliably by the passage of current to the first electromagnetic coil. After that, by passing current to the second electromagnetic coil and stopping the passage of current to the first electromagnetic coil, only the second and third plungers can be reliably attracted.

With the configuration, in the case of passing current to the second electromagnetic coil before current is passed to the first electromagnetic coil, since the second plunger is in the no-attraction state, the magnetic resistance between the second part and the second plunger can be increased. It suppresses flow of the magnetic flux of the second electromagnetic coil to the second plunger. Therefore, without attracting the second plunger, only the third plunger can be attracted.

The second plunger has a body to be attracted by the second fixed core and a diameter-enlarged part whose diameter is larger than that of the body. The body and the diameter-enlarged part are made of soft magnetic material. The yoke has a first part with which the body of the second plunger and the first plunger come into slide-contact, a second part which is apart from the first part and with which the third plunger comes into slide-contact, a third part connected to the third fixed core, a fourth part connected to the second fixed core and the first fixed core, a fifth part connecting the first and third parts, and a sixth part connecting the second and third parts. A notch for suppressing flow of the magnetic flux between the third and fourth parts is formed between the third and fourth parts. In an attraction state where the second plunger is attracted by the second fixed core, the diameter-enlarged part conies close to the second part and shortest distance from the second plunger to the second part becomes relatively short, and in a no-attraction state where the second plunger is not attracted by the second fixed core, the diameter-enlarged part is apart from the second part, and the shortest distance from the second plunger to the second part becomes longer than that in the attraction state.

In this case, since the notch is formed between the third and fourth parts in the yoke, the magnetic flux does not easily flow between the third and fourth parts. Consequently, if current is passed to the first electromagnetic coil in a state where the second plunger is in the no-attraction state, it can suppress that the magnetic flux generated flows from the second plunger to the second part and, further, to the fourth part via the sixth part and the third part. Therefore, the magnetic flux of the first electromagnetic coil flows in the second plunger more easily, and the second plunger can be attracted by the strong magnetic force. By forming the notch, when current is passed to the second electromagnetic coil, flow of the magnetic flux generated by the passage of current between the third part and the fourth part is disturbed. Accordingly, the magnetic flux of the second electromagnetic coil does not easily flow in the first plunger, the first fixed core, the fourth part, and the third part. Therefore, when the passage of current to the first electromagnetic coil is stopped, the attraction of the first plunger can be smoothly cancelled.

The solenoid device is constructed so that the shortest distance from the second plunger to the second part in the attraction state is shorter than that in the no-attraction state. Consequently, in the attraction state, the magnetic resistance between the second plunger and the second part can be made low, so that the magnetic flux generated by the passage of current to the second electromagnetic coil flows more easily in the second plunger. Therefore, when the passage of current to the first electromagnetic coil is stopped, the second plunger can be reliably attracted by the magnetic flux of the second electromagnetic coil.

With the configuration, by passing current to the first electromagnetic coil, the first and second plungers can be attracted reliably. After that, by passing current to the second electromagnetic coil and stopping the passage of current to the first electromagnetic coil, only the second and third plungers can be attracted reliably.

Although the third and fourth parts are completely apart from each other in the “notch”, the third and fourth parts may be magnetically slightly connected.

The center axis of one of the three plungers, the first, second, and third plungers, is in a direction different from the center axes of the other two plungers.

In this case, the solenoid device can be used also in a place where vibration easily occurs such as the inside of a vehicle. Specifically, when the three plungers are oriented in the same direction in a place where vibration easily occurs, there is a case that, due to vibration, the three plungers move in the same direction at the same time and, in the case of using the solenoid device for, for example, an electromagnetic relay, there is a case that three switches are turned on at the same time. However, by setting one of the three plungers in a direction different from the direction of the other two plungers, the three plungers can be prevented from being simultaneously moved in the same direction due to vibration. Therefore, also in the case of using the solenoid device for an electromagnetic relay, an inconvenience such that the three switches are simultaneously turned on can be prevented.

In at least one of the first, second, and third plungers, a flange which projects in the radial direction of the plunger is formed, and the magnetic flux passes through the flange.

In this case, the magnetic flux passes through the flange, so that the amount of the magnetic flux flowing in the plunger can be increased. Consequently, when current is passed to the first electromagnetic coil, the magnetic force generated in each of the plungers can be further enhanced, and the plunger can be attracted by stronger magnetic force. Since the contact area between the plunger and the fixed core increases, the fixed core and the plunger can be prevented from being magnetically saturated before the magnetic saturation part formed in the yoke.

First Embodiment

An embodiment of the solenoid device will be described with reference to FIGS. 1 to 6. As illustrated in FIG. 1, a solenoid device 1 of a first embodiment has a first electromagnetic coil 2a, a first plunger 3a, a second plunger 3b, a first fixed core 5a, a second fixed core 5b, and a yoke 4. When current is passed to the first electromagnetic coil 2a, a magnetic flux Φ is generated (refer to FIG. 3). Accompanying passage of current to the first electromagnetic coil 2a, the first and second plungers 3a and 3b move forward/backward. The first fixed core 5a is disposed so as to oppose to the first plunger 3a in the forward/backward movement direction of the first plunger 3a. The second fixed core 5b is disposed so as to oppose to second plunger 3b in the forward/backward movement direction of the second plunger 3b. A magnetic circuit in which the magnetic flux Φ flows is constructed by the yoke 4 together with the first plunger 3a, the first fixed core 5a, the second plunger 3b, and the second fixed core 5b (refer to FIG. 3).

The first plunger 3a is constructed to move forward/backward along the center axis of the turns on the inside of the first electromagnetic coil 2a. The second plunger 3b is disposed on the outside of the first electromagnetic coil 2a.

As illustrated in FIG. 1, in a no-current passage state in which no current is passed to the first electromagnetic coil 2a, a first gap G1 is formed between the first plunger 3a and the first fixed core 5a. A second gap G2 is formed between the second plunger 3b and the second fixed core 5b.

As illustrated in FIGS. 3 to 5, in a current passage state in which current is passed to the first electromagnetic coil 2a, the magnetic flux Φ flows in first and second magnetic circuits C1 and C2. The first magnetic circuit C1 is a magnetic circuit in which the magnetic flux Φ passes through the first plunger 3a, the first fixed core 5a, and the yoke 4. The second magnetic circuit C2 is a magnetic circuit in which the magnetic flux Φ passes through the first plunger 3a, the first fixed core 5a, the second plunger 3b, the second fixed core 5b, and the yoke 4.

As illustrated in FIG. 5, by magnetic force generated by the flow of the magnetic flux Φ in the first magnetic circuit C1, the first plunger 3a is attracted by the first fixed core 5a. By magnetic force generated by the flow of the magnetic flux Φ in the second magnetic circuit C2, the second plunger 3b is attracted by the second fixed core 5b.

As illustrated in FIG. 3, when the no-current passage state is switched to a current passage state, the magnetic flux Φ flowing in the first magnetic circuit C1 passes through the first gap G1, and the magnetic flux Φ flowing in the second magnetic circuit C2 passes through both the first and second gaps G1 and G2.

The solenoid device 1 of the embodiment is used for an electromagnetic relay 10. In the electromagnetic relay 10, two switches 19a and 19b are formed. Each switch 19 has a fixed contact 13, a moving contact 14, a fixed-contact supporting part 15 made of metal and supporting the fixed contact 13, and a moving-contact supporting part 16 made of metal and supporting the moving contact 14. To the moving-contact supporting part 16, a contact-side spring member 12 is attached. The contact-side spring member 12 presses the moving-contact supporting part 16 toward the fixed-contact supporting part 15 side.

Between the plunger 3 and the fixed core 5, a core-side spring member 11 is provided. The core-side spring member 11 presses the plunger 3 toward the moving-contact supporting part 16 side. The spring constant of the core-side spring member 11 is larger than that of the contact-side spring member 12.

As illustrated in FIG. 1, in the plunger 3, a flange 38 projected in the radial direction of the plunger 3 is formed. In the fixed core 5, a recessed conical surface 50 with which the plunger 3 comes into contact and an end face 51 parallel to the flange 38 are formed. A part of the magnetic flux Φ generated by passage of current to the first electromagnetic coil 2a passes through the flange 38 and goes toward the end face 51 of the fixed core 5. With the configuration, the amount of the magnetic flux Φ flowing in the plunger 3 is increased.

As illustrated in FIG. 1, the yoke 4 includes a sliding contact yoke 41, a bottom yoke 42, and a side-wall yoke 43. In the sliding contact yoke 41, a through hole 39 through which the plunger 3 passes is formed. The bottom yoke 42 is provided on the side opposite to the sliding contact yoke 41 of the first electromagnetic coil 2a in the axial direction (Z direction) of the plunger 3. The side-wall yoke 43 is provided in a position connecting ends 490 and 491 on the first plunger 3a side of the sliding contact yoke 41 and the bottom yoke 42 in the arrangement direction (X direction) of the two plungers 3a and 3b.

As illustrated in FIG. 2, a through hole 400 is formed in the side-wall yoke 43. By forming the through hole 400, the sectional area of the side-wall yoke 43 is reduced to form a magnetic saturation part 49.

As illustrated in FIG. 3, at the time of switching the first plunger 3a from the no-current passage state to the current passage state (refer to FIG. 4), the magnetic flux Φ flowing in the first magnetic circuit C1 passes through the first gap G1. The magnetic flux Φ flowing in the second magnetic circuit C2 passes through the first and second gaps G1 and G2. Since the first and second gaps G1 and G2 serve as magnetic resistors, the magnetic resistance of the first magnetic circuit C1 having only one gap is small, and the magnetic resistance of the second magnetic circuit C2 having two gaps is large. Consequently, the large amount of the magnetic flux Φ flows in the first magnetic circuit C1 and strong magnetic force which attracts the first plunger 3a is generated. On the other hand, the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small, and magnetic force which sufficiently attracts the second plunger 3b is not generated. Therefore, as illustrated in FIG. 4, the first plunger 3a is attracted before the second plunger 3b.

