WO2020216321A1 - 继电器线圈组件 - Google Patents

继电器线圈组件 Download PDF

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Publication number
WO2020216321A1
WO2020216321A1 PCT/CN2020/086644 CN2020086644W WO2020216321A1 WO 2020216321 A1 WO2020216321 A1 WO 2020216321A1 CN 2020086644 W CN2020086644 W CN 2020086644W WO 2020216321 A1 WO2020216321 A1 WO 2020216321A1
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WO
WIPO (PCT)
Prior art keywords
coil
yoke
static
slot
relay
Prior art date
Application number
PCT/CN2020/086644
Other languages
English (en)
French (fr)
Inventor
姚茂松
陈帅
魏连贵
彭文超
Original Assignee
厦门宏发汽车电子有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201920579850.XU external-priority patent/CN209843619U/zh
Priority claimed from CN201910338696.1A external-priority patent/CN110459439B/zh
Priority claimed from CN201910339071.7A external-priority patent/CN110459435A/zh
Priority claimed from CN201910338684.9A external-priority patent/CN110473743B/zh
Priority claimed from CN201910338719.9A external-priority patent/CN110459438A/zh
Application filed by 厦门宏发汽车电子有限公司 filed Critical 厦门宏发汽车电子有限公司
Priority to EP20794801.9A priority Critical patent/EP3961669A4/en
Priority to US17/605,957 priority patent/US11929224B2/en
Publication of WO2020216321A1 publication Critical patent/WO2020216321A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/44—Magnetic coils or windings
    • H01H50/443—Connections to coils
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F5/00—Coils
    • H01F5/04—Arrangements of electric connections to coils, e.g. leads
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
    • H01H50/041—Details concerning assembly of relays
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/14—Terminal arrangements
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/16—Magnetic circuit arrangements
    • H01H50/18—Movable parts of magnetic circuits, e.g. armature
    • H01H50/24—Parts rotatable or rockable outside coil
    • H01H50/28—Parts movable due to bending of a blade spring or reed
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/04—Mounting complete relay or separate parts of relay on a base or inside a case
    • H01H50/041—Details concerning assembly of relays
    • H01H2050/046—Assembling parts of a relay by using snap mounting techniques
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/44—Magnetic coils or windings
    • H01H2050/446—Details of the insulating support of the coil, e.g. spool, bobbin, former
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
    • H01H50/00—Details of electromagnetic relays
    • H01H50/02—Bases; Casings; Covers
    • H01H50/021—Bases; Casings; Covers structurally combining a relay and an electronic component, e.g. varistor, RC circuit

Definitions

  • the invention relates to the field of relay technology.
  • a relay is an electronic control device, which has a control system (also called an input loop) and a controlled system (also called an output loop). It is usually used in automatic control circuits. It actually uses a smaller current to control a larger An “automatic switch" of current. Therefore, it plays the role of automatic adjustment, safety protection, and conversion circuit in the circuit.
  • the Relays usually include coil components.
  • the coil components include a coil frame, enameled wire and coil pins.
  • the coil frame has a winding window.
  • the enameled wire is wound on the winding window of the coil frame.
  • the coil pins are mounted on the coil frame.
  • a part of the leg structure extends into the winding window of the coil frame to connect with the enameled wire, and the other part of the coil pin structure extends outside the coil frame to connect with the drive signal (ie control signal) , To make the enameled wire work under the driving signal.
  • the structure of the coil pin to connect with the drive signal is designed as a pin.
  • the introduction of the drive signal is a slot structure.
  • the pin of the coil pin of the coil component is matched with the slot structure to connect the drive signal to the enameled wire; the other is to use the coil pin to communicate with the drive signal.
  • the connected structure is designed as a welding pin, and the introduction of the drive signal is a signal wire.
  • Another relay includes a magnetic circuit part and a base.
  • split riveting or hot riveting is usually used to prevent the magnetic circuit part from exiting after being installed in the base.
  • split riveting the yoke installed with the coil is inserted into the through hole of the base, and then the end of the metal part (ie the yoke) is split to prevent the magnetic circuit part from withdrawing from the base.
  • the splitting position is easy to rust and oxidize, which will affect the normal use of the relay;
  • the coil frame is used to install the base, and the press-in part (ie the coil frame) is on the front or back Hot-melt the plastic part of the press-in part to deform and expand the plastic, so as to ensure that the coil frame will not return after being installed in the base.
  • the use of hot riveting technology cannot achieve over-travel adjustment in the automated assembly process, and it cannot Realize the correction-free problem in the automated assembly process.
  • Another type of relay includes a housing, a base, a coil assembly, an iron core, a yoke, an armature, a moving spring, and a static spring.
  • the coil assembly is horizontally mounted on the base, which is equivalent to the iron core of the coil frame of the coil assembly.
  • the axis of the mounting hole is arranged horizontally, the iron core is mounted in the iron core mounting hole of the bobbin of the coil assembly, the end face of the first end (ie the head) of the iron core is set as the pole face, and the yoke is L-shaped, One side of the yoke is fixed to the second end (ie the tail) of the iron core, and the other side of the yoke is fitted to the winding window on the upper side of the coil frame of the coil assembly.
  • the moving spring is also L-shaped.
  • One side of the reed is fixed to the yoke on the other side of the yoke, the other side of the movable reed is fixed to the armature, the upper part of the armature fits at the knife edge of the end of the other side of the yoke, and the armature or
  • the upper end of the movable spring is higher than the upper side of the other side of the yoke, the shell is installed on the base and the coil assembly, the iron core, the yoke, the armature and the movable spring are contained in the shell.
  • Another type of relay is an electronic control device, which is an electrical appliance that causes the controlled quantity to undergo a predetermined step change in the electrical output circuit when the input quantity (excitation quantity) changes to meet the specified requirements.
  • the coil With the help of the electromagnetic device installed in the relay, the coil generates a magnetic field by passing a small current to the coil. The generation or disappearance of the magnetic field attracts or releases the armature, thereby driving the movable contact and the static on the movable contact bridge. The static contact on the spring terminal is closed or opened to realize the control of high current operation.
  • the existing relays after the contacts of the relay are closed, there is no corresponding detection component to detect whether the contacts are conductive.
  • the number of contact openings and closings of the relay also has a certain life requirement, and the existing relay does not count the number of contact openings and closings of the relay. When the number of failures is reached, the accurate application of the relay will be affected.
  • Another type of electromagnetic relay is equipped with two static springs (as load terminals) on the base, each static spring is provided with a static contact, the coil in the magnetic circuit part is horizontally mounted on the base, and one end of the iron core is set It is the pole face, the other end of the iron core is fixed to the yoke, the yoke is L-shaped, except for the first part of the L-shaped yoke fixed to the other end of the iron core, the second part of the L-shaped yoke is Disposed beside the coil (that is, outside the winding window of the bobbin), the end of the L-shaped second part of the yoke is used as the knife edge of the yoke to match the armature, and the flexible moving spring is also bent into a roughly L-shape.
  • the L-shaped first part of the moving spring is fixed with the L-shaped second part of the yoke, and the L-shaped second part of the moving spring is fixed with the armature, so that the armature can be attracted by the blade of the yoke as the axis of rotation.
  • the second part of the L-shaped movable spring is provided with a bridge piece, and both ends of the bridge piece are provided with a movable contact to bridge the static contacts on the two static springs.
  • the purpose of the present invention is to overcome the shortcomings of the prior art and provide a relay coil assembly.
  • By improving the structure of the relay coil assembly the problem of welding and fixing the coil pins and signal wires of the relay coil assembly in the prior art is avoided. Disadvantages, and can ensure the solid reliability of the connection between the signal line and the coil pin of the relay coil assembly.
  • a relay coil assembly including a coil frame, enameled wire, coil pins and signal wires; the two ends of the coil frame are respectively provided with flanges, between the two flanges
  • the winding window constituting the coil frame, the enameled wire is wound in the winding window;
  • the coil pin includes a plug-in portion, an enameled wire fixing portion and a signal wire fixing portion, and the coil pin is inserted through the plug-in portion A flange at one end of the coil former;
  • the signal wire fixing part is provided with a first slot with a downward opening; the signal wire is clamped in the first slot; the first slot
  • One of the two sides of the groove wall is provided with a barb near the edge of the opening, and one of the two sides of the groove wall of the first card groove is also provided at a matching position corresponding to the signal line
  • the inclined surface section is used to squeeze the signal line against the outside of the one side of
  • the signal wire is clamped in the first slot of the coil pin, the signal wire is fixed to the coil pin by welding.
  • the groove wall provided with the inclined surface section and the groove wall provided with the barb are the same side groove wall, and the other side groove wall of the first groove is set as a straight wall.
  • the barb is one.
  • barbs There are two or more barbs, and the two or more barbs are arranged in order from the edge of the opening inward.
  • the coil pin also includes an electronic component fixing portion, the electronic component fixing portion is provided with a second slot with a downward opening; and the second slot is provided on the side of the first slot .
  • the straight wall of the first card slot is closer to the second card slot than the slot wall of the slope section of the first card slot.
  • the coil pin has a sheet-shaped structure; the axis of the iron core mounting hole of the coil former is horizontally arranged; the middle and upper part of the coil pin is the plug-in part and fits with the flange at one end of the coil former
  • the lower part of the coil pin is the signal wire fixing part and the electronic component fixing part; the middle part of the coil pin extends to one side to form the enameled wire fixing part, and the coil pin is inserted in the coil
  • the frame is bent to the winding window of the coil frame.
  • the enameled wire fixing part of the coil pin is also provided with a first tooth-shaped structure that is convenient for positioning and winding the enameled wire.
  • the plug-in portion of the coil pin is also provided with a second tooth-shaped structure for achieving interference fit with the matching slot of the coil former.
  • one of the groove walls on both sides of the first slot of the coil pin is provided with a barb near the edge of the opening, one of the groove walls on both sides of the first slot
  • the mating position of the side groove wall corresponding to the signal line is also set as a slope section that gradually increases the opening from the inside to the outside, so as to use when applying force to the outside of one of the side groove walls with barbs.
  • the inclined surface section squeezes the signal line in the first slot and uses the barb to prevent the signal line from falling out.
  • the structure of the present invention is equivalent to forming a triangular area through the bevel treatment in the first slot, and the flexible signal line is pressed into the first slot from the opening of the first slot along the edge of the barb.
