EP0768694B1 - Electromagnetic relay and method for its manufacture - Google Patents

Abstract

The relay incorporates a coil body (2) with flanges (21,22) and a winding (23), a rod-shaped core (31), an angle yoke (33), with a leg (34) joined to the end (31a) of the core and the other leg (35) parallel to the core next to the winding (23), and a movable armature (4) actuating a contact spring (41). The yoke leg (34) in the flange (21) is secured against axial motion and pivoting by means of holding elements, while the core (31) is joined to the side surface of the yoke leg only by its end face (31). The yoke legs (934) are pushed (drawer fashion) into the grooves of the coil flange (21). The core (31) is joined to the yoke leg by means of hard soldering. Alternatively, it is joined to the yoke leg by means of welding. There are two coil bodies (2) (each with a winding, a core, a yoke and an armature arranged in a mirror-image fashion. The two coil bodies are made as a single component with a central double flange and two end flanges. The coil body is mounted on a base (1) incorporating at least one fixed contact carrier (14,15), and at least one spring carrier (17) for each contact spring (41).

Description

• ein Spulenkörper besitzt einen ersten Flansch und mindestens einen zweiten Flansch, wobei zwischen dem ersten und dem zweiten Flansch jeweils eine Wicklung angeordnet ist;
• in dem Spulenkörper ist axial zu jeder Wicklung jeweils ein stabförmiger Kern angeordnet;
• ein abgewinkeltes Joch ist jeweils mit einem ersten Jochschenkel in dem Bereich des ersten Spulenflansches an ein erstes Ende des Kerns gekoppelt, während sich ein zweiter Jochschenkel parallel zum Kern neben der Wicklung erstreckt;
• ein beweglicher Anker verbindet unter Bildung eines Arbeitsluftspaltes jeweils den zweiten Jochschenkel mit dem zweiten Ende des Kerns und
• der Anker betätigt mindestens eine Kontaktfeder, die ihrerseits mit mindestens einem Festkontakt zusammenwirkt.

Außerdem betrifft die Erfindung die Herstellung eines derartigen Relais.The invention relates to an electromagnetic relay with the following features:

• a coil former has a first flange and at least one second flange, a winding being arranged between the first and the second flange;
• a rod-shaped core is arranged axially for each winding in the coil former;
• an angled yoke is coupled with a first yoke leg in the region of the first coil flange to a first end of the core, while a second yoke leg extends parallel to the core next to the winding;
• a movable armature connects the second yoke leg to the second end of the core and to form a working air gap
• the armature actuates at least one contact spring, which in turn interacts with at least one fixed contact.

In addition, the invention relates to the manufacture of such a relay.

Relays with such a general structure are numerous known; they can be designed as single or double relays be (e.g. DE 42 33 807 A1, DE 38 43 359 C2). The connection between the core and the first yoke leg usually by the fact that the core in a bore of the Yoke leg inserted and then by caulking, welding or fixed in some other way. With these usual However, connection techniques must be the connection point for the attack of large holding devices and tools be accessible. This is the case with individual relays, at Double relays, however, led to previous designs two individual magnet systems with coils, Core and yoke made and only after formation of the double relay were connected. For example, it was In these cases, a common bobbin is not possible for two magnet systems in one operation with both To provide windings and then in such a double coil to assemble the iron circle with yokes and cores.

Another problem is for relays of the type mentioned Kind in that the junction between the core and the yoke represents a magnetic resistance in the iron circuit that with the increasing miniaturization of the overall system and the associated reduction in material thicknesses for the yoke and the core increase in importance. For one thing it is important that the material connection between the core and Yoke is as good as possible and also over the life of the relay remains intact, that is, the connection is not external forces acting on the yoke are relaxed. To the another becomes the coupling surface between the core end and one annular recess in the yoke leg with decreasing Material thickness of the yoke increasingly smaller. At a This coupling surface represents sheet thickness of the yoke of less than 1 mm in a yoke hole even if the connection is good both parts represent a significant magnetic resistance.

The aim of the present invention is therefore a relay of the type mentioned at the outset to design and specify a procedure for the connection between the core and the yoke, with which in a simple manner even with low material thicknesses good mechanical and magnetic coupling between Core and yoke is made possible by action external mechanical forces on the yoke neither impaired can still be destroyed. This connection between Kern and yoke should be used with a single relay as well Can also be produced with a double relay without particular difficulty be, even if the connection point from the outside is not accessible to attack larger tools.