As illustrated in FIG. 4, when the first plunger 3a is attracted by the first fixed core 5a, by the pressing force of the contact-side spring member 12, the moving-contact supporting part 16 is pressed toward against the fixed-contact supporting part 15 side. As a result, the first switch 19a is turned on.

As illustrated in FIG. 4, when the first plunger 3a comes into contact with the first fixed core 5a, the first gap G1 disappears. Consequently, the magnetic resistance of the second magnetic circuit C2 decreases, and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 increases. Accordingly, as illustrated in FIG. 5, the second plunger 3b is attracted by the second fixed core 5b.

As described above, in the embodiment, the magnetic saturation part 49 is formed in the yoke 4 (the side-wall yoke 43) as a component of the first magnetic circuit C1. When the first plunger 3a is attracted, the magnetic flux Φ is saturated in the magnetic saturation part 49. Therefore, the magnetic flux Φ can be sufficiently passed also to the second magnetic circuit C2.

When the second plunger 3b is attracted by the second fixed core 5b, by the pressing force of the contact-side spring member 12, the moving-contact supporting part 16 is pressed toward the fixed-contact supporting part 15 side. As a result, the second switch 19b is turned on.

After that, as illustrated in FIG. 1, when the first electromagnetic coil 2a is set to the no-current passage state, the magnetic flux Φ disappears and, by the pressing force of the core-side spring member 11, the plunger 3 is pressed toward the moving-contact supporting part 16 side. An insulating part 30 attached to the plunger 3 comes into contact with the moving-contact supporting part 16 and, against the pressing force of the contact-side spring member 12, the moving-contact supporting part 16 is made apart from the fixed-contact supporting part 15. As a result, the switches 19a and 19b are turned off.

Next, a circuit using the electromagnetic relay 10 of the embodiment will be described. In the embodiment, as illustrated in FIG. 6, the electromagnetic relay 10 is provided for a power supply input part 66 connecting a DC power supply 6 and an electronic device 63. The power supply input part 66 has a positive-side line 64 connecting the positive electrode of the DC power supply 6 and the electronic device 63 and a negative-side line 65 connecting the negative electrode of the DC power supply 6 and the electronic device 63. Between the positive-side line 64 and the negative-side line 65, a smoothing capacitor 61 for smoothing DC voltage applied to the electronic device 63 is connected.

The positive-side line 64 is provided with the second switch 19b. A series member 67 in which a precharge resistor 62 and the first switch 19a are connected in, series is connected in parallel with the second switch 19b.

At the time of starting the electronic device 63, if the second switch 19b is turned on first, there is the possibility that inrush current flows in the smoothing capacitor 61 and the second switch 19b adheres. Consequently, the first switch 19a is turned on first, and current is gradually passed to the smoothing capacitor 61 via the precharge resistor 62. After charges are accumulated sufficiently in the smoothing capacitor 61, the second switch 19b is turned on.

As described above, the electromagnetic relay 10 of the embodiment can be suitably used for the circuit for a reason that when the first electromagnetic coil 2a is set to a current passage state, the first switch 19a is turned on first and, after that, the second switch 19b is turned on.

Although the first switch 19a, the precharge resistor 62, and the second switch 19b are provided for the positive-side line 64 in the embodiment, they may be provided for the negative-side line 65.

The operation and effect of the embodiment will be described. In the embodiment, as illustrated in FIG. 3, when the first electromagnetic coil 2a is switched from the no-current passage state to the current passage state, the magnetic flux Φ flowing in the first magnetic circuit C1 passes through one gap (first gap G1), and the magnetic flux Φ flowing in the second magnetic circuit C2 passes through two gaps (first and second gaps G1 and G2). Since those gaps become magnetic resistance larger than the yoke 4, the magnetic resistance of the first magnetic circuit C1 having only one gap is small, and the magnetic resistance of the second magnetic circuit C2 having two gaps is large. Consequently, the large amount of the magnetic flux Φ flows in the first magnetic circuit C1 and strong magnetic force which attracts the first plunger 3a is generated. On the other hand, the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small, and magnetic force which sufficiently attracts the second plunger 3b is not generated. Therefore, as illustrated in FIG. 4, the first plunger 3a is attracted before the second plunger 3b.

When the first plunger 3a is attracted and comes into contact with the first fixed core 5a, the first gap G1 disappears. Consequently, the magnetic resistance of the second magnetic circuit C2 decreases, and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 increases. Accordingly, as illustrated in FIG. 5, the second plunger 3b is attracted.

In such a manner, the first plunger 3a can be attracted first and, after that, the second plunger 3b can be attracted.

The solenoid device 1 of the embodiment does not have to be provided with an electromagnetic coil dedicated to attract the second plunger 3b. Therefore, the manufacture cost of the solenoid device 1 can be reduced, and the solenoid device 1 can be miniaturized.

In the embodiment, the second gap G2 can be made larger than the first gap G1. In such a manner, time since the first plunger 3a is attracted until the second plunger 3b is attracted can be made longer. The spring constant of the plunger-side spring member 11b used for the second plunger 3b can be made larger than that of the plunger-side spring member 11a used for the first plunger 3a. Also in this case, time since first plunger 3a is attracted until the second plunger 3b is attracted can be made longer. The second plunger 3b can be made heavier than the first plunger 3a.

As illustrated in FIG. 2, in the yoke 4 (side-wall yoke 43) existing on the first magnetic circuit C1, the magnetic saturation part 49 in which magnetic saturation occurs locally. By the magnetic saturation part 49, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 is regulated.

In such a manner, when the magnetic flux Φ is passed, the two plungers 3a and 3b can be attracted reliably. Specifically, a problem occurs such that if the magnetic flux Φ flowing in the first magnetic circuit C1 becomes too large when the first plunger 3a is attracted, the magnetic flux Φ flowing in the second magnetic circuit C2 becomes small so that it becomes difficult to attract the second plunger 3b. However, by forming the magnetic saturation part 49 as described above, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 can be regulated. Consequently, after the first plunger 3a is attracted, the magnetic flux Φ can be sufficiently passed also to the second magnetic circuit C2. Thus, both the first and second plungers 3a and 3b can be attracted reliably.

As illustrated in FIG. 3, each plunger 3 has the flange 38 which projects in the radial direction of the plunger 3. The magnetic flux Φ generated by passage of current to the first electromagnetic coil 2a passes through the flange 38.

With such a configuration, the magnetic flux Φ passes through the flange 38, so that the amount of the magnetic flux Φ flowing in the plunger 3 can be increased. Consequently, when current is passed to the first electromagnetic coil 2a, the magnetic force generated in the plunger 3 can be further enhanced, and the plunger 3 can be attracted by stronger magnetic force. Since the contact area between the plunger 3 and the fixed core 5 increases, the fixed core 5 and the plunger 3 can be prevented from being magnetically saturated before the magnetic saturation part 49.

As described above, according to the embodiment, the solenoid device in which the plurality of plungers can be attracted in predetermined order can be provided at lower manufacture cost.

Although the magnetic saturation part 49 is formed by partly reducing the sectional area by forming the through hole 400 in the yoke 4 in the embodiment, the magnetic saturation part 49 may be formed by using a material which easily magnetically saturates for a part of the yoke 4.

Second Embodiment

In a second embodiment, the number of the plungers 3 and the number of the electromagnetic coils 2 are changed as illustrated in FIGS. 7 to 12. As illustrated in FIG. 7, the solenoid device 1 of the embodiment has three plungers 3 which are a first plunger 3a, a second plunger 3b, and a third plunger 3c. The solenoid device 1 has two electromagnetic coils 2 which are a first electromagnetic coil 2a and a second electromagnetic coil 2b. In a manner similar to the first embodiment, the first plunger 3a is disposed on the inside of the first electromagnetic coil 2a, and the second plunger 3b is disposed on the outside of the first electromagnetic coil 2a. In the embodiment, the third plunger 3c is disposed on the inside of the second electromagnetic coil 2b. In a position opposed to the third plunger 3c in the forward/backward movement directions (Z directions) of the third plunger 3c, a third fixed core 5c made of soft magnetic material is provided.

In the embodiment, as illustrated in FIG. 7, the second plunger 3b has a body 300 to be attracted by the second fixed core 5b, a diameter-reduced part 31, and a diameter-enlarged part 32. The diameter-reduced part 31 is projected from the body 300 to the side opposite to the second fixed core 5b in the Z direction. The diameter-enlarged part 32 is formed in the diameter-reduced part 31 and has a diameter larger than that of the diameter-reduced part 31. The body 300, the diameter-reduced part 31, and the diameter-enlarged part 32 are made of soft magnetic material.

The yoke 4 has a first part 41a along which the body 300 of the second plunger 3b slides and a second part 41b which is apart from the first part 41a and along which the third plunger 3c slides. As illustrated in FIG. 11, in an attraction state where the second plunger 3b is attracted by the second fixed core 5b, the diameter-enlarged part 32 comes close to the second part 41b, and a gap “g” between the second plunger 3b and the second part 41b becomes relatively small. As illustrated in FIG. 7, in a no-attraction state where the second plunger 3b is not attracted by the second fixed core 5b, the diameter-enlarged part 32 is apart from the second part 41b and the diameter-reduced part 31 moves close to the second part 41b. Consequently, the gap “g” between the second plunger 3b and the second part 41b becomes wider than that in the attraction state (refer to FIG. 11).

Each of the first and second parts 41a and 41b is formed in a plate shape. The first and second parts 41a and 41b are disposed at a predetermined interval in the Z direction so as to be partly overlapped. In the overlapped part, through holes 47 and 48 are formed in the first and second parts 41a and 41b, respectively. The second plunger 3b is inserted in the through holes 47 and 48. The body 300 of the second plunger 3b slides along the inner face of the through hole 47 in association with the forward/backward moving operations.