  • the signal line is clamped in the first slot of the coil pin, the signal line is fixed to the coil pin by welding.
  • the structure of the present invention forms a double insurance of clamping and welding, no virtual welding occurs, and the connection between the signal line and the coil pin is more reliable.
  • the enameled wire fixing part of the coil pin is also provided with a first tooth-shaped structure which is convenient for positioning and winding the enameled wire.
  • the structure of the present invention uses the first tooth-shaped structure to control the starting position of the first coil of enameled wire. When the enameled wire is wound and then bent, the enameled wire can be prevented from overlapping with the coil frame and the enameled wire is prevented from being jammed.
  • the present invention also provides a high-current relay with adjustable over-travel.
  • a high-current relay with adjustable over-travel.
  • the high-current relay with adjustable over-travel of the present invention includes a coil former, a moving spring armature component and a base; the axis of the iron core mounting hole of the coil former is horizontally arranged, and two flanges are respectively provided at both ends of the coil former.
  • a winding window is formed between the movable spring armature component and the coil frame, and the movable contact of the movable spring armature component is in a mating state with the stationary contact on the outside of one end of the coil frame;
  • the flange at one end is provided with a first hook member downward, the corresponding position of the base is provided with a first clamping hole, and the first hook member of the coil former is fitted in the first clamping hole of the base to include the coil former and the moving spring armature
  • the integral part of the component is restricted along the vertical direction and the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the first hole, and there is a movable first part along the axis of the iron core mounting hole.
  • the flange at the other end of the coil former is downwardly provided with a second hook member
  • the corresponding position of the base is provided with a second clamping hole
  • the second hook member of the coil former is fitted in the second clamping hole of the base
  • the integral part is restricted along the vertical direction and the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the second clamping hole, and there is movable along the axis of the iron core mounting hole
  • the second gap thereby using the first gap and the second gap to achieve the adjustment of the contact overtravel.
  • first hook member There is one first hook member, and the first hook member is provided directly below the axis of the iron core mounting hole; there are two second hook members, and the two second hook members are symmetrically provided on the iron core The two sides directly below the axis of the mounting hole.
  • the first hook member includes two hooks facing opposite directions and a first avoiding groove between the two hooks that enables the corresponding hook to swing elastically; the hook heads of the two hooks respectively face the iron core mounting hole The two sides directly below the axis.
  • a first step with a step surface facing down is respectively provided at the bottom of the first hole at the position corresponding to the hook head; the upper part of the first hook member is provided with fins for preventing overpressure on both sides.
  • the first hook part is in transitional fit with the two opposite hole walls of the first snap hole along the horizontal direction perpendicular to the axis of the iron core mounting hole, so that the integral part corresponds to the first
  • the position of the clamping hole is restricted along the horizontal direction perpendicular to the axis of the iron core mounting hole.
  • the second hook component includes a hook whose hook head faces the outside of the bobbin and a second avoiding groove arranged beside the hook so that the hook can elastically swing in the direction of the bobbin.
  • the bottom of the second locking hole is provided with a second step facing down at the position corresponding to the hook head; the upper part of the second hook member is provided with a third step facing down to prevent overpressure.
  • a step when the second hook member is fitted into the second hole, the hook of the second hook member is hooked at the second step of the second hole, and the third step of the second hook member abuts on the second hole On the base of the edge beside the hole edge, the integral part is vertically limited at the position corresponding to the second hole.
  • the second hook part is in transitional fit with the two opposite hole walls of the second snap hole along the horizontal direction perpendicular to the axis of the iron core mounting hole, so that the integral part is in a corresponding position
  • the position of the clamping hole is restricted along the horizontal direction perpendicular to the axis of the iron core mounting hole; of the two opposite hole walls of the second clamping hole along the horizontal direction perpendicular to the axis of the iron core mounting hole
  • One is also set as a wave-shaped wall surface, so that after the first gap and the second gap are used to adjust the contact over-travel, the heat-melting treatment between the wave-shaped wall surface of the second hole and the second hook member is performed, Fix the second hook part and the base together, so that the integral part is simultaneously restricted along the axis of the core mounting hole and the horizontal direction perpendicular to the axis of the core mounting hole at the position corresponding to the second locking hole.
  • the wavy wall surface is used to realize the fine adjustment of the integral part along the horizontal direction
  • the yoke is provided with mounting feet, the mounting feet of the yoke and the second hook member are fitted in the second clamping hole, and the mounting feet of the yoke Relative to the second hook member, it is closer to directly below the axis of the iron core mounting hole; of the two opposite hole walls of the second locking hole along the horizontal direction perpendicular to the axis of the iron core mounting hole One is farther away from the other directly below the axis of the iron core mounting hole.
  • the flange of one end of the coil former is provided with the first hook member downwards, the corresponding position of the base is provided with the first clamping hole, and the first hook member of the coil former is fitted in the first clamping hole of the base.
  • the integral part including the coil former and the moving spring armature component is restricted along the vertical direction and the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the first locking hole, and along the iron core mounting hole
  • the structure of the present invention not only realizes the hooking and fixing between the bobbin and the base, avoids
  • one first hook member is provided, and the first hook member is provided directly below the axis of the iron core mounting hole; the second hook member is provided two, and the two second hook members are symmetrically arranged The two sides directly below the axis of the iron core mounting hole.
  • the first hook component is designed to include two hooks facing opposite directions and a first avoiding groove between the two hooks so that the corresponding hook can swing elastically; the hook heads of the two hooks are respectively facing The two sides directly below the axis of the iron core mounting hole; the second hook component is designed to include a hook head facing the other end of the coil former and facing the hook outside the coil former, and a hook set beside the hook so that the hook A second escape groove capable of elastically swinging in the direction of the bobbin.
  • one of the two opposite hole walls along the horizontal direction perpendicular to the axis of the iron core mounting hole of the second clamping hole is also set as a wave-shaped wall surface.
  • one side wall of the second card hole is designed into a wave-shaped structure, and the second hook member is thermally melted after the overtravel is adjusted.
  • the hot melt of the second hook member fills the wave-shaped surface . It can be realized that the integral part is simultaneously restricted along the axis of the core mounting hole and the horizontal direction perpendicular to the axis of the core mounting hole at the position corresponding to the second clamping hole. At the same time, the wavy surface can increase the first The mating area of the hot melt between the two card holes and the hook increases the fixing strength.
  • the present invention also provides a relay that can ensure the normal operation of the armature. Through structural improvement, the phenomenon that the armature or the moving reed is stuck is avoided, and the normal operation of the armature or the moving reed can be ensured, thereby ensuring the normal use of the relay.
  • the relay capable of ensuring the normal operation of the armature or the moving reed of the present invention includes a housing, a base, a coil assembly, an iron core, a yoke, an armature and a moving reed; the coil assembly is horizontally mounted on the base, and the iron core is mounted on the coil In the iron core mounting hole of the assembly, the end face of the first end of the iron core is set as the pole face; the first part of the yoke is fixed to the second end of the iron core, and the second part of the yoke is fitted on the top of the coil assembly ,
  • the first end of the moving spring is fixed with the second part of the yoke, and the second end of the moving spring is fixed with the armature, and the armature corresponds to the pole face of the iron core and the upper part of the armature is adapted At the knife edge of the yoke, and the upper end of the armature is higher than the upper surface of the second part of the yoke and
  • the housing in the side walls corresponding to the axis of the core mounting hole of the coil assembly, there are further limiting ribs that can fit on both sides of the second part of the yoke, and There is a preset gap between the limiting rib and the corresponding side of the second part of the yoke to prevent the magnetic circuit part including the yoke from moving in the preset direction.
  • the yoke is L-shaped, and the L-shaped side of the yoke serves as the first part of the yoke, which is fixed to the second end of the iron core, and the other side of the L-shaped yoke serves as the The second part of the yoke is fitted on the upper side of the coil assembly; the moving reed is L-shaped, and the L-shaped side of the moving reed serves as the first part of the moving reed, The first part is fixed to the yoke on the upper surface of the second part of the yoke, and the other side of the L-shape of the moving spring is used as the second part of the moving spring, and the second part is fixed to the armature.
  • the two sides of the end of the second part of the yoke are respectively provided with protruding columns extending outward, and a knife edge of the yoke is formed between the two protruding columns;
  • the upper part of the armature is provided with first Grooves, the first grooves on both sides of the upper part of the armature are respectively matched with the two protruding posts at the end of the second part of the yoke, so that the upper part of the armature fits on the yoke Of the knife.
  • the top end of the armature is provided with a second groove, and the first part of the movable reed crosses the second groove of the top end of the armature so that the upper end of the armature is higher than the second part of the yoke The top and moving reed.
  • the first part of the moving spring is also provided with a stopper for limiting the top of the armature, so as to limit the upper part of the armature at the knife edge of the yoke.
  • the two sides of the end of the second part of the yoke are respectively provided with protruding columns extending outward, and a knife edge of the yoke is formed between the two protruding columns; shoulders are respectively provided on both sides of the upper part of the armature The shoulders on both sides of the upper part of the armature are respectively matched with the two protruding posts at the end of the second part of the yoke, so that the upper part of the armature fits at the knife edge of the yoke.
  • the first part of the movable leaf spring straddles the top end of the armature so that the upper end of the movable leaf spring is higher than the upper surface of the second part of the yoke and the armature.
  • the inner surface of the top of the housing is also provided with a downwardly protruding protrusion that can abut against the upper surface of the second part of the yoke, and the bottom surface of the protrusion and the yoke
  • the distance between the upper surface of the second part of the iron is smaller than the distance between the top inner surface of the housing and the upper end of the armature or the movable spring.
  • the present invention there are three protrusions on the inner side of the top of the housing, and they are distributed in a triangle.
  • the structure of the present invention can ensure that the top of the housing is in smooth contact with the yoke when it is deformed under force, and the housing will not contact the armature or the movable reed, and the normal operation of the armature or the movable reed is ensured.
  • the side walls corresponding to the axis of the core mounting hole of the coil assembly are also provided with limiting ribs that can fit on both sides of the second part of the yoke And there is a preset gap between the limiting rib and the corresponding side of the second part of the yoke.
  • the structure of the present invention can prevent the movement of the magnetic circuit part including the yoke in the preset direction.