According to the invention, this goal is at the beginning of a relay mentioned type achieved in that the first yoke leg against in the first coil flange by holding elements Movement in the axial direction and secured against swiveling and that the core is blunt at its first end the side surface of the first yoke leg butts and only connected to it in a materially integral manner via its end face is.

In the construction according to the invention, the bore is therefore omitted in the first yoke leg to accommodate the core end; much more is this core with its end face on the side surface of the yoke butt-welded or soldered. About these A larger coupling surface is reached between the front Core and yoke than over the yoke bore that has been common until now, since the ring-shaped coupling surface in the bore with very thin material the yoke becomes very small. By the additional Fixation of the yoke by holding elements of the coil flange it also ensures that the welding or A good quality soldered connection during manufacture receives and that this quality of connection also through the Lifetime of the relay is guaranteed because external forces on The yoke is caught by fixing it in the coil flange, can not affect the connection point.

The holder of the first yoke leg in the coil flange is preferably that the first yoke leg with parallel side edges in grooves of the first coil flange is inserted in a drawer-like manner perpendicular to the coil axis. The yoke leg is expediently from three sides caught in grooves of the coil flange, so that only a movement in the direction of insertion is possible up to the stop is.

The connection of core and yoke specified according to the invention is fundamentally also advantageous for individual relays, in particular when using quite thin yoke sheets, for example with a thickness of less than 1 mm. A special But there is an advantage if two bobbins with one winding, one core, one yoke and one Anchors constructed in such a mirror image and connected to each other are that the coil axes are aligned and the first two yoke legs in parallel - under observance an insulation distance - lie together. In this case it is particularly possible to use the two bobbins to form by a one-piece double bobbin, wherein a common first flange as the middle flange the two carries the first yoke leg and the two second flanges as End flanges sit on opposite sides of the relay. There the first two yoke legs of such a double relay with the corresponding core ends for another joining process are not accessible, in this case enables the invention Type of connection only such a relay structure, in which both windings previously on a common Coil formers can be applied and the two Cores subsequently from two opposite sides in the double bobbin are used. It is also there possible to use cores with enlarged pole plates, because the cores from the armature side into the respective coil body be plugged in.

a) das Joch wird jeweils mit seinem ersten Jochschenkel senkrecht zur Spulenachse in Nuten des ersten Spulenflansches eingesteckt;

b) der jeweilige Kern wird in Axialrichtung in den Spulenkorper eingesteckt, bis sein erstes Ende mit der Stirnflache an die Seitenoberfläche des ersten Jochschenkels anstößt; und

c) durch Anlegen einer Spannung zwischen dem Joch und dem Kern werden die beiden Elemente an ihrer Stoßstelle durch Widerstandserwärmung stoffschlüssig verbunden.

A method for producing a relay according to the invention essentially comprises the following steps:

a) the yoke is inserted with its first yoke leg perpendicular to the coil axis in grooves of the first coil flange;

b) the respective core is inserted in the axial direction into the coil former until its first end abuts the side surface of the first yoke leg with its end face; and

c) by applying a voltage between the yoke and the core, the two elements are integrally connected at their joint by resistance heating.

This procedure is also analogous for the double relay mentioned applicable, in which case the first two yoke legs parallel in corresponding grooves of the middle flange be inserted and preferably these first two yoke legs through an interposed contact plate be placed on a first sweat potential while the two cores connected in parallel to a second welding potential become. In this way, the two core-yoke connections be produced at the same time. Conveniently, the welding current is dimensioned so that between a kind of hard soldering to the respective core and the respective yoke arises, whereby a surface coating of the parts with copper, silver or another brazing material Connection forms. There is essentially no additional Effort, since the iron parts normally anyway coated with copper or the like as corrosion protection become. All metals can be used with Alloy iron and have a lower melting point than iron have, for example around 1000 ° C or lower. The Layer thickness of the brazing material on the surface of the The core or yoke is usually between 4 and 6 around. The contacting plate mentioned does not weld the two yoke legs as it is a very large one Forms contact surface; after welding or Brazing easily pulled out of the middle flange become.