As illustrated in FIG. 7, in the no-attraction state, the diameter-reduced part 31 is positioned in the through hole 48 in the second part 41b. As illustrated in FIG. 11, in the attraction state, the diameter enlarged part 32 moves in the through hole 48 in the second part 41b.

As illustrated in FIG. 8, when current is passed to the first electromagnetic coil 2a, the magnetic flux Φ flows separately in the first and second magnetic circuits C1 and C2. In a manner similar to the first embodiment, the first gap G1 is formed in the first magnetic circuit C1, and the two gaps, the first and second gaps G1 and G2, are formed in the second magnetic circuit C2. Consequently, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 is large, and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small. Therefore, as illustrated in FIG. 9, the first plunger 3a is attracted first, and the first switch 19a is turned on.

As illustrated in FIG. 9, when the first plunger 3a is attracted, the first gap G1 disappears, so that the magnetic resistance of the second magnetic circuit C2 decreases. Consequently, the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 increases. As described above, in a state where the second plunger 3b is not attracted (no-attraction state), the gap “g” between the second part 41b and the second plunger 3b is wide, so that the magnetic resistance between them is large. As a result, the magnetic flux Φ does not flow in the second part 41b so much but easily flows in the second plunger 3b.

As illustrated in FIG. 10, when the magnetic flux Φ flowing in the second magnetic circuit C2 increases, the second plunger 3b is attracted by the second fixed core 5b by the magnetic force. As a result, the second switch 19b is turned on.

After that, as illustrated in FIG. 11, current is passed to the second electromagnetic coil 2b, and the magnetic flux Φ is passed to the third plunger 3c and the third fixed core 5c. By the magnetic force generated by the operation, the third plunger 3c is attracted by the third fixed core 5c, and the third switch 19c is turned on.

As described above, in a state where the second plunger 3b is attracted (attraction state), the gap “g” between the second plunger 3b and the second part 41b is narrow, and the magnetic resistance between them is small. Consequently, magnetic flux Φ of the second electromagnetic coil 2b flows from the second part 41b to a diameter-enlarged part 48 (second plunger 3b) via the gap “g”.

In the embodiment, as illustrated in FIG. 11, the directions of currents passed to the first and second electromagnetic coils 2a and 2b are determined so that the direction of the magnetic flux Φ generated by the first electromagnetic coil 2a and flowing to the second plunger 3b and that of the magnetic flux Φ generated by the second electromagnetic coil 2b and flowing to the second plunger 3b become the same for enhancement.

In the embodiment, two side-wall yokes 43 which are a first side-wall yoke 43a and a second side-wall yoke 43b, are provided. Magnetic saturation parts 49a and 49b are formed in the side-wall yokes 43a and 43b, respectively. A part of the magnetic flux Φ generated by the current passage to the second electromagnetic coil 2b flows in the magnetic saturation part 49b where magnetic saturation occurs. Therefore, the magnetic flux Φ can be efficiently passed to the second plunger 3b.

After current is passed to the second electromagnetic coil 2b, as illustrated in FIG. 12, current passage to the first electromagnetic coil 2a is stopped. The magnetic flux Φ flowing in the first magnetic circuit C1 decreases, attraction of the first plunger 3c is cancelled, and the first switch 19a is turned off. Since the magnetic flux Φ generated by the passage of current to the second electromagnetic coil 2b flows in the second and third plungers 3b and 3c, even when the passage of current to the first electromagnetic coil 2a is stopped, the second and third plungers 3b and 3c are continuously attracted.

On the other hand, as illustrated in FIG. 14, in the case where current is passed to the second electromagnetic coil 2b before current is passed to the first electromagnetic coil 2a, only the third plunger 3c is attracted. In a state where current is not passed to the first electromagnetic coil 2a, as illustrated in FIG. 7, the second plunger 3b is not attracted, and the magnetic resistance between the second plunger 3b and the second part 41b is large. Consequently, when current is passed to the second electromagnetic coil 2b in this state, as illustrated in FIG. 14, the magnetic flux Φ of the second electromagnetic coil 2b does not easily flow to the second plunger 3b, and the second plunger 3b is not attracted. Therefore, by the magnetic flux Φ of the second electromagnetic coil 2b, only the third plunger 3c is attracted. In the embodiment, as will be described later, in this state, whether the second switch 19b is adhered or not is determined.

Next, a circuit using the electromagnetic relay 10 of the embodiment will be described. In the embodiment, as illustrated in FIG. 13, the electromagnetic relay 10 is provided for the power supply input part 66 connecting the DC power supply 6 and the electronic device 63. The power supply input part 66 has the positive-side line 64 connecting the positive electrode of the DC power supply 6 and the electronic device 63 and the negative-side line 65 connecting the negative electrode of the DC power supply 6 and the electronic device 63. Between the positive-side line 64 and the negative-side line 65, the smoothing capacitor 61 for smoothing DC voltage applied to the electronic device 63 is connected.

The positive-side line 64 is provided with a third switch 19c, and the negative-side line 65 is provided with the second switch 19b. The series member 67 in which the precharge resistor 62 and the first switch 19a are connected in series is connected in parallel with the third switch 19c.

In the embodiment, before the electronic device 63 is started, whether the second switch 19b is adhered or not is determined. At the time of performing the determination, first, current is passed to the second electromagnetic coil 2b in a state where no current is passed to the first electromagnetic coil 2a and only the third switch 19c is turned on (refer to FIG. 14). If the second switch 19b is adhered at this time, current flows in the capacitor 61, charges are accumulated, and the voltage of the capacitor 61 rises. Consequently, by attaching a voltage sensor to the capacitor 61 and measuring the voltage of the capacitor 61, whether the second switch 19b is adhered or not can be determined. Only in the case where it is determined that the second switch 19b is not adhered, the electronic device is started.

At the time of starting the electromagnetic device 63, by passing current to the first electromagnetic coil 2a, the first and second switches 19a and 19b are turned on. Current is gradually passed to the smoothing capacitor 61 via the precharge resistor 62. After charges are accumulated sufficiently in the smoothing capacitor 61, current is passed to the second switch 19b, and the third switch 19c is turned on.

After that, current passage to the first electromagnetic coil 2a is stopped, and the first switch 19a is turned off. In a state where only the second and third switches 19b and 19c are turned on, power is supplied to the electronic device 63.

The operation and effect of the embodiment will be described. In the embodiment, as illustrated in FIG. 11, current is passed to the first electromagnetic coil 2a to attract the first and second plungers 3a and 3b. After that, current is passed to the second electromagnetic coil 2b to attract the third plunger 3c.

In such a manner, two attraction states; the state where the first and second plungers 3a and 3b are attracted (first attraction state, refer to FIG. 10) and the state where the first to third plungers 3a to 3c are attracted (second attraction state, refer to FIG. 11) can be obtained by the passage of current/no current to the two electromagnetic coils.

In the embodiment, as illustrated in FIG. 11, by passing current to the first electromagnetic coil 2a and, after that, passing current to the second electromagnetic coil 2b, the magnetic flux Φ generated by the passage of current to the second electromagnetic coil 2b flows also in the second plunger 3b. By passing current to the second electromagnetic coil 2b and, after that, stopping the passage of current to the first electromagnetic coil 2a as illustrated in FIG. 12, attraction of only the first plunger 3a is cancelled in a state where the second and third plungers 3b and 3c are attracted by the magnetic flux Φ of the second electromagnetic coil 2b.

In such a manner, three attraction states, a state where only the second and third plungers 3b and 3c are attracted (third attraction state, refer to FIG. 12) and the first and second attraction states, can be obtained by the passage of current/no current to the two electromagnetic coils 2a and 2b.

Consequently, in a state where the second and third switches 19b and 19c are on, the first switch 19a can be turned off. In the case where sudden surge occurs when power is supplied to the electronic device 63, adhesion of the first switch 19a can be suppressed.

In the embodiment, in the case where current is passed to the second electromagnetic coil 2b before current is passed to the first electromagnetic coil 2a, only the third plungers 3c is attracted in the first to third plungers 3a to 3c (refer to FIG. 14).

With the configuration, only the third plunger 3c can be attracted, so that only the third switch 19c can be turned on. Consequently, whether another switch (second switch 19b) is adhered or not can be determined.

In the embodiment, the gap “g” between the second plunger 3b and the second part 41b in the no-attraction state (refer to FIG. 7) is wider than that in the attraction state (refer to FIG. 11).

With the configuration, in the no-attraction state, the magnetic resistance between the second plunger 3b and the second part 41b can be made large in the no-attraction state. Consequently, in the no-attraction state, the magnetic flux Φ of the first electromagnetic coil 2a does not easily flow in the second part 41b. Therefore, the magnetic flux Φ of the first electromagnetic coil 2a flows in the second plunger 3b more easily, and the second plunger 3b can be attracted with stronger magnetic force.

In the embodiment, in the attraction state (refer to FIG. 11), the gap “g” between the second plunger 3b and the second part 41b is narrower than that in the no-attraction state (refer to FIG. 7).

With the configuration, the magnetic resistance between the second plunger 3b and the second part 41b can be decreased. Consequently, the magnetic flux Φ generated by the passage of current to the second electromagnetic coil 2b flows in the second plunger 3b more easily. Therefore, as illustrated in FIG. 12, when the passage of current to the first electromagnetic coil 2a is stopped, the second plunger 3b can be attracted reliably by the magnetic flux Φ of the second electromagnetic coil 2b.

As described above, in the embodiment, the first and second plungers 3a and 3b can be attracted reliably by the passage of current to the first electromagnetic coil 2a. After that, by passing current to the second electromagnetic coil 2b and stopping the passage of current to the first electromagnetic coil 2a (refer to FIG. 12), only the second and third plungers 3b and 3c can be reliably attracted.

With the configuration, in the case of passing current to the second electromagnetic coil 2b before current is passed to the first electromagnetic coil 2a, since the second plunger 3b is in the no-attraction state (refer to FIG. 7), the magnetic resistance between the second part 41b and the second plunger 3b can be increased. It suppresses flow of the magnetic flux Φ of the second electromagnetic coil 2b to the second plunger 3b. Therefore, without attracting the second plunger 3b, only the third plunger 3c can be attracted.