  • the high-current relay with signal monitoring of the load terminal of the present invention includes a core part and a base; the core part includes a magnetic circuit part and a moving spring armature part operated by the magnetic circuit part; the base includes two A static spring and a plastic body that insulates the two static springs together by injection molding; the static spring is provided with a static contact; the movement part is installed on the base and makes the movement spring armature part of the movement part
  • the moving contact of the static spring is matched with the static contact of the static spring, so that when the contact is closed, the current flows in from the load terminal of one static spring and flows out from the load terminal of the other static spring;
  • the two static springs are also equipped with one A convex part that protrudes upward and is not covered by the plastic body, and a signal line is respectively connected to the convex parts of the two static springs to realize the signal collection of the contact closed state and the number of contact opening and closing times .
  • the moving spring armature part includes a bridge piece and moving contacts arranged at both ends of the bridge piece;
  • the static spring is a sheet-shaped structure including horizontally buried in the main body of the plastic body, bent to be exposed on the plastic body
  • the upper contact part and horizontally exposed on the side of the plastic body are used as the connection part of the load terminal.
  • the static contact is provided at the contact part; the two ends of the bridge piece of the core part are connected with the two static springs respectively.
  • the contact portion corresponds; the convex portion is provided on the main body of the static spring.
  • a metal conductive sheet is also provided between the signal line and the convex portion of the static spring, the metal conductive sheet is provided with a first through hole, and the first through hole of the metal conductive sheet is fitted to the convex portion of the static spring And connect them by welding or riveting.
  • Each end of the two signal wires is connected to a corresponding metal conductive sheet, and each other end of the two signal wires is connected to a connector, and is connected to a control module outside the relay through the connector.
  • the convex part of the static spring and the main part of the static spring are an integral structure, and are formed by tapping the main part of the static spring upward from the bottom surface.
  • a relief area is provided on the periphery of the convex portion corresponding to the two static springs, and the convex portions of the two static springs are respectively sleeved with springs, and the springs are in the corresponding relief areas.
  • the bit zone is compressed between the metal conductive sheet and the main body of the static spring, so as to use the spring to increase the electrical contact area between the metal conductive sheet and the static spring.
  • the convex part of the static spring and the main body of the static spring are separate parts, the convex part of the static spring is a metal rivet, and the corresponding position of the main body of the static spring is provided with a second through hole.
  • the metal rivet is fitted in the second through hole of the main body of the static spring, and the bottom of the metal rivet is riveted and matched with the second through hole of the main body of the static spring.
  • a step is provided on the top of the metal rivet, and the first through hole of the metal conductive sheet is fitted at the step of the metal rivet.
  • the signal wire is a flexible wire.
  • the present invention uses a convex part that protrudes upward in the main body of the two static springs and is not covered by the plastic body, and the convex parts of the two static springs are also connected respectively A signal line to collect the signals of the contact closure state and the number of contact opening and closing times.
  • the two signal lines are also connected.
  • the state of the contacts determine whether the relay is working normally, and timely investigate the risks; on the other hand, the number of opening and closing times of the relay can be collected and counted. When the number of failures is reached, the replacement or maintenance can be automatically reminded to ensure the relay’s Normal application.
  • the invention adds the signal monitoring function to the relay.
  • the convex part of the static spring and the main body of the static spring are used as separate parts, and the convex part of the static spring is a metal rivet, and the corresponding position of the main body of the static spring is provided with a second pass.
  • the metal rivet is fitted into the second through hole of the main body of the static spring, and the bottom of the metal rivet is riveted and matched with the second through hole of the main body of the static spring.
  • the structure of the present invention is convenient for the process of making the convex part of the static spring, and when the convex part of the static spring is matched with the metal conductive sheet, it will not cause damage to the plastic body. Since the metal rivet is a solid body, it can also improve The stability of the contact between the metal conductive sheet and the convex part of the static spring.
  • a step is provided on the top of the metal rivet, and the first through hole of the metal conductive sheet is fitted to the step of the metal rivet.
  • the structure of the present invention can use the step of the metal rivet to increase the conductive area of the metal conductive sheet and the static spring, and improve the reliability of the conduction.
  • the present invention adopts the plastic body, there are also space areas corresponding to the convex parts of the two static springs. Springs are respectively sleeved on the convex parts of the two static springs. The corresponding relief area is compressed between the metal conductive sheet and the main body of the static spring.
  • the structure of the present invention utilizes the deformability of the spring to always contact the metal conductive sheet and the main body of the static spring after the spring is deformed, thereby ensuring that the signal diagnostic terminal (ie, the metal conductive sheet) and the load terminal (ie, static).
  • the reliable connection between the main parts of the springs further ensures the transmission of the diagnostic signal, thereby ensuring the effective reading of the monitoring signal by the system.
  • the present invention uses the signal wire as a soft wire, and one end of the signal wire is connected to a metal conductive sheet, and the other end of the signal wire is connected to a connector, the present invention uses a soft wire to eliminate the hard connection (metal sheet and metal The sheet is directly connected and easy to fall off), thereby improving the reliability of the connection.
  • the present invention also provides a bridge-type high-current electromagnetic relay.
  • the current-carrying capacity can be improved, the heat at the contacts can be reduced, and the arcing when the contacts are broken, thereby improving Product performance.
  • the bridge-type high-current electromagnetic relay of the present invention includes a base, two static springs with rigid characteristics mounted on the base, a coil mounted on the base horizontally, and one of an armature and a yoke connected to the vicinity of the coil.
  • a bridge piece with rigid characteristics is also fixed to the end of the movable reed connected with the armature, and the two ends of the bridge are respectively corresponding to the two static springs;
  • Two static contacts are respectively provided on each static spring, two moving contacts are respectively provided at both ends of the bridge piece, and the four moving contacts are arranged in a line.
  • the two moving contacts on both ends of the bridge piece and the two static contacts on the two static springs are respectively set in a square structure.
  • the contact surfaces of the two movable contacts on both ends of the bridge piece and the two static contacts on the two static springs are respectively set as arc surfaces protruding outward.
  • the yoke is L-shaped, one side of the L-shaped yoke is the first part, and the first part is fixed to the core, and the other side of the L-shaped yoke is the second part, and the second part is arranged on the coil Above.
  • the two static springs are respectively arranged between the bridge piece and the coil.
  • the two static springs are respectively installed symmetrically on both sides of the base.
  • a stop block is also installed on the side of the bridge piece that faces away from the moving contact.
  • a buffer pad is also installed in the stop block.
  • two static contacts are respectively provided on each static spring
  • two moving contacts are respectively provided at both ends of the bridge piece
  • the four moving contacts are arranged in a line.
  • each load terminal ie, static spring
  • the bridge piece of the moving spring is correspondingly provided Four contacts, and let the four contacts on the bridge piece correspond to the two contacts on the load terminal respectively
  • the two load terminals ie static spring
  • the parallel connection of the double contacts makes the equivalent resistance halved (also equivalent to current shunt, which can improve the current-carrying capacity), so under the same current condition, the power consumption is reduced to 1/2 of the original, thus greatly Reduce the power consumption of the contacts, that is, reduce the heat at the contacts, thereby improving the performance of the product-higher load capacity
  • two load terminals are connected in series with the help of a bridge to realize the synchronous double disconnection of the current loop and also make the arc energy appear Halve to achieve the purpose of reducing arcing when the contact is broken.
  • the two moving contacts at both ends of the bridge piece and the two static contacts on the two static springs are respectively set as a square structure, and the two moving contacts and two static springs at both ends of the bridge piece
  • the contact surfaces of the two static contacts on the upper side are respectively set as arc surfaces protruding outward.
  • the structure of the present invention can utilize the cooperation of the square structure and the arc-shaped surface to make the contact between the dynamic and static contacts be line contact, thereby improving the reliability of the contact between the dynamic and static contacts.
  • a bridge piece with rigid characteristics is fixed to the end of the movable spring piece connected with the armature, and the two ends of the bridge piece correspond to the two static springs respectively.
  • the structure of the present invention makes the moving spring only need to bear the mechanical fatigue strength of the moving spring component back and forth without bearing the current-carrying capacity, while the bridge piece only bears the current-carrying capacity but not the load-resistant mechanical fatigue capacity.
  • the dynamic spring material can be randomly selected without the need to select a special dynamic spring material, and the load circuit path is shorter (the current only flows through the bridge and not the moving spring), that is, the shorter distance is There is a smaller line resistance, so under the same load (current) conditions, the heat will be smaller.
  • FIG. 1 is a schematic diagram of the three-dimensional structure of the first embodiment of the relay coil assembly of the present invention
  • Fig. 2 is an enlarged schematic diagram of part A in Fig. 1;
  • FIG. 3 is a schematic diagram of the cooperation between the coil former and the coil pins in the first embodiment of the present invention
  • Fig. 4 is an enlarged schematic diagram of part B in Fig. 3;
  • FIG. 5 is a schematic diagram of the three-dimensional structure of the coil pin of the first embodiment of the present invention.
  • Fig. 6 is a schematic diagram of the coil former, enameled wire and coil pins in the first embodiment of the present invention.
  • Fig. 7 is an enlarged schematic diagram of part C in Fig. 6;
  • FIG. 8 is a schematic diagram of the first embodiment of the first embodiment of the present invention in which the signal wire is inserted into the coil pin;
  • FIG. 9 is a schematic diagram of the second embodiment of the process of installing the signal wire into the coil pin of the first embodiment of the present invention.
  • FIG. 10 is a schematic diagram of the third embodiment of the process of installing the signal wire into the coil pin of the first embodiment of the present invention.
  • FIG. 11 is a schematic diagram of the structure of the electronic component of the first embodiment of the present invention.
  • FIG. 12 is a schematic diagram of the electronic component and the coil pin of the first embodiment of the present invention.
  • FIG. 13 is a schematic diagram of the three-dimensional structure of the coil pin of the second embodiment of the relay coil assembly of the present invention.
  • Figure 15 is a front view of an embodiment of the present invention (without housing);
  • Figure 16 is a bottom view of an embodiment of the present invention (without housing);
  • Figure 17 is a sectional view taken along line A-A in Figure 16;
  • Fig. 18 is an enlarged schematic diagram of part D in Fig. 17;
  • Fig. 19 is an enlarged schematic diagram of part E in Fig. 17;
  • Figure 20 is a bottom view of an embodiment of the present invention (without housing and rotated at an angle);
  • Figure 21 is a sectional view taken along line D-D in Figure 20;
  • 22 is a schematic diagram of the cooperation of the coil former, the moving spring armature component and the yoke of the embodiment of the present invention.