Finally, it should be mentioned that the arrangement of the two switching systems with cores aligned with each other and closely spaced first yoke legs that pass through the type of core-yoke connection possible is also a close magnetic coupling of the two switching systems he follows. This magnetic coupling can also be used of the double relay can be used. If, for example the two excitation coils are wound and excited so that the magnetic fluxes through both cores are in series the excitation of one magnet system also the response the other, so that overall the responsiveness of the Double relay is improved. In certain cases, the mutual influence also by correspondingly opposite Excitation can be exploited.

Figur 1

ein erfindungsgemäß gestaltetes Doppelrelais in perspektivischer Darstellung (ohne Kappe),

Figur 2

die Einzelteile des Relais von Figur 1 in Explosionsdarstellung,

Figur 3

einen Längsschnitt durch die Kerne und Joche des Doppelrelais gemäß Figur 1 oder 2 mit einer schematisch gezeigten Schweißanordnung,

Figur 4

einen Schnitt durch das Relais von Figur 1 entlang seiner Spiegelebene,

Figur 5

einen senkrechten Schnitt durch das Relais von Figur 1 und

Figur 6

einen waagerechten Schnitt durch das Relais von Figur 1.

The invention is explained in more detail below using exemplary embodiments with reference to the drawing. It shows:

Figure 1

a double relay designed according to the invention in a perspective view (without cap),

Figure 2

the individual parts of the relay of Figure 1 in an exploded view,

Figure 3

2 shows a longitudinal section through the cores and yokes of the double relay according to FIG. 1 or 2 with a schematically shown welding arrangement,

Figure 4

2 shows a section through the relay of FIG. 1 along its mirror plane,

Figure 5

a vertical section through the relay of Figure 1 and

Figure 6

a horizontal section through the relay of Figure 1.

The relay shown in Figures 1 and 2 has one Socket 1, on which two switching systems A and B are mirror-symmetrical to a in Figure 1 by the coordinates x and z defined symmetry plane are arranged. Because in the two Switching systems A and B all parts either mirror symmetrical are arranged or designed mirror-symmetrical and the have the same function, the same reference numerals for both switching systems used.

The base 1 is essentially designed as a flat plate, which defines a bottom side 11; on this is vertical a projection 12 is formed on top, the labyrinthine is designed to plug channels 13 for two pairs of fixed contact carriers 14 and 15 and plug-in channels 16 for two spring supports 17 to form. The fixed contact carriers and the spring carriers connect to the bottom of the base with pins 1 off. The fixed contact carrier 14 carries an NC contact 14a, while the fixed contact carrier 15 with a Normally open contact 15a is provided. Each of the two spring supports 17 has a solder tab 17a bent to the side.

A double bobbin 2 is arranged on the base. He has one in the plane of symmetry between the two switching systems horizontal center flange 21 and two end flanges 22, each between the center flange and each of the end flanges a winding 23 is arranged. Each of the end flanges 22 has on the spring supports 14 and 15 facing away Page a flange 24 with two coil pins anchored therein 25. Inside each winding is 23 a core 31 with a pole plate from the outside into the coil former 32 inserted so that the pole plate 32 partially in a recess of the end flange 22; to the flange approach 24 the pole plate is cut on one side. Farther each switching system has an angled yoke 33 with a first yoke leg 34 and a second yoke leg 35, both with their planes perpendicular to each other and stand perpendicular to the bottom side 11. The first two yoke legs 34 are parallel to each other in a lateral opening 26 of the middle flange 21 inserted (see also FIG 6). This opening 26 in the central web has a circumferential one Center web 27, whereby one for each of the yoke legs 34 three sides circumferential edge groove 28 is formed, in which the respective yoke leg 34 is inserted like a drawer.

At the same time, the thickness of the web 27 makes the insulation distance ensured between the two yoke legs 34.