The other operations and effects of the second embodiment are similar to those of the first embodiment.

In the embodiment, after current is passed to the second electromagnetic coil 2b, the passage of current to the first electromagnetic coil 2a is stopped (refer to FIG. 12), attraction of only the first plunger 3a is cancelled, and only the first switch 19a is turned off. Alternatively, without cancelling the attraction of the first plunger 3a, the first switch 19a may be continuously in the on state. In this case, power is supplied to the electromagnetic device 63 in a state where the three switches 19a to 19c are on (refer to FIG. 13). However, since the resistance value of the precharge resistor 62 is large, most of current flows in the second and third switches 19b and 19c and current hardly flows in the precharge resistor 62. Consequently, even when the first switch 19a is continuously on, there is no big problem in practice.

Third Embodiment

In a third embodiment, the orientations of the plungers 3 are changed. In the embodiment, as illustrated in FIG. 15, the center axis of the third plunger 3c is set in a direction different from the direction of the center axes of the first and second plungers 3a and 3b. The center axis of the third plunger 3c is parallel to the X direction, and the center axes of the first and second plungers 3a and 3b are parallel to the Z direction.

The other configuration is similar to that of the second embodiment.

The operation and effect of the embodiment will be described. With the configuration, the electromagnetic relay 10 can be used also in a place where vibration easily occurs such as the inside of a vehicle. Specifically, when the three plungers 3 are oriented in the same direction in a place where vibration easily occurs, there is a case that, due to vibration, the three plungers move in the same direction at the same time, and three switches 19 are turned on at the same time. However, by setting one (the third plunger 3c) of the three plungers 3a to 3c in a direction different from the direction of the other two plungers (the first and second plungers 3a and 3b), the three plungers 3 can be prevented from being simultaneously moved in the same direction due to vibration. Therefore, an inconvenience such that the three switches 19 are simultaneously turned on can be prevented.

Fourth Embodiment

In a fourth embodiment, as illustrated in FIG. 16, the first electromagnetic coil 1 is divided into two parts, a first coil part 21 and a second coil part 22. Current can be separately passed to each of the first and second coil parts 21 and 22. That is, current can be passed only to one of the first and second coil parts 21 and 22 or can be simultaneously passed to both of them.

As illustrated in FIG. 17, when current is passed to the first coil part 21 while no current is passed to the second coil part 22, only the first plunger 3a is attracted by the first fixed core 5a by the generated magnetic flux Φ. In the embodiment, for example, the spring constant of the plunger-side spring member 11b of the second plunger 3b is set to be larger than that of the plunger-side spring member 11a of the first plunger 3a. With the configuration, even when current is passed only to the first coil part 21 and the magnetic flux Φ is generated, only the first plunger 3a is attracted, and the second plunger 3b is not attracted. Consequently, only the first switch 19a is turned on.

As illustrated in FIG. 18, when current is passed to both of the first and second coil parts 21 and 22, large magnetic flux Φ is generated. By the magnetic flux Φ, both of the first and second plungers 3a and 3b are attracted. Accordingly, both of the two switches 19a and 19b are turned on.

The other configuration is similar to that of the first embodiment.

The operation and effect of the fourth embodiment will be described. In the embodiment, in a manner similar to the first embodiment, an electromagnetic coil dedicated to attract the second plunger 3b is not provided. Consequently, as compared with the case of attracting each of the plungers by using the electromagnetic coil, the amount of copper lines constructing the electromagnetic coil can be decreased. Thus, the manufacture cost of the electromagnetic relay 10 can be reduced.

In the embodiment, time to attract the second plunger 3b can be controlled. That is, current is passed only to the first coil part 21 to attract only the first plunger 3a. After lapse of predetermined time, current is passed also to the second coil part 22 to attract the second plunger 3b as well. Consequently, by controlling the time to pass current to the second coil part 22, the time to attract the second plunger 3b can be controlled.

Since there is no gap “G” after attracting the plungers 3a and 3b, the magnetic resistance in the magnetic circuit becomes small. Consequently, also by decreasing the amount of the magnetic flux Φ generated by stopping the passage of current to the second coil part 22 after attracting the plungers 3a and 3b, the plungers 3a and 3b can be continuously attracted. In such a manner, the power consumption in the first electromagnetic coil 2a can be decreased.

The other configuration is similar to that of the first embodiment.

In the embodiment, after passing current only to the first coil part 21, current is passed also to the second coil part 22. The order of passing current may be opposite. That is, current may be passed only to the second coil part 22 and, after that, also to the first coil part 21.

Fifth Embodiment

In the embodiment, as illustrated in FIG. 19, the position of the first electromagnetic coil 2a is changed. As illustrated in the diagram, in the embodiment, a pillar-shaped yoke 44 is disposed in the center of the first electromagnetic coil 2a and is in contact with the first fixed core 5a and the side-wall yoke 43. By the pillar-shaped yoke 44, the first fixed core 5a, the first plunger 3a, the sliding contact yoke 41, and the side-wall yoke 43, the first magnetic circuit C1 in which the magnetic flux Φ flows is constructed.

With the second fixed core 5b, a yoke 45 for the core is in contact. The yoke 45 for the core is also in contact with the bottom yoke 42. By the first plunger 3a, the sliding contact yoke 41, the second plunger 3b, the second fixed core 5b, the yoke 45 for the core, the bottom yoke 42, the side-wall yoke 43, the pillar-shaped yoke 44, and the first fixed core 5a, the second magnetic circuit C2 in which the magnetic flux Φ flows is constructed.

The other configuration, operation, and effect of the fifth embodiment are similar to those of the first embodiment.

Sixth Embodiment

In a sixth embodiment, as illustrated in FIG. 20, the position of the second electromagnetic coil 2b is changed. As illustrated in the diagram, in the embodiment, the pillar-shaped yoke 44 is disposed in the center of the second electromagnetic coil 2b and is in contact with the second part 41b of the yoke 4 and the bottom yoke 42. By the magnetic flux Φ generated by the passage of current to the second electromagnetic coil 2b, the third plunger 3c is attracted.

The other configuration, operation, and effect of the sixth embodiment are similar to those of the first embodiment.

Seventh Embodiment

In a seventh embodiment, as illustrated in FIG. 21, the diameter-reduced part 31 and the diameter-enlarged part 32 are not formed but only the body 300 is formed in the second plunger 3b.

The other configuration, operation, and effect of the seventh embodiment are similar to those of the first embodiment.

Eighth Embodiment

In an eighth embodiment, as illustrated in FIGS. 22 and 23, the through hole 48 formed in the second part 41b of the yoke 4 is made smaller than the diameter-enlarged part 32. It is constructed so that when the second plunger 3b is attracted, the diameter-enlarged part 32 comes into contact with the surface of the second part 41b.

With such a configuration, when the second plunger 3b is attracted, the second part 41b and the second plunger 3b come into contact with each other, so that the magnetic resistance between the second part 41b and the second plunger 3b can be further decreased. Consequently, when current is passed to the second electromagnetic coil 2b, the magnetic flux Φ of the second electromagnetic coil 2b flows more easily from the second part 41b to the diameter-enlarged part 32 (the second plunger 3b). Therefore, when the passage of current to the first electromagnetic coil 2a is stopped (refer to FIG. 12), the second plunger 3b can be reliably attracted by the magnetic flux Φ of the second electromagnetic coil 2b.

The other configuration, operation, and effect are similar to those of the first embodiment.

Ninth Embodiment

In a ninth embodiment, as illustrated in FIGS. 24 and 25, the orientations of the switches 19a and 19b and the disposition positions of the spring members 11 and 12 are changed. In the embodiment, the fixed contact 13 and the fixed-contact supporting part 15 are provided in a position far from the plunger 3 in the Z direction, and the moving contact 14 and the moving-contact supporting part 16 are provided in a position close to the plunger 3 in the Z direction. The moving-contact supporting part 16 is attached to the plunger 3. Accompanying the forward/backward moving operation of the plunger 3, the moving contact 14 comes into contact with/moves apart from the fixed contact 13. The contact-side spring member 12 presses the moving-contact supporting part 16 toward the fixed-contact supporting part 15 side. The plunger-side spring member 11 presses the plunger 3a toward the bottom yoke 42 side.

As illustrated in FIG. 24, in the case where no current is passed to the first electromagnetic coil 2a, by the pressing force of the plunger-side spring member 11, the plunger 3a is pressed to the bottom yoke 42 side, and the switches 19a and 19b are turned off.

As illustrated in FIG. 25, when current is passed to the first electromagnetic coil 2a, the plungers 3a and 3b are pressed toward the fixed-contact supporting part 15 side. Consequently, the moving contact 14 comes into contact with the fixed contact 13, and the switches 19a and 19b are turned on.

The other configuration, operation, and effect of the ninth embodiment are similar to those of the first embodiment.

Tenth Embodiment

In a tenth embodiment, the shape of the first electromagnetic coil 2a and that of the yoke 4 are changed. As illustrated in FIG. 26, the first electromagnetic coil 2a has the first coil part 21 and the second coil part 22 to which current can be separately passed. The first coil part 21 is disposed in a position closer to the first fixed core 5a than the second coil part 22 in the forward/backward movement direction of the first plunger 3a. The yoke 4 has an intermediate yoke 46 and the sliding contact yoke 41. The intermediate yoke 46 is disposed between the first and second coil parts 21 and 22. The sliding contact yoke 41 is provided in a position far from the first fixed core 5a as compared with the intermediate yoke 46 in the forward/backward movement direction (Z direction) of the first plunger 3a. With the sliding contact yoke 41, the first and second plungers 3a and 3b come into sliding-contact.