  • Figure 23 is a schematic diagram of the cooperation of the coil bobbin, the moving spring armature component and the yoke (turned by an angle) of the embodiment of the present invention
  • 24 is a schematic diagram of the cooperation of the base and the static spring of the embodiment of the present invention.
  • Fig. 25 is an enlarged schematic diagram of part F in Fig. 24;
  • FIG. 26 is a schematic diagram of a three-dimensional structure of an embodiment of the present invention (without housing and bottom flipped);
  • Fig. 27 is an enlarged schematic diagram of part G in Fig. 26;
  • FIG. 28 is a schematic diagram of the three-dimensional structure of the first embodiment of the relay (without housing) that ensures the normal operation of the armature or the moving reed according to the present invention
  • Figure 29 is a three-dimensional schematic diagram (turned at an angle) of the first embodiment of the present invention (without housing);
  • Figure 30 is a top view of the first embodiment of the present invention.
  • Figure 31 is a cross-sectional view taken along line B-B in Figure 30;
  • Figure 32 is an enlarged schematic view of a part of the structure of the H part in Figure 31 (the protruding part of the housing is not in contact with the yoke);
  • Figure 33 is an enlarged schematic view of a part of the structure of part H in Figure 31 (the protruding part of the housing is in contact with the yoke);
  • FIG. 34 is a schematic diagram of the three-dimensional structure of the housing of the first embodiment of the present invention.
  • 35 is a schematic diagram of the three-dimensional structure of the housing (inverted state) of the first embodiment of the present invention.
  • Figure 36 is a bottom view of the housing of the first embodiment of the present invention.
  • Figure 39 is a top view of the second embodiment of the present invention.
  • Figure 40 is a cross-sectional view taken along line C-C in Figure 39;
  • Fig. 41 is an enlarged schematic diagram of a part of the structure of part J in Fig. 40 (the protruding part of the housing is not in contact with the yoke);
  • Fig. 42 is an enlarged schematic diagram of a partial structure of the J part in Fig. 40 (the protruding part of the housing is in contact with the yoke);
  • FIG. 43 is a schematic diagram of the three-dimensional structure of the first embodiment of the high current relay with signal monitoring at the load terminal of the present invention.
  • Figure 44 is an exploded schematic view of the three-dimensional structure of the first embodiment of the present invention.
  • Figure 46 is a top view of the base portion of the first embodiment of the present invention.
  • FIG. 47 is a schematic diagram of the inverted side of the base part of the first embodiment of the present invention.
  • Fig. 48 is a schematic diagram of the static spring part and the signal line in the first embodiment of the present invention.
  • FIG. 49 is an exploded schematic diagram of the cooperation of the static spring part and the signal line in the first embodiment of the present invention.
  • 51 is a schematic diagram of the flip side of the static spring part and the signal line in the first embodiment of the present invention.
  • Figure 52 is a cross-sectional view taken along line E-E in Figure 51;
  • Figure 53 is a sectional view taken along line F-F in Figure 51 (before riveting);
  • Figure 54 is a sectional view taken along line F-F in Figure 51 (after riveting);
  • FIG. 55 is an exploded schematic diagram of the cooperation of the static spring part and the signal line of the second embodiment of the present invention.
  • Figure 57 is a cross-sectional view taken along line P-P in Figure 56;
  • Figure 58 is a cross-sectional view taken along line Q-Q in Figure 56;
  • 59 is a schematic diagram of the static spring part and the signal line in the third embodiment of the present invention.
  • FIG. 60 is an exploded schematic diagram of the cooperation between the static spring part and the signal line of the third embodiment of the present invention.
  • 61 is a schematic diagram of the flip side of the static spring part and the signal line in the third embodiment of the present invention.
  • Figure 62 is a sectional view taken along the line M-M in Figure 61;
  • Figure 63 is a cross-sectional view taken along line N-N in Figure 61;
  • Figure 64 is an exploded schematic view of the three-dimensional structure of the embodiment of the present invention.
  • Figure 65 is a three-dimensional schematic diagram of an embodiment of the present invention (without housing);
  • FIG. 66 is a schematic diagram of the three-dimensional structure of the bridge piece of the embodiment of the present invention.
  • FIG. 67 is a schematic diagram of the three-dimensional structure of the static spring of the embodiment of the present invention.
  • FIG. 68 is a schematic diagram of the static spring installed on the base and the bridge piece in accordance with the embodiment of the present invention.
  • Fig. 69 is a plan view of the static spring installed on the base and the bridge piece cooperated with the embodiment of the present invention.
  • a structure When a structure is “on” another structure, it may mean that a certain structure is integrally formed on another structure, or that a certain structure is “directly” arranged on another structure, or that a certain structure is “indirectly” arranged on another structure through another structure. On other structures.
  • a relay coil assembly of the present invention includes a coil frame 1, an enameled wire 200, a coil pin 3 and a signal wire 400; both ends of the coil frame 1 are respectively provided with flanges 11, The winding window 12 of the coil frame is formed between the two flanges 11, and the enameled wire 200 is wound in the winding window 12; the coil pin 3 includes a plug-in part 31, an enameled wire fixing part 32 and a signal wire fixing part 33.
  • the coil pin 3 is inserted into the flange 11 at one end of the coil former 1 through the insertion portion 31; the signal wire fixing portion 33 is provided with a first slot 331 that opens downward;
  • the signal line 400 is clamped in the first card slot 331; one of the groove walls on both sides of the first card slot 331 is provided with a barb 332 near the edge of the opening, the first card slot
  • One of the groove walls on both sides of the 331 is provided with a slope section 333 that gradually increases the opening from the inside to the outside at the matching position corresponding to the signal line, so as to be opposite to the side where the barb 332 is provided.
  • the bevel section 333 is used to squeeze the signal line 400 into the first slot 331, and the barb 332 is used to prevent the signal line 400 from passing through the first slot 331. Prolapse.
  • the signal wire 400 is clamped to the first slot 331 of the coil pin 3
  • the signal wire 400 is fixed to the coil pin 3 by welding.
  • the groove wall with the inclined section 333 and the groove wall with the barb 332 are the same side groove wall, and the other side groove wall of the first groove 331 Set as straight-face-shaped wall.
  • the coil pin 3 further includes an electronic component fixing portion 34, the electronic component 500 is a resistor or a diode; the electronic component fixing portion 34 is provided with a second slot 341 that opens downward; and the second card The slot 341 is provided on the side of the first slot 331.
  • the straight wall of the first groove 331 is closer to the second groove 341 than the groove wall of the inclined surface section 333 of the first groove 331.
  • the coil pin 3 is a sheet-shaped structure; the axis Z of the core mounting hole 13 of the coil former 1 (see FIG. 6) is horizontally arranged; the middle and upper part of the coil pin 3 is the insert
  • the connecting portion 31 is fitted in the fitting groove 14 of the flange 11 at one end of the coil former 1; the lower part of the coil pin 3 is the signal wire fixing portion 33 and the electronic component fixing portion 34; the coil pin 3
  • the middle portion extends to one side to form the enameled wire fixing portion 32, and is bent to the winding window 12 of the coil frame after the coil pin 3 is inserted into the coil frame 1.
  • the enameled wire fixing portion 32 of the coil pin 3 is further provided with a first tooth-shaped structure 321 that is convenient for positioning and winding the enameled wire.
  • the plug-in portion 31 of the coil pin 3 is also provided with a second tooth structure 311 for achieving interference fit with the matching slot of the coil former.
  • a barb 332 is provided on one of the groove walls on both sides of the first slot 331 of the coil pin 3 near the edge of the opening.
  • the mating position of one of the groove walls on the two sides corresponding to the signal line is also set as a slope section 333 whose opening gradually increases from the inside to the outside, so as to oppose one of the barbs.
  • the flexible signal line is pressed into the first slot from the opening of the first slot along the edge of the barb 332.
  • the barb 332 of the side groove wall is deformed toward the other side groove wall, so that the space in the groove is changed.
  • the signal line 400 is in an interference fit with the first slot 331, so that the signal line 400 can be clamped so as not to fall off easily.
  • a relay coil assembly of the present invention After the signal wire 400 is clamped in the first slot 331 of the coil pin 3, the signal wire 400 is fixed to the coil pin 3 by welding.
  • the structure of the present invention forms a double insurance of clamping and welding, no virtual welding occurs, and the connection between the signal line and the coil pin is more reliable.
  • the enameled wire fixing portion 32 of the coil pin 3 is further provided with a first tooth structure 321 that is convenient for positioning and winding the enameled wire.
  • the first tooth structure 321 is used to control the starting position of the first coil of enameled wire.
  • the difference between the relay coil assembly of the present invention and the first embodiment is that there is only one barb 332.
  • a high-current relay with adjustable overtravel of the present invention includes a housing 2, a coil frame 1, a moving spring armature component 15 and a base 300; the core mounting hole 13 of the coil frame 1 The axis is arranged horizontally, the iron core mounting hole 13 is equipped with an iron core, the two ends of the coil frame 1 are respectively provided with flanges 11, a winding window is formed between the two flanges 11, and the winding window is wound with enameled wire; the moving spring armature The component 15 is assembled with the coil former 1, and the movable contact 150 of the movable spring armature component 15 is in a mating state with the stationary contact 41 outside one end of the coil former 1.
  • the stationary contact 41 is arranged on the stationary spring 4,
  • the static spring 4 is mounted on the base 300; the flange 11 at one end of the coil former 1 extends downwards with a first hook member 5 (see Figures 19-21), and the corresponding position of the base 300 is provided with a first clamping hole 310.
  • the first hook member 5 of the bobbin 1 is fitted in the first clamping hole 310 of the base 300 to make an integral part including the bobbin and the moving spring armature (the integral part also includes a yoke, iron core, enameled wire, etc.) It is restricted along the vertical direction and the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the first locking hole, and there is a movable second along the axis of the iron core mounting hole.
  • a gap H1 with the axis of the iron core as the Z axis, the vertical as the X axis, and the horizontal direction perpendicular to the axis of the iron core mounting hole as the Y axis, the first hook member 5 of the coil former and the first hook member of the base 300
  • the integral part cannot move relative to the base 300 along the positive and negative directions of the X axis, and the integral part cannot move relative to the base 300 along the positive and negative directions of the Y axis.