An approximately plate-shaped anchor 4 stands with its main plane also perpendicular to the bottom side 11; he is in the present Example only in adaptation to the bobbin shape slightly cranked. The anchor 4 is on the free end edge 35a of the second yoke leg 35, without with the yoke over a bearing spring or the like to be connected. The anchor is stored and held rather via a contact spring 41, which has an end portion 41a rests laterally on the anchor and over a or two rivets 42 is connected to the anchor. Starting from the end portion 41a is the contact spring 41 toward the free end of the anchor is split in a fork shape and thus forms a contact leg 43 with a movable center contact 43a and a connecting leg 44. All sections of the cranked and bent contact spring 41 are perpendicular to Bottom side 11, so that the contact leg 43 essentially lies above the connecting leg 44. On the connecting leg 44 is a fastening portion approximately perpendicular 45 bent, the hook-shaped at its free end inwardly curved spring tab 46 carries. The fastening section 45 is between a vertical insulating wall 18 of the Base approach 12 on the one hand and the soldering tab 17a of the spring support 17 inserted and to the approach 12 of the base 1 with the spring tab 46 clamped. In addition, the soldering tab 17a each conductively connected to the fastening section 45, preferably soldered or welded.

The function of the two switching systems of the double relay is easily seen. When the respective coil is excited 23 the associated armature 4 becomes the associated pole plate 32 attracted, he moving the contact leg 43 Middle contact 43a from the normally closed contact 14a to the normally open contact 15a switches. Both switching systems can be used individually or operated together. Of course it is also possible Both switching systems can be used together as reversing polarity relays. In this case, the two spring supports 17, as in Figure 2 shown, stay connected and the break contact carrier 14 and the two NO contact carriers 15 each be connected to each other externally.

In the manufacture of the relay described first the base 1 is equipped with the contact carriers. You can the fixed contact carrier 14 and 15 for both switching systems cut from a band in pairs and in their final shape will be bent. Preferably be both pairs of fixed contact carriers 14 and 15 in simultaneously the base inserted and only then separated. The two too Spring carriers 17 for both switching systems are preferred used contiguously in the base 1 and only then the separation point 143 separated from each other.

When assembling the two cores, they become, as in Figure 3 shown, inserted into the bobbin 2, so that the respective core with its inner end face 31a on the flat side of the yoke leg 34 abuts. Then over the respective yoke 33 and the respective core 31 a welding current conducted at the point of contact by resistance heating welding or brazing the two Parts causes. In this brazing process the serves as Surface coating already available copper coating of core and / or yoke as braze. This way there is an almost gap-free connection between the core and the yoke, which minimizes the magnetic resistance. The intended butt welding of the core to the Yoke leg 34 is particularly advantageous if the yoke is made of a thin and space-saving sheet, for example with a thickness of <1 mm. The one there effective magnetic saturation values for thin sheets also has a positive effect on the magnetic circuit.

This type of butt welding or soldering on the core can therefore be carried out in the relay according to the invention, because the first yoke leg 34 in the grooves 28 of the central flange 21 guided and kept stable. Because the core 31 itself is also held in the bobbin, the Junction 36 (see Figures 5 and 6) by no leverage loaded so that the butt solder joint is not is endangered. Otherwise, the two core-yoke connections be produced at the same time. To this end is in the insulating gap between the first two yoke legs 34 introduced a contact plate 37, which with the a pole of the welding power source is connected. One connects then the two cores in parallel with the other via electrodes 38 Pole of the welding power source, so the two connection points 36 welded or brazed at the same time become. The contact plate 37 is then again from the Pulled out bobbin. The one with the seeds and yokes Coil body 2 is positioned on the base, whereby Holding lugs 29 on the central flange 21 and on the flange attachments 29 in correspondingly undercut recesses 19 of the base.

The two anchors 4 with the mirror-image bent contact springs 41 are inserted into the base after the coil former, the fastening section 45 of the respective contact spring between the insulating wall 18 and the soldering tab 17a inserted by means of the spring tab 46 on the neck 12 of the Base is clamped. Preferably, the solder tab is 17a on the side facing the fastening section 45 provided with a tin coating 17b so that it can be coated with a Heat source to the attachment portion 45 of the contact spring 41 can be soldered. This is done, for example using a TIG arc. But one would also be possible Soldering or welding connection using a laser or using a other heat source.

Since the free ends of the fixed contact carrier 14 and 15 with the Fixed contacts 14a and 15a via the connecting leg 44 or the fastening section 45 of the contact spring protrude, they are easily accessible for any necessary bend adjustment.