As illustrated in FIG. 27, when current is passed only to the first coil part 21 as one of the first and second coil parts 21 and 22, by the magnetic force generated by the magnetic flux Φ flowing in the intermediate yoke 46, the first plunger 3a, and the first fixed core 5a, the first plunger 3a is attracted by the first fixed core 5a. As illustrated in FIG. 29, when current is passed only to the second coil part 22 as one of the first and second coil parts 21 and 22, by the magnetic force generated by the magnetic flux Φ flowing in the intermediate yoke 46, the first plunger 3a, and the sliding-contact yoke 41, the first plunger 3a is attracted by the sliding-contact yoke 41, and the first plunger 3a moves apart from the first fixed core 5a.

In a manner similar to the first embodiment, the yoke 4 of the tenth embodiment has the side-wall yoke 43 and the bottom yoke 42. The side-wall yoke 43 is provided with the magnetic saturation part 49. In the sliding contact yoke 41, the through hole 39 through which the plunger 3 is inserted is formed. In the periphery of the through hole 39, opening walls 391 and 392 projected to the fixed core 5 side are formed. When the plunger 3 performs the forward/backward moving operation, the plunger 3 comes into slide-contact with the inner peripheral face of the opening walls 391 and 392. The opening wall 391 projects to the inside of the second coil part 22 of the first electromagnetic coil 2a.

In a manner similar to the first embodiment, the flange 38 is formed in the plunger 3. In the no-current passage state, length L1 from the flange 38 to the sliding contact yoke 41 (opening wall 391) in the Z direction is shorter than length L2 from the intermediate yoke 46 to the flange 38.

The intermediate yoke 46 is formed in a plate shape. In the intermediate yoke 46, a through hole 460 which penetrates in the Z direction is formed. The first plunger 3a is inserted in the through hole 460.

The current passage modes in the solenoid device 1 of the embodiment are the first current passage mode in which, as illustrated in FIGS. 27 and 28, current is passed to the first coil part 21 first and, while maintaining the current passage, current is then passed to the second coil part 22, and the second current passage mode in which, as illustrated in FIGS. 29 and 30, current is passed to the second coil part 22 first and, while maintaining the current passage, current is then passed to the first coil part 21.

As illustrated in FIG. 27, in the first current passage mode, when current is passed to the first coil part 21, the magnetic flux Φ is generated. The magnetic flux Φ flows in the first magnetic circuit C1, the second magnetic circuit C2, and the third magnetic circuit C3. The first magnetic circuit C1 is made by the intermediate yoke 46, the side-wall yoke 43, the bottom yoke 42, the first fixed core 5a, and the first plunger 3a. The second magnetic circuit C2 is made by the first plunger 3a, the sliding contact yoke 41, the second plunger 3b, the second fixed core 5b, the bottom yoke 42, and the first fixed core 5a. The third magnetic circuit C3 is made by the first plunger 3a, the sliding contact yoke 41, the side-wall yoke 43, the bottom yoke 42, and the first fixed core 5a.

At the time of switching the first coil part 21 from the no-current passage state (refer to FIG. 26) to the current passage state (refer to FIG. 27), the magnetic flux Φ flowing in the first magnetic circuit C1 passes through the first gap G1. The magnetic flux Φ flowing in the second magnetic circuit C2 passes through both the first and second gaps G1 and G2. The magnetic flux Φ flowing in the first magnetic circuit C1, the magnetic flux Φ flowing in the second magnetic circuit C2, and the magnetic flux Φ flowing in the third magnetic circuit C3 pass through the first gap G1. Particularly, the strong magnetic flux Φ flows in the first and third magnetic circuits C1 and C3. By the magnetic force generated by the magnetic flux Φ, the first plunger 3a is attracted by the first fixed core 5a. When the first plunger 3a is attracted, the flange 38 comes into contact with the surface of the intermediate yoke 46.

As illustrated in FIG. 27, in the embodiment, when current is passed only to the first coil part 21, the magnetic flux Φ does not sufficiently flow in the second magnetic circuit C2, and the second plunger 3b is not attracted. As illustrated in FIG. 28, when current is passed to the first coil part 21 and, after that, current is passed also to the second coil part 22, the magnetic flux Φ of the first coil part 21 and the magnetic flux Φ of the second coil part 22 are added, and a large amount of the magnetic flux Φ flows in the second magnetic circuit C2. Consequently, the second plunger 3b is attracted by the second fixed core 5b.

As illustrated in FIG. 29, in the second current passage mode, when current is passed to only the second coil part 22 as one of the first and second coil parts 21 and 22, a part of the magnetic flux Φ flows in the first plunger 3a, the sliding contact yoke 41, the side-wall yoke 43, and the intermediate yoke 46. At this time, the magnetic flux Φ flows also between the flange 38 and the opening wall 391. By the magnetic force generated, the flange 38 is attracted by the opening wall 391.

Another part of the magnetic flux Φ flows in the first plunger 3a, the sliding contact yoke 41, the second plunger 3b, the second fixed core 5b, the bottom yoke 42, and the first fixed core 5a. In the embodiment, even when current is passed only to the second coil part 22, the magnetic flux Φ does not sufficiently flow in the second plunger 3b, and the second plunger 3b is not attracted. As illustrated in FIG. 30, when current is passed to the second coil part 22 and, after that, also to the first coil part 21, the magnetic flux Φ of the first coil part 21 and the magnetic flux Φ of the second coil part 22 are added, and a large amount of the magnetic flux Φ flows in the second plunger 3b. Consequently, strong magnetic force is generated in the second plunger 3b, and the second plunger 3b is attracted by the second fixed core 5b.

As described above, in the embodiment, in the first current passage mode (refer to FIGS. 27 and 28), the first plunger 3a is attracted by the first fixed core 5a, and the second plunger 3b is attracted by the second fixed core 5b. In the second current passage mode (refer to FIGS. 29 and 30), the first plunger 3a is attracted by the sliding contact yoke 41, and the second plunger 3b is attracted by the second fixed core 5b.

In the embodiment, in a manner similar to the first embodiment, the solenoid device 1 is used as the electromagnetic relay 10. The electromagnetic relay 10 can be provided for the power supply input unit 66 (refer to FIG. 6) in a manner similar to the first embodiment. For example, the second switch 19b (refer to FIG. 6) is opened/closed by the first plunger 3a, and the first switch 19a is opened/closed by the second plunger 3b. At the time of precharging the smoothing capacitor 61, it is necessary to turn on only the first switch 19a and turn off the second switch 19b. Consequently, at this time, current is passed to the first electromagnetic coil 2a by the second current passage mode (refer to FIGS. 29 and 30). By the operation, the first plunger 3a is moved apart from the first fixed core 5a, while preventing the second switch 19b from being turned on, the second plunger 3b is attracted to turn on the first switch 19a.

After completion of precharging the smoothing capacitor 61, passage of current to the first and second coil parts 21 and 22 is temporarily stopped, and current is passed only to the first coil part 21 (refer to FIG. 27). It turns on only the second switch 19b (refer to FIG. 6), and power is supplied to the electronic device 63. Alternatively, current is passed also to the second coil part 22 (refer to FIG. 28) to turn on both of the first and second switches 19a and 19b.

The operation and effect of the embodiment will be described. In the embodiment, as illustrated in FIG. 27, by passing current only to the first coil part 21, the first plunger 3a is attracted by the first fixed core 5a. Alternatively, by passing current only to the second coil part 22, the first plunger 3a can be attracted by the sliding contact yoke 41. That is, the first plunger 3a can be moved close to the first fixed core 5a or apart from the first fixed core 5a. Consequently, in the case where the first plunger 3a is not attracted by the first fixed core 5a, the first plunger 3a can be moved forcedly apart from the first fixed core 5a. Thus, the first plunger 3a can be prevented from being erroneously attracted by the first fixed core 5a.

As illustrated in FIG. 26, in the no-current passage state, the length L1 from the flange 38 of the first plunger 3a to the sliding contact yoke 41 (the opening wall 391) in the Z direction is shorter than the length L2 from the intermediate yoke 46 to the flange 38.

Consequently, when current is passed only to the second coil part 22, strong magnetic force is generated between the flange 38 and the sliding contact yoke 41 (opening wall 391). Therefore, the first plunger 3a can be reliably attracted by the sliding contact yoke 41, and the first plunger 3a can be prevented from being attracted by the intermediate yoke 46.

In the embodiment, when the two plungers 3a and 3b move to the same side (the bottom yoke 42 side), the two switches 19a and 19b are turned one. As illustrated in FIG. 31, when the two plungers 3a and 3b move to the sides opposite to each other, the switches 19a and 19b may be turned on. In such a manner, when vibration occurs and the two plungers 3a and 3b move in the same direction, the two switches 19a and 19b can be prevented from being turned on simultaneously. Consequently, supply of power to the electronic device 63 (refer to FIG. 6) at unintended time is more suppressed.

The rest is similar to the first embodiment. Unless otherwise described, the same reference numerals as those used in the first embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the first embodiment.

Eleventh Embodiment

In an eleventh embodiment, the shape of the first plunger 3a and the shape of the sliding contact yoke are changed. As illustrated in FIG. 32, the solenoid device 1 of the embodiment has two sliding contact yokes; a first sliding contact yoke 411 and a second sliding contact yoke 412. The first sliding contact yoke 411 has a plate shape, and two through holes 39 are formed. The second sliding contact yoke 412 is disposed in the center of the second coil part 22 and fixed to the first sliding contact yoke 411. In the second sliding contact yoke 412, a through hole 419 penetrating in the Z direction and a conical face 418 are formed. A through hole 39a in the first sliding contact yoke 411 and the through hole 419 in the second sliding contact yoke 412 are communicated with each other.

In the first plunger 3a, tapered surfaces 318 and 319 each having a conical shape are formed. The tapered surface 318 is in contact with the conical surface 50 of the first fixed core 5a, and the other tapered surface 319 is in contact with the conical surface 418 of the second sliding contact yoke 412.