  • the integral part can move relative to the base 300 by a first gap; the flange 11 at the other end of the coil former 1 extends downwards with a second hook part 6, and the base 300
  • a second locking hole 320 is provided at the corresponding position.
  • the second hook member 6 of the bobbin 1 is fitted into the second locking hole 320 of the base, so that the integral part moves along the vertical direction at the position corresponding to the second locking hole.
  • the second hook of the coil former 1 The part 6 cooperates with the second hole 320 of the base 300, the whole part cannot move in the positive and negative direction of the X axis relative to the base 300, and the whole part cannot move in the positive and negative direction of the Y axis relative to the base 300, but , Along the Z axis, the integral part can move relative to the base 300 by the distance of the second gap; thus, the first gap H1 and the second gap H2 can be used to adjust the contact overtravel; the first gap H1 and the second gap H2 is equal.
  • the number of the first hook member 5 is one, and the first hook member 5 is provided directly below the axis Z of the iron core mounting hole 13; the number of the second hook members 6 is two, and the number of second hook members 6 is two. Two hook members 6 are symmetrically arranged on both sides directly below the axis Z of the iron core mounting hole 13.
  • the first hook member includes two hooks 51, 52 facing opposite directions, and a first avoiding groove 53 located between the two hooks 51, 52 so that the hook can swing elastically.
  • the hooks 50 of the two hooks 51, 52 are respectively facing the two sides directly below the axis Z of the iron core mounting hole.
  • the position of the bottom of the first locking hole 310 corresponding to the hook head 50 is respectively provided with a first step 311 with a stepped surface facing down; the upper two sides of the first hook member 5 are provided with The over-pressured flap 54.
  • the hook heads 50 of the two hooks 51 and 52 of the first hook member 5 are respectively hooked on the first step 311 of the first hole
  • the wings 54 on both sides of the first hook member 5 abut on the base of the edge of the first hole 310, so that the integral part is vertically limited at the position corresponding to the first hole.
  • the first hook member 5 is in transitional fit with the two opposite hole walls of the first locking hole 310 along the horizontal direction perpendicular to the axis of the iron core mounting hole, so that the The integral part is restricted along the horizontal direction perpendicular to the axis of the iron core installation hole at the position corresponding to the first locking hole.
  • the second hook member 6 includes a hook 61 with a hook head 60 facing the outside of the bobbin and a second escape groove 62 provided beside the hook 61 so that the hook 61 can swing inwardly of the bobbin.
  • a second step 321 with a stepped surface facing down is provided at the bottom of the second locking hole 320 at a position corresponding to the hook 60; the upper part of the second hook member 6 is provided with a second step for preventing overpressure And it is the third step 63 with the step surface facing down.
  • the second hook member 6 is in transitional fit with the two opposite hole walls of the second locking hole 320 along the horizontal direction perpendicular to the axis of the iron core mounting hole, so that the The integral part is restricted along the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the second clamping hole 320; the horizontal direction of the second clamping hole is along the horizontal direction perpendicular to the axis of the iron core mounting hole
  • One of the two opposite hole walls is also set as a wave-shaped wall surface 322, so that after the first gap and the second gap are used to adjust the contact over-travel, the wave-shaped wall surface 322 and the second hole 320
  • the heat fusion process between the second hook parts makes the second hook part 6 and the base 300 fixed together, so that the integral part is perpendicular to the axis of the iron core mounting hole at the position corresponding to the second hole.
  • the horizontal direction of the axis of the iron core mounting hole is simultaneously restricted, and the wavy wall surface 322 is used to realize the fine adjustment of the integral part along the horizontal direction perpendicular to the axis of the iron core mounting hole at the position corresponding to the second hole
  • the second card hole 320 has a wavy wall surface 322
  • the bobbin (and the integral part) corresponds to the second
  • the position of the clamping hole has a slight movement along the horizontal direction perpendicular to the axis of the iron core mounting hole.
  • the high-current relay of the present invention further includes a yoke 7, the yoke 7 is provided with mounting feet 70, and the mounting feet 70 of the yoke 7 cooperate with the second hook member 6 in the second In the locking hole 320, and the mounting foot 70 of the yoke is closer to directly below the axis of the iron core mounting hole relative to the second hook member 6; One of the two opposite hole walls in the horizontal direction of the axis of the core mounting hole is farther away from the other directly below the axis of the core mounting hole.
  • the flange 11 at one end of the coil former 1 is provided with a first hook member 5 downwards
  • the corresponding position of the base 300 is provided with a first clamping hole 310
  • the first hook member 5 is fitted in the first locking hole 310 of the base, so that the integral part including the coil former and the moving spring armature component is installed along the vertical direction and perpendicular to the iron core at a position corresponding to the first locking hole 310
  • the horizontal direction of the axis of the hole is limited, and there is a movable first gap along the axis of the iron core mounting hole;
  • the flange 11 at the other end of the coil former 1 extends downward with a second hook member 6,
  • the corresponding position of the base 300 is provided with a second clamping hole 320, and the second hook member 6 of the coil former is fitted in the second clamping hole 320 of the base, so that the integral part is aligned along the position corresponding to the second clamping hole.
  • the vertical direction and the horizontal direction perpendicular to the axis of the iron core mounting hole are restricted, and there is a movable second gap along the axis of the iron core mounting hole; thereby using the first gap and the second gap to achieve contact Point over-travel adjustment.
  • the structure of the present invention not only realizes the hooking and fixing between the bobbin 1 and the base 300, avoids the drawbacks caused by the split riveting fixation in the prior art, but also realizes the overstroke adjustment of the high current relay.
  • one first hook member 5 is provided, and the first hook member 5 is provided directly below the axis of the iron core mounting hole; the second hook member 6 is provided Two, two second hook members 6 are symmetrically arranged on both sides directly below the axis of the iron core mounting hole.
  • the first hook component 5 is designed to include two hooks 51, 52 facing opposite directions and one of the two hooks 51, 52 so that the corresponding hook can swing elastically
  • the hooks 50 of the two hooks 51, 52 are respectively facing the two sides directly below the axis of the iron core mounting hole;
  • the second hook member 6 is designed to include a hook 60 facing A hook 61 outside the coil former and a second escape groove 62 arranged beside the hook so that the hook can elastically swing in the direction of the coil former.
  • one of the two opposite hole walls along the horizontal direction perpendicular to the axis of the iron core mounting hole of the second clamping hole 320 is also set as a wave-shaped wall surface 322 .
  • this structure of the present invention by designing a side wall of the second card hole 320 into a wave-shaped structure, after adjusting the overstroke, the second hook member 6 is hot melted, and the hot melt of the second hook member 6 is filled
  • the wavy surface 322 can realize that the integral part is simultaneously restricted along the axis of the core mounting hole and the horizontal direction perpendicular to the axis of the core mounting hole at the position corresponding to the second clamping hole.
  • the wavy The surface can increase the mating area of the hot melt between the second clamping hole 320 and the hook 61 to increase the fixing strength.
  • a relay of the present invention that can ensure the normal operation of the armature or moving spring, includes a housing 2, a base 300, a coil assembly 100, an iron core 49, a yoke 7, an armature 67 and a moving spring Sheet 8; the coil assembly 100 includes the coil frame 1, the enameled wire 200 and the coil pin 3.
  • the coil assembly 100 is horizontally mounted on the base 300, and the iron core 49 is mounted in the iron core mounting hole of the coil frame 1 of the coil assembly 100,
  • the end face of the first end of the iron core 49 is set as a pole face;
  • the first part 71 of the yoke 7 is fixed to the second end of the iron core 49, and the second part 72 of the yoke 7 is fitted on the upper surface of the coil assembly 100 ,
  • the first part 81 of the moving spring 8 is fixed with the second part 72 of the yoke 7, and the second end 82 of the moving spring 8 is fixed with the armature 67, and the armature 67 is opposite to the pole face of the iron core 49
  • the upper part of the armature 67 fits at the knife edge of the yoke 7, and the upper end of the armature 67 is higher than the upper part of the second part 72 of the yoke 7 and the upper part of the first part 81 of the movable spring 8;
  • the housing 2 is mounted on
  • a downwardly protruding inner surface of the housing 2 is also provided
  • the protrusion 21 that can abut the upper surface of the second portion 72 of the yoke, and the distance D1 between the bottom surface of the protrusion 21 and the upper surface of the second portion 72 of the yoke is less than
  • the distance D2 between the top inner surface of the housing 2 and the upper end of the armature 67 is such that when the housing 2 is deformed downwards, the protrusion 21 is used to abut the upper surface of the second part 72 of the yoke, thereby Ensure that the housing 2 does not press the armature 67.
  • the protruding part is a flat cylinder, and can also be a rib or other similar structure.
  • protrusions 21 there are three protrusions 21 on the inner surface of the top of the housing 2 and they are distributed in a triangle shape.
  • the side walls corresponding to the axis of the core mounting hole of the coil assembly 100 are further provided with two sides of the second part 72 that can fit on the yoke.
  • the yoke 7 is L-shaped, and the L-shaped side of the yoke 7 serves as the first part 71 of the yoke, and the first part 71 is fixed to the second end of the iron core 49,
  • the other side of the L-shape of the yoke serves as the second part 72 of the yoke, which is fitted on the upper side of the coil assembly 100;
  • the movable reed 8 is L-shaped, and the movable reed One side of the L-shape serves as the first part 81 of the moving reed.
  • the first part 81 is fixed to the yoke 7 on the second part 72 of the yoke 7, and the other side of the L-shape of the moving spring 8 serves as The second part 82 of the moving reed is fixed to the armature 67.
  • the two sides of the end of the second part 72 of the yoke are respectively provided with convex posts 721 extending outward, and the knife edge of the yoke is formed between the two convex posts 721;
  • the two sides of the upper part are respectively provided with first grooves 671, and the first grooves 671 on both sides of the upper part of the armature 67 are respectively matched with the two convex posts 721 at the end of the second part 72 of the yoke ,
  • the upper part of the armature 67 is fitted to the knife edge of the yoke 7.
  • the top end of the armature 67 is provided with a second groove 672, and the first part 81 of the movable spring 8 straddles the second groove 672 at the top end of the armature 67, so that the armature 67
  • the top end of the yoke 7 is higher than the upper surface of the second part 72 of the yoke 7 and the upper surface of the first part 81 of the movable spring 8.