As already stated at the beginning, the method according to the invention can be used Construction not only as a double relay, but also also run as a single relay. For this purpose only needs the described construction of the double relay along the mirror plane, as indicated in Figure 1, halved become. Such a section is shown in FIG. 4. For completion it is only the resulting single relay necessary, the halved base and the halved bobbin to adjust on the cutting side, so that also with one the half-sized housing cap the closed Individual relay is created. The remaining parts can be left unchanged can also be used for the single relay, so that there is a own description unnecessary.

Claims (11)

1. An electromagnetic relay having the following features:

   a coil body (2) has a first flange (21) and at least one second flange (22), a winding (23) being arranged between the first and the second flange in each case;

   a rod-shaped core (31) is arranged in the coil body (2), axially with respect to each winding (23);

   an angled yoke (33) is coupled in each case by a first yoke limb (34) in the region of the first coil flange to a first end (31a) of the core, while a second yoke limb (35) extends next to the winding (23) parallel to the core;

   a movable armature (4) connects the second yoke limb (35) to the second end (32) of the core (31) in each case, forming an operational air gap; and

   the armature (4) actuates at least one spring contact (41) which in turn cooperates with at least one fixed contact (14a, 15a),

      characterised in that the first yoke limb (34) is secured in the first coil flange (21) by holding elements (27) to prevent movement in the axial direction and to prevent pivoting, and in that the core (31) butts by means of its first end (31a) against the lateral surface of the first yoke limb (34) and is materially connected thereto only by way of its end face (31a).
2. A relay according to Claim 1, characterised in that the first yoke limb (34) is inserted in the manner of a drawer by means of parallel side edges into grooves (28) in the first coil flange (21), perpendicular to the coil axis.
3. A relay according to Claim 1 or 2, characterised in that the core (31) is hard soldered to the first yoke limb (34).
4. A relay according to Claim 1 or 2, characterised in that the core (31) is welded to the first yoke limb (34).
5. A relay according to one of Claims 1 to 4, characterised in that two coil bodies each having a winding (23), a core (31), a yoke (33) and an armature (4) are constructed in a mirror-image arrangement and connected to one another such that the coil axes are flush with one another and the two first yoke limbs (34) abut against one another in parallel arrangement, while maintaining an insulating spacing.
6. A relay according to Claim 5, characterised in that the two coil bodies are formed by a one-piece double coil body (2), with a common first flange (21) as the centre flange carrying the two first yoke limbs (34) and with the two second flanges (22) being seated on opposing sides of the relay as end flanges.
7. A relay according to Claim 5 or 6, characterised in that the two first yoke limbs (34) are secured such that they may be inserted into parallel grooves (28), separated from one another by a peripheral web, in the centre flange (21).
8. A relay according to one of Claims 1 to 7, characterised in that each coil body (2) is secured to a header (1) in which at least one fixed contact carrier (14, 15) and at least one spring carrier (17) for each spring contact (41) are anchored.
9. A process for manufacturing a relay according to one of Claims 1 to 8, having the following steps:

   a) the yoke (33) is inserted in each case by means of its first yoke limb (34) perpendicular to the coil axis into grooves (28) in the first coil flange (21);

   b) each core (31) is inserted into the coil body (2) in the axial direction until its first end (31a) abuts by means of the end face against the lateral surface of the first yoke limb (34); and

   c) by applying a voltage between the yoke (33) and the core (31) the two elements are materially connected at their point of abutment (36) by resistance heating.
10. A process according to Claim 9, characterised in that with the mirror-image arrangement of two yokes (33) and two cores (31) in a double coil body (2) the two first yoke limbs (34) are inserted in parallel arrangement and spaced into corresponding grooves (28) in the centre flange (21), in that the two cores (31) are inserted into the coil body (2) from opposing sides, in that by way of an interposed contact-making plate (37) a first potential is then applied across the two first yoke limbs (34) and by way of electrodes (38) a second potential is applied across the two cores (31) in parallel arrangement.
11. A process according to Claim 9 or'10, characterised in that by appropriately dimensioning the current flow through the points of abutment (36) of the core and the yoke in each case hard soldering is produced, with a surface coating of the core (31) and/or the yoke (33) with a material of correspondingly low melting point serving as the hard solder.

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