In the embodiment, when current is passed only to the first coil part 21 as one of the first and second coil parts 21 and 22, the first plunger 3a is attracted by the first fixed core 5a. Subsequently, when current is passed also to the second coil part 22, the magnetic fluxes Φ of the two coil parts 21 and 22 flow in the second plunger 3b, strong magnetic force is generated, and the second plunger 3b is attracted by the second fixed core 5b. When current is passed only to the second coil part 22, the first plunger 3a is attracted by the second sliding contact yoke 412. Subsequently, when current is passed also to the first coil part 21, the magnetic fluxes Φ of the two coil parts 21 and 22 flow in the second plunger 3b, strong magnetic force is generated, and the second plunger 3b is attracted by the second fixed core 5b.

The rest is similar to the tenth embodiment. The same reference numerals used in the tenth embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the tenth embodiment.

Twelfth Embodiment

In twelfth embodiment, the number of the plungers 3 and the shape of the yoke 4 are changed. The solenoid device of the embodiment has three plungers 3a to 3c in a manner similar to the second embodiment as illustrated in FIG. 33. The second plunger 3b has the body 300 attracted by the second fixed core 5b and the diameter-enlarged part 32 whose diameter is larger than the body 300. The body 300 and the diameter-enlarged part 32 are made of soft magnetic material.

The yoke 4 has the first part 41a and the second part 41b. In the first part 41a, the two through holes 39a and 47 are formed. The plungers 3a and 3b are inserted in the through holes 39a and 47. When the plungers 3a and 3b move forward/backward, the plungers 3a and 3b slide-contact with the inner peripheral face of the through holes 39a and 47. The first part 41a is formed in a step shape. A part 414 in which the through hole 47 for the second plunger 3b in the first part 41a is formed is positioned on the side closer, in the Z direction, to a fourth part 41d than a part 413 in which the through hole 39a for the first plunger 3a is formed.

The second part 41b of the yoke 4 is apart from the first part 41a. In the second part 41b, the two through holes 48 and 39b are formed. The plungers 3b and 3c are inserted in the through holes 48 and 39b. When the third plunger 3c moves forward/backward, the third plunger 3c slide-contacts with the inner peripheral face of the through hole 39b. The inside diameter of the through hole 48 for the second plunger 3b is larger than the outside diameter of the body 300 and smaller than the outside diameter of the diameter-enlarged part 32.

The yoke 4 has a third part 41c and a fourth part 41d. The third part 41c is magnetically connected to the third fixed core 5c. The fourth part 41d is magnetically connected to the second fixed core 5b and the first fixed core 5a. A notch 450 for suppressing flow of the magnetic flux Φ between the third and fourth parts 41c and 41d is formed between the third and fourth parts 41c and 41d.

The yoke 4 also has a fifth part 41e, a sixth part 41f, and a seventh part 41g. The fifth part 41e connects the first part 41a and the third part 41c. The sixth part 41f connects the second and third parts 41b and 41c. The seventh part 41g couples the first and fourth parts 41a and 41d at an end 499 on the first plunger 3a side in the X direction.

As illustrated in FIG. 34, when current is passed to the first electromagnetic coil 2a, a part of the magnetic flux Φ flows in the first magnetic circuit C1 made by the first plunger 3a, a part of the yoke 4 (the first, seventh, and fourth parts 41a, 41g, and 41d), and the first fixed core 5a. Another part of the magnetic flux Φ flows in the second magnetic circuit C2 made by the first plunger 3a, the first part 41a, the second plunger 3b, the second fixed core 5b, the fourth part 41d, and the first fixed core 5a. As illustrated in FIGS. 34 to 36, the first plunger 3a is attracted by the first fixed core 5a, and the second plunger 3b is attracted by the second fixed core 5b.

To pass the stable magnetic flux Φ to the second magnetic circuit C2 at this time, it is important to magnetically saturate the first plunger 3a in the state of FIG. 35. It is therefore desirable to design so that any part of the yoke 4 (the first part 41a, the seventh part 41g, and the fourth part 41d) in the first magnetic circuit C1 magnetically saturates before the first plunger 3a.

As illustrated in FIG. 36, in a state where the second plunger 3b is attracted (attraction state), the diameter-enlarged part 32 comes close to the second part 41b. That is, the diameter-enlarged part 32 comes into contact with the peripheral part of the through hole 48. As illustrated in FIG. 34, in a state where the second plunger 3b is not attracted by the second fixed core 5b (no-attraction state), the diameter-enlarged part 32 is apart from the second part 41b, and the shortest distance from the second plunger 3b to the second part 41b becomes longer than that in the attraction state (refer to FIG. 36).

When current is passed to the second electromagnetic coil 2b after attracting the first and second plungers 3a and 3b (refer to FIG. 36), the magnetic flux Φ is generated as illustrated in FIG. 37. A part of the magnetic flux Φ of the second electromagnetic coil 2b flows in the third plunger 3c, the second part 41b, the sixth part 41f, the third part 41c, and the third fixed core 5c. By the magnetic force generated, the third plunger 3c is attracted by the third fixed core 5c. Another part of the magnetic flux Φ of the second electromagnetic coil 2b flows in the third plunger 3c, the second part 41b, the diameter-enlarged part 32, the second plunger 3b, the first part 41a, the fifth part 41e, the third part 41c, and the third fixed core 5c. By the magnetic force generated, the diameter-enlarged part 32 is attracted by the second part 41b.

The direction of the passage of current in the second electromagnetic coil 2b may be opposite.

After that, as illustrated in FIG. 38, when the passage of current to the first electromagnetic coil 2a is stopped, the magnetic flux Φ of the first electromagnetic coil 2a disappears, and attraction of the first plunger 3a is cancelled. However, since the magnetic flux Φ of the second electromagnetic coil 2b continues to flow between the second part 41b and the diameter-enlarged part 32, the diameter-enlarged part 32 is continuously attracted by the second part 41b.

The operation and effect of the embodiment will be described. In the embodiment, since the notch 450 is formed between the third and fourth parts 41c and 41d, the magnetic flux Φ does not easily flow between the third and fourth parts 41c and 41d. Consequently, if current is passed to the first electromagnetic coil 2a in a state where the second plunger 3b is not attracted (refer to FIGS. 34 and 34), it can suppress that the magnetic flux Φ generated flows from the second plunger 3b to the second part 41b and, further, to the fourth part 41d via the sixth part 41f and the third part 41c. Therefore, the magnetic flux Φ of the first electromagnetic coil 2a flows in the second plunger 3b more easily, and the second plunger 3b can be attracted by the strong magnetic force (refer to FIGS. 35 and 36).

Since no magnetomotive force exists between the first part 41a and the second part 41b, as illustrated in FIG. 36, the magnetic flux Φ of the first electromagnetic coil 2a hardly flows in the magnetic circuit made by the first part 41a, the second plunger 3b, the second part 41b, the sixth part 41f, the third part 41c, and the fifth part 41e.

As illustrated in FIGS. 37 and 38, since the notch 450 is formed in the embodiment, when current is passed to the second electromagnetic coil 2b, flow of the magnetic flux Φ of the second electromagnetic coil 2b between the third part 41c and the fourth part 41d is disturbed. Accordingly, the magnetic flux Φ of the second electromagnetic coil 2b does not easily flow in the magnetic circuit made by the first part 41a, the first plunger 3a, the first fixed core 5a, the fourth part 41d, and the third part 41c. Therefore, when the passage of current to the first electromagnetic coil 2a is stopped, the first plunger 3a is not continuously attracted by the magnetic flux Φ of the second electromagnetic coil 2b, and the attraction of the first plunger 3a can be smoothly cancelled.

The solenoid device 1 of the embodiment is constructed so that, as illustrated in FIGS. 36 and 37, the shortest distance from the second plunger 3b to the second part 41b in the state where the second plunger 3b is attracted (attraction state) is shorter than that in the no-attraction state (refer to FIG. 35). Consequently, in the attraction state, the magnetic resistance between the second plunger 3b and the second part 41b can be made low, so that the magnetic flux Φ generated by the passage of current to the second electromagnetic coil 2b flows more easily in the second plunger 3b. Therefore, as illustrated in FIG. 38, when the passage of current to the first electromagnetic coil 2a is stopped, the second plunger 3b can be reliably attracted by the magnetic flux Φ of the second electromagnetic coil 2b.

Although the diameter-enlarged part 32 of the second plunger 3 is in contact with the second part 41b in the attraction state as illustrated in FIG. 36 in the embodiment, they may be slightly apart from each other.

The electromagnetic relay 10 of the embodiment is used for the circuit illustrated in FIG. 13. When current is passed to the first electromagnetic coil 2a, the first and second switches 19a and 19b are turned on (refer to FIGS. 34 to 36). Current can be gradually passed via the precharge resistor 62 (refer to FIG. 13) to charge the smoothing capacitor 61. When current is passed to the second electromagnetic coil 2b after completion of the charging (refer to FIG. 37), the third switch 19c is turned on. After that, when the passage of current to the first electromagnetic coil 2a is stopped (refer to FIG. 38), while setting the second and third switches 19b and 19c in the on state by the magnetic force generated by the magnetic flux Φ of the second electromagnetic coil 2b, the first switch 19a can be turned off. In this state, power can be supplied to the electronic device 63. Although the state of supplying power to the electronic device 63 lasts relatively long, since current is passed only to the electromagnetic coil 2 (the second electromagnetic coil 2b) as one of the two electromagnetic coils 2a and 2b, the power consumption in the electromagnetic coils 2 can be reduced to the half of that in the case of passing current to both of the two electromagnetic coils 2a and 2b.

As described above, in the embodiment, by passing current to the first electromagnetic coil 2a, the first and second plungers 3a and 3b can be reliably attracted (refer to FIG. 36). After that, by passing current to the second electromagnetic coil 2b to stop the passage of current to the first electromagnetic coil 2a, only the second and third plungers 3b and 3c can be reliably attracted (refer to FIG. 38).

In the embodiment, in the case of passing current to the second electromagnetic coil 2b before the first electromagnetic coil 2a, since the second plunger 3b is in the no-attraction state, the magnetic resistance between the second part 41b and the second plunger 3b is high. Due to this, flow of the magnetic flux Φ generated by the second electromagnetic coil 2b into the second plunger 3b is suppressed. Therefore, the second plunger 3b is not attracted, and only the third plunger 3c can be attracted.