  • the first part 81 of the movable reed 8 is further provided with a stopper 811 that limits the top of the armature, so as to limit the upper part of the armature 67 to the yoke. 7 at the knife edge.
  • the relay of the present invention can ensure the normal operation of the armature or the moving reed.
  • On the inner side of the top of the housing 2 is also provided with a downwardly protruding protruding part capable of pressing against the upper surface of the second part of the yoke 21, and the distance D1 between the bottom surface of the protrusion 21 and the upper surface of the second part of the yoke is smaller than the distance D2 between the inner surface of the top of the housing and the upper end of the armature.
  • the housing 2 when the top of the housing 2 is deformed by force, the housing 2 will simultaneously move the protruding portion 21 downward, and the protruding portion 21 will first contact the yoke 7, thereby avoiding contact between the housing 2 and the armature 67 , If the armature 67 is stuck, it can ensure the normal operation of the armature 67, thus ensuring the normal use of the relay.
  • the protruding parts 21 on the inner side of the top of the housing 2 are set to three, which are distributed in a triangle.
  • the structure of the present invention can ensure that the top of the housing 2 is in smooth contact with the yoke 7 when the top of the housing 2 is deformed under force, and the housing 2 will not contact the armature 67, and the armature 67 can be operated normally.
  • the side walls of the housing 2 corresponding to the axis of the core mounting hole of the coil assembly are also provided with the yoke
  • the structure of the present invention can prevent the movement of the magnetic circuit part including the yoke in the preset direction.
  • a relay of the present invention that can ensure the normal operation of the armature or moving reed is different from the first embodiment in that shoulders are provided on both sides of the upper part of the armature 67. 673.
  • the shoulders 673 on both sides of the upper part of the armature are respectively matched with the two protruding posts 721 at the end of the second part 72 of the yoke, so that the upper part of the armature 67 fits on the yoke.
  • the first part 81 of the movable reed 8 straddles the top end of the armature 67 so that the upper end of the movable reed 8 is higher than the upper surface of the second part 72 of the yoke and the armature.
  • the distance D1 between the bottom surface of the protruding portion 21 and the upper surface of the second portion 72 of the yoke is smaller than the distance D3 between the top inner surface of the housing 2 and the upper end of the movable spring 8.
  • the housing 2 When the top of the housing 2 is deformed under force, the housing 2 will simultaneously move the protruding portion 21 downward, and the protruding portion 21 will first contact the yoke 7, so as to prevent the housing 2 from contacting the movable spring 8 and jam the movable spring.
  • the sheet 8 can ensure the normal action of the movable reed 8 to ensure the normal use of the relay.
  • a load terminal with signal monitoring high-current relay of the present invention includes a housing 2, a core part 8 and a base 300; the housing 2 is mounted on the base 300 and accommodates the core part 8
  • the core part 8 includes a magnetic circuit part 81 and a moving spring armature part 15 operated by the magnetic circuit part; the moving spring armature part 15 includes a bridge piece 78 and two ends of the bridge piece 78
  • the movable contact 150; the movable contact 150 of this embodiment is a separate part and is fixed on the bridge 78.
  • the movable contact can also be protruding integrally formed by the bridge 78, or by the bridge 78
  • the base 300 includes two static springs 4 and a plastic body 92 that is insulated from each other and fixed together by injection molding;
  • the static spring 4 is a sheet-shaped structure including a horizontal
  • the main body part 911 buried in the plastic body, the contact part 912 bent to be exposed on the plastic body, and the connecting part 913 exposed horizontally on the side of the plastic body 92 as the load terminal, the contact part 912 is provided with static contact
  • the static contact 914 of this embodiment is a separate part and is fixed on the contact portion 912 of the static spring 4.
  • the static contact can also be protruding integrally formed by the contact portion 912 of the static spring 4, or
  • the contact portion 912 of the static spring 4 directly constitutes a static contact; the movement portion 8 is mounted on the base 300 and the two ends of the bridge piece 78 of the movement portion 8 are respectively contacted with the contact portions 912 of the two static springs 4
  • the contact is closed (that is, the moving contacts 150 at both ends of the bridge 78 are in contact with the static contacts 41 of the contact parts 912 of the two static springs 4)
  • the current is loaded by one static spring.
  • the terminals flow in and flow out from the load terminal of the other static spring; the main body portions 911 of the two static springs 4 are respectively provided with a convex portion 42 that protrudes upward and is not covered by the plastic body 92.
  • a signal line 400 is also connected to the convex portion 42 of each static spring 4 to realize the signal collection of the contact closed state and the number of contact opening and closing times.
  • a metal conductive sheet 65 is further provided between the signal line 400 and the convex portion 42 of the static spring.
  • the metal conductive sheet 65 is provided with a first through hole 610, and the metal conductive sheet 65 has a first through hole 610. It fits on the convex portion 42 of the static spring 4 and is connected by welding or riveting.
  • each end of the two signal lines 400 is respectively connected to a corresponding metal conductive sheet 65, and each other end of the two signal lines 400 is respectively connected to a connector 700, and is connected to each other through the connector 700
  • the control module outside the relay is connected.
  • the convex portion 42 of the static spring and the main body portion 911 of the static spring are separate parts, and the convex portion 42 of the static spring is a metal rivet.
  • the corresponding position of the main body portion 911 of the static spring A second through hole 915 is provided, and the metal rivet is fitted in the second through hole 915 of the main body 911 of the static spring.
  • the bottom of the metal rivet is connected to the second through hole of the main body 911 of the static spring. 915 riveted to match.
  • the top of the metal rivet is provided with a step 421, and the first through hole 610 of the metal conductive sheet 65 is fitted at the step 421 of the metal rivet and is fixed by riveting.
  • the signal wire 400 is a flexible wire.
  • a high-current relay with signal monitoring for a load terminal of the present invention uses a convex portion 42 that protrudes upward and is not covered by the plastic body in the main body portions 911 of the two static springs 4, respectively.
  • a signal line 400 is also connected to the convex portions 42 of the two static springs 4 to realize the signal collection of the contact closed state and the number of contact opening and closing times.
  • the invention By collecting the communication signals of the two signal lines, on the one hand, it can be real-time Monitor the state of the contacts, determine whether the relay is working normally, and troubleshoot the risks in time; on the other hand, it can collect and count the number of opening and closing contacts of the relay. When the number of failures is reached, it can automatically remind to replace or repair, thus ensuring the relay Normal application.
  • the invention adds the signal monitoring function to the relay.
  • a high-current relay with signal monitoring for a load terminal of the present invention uses the convex portion 42 of the static spring and the main body 911 of the static spring as separate parts, and the convex portion 42 of the static spring is a metal rivet.
  • a second through hole 915 is provided at the corresponding position of the main body 911 of the static spring. The metal rivet is fitted into the second through hole 915 of the main body 911 of the static spring, and the bottom of the metal rivet is connected to the main body 911 of the static spring.
  • the second through hole 915 is riveted to fit.
  • the structure of the present invention is convenient for the process of making the convex part of the static spring, and when the convex part of the static spring is matched with the metal conductive sheet, it will not cause damage to the plastic body. Since the metal rivet is a solid body, it can also improve The stability of the contact between the metal conductive sheet and the convex part of the static spring.
  • a high current relay with signal monitoring for load terminals of the present invention adopts a step 421 on the top of a metal rivet, and the first through hole 610 of the metal conductive sheet 65 is fitted to the step 421 of the metal rivet.
  • the step 421 of the metal rivet can be used to increase the conductive area between the metal conductive sheet 65 and the static spring 4, and improve the reliability of conduction.
  • a high-current relay with signal monitoring on load terminals of the present invention uses a signal wire 400 as a flexible wire, and one end of the signal wire 400 is connected to a metal conductive sheet 65, and the other end of the signal wire 400 is connected to a connector 700.
  • the invention uses a soft wire to eliminate the stress generated between hard connections (the metal sheet is directly connected to the metal sheet and is easy to fall off), thereby improving the reliability of the connection.
  • a high-current relay with signal monitoring on the load terminal of the present invention is different from the first embodiment in that the convex part of the static spring is formed differently.
  • the static The convex portion 42 of the spring and the main body 911 of the static spring are an integral structure, and are formed by tapping the main body 911 of the static spring upward from the bottom surface.
  • a large current relay with signal monitoring at load terminals of the present invention differs from the second embodiment in that in the plastic body 92, the two static springs
  • the perimeter of the convex part 42 is also provided with a relief area, that is, when the two static springs 4 are injection molded to form the base 300, the plastic is not covered in the convex part 42, and there is a circle beside the convex part 42 without plastic ,
  • the main part 911 of the static spring at this position is also exposed, and the convex parts 42 of the two static springs are respectively sleeved with springs 95, and the springs 95 are compressed in the corresponding place area on the metal conductive
  • the spring 95 is used to increase the electrical contact area between the metal conductive sheet 65 and the static spring 4; the spring 95 serves to communicate with the load terminal (ie, the static spring). 4)
  • a high-current relay with signal monitoring for load terminals of the present invention is adopted in a plastic body 92, and there are separate areas corresponding to the protrusions 42 of the two static springs 4.
  • the convex parts of the static spring are respectively sleeved with a spring 95, and the spring 95 is compressed between the metal conductive sheet 65 and the main part 911 of the static spring in the corresponding relief area.
  • the structure of the present invention uses the deformability of the spring 95 to always contact the metal conductive sheet 65 and the main body 911 of the static spring after the spring 95 is deformed, thereby ensuring that the signal diagnostic terminal (ie, the metal conductive sheet) and the load
  • the reliable connection between the terminals that is, the main part of the static spring) further ensures the transmission of the diagnostic signal, thereby ensuring the effective reading of the monitoring signal by the system.
  • a bridge type high current electromagnetic relay of the present invention includes a housing 2, a base 300, two static springs 4 with rigid characteristics mounted on the base 300, and horizontally mounted on the base.
  • a characteristic bridge piece 78, and the two ends of the bridge piece 78 correspond to the two static springs 4 respectively; each static spring 4 is provided with two static contacts 41, and both ends of the bridge piece 78
  • Two movable contacts 150 are respectively provided, and the four movable contacts 150 are arranged in a horizontal in-line shape.
  • the two static contacts 41 on the static spring 4 are also arranged horizontally.
  • One end of the iron core 49 is set as a pole surface.
  • the other end of the iron core 49 is fixed to the yoke 7.