Although the third and fourth parts 41c and 41d are completely apart from each other in the notch 450 in the embodiment, the third and fourth parts 41c and 41d may be magnetically slightly connected to each other.

The rest is similar to the second embodiment. Unless otherwise described, the same reference numerals as those used in the second embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the second embodiment.

Thirteenth Embodiment

In a thirteenth embodiment, the shape of the plunger 3 and the shape of the fixed core 5 are changed. As illustrated in FIG. 39, each of the first and second plungers 3a and 3b of the embodiment is formed in a plate shape. The plunger 3 moves forward/backward in the plate thickness directions (Z directions). In the embodiment, each of the fixed cores 5 (5a and 5b) is formed in a pillar shape. The first fixed core 5a is disposed in the center of the first electromagnetic coil 2a, and its one end 515 is opposed to the center 350 of the first plunger 3a. The diameter of the one end 515 of the first fixed core 5a is larger than a part 599 disposed in the center of the first electromagnetic coil 2a.

The yoke 4 is formed by a contact/separate yoke 415 to/from which the plunger 3 comes into contact/is apart, the bottom yoke 42, and the side-wall yoke 43 connecting the bottom yoke 42 and the contact/separate yoke 415. A through hole 470 is formed in the contact/separate yoke 415. The other end 516 of the fixed core 5 is in contact with the bottom yoke 42. The bottom yoke 42 is provided with the magnetic saturation part 49.

As illustrated in FIG. 43, the plunger 3 has a disc shape. As illustrated in FIGS. 41 and 42, when the plunger 3 moves forward/backward, the outer periphery 365 of the plunger 3 comes into contact with/is apart from the surface of the contact/separate yoke 415, and the center 350 of the plunger 3 comes into contact with/is apart from the surface of the one end 515 of the fixed core 5.

As illustrated in FIG. 40, when the first electromagnetic coil 2a is set to the current passage state, the magnetic flux Φ is generated. A part of the magnetic flux Φ flows in the first magnetic circuit C1 made by the first fixed core 5a, the first plunger 3a, and the yoke 4. Another part of the magnetic flux Φ flows in the second magnetic circuit C2 made by the first fixed core 5a, the first plunger 3a, the contact/separate yoke 415, the second plunger 3b, the second fixed core 5b, and the bottom yoke 42.

As illustrated in FIG. 40, at the time of switching the first electromagnetic coil 2a from the no-current passage state to the current passage state, the magnetic flux Φ flowing in the first magnetic circuit C1 flows in the first gap G1 between the first fixed core 5a and the first plunger 3a and the third gap G3 between the first plunger 3a and the contact/separate yoke 415. The magnetic flux Φ flowing in the second magnetic circuit C2 flows in the above-described two gaps G1 and G3 and, in addition, a fourth gap G4 between the contact/separate yoke 415 and the second plunger 3b and a second gap G2 between the second plunger 3b and the second fixed core 5b. Since the number of gaps in the first magnetic circuit C1 is smaller than that in the second magnetic circuit C2, strong magnetic flux Φ flows in the first magnetic circuit C1. Consequently, as illustrated in FIG. 41, the first plunger 3a is attracted first. When the first plunger 3a is attracted, the gaps G1 and G3 disappear, the magnetic resistance of the second magnetic circuit C2 decreases, and the large amount of the magnetic flux Φ flows in the second magnetic circuit C2. As a result, as illustrated in FIG. 42, the second plunger 3b is attracted.

The operation and effect of the embodiment will be described. In the embodiment, the plunger 3 does not slide-contact with the yoke 4 in its forward/backward moving operation. Consequently, abrasion of the plunger 3 can be suppressed. In the case where the plunger 3 slide-contacts with the yoke 4, to prevent abrasion of the plunger 3, a thin film made of solid lubricant or the like is often formed on the surface of the plunger 3. However, by preventing the plunger 3 from coming into slide-contact with the yoke 4 like in the embodiment, it becomes unnecessary to form a thin film made of solid lubricant. It can reduce the manufacture cost of the plunger 3.

The rest is similar to the first embodiment. The same reference numerals used in the first embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the first embodiment.

Fourteenth Embodiment

In a fourteenth embodiment, the shape of the yoke 4 and the shape of the plunger 3 are changed. As illustrated in FIGS. 44 and 45, the yoke 4 of the embodiment has two contact/separate yokes 415 and 416 which are parallel to each other and two side-wall yokes 43. The first electromagnetic coil 2a is provided in the yoke 4. In each of the contact/separate yokes 415 and 416, in a manner similar to the thirteenth embodiment, the through hole 470 which penetrates in the Z direction is formed.

In the center of the first electromagnetic coil 2a, a pillar-shaped core 59 in which the first and second fixed cores 5a and 5b are integrated is provided. One end part of the pillar-shaped core 59 serves as the first fixed core 5a, and the other end part of the pillar-shaped core 59 serves as the second fixed core 5b.

The second fixed core 5b and the side-wall yoke 43 are connected to each other via the magnetic saturation part 49. The minimum cross area of the magnetic saturation part 49 is smaller than that of the side-wall yoke 43 or the pillar-shaped core 59. When current is passed to the first electromagnetic coil 2a and the first plunger 3a is attracted, the magnetic saturation part 49 magnetically saturates.

As illustrated in FIG. 45, each of the two plungers 3 (3a and 3b) has a plate shape. The first plunger 3a is provided on one of the sides in the axial direction (Z direction) of the pillar-shaped core 59 for the first electromagnetic coil 2a. The second plunger 3b is provided on the other side in the Z direction for the first electromagnetic coil 2a.

As illustrated in FIGS. 47 and 48, the center 350 of the plunger 3 is attracted by the fixed core 5. When the plunger 3 performs the forward/backward moving operation, the outer periphery 365 of the plunger 3 comes into contact with/is apart from the surface of the contact/separate yokes 415 and 416.

As illustrated in FIG. 46, when the first electromagnetic coil 2a is set to the current passage state, the magnetic flux Φ is generated. A part of the magnetic flux Φ flows in the first magnetic circuit C1 made by the pillar-shaped core 59, the first plunger 3a, the contact/separate yoke 415, the side-wall yoke 43, and the magnetic saturation part 49. Another part of the magnetic flux Φ flows in the second magnetic circuit C2 made by the pillar-shaped core 59, the first plunger 3a, the contact/separate yoke 415, the side-wall yoke 43, the other contact/separate yoke 416, and the second plunger 3b.

The magnetic flux Φ flowing in the first magnetic circuit C1 passes through the first gap G1 between the first fixed core 5a and the first plunger 3a and the third gap G3 between the first plunger 3a and the contact/separate yoke 415. The magnetic flux Φ flowing in the second magnetic circuit C2 passes through the above-described two gaps G1 and G3 and, in addition, the fourth gap G4 between the other contact/separate yoke 416 and the second plunger 3b and the second gap G2 between the second plunger 3b and the second fixed core 5b. The number of gaps in the first magnetic circuit C1 is smaller than that in the second magnetic circuit C2. Consequently, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 is large and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small. Therefore, strong magnetic force is generated in the first plunger 3a and, as illustrated in FIG. 47, the first plunger 3a is attracted first.

When the first plunger 3a is attracted, the gaps G1 and G3 disappear, and the magnetic resistance decreases. Due to this, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 increases. Since the magnetic flux Φ of the first magnetic circuit C1 passes through the magnetic saturation part 49, after the magnetic flux Φ increases, magnetic saturation occurs in the magnetic saturation part 49. Therefore, by the magnetic saturation part 49, the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 is regulated and, instead, the amount of the magnetic flux Φ in the second magnetic circuit C2 increases. As a result, the magnetic force generated in the second plunger 3b increases and, as illustrated in FIG. 48, the second plunger 3b is attracted by the second fixed core 5b.

The operation and effect of the embodiment will be described. Since the first and second fixed cores 5a and 5b are integrated, as compared with the case where the first and second fixed cores 5a and 5b are separately formed, the core 5 can be miniaturized. In addition, the number of components can be decreased, so that the manufacture cost of the solenoid device 1 can be reduced.

In the embodiment, since the magnetic saturation part 49 is provided in the first magnetic circuit C1, even when the first plunger 3a is attracted and the magnetic flux Φ of the first magnetic circuit C1 increases, the amount of the magnetic flux Φ can be regulated by the magnetic saturation part 49. Consequently, the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 can be increased, and the second plunger 3b can be reliably attracted.

The rest is similar to the thirteenth embodiment. Unless otherwise described, the same reference numerals used in the thirteenth embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the thirteenth embodiment.

Fifteenth Embodiment

In a fifteenth embodiment, the number of plungers 3 is changed. As illustrated in FIG. 49, the solenoid device 1 of the embodiment has three plungers 3 (3a to 3c). Each of the three plungers 3a to 3c is formed in a plate shape. In the embodiment, the side-wall yoke 43a as one of the two side-wall yokes 43 (43a and 43b) is used as a third fixed core 439. By the third fixed core 349, the third plunger 3c is attracted. The third fixed core 439 is divided into two parts; a first core part 439a and a second core part 439b. When the third plunger 3c moves forward/backward, one end 381 of the third plunger 3c comes into contact with/is apart from the first core part 439a, and the other end 382 comes into contact with/is apart from the second core part 439b.

In the solenoid device 1 of the embodiment, in a manner similar to the fourteenth embodiment, the magnetic flux Φ of the first electromagnetic coil 2a flows in the first and second magnetic circuits C1 and C2. In the embodiment, the magnetic flux Φ flows in the magnetic circuits C1 and C2 and, in addition, the third magnetic circuit C3. The third magnetic circuit C3 is made by the pillar-shaped core 59, the contact/separate yoke 415, the first core part 439a, the third plunger 3c, the second core part 439b, and the magnetic saturation part 49. In a state where the third plunger 3c is not attracted, a fifth gap G5 is formed between the first core part 439a and the third plunger 3c, and a sixth gap G6 is formed between the second core part 439b and the third plunger 3c.

The magnetic flux Φ generated by the passage of current to the first electromagnetic coil 2a flows so as to be split to the three magnetic circuits C1, C2, and C3. When the first electromagnetic coil 2a is switched from the no-current passage state to the current passage state, the magnetic flux Φ of the first magnetic circuit C1 passes through the first and third gaps G1 and G3. The magnetic flux Φ of the second magnetic circuit C2 passes through the four gaps G1, G3, G2, and G4. The magnetic flux Φ of the third magnetic circuit C3 passes through the four gaps G1, G3, G5, and G6. As described above, the number of gaps G in the first magnetic circuit C1 is smaller than that in the second magnetic circuit C2 or the third magnetic circuit C3, Consequently, the large amount of the magnetic flux Φ flows in the first magnetic circuit C1 and the amount of the magnetic flux Φ flowing in the second and third magnetic circuits C2 and C3 is small. Therefore, the first plunger 3a is attracted first.

When the first plunger 3a is attracted, the gaps G1 and G3 disappear, the magnetic resistance decreases, and the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 increases. Since the magnetic flux Φ of the first magnetic circuit C1 passes through the magnetic saturation part 49, after the magnetic flux Φ increases, magnetic saturation occurs in the magnetic saturation part 49. Therefore, by the magnetic saturation part 49, the amount of the magnetic flux Φ in the first magnetic circuit C1 is regulated and, instead, the amount of the magnetic flux Φ in the second and third magnetic circuits C2 and C3 increases. As a result, the magnetic force acting on the second and third plungers 3b and 3c increases, the second plunger 3b is attracted by the second fixed core 5b, and the third plunger 3c is attracted by the side-wall yoke 43a.

The operation and effect of the embodiment will be described. With the configuration, the larger number of the plungers 3 can be moved forward/backward. The attraction direction of the first plunger 3a and that of the second plunger 3b are opposite to each other, and the direction of attracting the third plunger 3c is orthogonal to the attraction directions of the first and second plungers 3a and 3b. Therefore, even if the plungers 3a to 3c swing due to the vibration from the outside when no current is passed to the first electromagnetic coil 2a, the plungers 3a to 3c do not simultaneously come close to the yoke 4. Consequently, for example, in the case where the electromagnetic relay 10 is constructed by the solenoid device 1, switches (not illustrated) which are turned on/off by the plungers 3 can be prevented from being simultaneously turned on.

The rest is similar to the fourteenth embodiment. Unless otherwise described, the same reference numerals used in the fourteenth embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar to those of the fourteenth embodiment.

Sixteenth Embodiment

In a sixteenth embodiment, the number and positions of plungers 3 are changed. As illustrated in FIG. 50, the solenoid device 1 of the embodiment has two plungers 3 (3a and 3b) each formed in a plate shape. In a manner similar to the fourteenth embodiment, the pillar-shaped core 59 is provided in the center of the first electromagnetic coil 2a. The first fixed core 5a is constructed at one end of the pillar-shaped core 59. The other end of the pillar-shaped core 59 is connected to the magnetic saturation part 49.

In the embodiment, the side-wall yoke 43a as one of the two side-wall yokes 43 (43a and 43b) is used as the second fixed core 5b. The second fixed core 5b is made by a first core part 501 connected to the contact/separate yoke 415 and a second core part 502 connected to the magnetic saturation part 49. In a state where the second plunger 3b is not attracted, the second gap G2 is formed between the first core part 501 and the second plunger 3b, and the fourth gap G4 is formed between the second core part 502 and the second plunger 3b.

The magnetic flux Φ generated by the passage of current to the first electromagnetic coil 2a flows so as to be split to the first and second magnetic circuits C1 and C2. The second magnetic circuit C2 of the embodiment is made by the pillar-shaped core 59, the contact/separate yoke 415, the first core part 501, the second yoke 3b, the second core part 502, and the magnetic saturation part 49. When the first electromagnetic coil 2a is switched from the no-current passage state to the current passage state, the magnetic flux Φ of the first magnetic circuit C1 passes through the first and third gaps G1 and G3. The magnetic flux Φ of the second magnetic circuit C2 passes through the second and fourth gaps G2 and G4 in addition to the first and third gaps G1 and G3. As described above, the number of gaps G in the first magnetic circuit C1 is smaller than that in the second magnetic circuit C2. Consequently, the large amount of the magnetic flux Φ flows in the first magnetic circuit C1 and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small. Therefore, the first plunger 3a is attracted first.

When the first plunger 3a is attracted, the first and third gaps G1 and G3 disappear, the magnetic resistance decreases, and the amount of the magnetic flux Φ flowing in the first magnetic circuit C1 increases. Since the magnetic flux Φ of the first magnetic circuit C1 passes through the magnetic saturation part 49, after the magnetic flux Φ increases, magnetic saturation occurs in the magnetic saturation part 49. Therefore, by the magnetic saturation part 49, the amount of the magnetic flux Φ in the first magnetic circuit C1 is regulated and the amount of the magnetic flux Φ in the second magnetic circuit C2 increases. As a result, the magnetic force acting on the second plunger 3b increases, and the second plunger 3b is attracted by the second fixed core 5b.

The operation and effect of the embodiment will be described. In the embodiment, the attraction direction of the first plunger 3a and that of the second plunger 3b are orthogonal to each other. Therefore, even if the plungers 3a and 3b swing due to the vibration from the outside when no current is passed to the first electromagnetic coil 2a, the two plungers 3a and 3b do not simultaneously come close to the fixed cores 5 (5a and 5b), Consequently, in the case where the electromagnetic relay 10 is constructed by the solenoid device 1, switches (not illustrated) which are turned on/off by the plungers 3a and 3b can be prevented from being turned on simultaneously.

Seventeenth Embodiment

In a seventeenth embodiment, the number and positions of plungers 3 are changed. As illustrated in FIG. 51, the solenoid device 1 of the embodiment has two plungers 3 (3a and 3b) each formed in a plate shape. In the seventeenth embodiment, in a manner similar to the sixteenth embodiment, the side-wall yoke 43a as one of the two side-wall yokes 43 (43a and 43b) is used as the second fixed core 5b. The second fixed core 5b is made by the first core part 501 connected to the contact/separate yoke 415, the second core part 502 connected to the magnetic saturation part 49, and a third core part 503 disposed between the first and second core parts 501 and 502.

Between the third core part 503 and the pillar-shaped core 59, an auxiliary yoke 485 is provided. The magnetic saturation part 49 is provided with a plate-shaped member 119 made of resin. A part of the plunger-side spring member 11d of the second plunger 3b is attached to the plate-shaped member 119.

In a state where the second plunger 3b is not attracted, the second gap G2 is formed between the second plunger 3b and the first core part 501, and the fourth gap G4 is formed between the second plunger 3b and the second core part 502. The fifth gap G5 is formed between the second plunger 3b and the third core part 503.

The magnetic flux Φ generated by the passage of current to the first electromagnetic coil 2a flows so as to be split to the first and second magnetic circuits C1 and C2. The second magnetic circuit C2 of the embodiment is made by the pillar-shaped core 59, the first plunger 3a, the contact/separate yoke 415, the first core part 501, the second yoke 3b, the second core part 502, and the magnetic saturation part 49. When the first electromagnetic coil 2a is switched from the no-current passage state to the current passage state, the magnetic flux Φ of the first magnetic circuit C1 passes through the first and third gaps G1 and G3. The magnetic flux Φ of the second magnetic circuit C2 passes through the second and fourth gaps G2 and G4 in addition to the first and third gaps G1 and G3. As described above, the number of gaps G in the first magnetic circuit C1 is smaller than that in the second magnetic circuit C2. Consequently, the large amount of the magnetic flux Φ flows in the first magnetic circuit C1 and the amount of the magnetic flux Φ flowing in the second magnetic circuit C2 is small. Therefore, the first plunger 3a is attracted first.

A part of the magnetic flux Φ flowing in the second magnetic circuit C2 is split in some midpoint, passes through the third core part 503 and the auxiliary yoke 485, and flows in the pillar-shaped core 59.

The operation and effect of the embodiment will be described. In the embodiment, a part of the plunger-side spring member 11d of the second plunger 3b can be attached to the plate-shaped member 119, Consequently, as compared with the case of attaching all of the plunger-side spring member 11d to the surface (curved face) of the first electromagnetic coil 2a as in the sixteenth embodiment (refer to FIG. 50), the plunger-side spring member 11d can be attached more easily at the time of manufacture. Therefore, the solenoid device 1 is manufactured more easily.

The rest is similar to the sixteenth embodiment. Unless otherwise described, the same reference numerals used in the sixteenth embodiment in the reference numerals used for the drawings related to the embodiment refer to components similar, to those of the sixteenth embodiment.

While the present disclosure has been described with reference to embodiments thereof, it is to be understood that the disclosure is not limited to the embodiments and constructions. The present disclosure is intended to cover various modification and equivalent arrangements. In addition, while the various combinations and configurations, other combinations and configurations, including more, less or only a single element, are also within the spirit and scope of the present disclosure.

Number	Date	Country	Kind
2012-044055	Feb 2012	JP	national
2012-253654	Nov 2012	JP	national

Number	Name	Date	Kind
269453	Parker	Dec 1882	A
634912	Richardson et al.	Oct 1899	A
731741	Baxter	Jun 1903	A
946215	Geissinger	Jan 1910	A
2138275	Heinrich	Nov 1938	A
2528777	Persons	Nov 1950	A
20100207713	Sugisawa	Aug 2010	A1

Number	Date	Country
A-2005-222871	Aug 2005	JP
A-2010-212035	Sep 2010	JP
A-2010-287455	Dec 2010	JP
2013-164900	Aug 2013	JP
2013-182701	Sep 2013	JP
2013-182702	Sep 2013	JP

Solenoid device

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