  • the yoke 7 is L-shaped. One side of the L-shape of the yoke 7 is the first part 71, which is fixed to the other end of the core 49, and the other side of the L-shape of the yoke 7 is the second part 72.
  • the second part 72 is arranged beside the coil (that is, outside the winding window of the bobbin). In this embodiment, the second part 72 of the yoke 7 is arranged on the coil 201, and the second part 72 of the yoke 7 The end of the yoke 7 is used as the knife edge of the armature 67.
  • the movable reed 8 with flexible features is also bent into a substantially L-shape.
  • the L-shaped side of the movable reed 8 is the first part 81, which is fixed to the second part 72 of the yoke 7.
  • On the other side is the second part 82, which is fixed to the armature 67, so that the armature 67 can be attracted to the pole surface of 4 with the knife edge of the yoke 7 as the rotation axis.
  • the armature 67 When the coil 201 works, the armature 67 is attracted to the pole surface of the iron core 49, the armature 67 drives the second part 82 of the moving spring 8 to swing, and the second part 82 of the moving spring 8 then drives the bridge 78 to move, so that The two ends of the bridge piece 78 are in contact with the two static spring points 41, and the two moving contacts 150 at both ends of the bridge piece 78 are in contact with the two static contacts 41 on the two static springs 4 respectively. .
  • the two movable contacts 150 at both ends of the bridge piece 78 and the two static contacts 41 on the two static springs 4 are respectively configured as square structures.
  • the contact surfaces of the two movable contacts 150 at both ends of the bridge piece 78 and the two static contacts 41 on the two static springs 4 are respectively set as arc surfaces protruding outward.
  • the two static springs 4 are respectively arranged between the bridge piece 78 and the coil 201.
  • the two static springs 4 are symmetrically installed on both sides of the base 300 respectively.
  • a stopper 85 is also installed on the side of the bridge piece 78 that faces away from the movable contact; there are also two stoppers 85.
  • the stop block 85 in this embodiment is a separate part and is mounted on the base 300.
  • the stop block 85 can also be integrally formed by the base.
  • the stopper 85 is also provided with a cushion 851.
  • the buffer pad 851 is used to reduce the noise when the relay is released.
  • the bridge piece 78 will lean against the stopper 85 with the release of the armature 67.
  • the stopper 85 has a buffer pad 851, it can cushion the bridge piece 78. Impact force, thereby reducing the noise generated by impact.
  • each static spring 4 is provided with two static contacts 41, two moving contacts 150 are respectively provided at both ends of the bridge piece 78, and four The movable contacts 150 are arranged in a straight line.
  • the coil 201 works and the two ends of the bridge 78 are in contact with the two static springs 4, the two movable contacts at both ends of the bridge 78 150 respectively contact the two static contacts 41 on the two static springs 4 correspondingly.
  • each load terminal ie, static spring
  • the bridge piece of the moving spring is correspondingly provided Four contacts, and let the four contacts on the bridge piece correspond to the two contacts on the load terminal respectively
  • the two load terminals ie static spring
  • the parallel connection of the double contacts makes the equivalent resistance halved (also equivalent to current shunt, which can improve the current-carrying capacity), so under the same current condition, the power consumption is reduced to 1/2 of the original, thus greatly Reduce the power consumption of the contacts, that is, reduce the heat at the contacts, thereby improving the performance of the product-higher load capacity
  • two load terminals are connected in series with the help of a bridge to realize the synchronous double disconnection of the current loop and also make the arc energy appear Halve to achieve the purpose of reducing arcing when the contact is broken.
  • the two movable contacts 150 at both ends of the bridge piece 78 and the two static contacts 41 on the two static springs 4 are respectively set in a square structure, and the bridge piece 78
  • the contact surfaces of the two movable contacts 150 on the two ends of and the two static contacts 41 on the two static springs 4 are respectively set as arc surfaces protruding outward.
  • the structure of the present invention can utilize the cooperation of the square structure and the arc-shaped surface to make the contact between the dynamic and static contacts be line contact, thereby improving the reliability of the contact between the dynamic and static contacts.
  • a bridge piece 78 with rigid characteristics is also fixed to the end of the movable spring 2 connected to the armature 67, and the two ends of the bridge piece 78 are respectively connected to two static Spring 4 corresponds.
  • the moving reed 2 only needs to bear the mechanical fatigue strength of the moving spring component's back and forth movement but not the current-carrying capacity, while the bridge piece 78 only bears the current-carrying capacity but not the load-resistant mechanical fatigue resistance.
  • the dynamic spring material can be randomly selected without the need to select a special dynamic spring material, and the load circuit path is shorter (the current only flows through the bridge piece 78 and does not pass through the moving spring 2), that is, more A short distance has a smaller line resistance, so under the same load (current) conditions, the heat will be smaller.

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Abstract

本发明公开了一种继电器线圈组件，包括线圈架、漆包线、线圈引脚和信号线；线圈引脚包括插接部、漆包线固定部和信号线固定部，信号线固定部设有开口向下的第一卡槽；信号线卡接在第一卡槽中；第一卡槽的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩，第一卡槽的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段。本发明避免了现有技术的继电器线圈组件的线圈引脚与信号线采用焊接固定所存在的弊端，并且能够保证信号线与继电器线圈组件的线圈引脚的连接的牢固可靠性。

Description

继电器线圈组件
交叉引用
本公开要求于2019年4月25日提交的申请号分别为201910338719.9、201910339071.7、201910338684.9、201910338696.1、201920579850.X的5件中国专利申请的优先权，该5件中国专利申请的全部内容通过引用全部并入本文。
技术领域
本发明涉及继电器技术领域。
背景技术
继电器是一种电子控制器件，它具有控制系统(又称输入回路)和被控制系统(又称输出回路)，通常应用于自动控制电路中，它实际上是用较小的电流去控制较大电流的一种“自动开关”。故在电路中起着自动调节、安全保护、转换电路等作用。
继电器通常包括线圈组件，线圈组件包括线圈架、漆包线和线圈引脚，线圈架具有绕线窗口，漆包线是缠绕在线圈架的绕线窗口处，线圈引脚则是装在线圈架上，线圈引脚结构中的一部分是伸到线圈架的绕线窗口内用来与漆包线相连接，线圈引脚的结构中的另一部分是伸到线圈架外，用来与驱动信号(即控制信号)相连接，以在驱动信号驱动下使漆包线工作。
现有技术的继电器线圈组件的线圈引脚中，用来与驱动信号相连接的方式主要有两种，一种是将线圈引脚中用来与驱动信号相连接的结构设计成插接脚，驱动信号的引入则为插槽结构，通过线圈组件的线圈引脚的插接脚与插槽结构相配合，实现将驱动信号接至漆包线；另一种是将线圈引脚中用来与驱动信号相连接的结构设计成焊接脚，驱动信号的引入则为信号线，通过将信号线搭在线圈组件的线圈引脚的焊接脚上直接焊接连接，实现将驱动信号接至漆包线。对于以信号线引入驱动信号的结构，由于将信号线搭在焊接脚上直接焊接，容易产生虚焊而造成继电器不工作。
另一继电器包括磁路部分和底座，现有技术中，在将磁路部分装入底座固定时，通常是采用劈铆或热铆的方式来实现磁路部分装入底座后的防退出。采用劈铆时，是利用与线圈装在一起的轭铁插入底座的通孔中，然后对金属零件(即轭铁)的端部进行劈开，从而防止装入磁路部分从底座上退出，但是，采用金属劈铆后，劈开位置易生锈氧化，会影响继电器的正常使用；采用热铆时，是利用线圈架来装入底座，在压入部件(即线圈架)的正面或反面对压入部件的塑料部分进行热熔，使其塑料变形后扩大，从而保证线圈架装入底座后不会退回，但是，采用热铆工艺无法实现在自动化装配过程中超行程的调整，也就无法实现自动化装配过程中的免校正问题。
另外，为了在自动化装配过程中实现免校正，需要进行超行程调整，对于小型、ISO、PCB常规继电器，由于其零件较小，在产品免校正的提升方面通常采用直接法，即通过对铁芯极靴与轭铁刀口的落差大小进行微调整，来满足继电器的参数方面的要求。而对于大电流继电器，由于继电器本身体积和零件较大，同时，材料硬度较高，用现有技术的调整方法不能满足和达到调整的目的。
另一种继电器包括外壳、底座、线圈组件、铁芯、轭铁、衔铁、动簧片和静簧等部件，线圈组件呈卧式安装在底座上，即相当于线圈组件的线圈架的铁芯安装孔的轴线是呈水平设置，铁芯装在线圈组件的线圈架的铁芯安装孔中，铁芯的第一端部(即头部)的端面设为极面，轭铁为L型，轭铁的一边与铁芯的第二端部(即尾部)相固定，轭铁的另一边适配在线圈组件的线圈架的上侧的绕线窗口边，动簧片也为L型，动簧片的一边在轭铁的另一边的上面与轭铁相固定，动簧片的另一边与衔铁相固定，衔铁的上部适配在轭铁的另一边的端部的刀口处，且衔铁或动簧片的上端高出所述轭铁的另一边的上面，外壳装在底座上并将线圈组件、铁芯、轭铁、衔铁和动簧片等部件容纳在外壳内。这种结构的继电器，当外壳受到来自上面方向的冲击或挤压时，外壳的顶面内壁将向下变形，变形到一定程度时就会压到衔铁或动簧片的上端，致使衔铁或动簧片被卡死而无法动作，从而导致继电器失效。
另一种继电器是一种电子控制器件，是当输入量(激励量)的变化达到规定要求时，在电气输出电路中使被控量发生预定的阶跃变化的一种电器。继电器借助设置于内部的电磁装置，通过对线圈通入较小的电流，使得线圈产生磁场，利用磁场的产生或消失而吸合或松开衔铁，进而驱使动触桥上的动触点与静簧端子上的静触点闭合或断开，实现控制大电流运作。在现有继电器中，继电器的触点吸合后，没有相应的检测组件来检测触点是否导通，一旦触点不导通或触点粘接，在继电器使用时很难快速地检测并反馈出问题；另一方面，继电器的触点开闭次数也有一定的寿命要求，而现有的继电器没有对继电器的触点开闭次数进行统计，当达到失效次数时将会影响继电器的准确应用。
另一种电磁继电器在底座上装有两个静簧(作为负载端子)，每个静簧上设有一个静触点，磁路部分中的线圈呈卧式安装在底座上，铁芯的一端设为极面，铁芯的另一端与轭铁相固定，轭铁为L型，除了轭铁的L型的第一部分与铁芯的另一端相固定外，轭铁的L型的第二部分则配置在线圈的旁边(即线圈架的绕线窗口外)，轭铁的L型的第二部分的端头作为轭铁的刀口用来配合衔铁，柔性的动簧片也弯成大致L型，动簧片的L型的第一部分与轭铁的L型的第二部分相固定，动簧片的L型的第二部分则与衔铁相固定，使得衔铁能够以轭铁的刀口为转轴吸向铁芯的极面，动簧片的L型的第二部分设有桥接片，桥接片的两端各设有一个动触点，用来桥接两个静簧上的静触点。这种结构的电磁继电器，当应用于大电流环境时，触点分断时燃弧比较大，产品容易失效。
发明内容
本发明的目的在于克服现有技术之不足，提供一种继电器线圈组件，通过对继电器线圈组件的结构改进，避免了现有技术的继电器线圈组件的线圈引脚与信号线采用焊接固定所存在的弊端，并且能够保证信号线与继电器线圈组件的线圈引脚的连接的牢固可靠性。
本发明解决其技术问题所采用的技术方案是：一种继电器线圈组件，包括线圈架、漆包线、线圈引脚和信号线；所述线圈架的两端分别设有凸缘，两凸缘之间构成线圈架的绕线窗口，所述漆包线缠绕在所述绕线窗口中；所述线圈引脚包括插接部、漆包线固定部和信号线固定部，所述线圈引脚通过插接部插装于所述线圈架的其中一端的凸缘；所述信号线固定部设有开口向下的第一卡槽；所述信号线卡接在所述第一卡槽中；所述第一卡槽的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩，所述第一卡槽的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段，以在对设有倒钩的所述的其中一侧槽壁的外部施力时利用所述斜面段将所述信号线挤压在所述第一卡槽内并利用所述倒钩防止所述信号线脱出。
所述信号线卡接在所述线圈引脚的第一卡槽后还通过焊接方式使信号线与线圈引脚固定。
所述第一卡槽中，设有斜面段的槽壁与设有倒钩的槽壁为同一侧槽壁，所述第一卡槽的另一侧槽壁设为直面形壁。
所述倒钩为一个。
所述倒钩为两个或两个以上，所述两个或两个以上的倒钩由开口边沿向内呈顺序排列。
进一步的，所述线圈引脚还包括电子元件固定部，所述电子元件固定部设有开口向下的第二卡槽；且所述第二卡槽设在所述第一卡槽的侧边。
所述第一卡槽的直面形壁比第一卡槽的斜面段的槽壁更加靠近所述第二卡槽。
所述线圈引脚为片形结构；线圈架的铁芯安装孔的轴线呈水平设置；所述线圈引脚的中上部为所述插接部并配合在线圈架的其中一端的凸缘的配合槽中；所述线圈引脚的下部为信号线固定部和电子元件固定部；所述线圈引脚的中部向一侧延伸构成所述漆包线固定部，并在线圈引脚插装于所述线圈架后弯向线圈架的绕线窗口。
所述线圈引脚的漆包线固定部还设有便于定位及缠绕漆包线的第一齿形结构。
所述线圈引脚的插接部中还设有用来与所述线圈架的配合槽实现过盈配合的第二齿形结构。
与现有技术相比较，本发明的有益效果是：
1、本发明由于在线圈引脚的第一卡槽的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩，所述第一卡槽的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段，以在对设有倒钩的所述的其中一侧槽壁的 外部施力时利用所述斜面段将所述信号线挤压在所述第一卡槽内并利用所述倒钩防止所述信号线脱出。本发明的这种结构，通过在第一卡槽内有做斜面处理，相当于形成一个三角区，柔性信号线从第一卡槽的开口处沿着倒钩边缘位置处压入第一卡槽内后，通过对第一卡槽的具有倒钩的一侧槽壁的外部进行挤压，使该侧槽壁的倒钩向另一侧槽壁方向发生变形，使槽内空间变小，信号线与第一卡槽呈过盈配合，从而实现将信号线卡住，使之不容易脱落。
2、本发明由于信号线卡接在所述线圈引脚的第一卡槽后还通过焊接方式使信号线与线圈引脚固定。本发明的这种结构，形成卡接加焊接的双重保险，不会出现虚焊，使信号线与线圈引脚的连接更可靠。
3、本发明由于在线圈引脚的漆包线固定部还设有便于定位及缠绕漆包线的第一齿形结构。本发明的这种结构，利用第一齿形结构来控制第一圈漆包线的起始位置，在绕好漆包线后再折弯时，可以避免漆包线与线圈架相重叠，防止漆包线被卡住。
本发明还提供一种可调整超行程的大电流继电器，通过结构改进，一方面，能够在实现磁路部分与底座之间稳固固定的基础上，避免现有技术采用劈铆固定所带来的弊端；另一方面，能够实现大电流继电器的超行程调整。
本发明的可调整超行程的大电流继电器，包括线圈架、动簧衔铁部件和底座；线圈架的铁芯安装孔的轴线呈水平设置，线圈架的两端分别设有凸缘，两凸缘之间构成绕线窗口；所述动簧衔铁部件与线圈架装配在一起，并使动簧衔铁部件的动触点在线圈架的一端的外侧与静触点呈配合状态；所述线圈架的一端的凸缘向下设有第一挂钩部件，底座的对应位置设有第一卡孔，线圈架的第一挂钩部件配合在底座的第一卡孔中，使包含有线圈架和动簧衔铁部件的整体部件在对应于第一卡孔的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第一间隙；所述线圈架的另一端的凸缘向下设有第二挂钩部件，底座的对应位置设有第二卡孔，所述线圈架的第二挂钩部件配合在底座的第二卡孔中，使所述整体部件在对应于第二卡孔的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第二间隙；从而利用所述第一间隙和第二间隙实现触点超行程的调节。
所述第一挂钩部件为一个，第一挂钩部件设在所述铁芯安装孔的轴线的正下方；所述第二挂钩部件为两个，两个第二挂钩部件对称设在所述铁芯安装孔的轴线的正下方的两侧。
所述第一挂钩部件包括两个朝向相反的挂钩和两个挂钩之间的一个使对应的挂钩能够弹性摆动的第一避让槽；所述两个挂钩的钩头分别朝向所述铁芯安装孔的轴线的正下方的两侧。
所述第一卡孔的底部的对应于钩头的位置分别设有台阶面朝下的第一台阶；所述第一挂钩部件的上部向两侧设有用来防止过压的翼片，当第一挂钩部件配合在第一 卡孔时，第一挂钩部件的钩头钩在第一卡孔的第一台阶处，第一挂钩部件的两侧的翼片抵在第一卡孔的上孔沿的旁边的边沿的底座上，从而使所述整体部件在对应于第一卡孔的位置处沿着竖向被限位。
所述第一挂钩部件与所述第一卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁之间呈过渡配合，使所述整体部件在对应于第一卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向被限位。
所述第二挂钩部件包括一个钩头是朝向线圈架外的挂钩和设在挂钩旁边使所述挂钩能够向线圈架内方向弹性摆动的第二避让槽。
所述第二卡孔的底部的对应于钩头的位置设有台阶面朝下的第二台阶；所述第二挂钩部件的上部设有用来防止过压的且是台阶面朝下的第三台阶，当第二挂钩部件配合在第二卡孔时，第二挂钩部件的钩头钩在第二卡孔的第二台阶处，第二挂钩部件的第三台阶抵在第二卡孔的上孔沿的旁边的边沿的底座上，从而使所述整体部件在对应于第二卡孔的位置处沿着竖向被限位。
所述第二挂钩部件与所述第二卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁之间呈过渡配合，使所述整体部件在对应于第二卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向被限位；所述第二卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个还设为波浪形壁面，以在利用所述第一间隙和第二间隙实现触点超行程的调节后，对第二卡孔的波浪形壁面和第二挂钩部件之间的热融处理，使第二挂钩部件与底座固定在一起，使所述整体部件在对应于第二卡孔的位置处沿着铁芯安装孔的轴线方向和垂直于铁芯安装孔的轴线的水平方向同时被限位，并利用波浪形壁面实现整体部件在对应于第二卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向的微调整。
进一步的，还包括轭铁，所述轭铁设有安装脚，所述轭铁的安装脚与所述第二挂钩部件一起配合在所述第二卡孔中，且所述轭铁的安装脚相对于所述第二挂钩部件更加靠近所述铁芯安装孔的轴线的正下方；所述第二卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个相对于另一个更加远离所述铁芯安装孔的轴线的正下方。
与现有技术相比较，本发明的有益效果是：
1、本发明由于在线圈架的一端的凸缘向下设有第一挂钩部件，底座的对应位置设有第一卡孔，线圈架的第一挂钩部件配合在底座的第一卡孔中，使包含有线圈架和动簧衔铁部件的整体部件在对应于第一卡孔的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第一间隙；在线圈架的另一端的凸缘向下延伸设有第二挂钩部件，底座的对应位置设有第二卡孔，所述线圈架的第二挂钩部件配合在底座的第二卡孔中，使所述整体部件在对应于第二卡孔的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安 装孔的轴线方向存在可移动的第二间隙；从而利用所述第一间隙和第二间隙实现触点超行程的调节。本发明的这种结构，既实现了线圈架与底座之间的钩挂固定，避免了现有技术采用劈铆固定所带来的弊端，而且还能够实现大电流继电器的超行程调整。
2、本发明由于第一挂钩部件设为一个，且第一挂钩部件设在所述铁芯安装孔的轴线的正下方；第二挂钩部件设为两个，两个第二挂钩部件对称设在所述铁芯安装孔的轴线的正下方的两侧。本发明的这种结构，通过线圈架与底座之间的三点配合，使得线圈架与底座之间能够获得稳固的连接。
3、本发明由于将第一挂钩部件设计成包括两个朝向相反的挂钩和两个挂钩之间的一个使对应的挂钩能够弹性摆动的第一避让槽；所述两个挂钩的钩头分别朝向所述铁芯安装孔的轴线的正下方的两侧；将第二挂钩部件设计成包括一个钩头是朝向线圈架的另一端端外朝向线圈架外的挂钩和设在挂钩旁边使所述挂钩能够向线圈架内方向弹性摆动的第二避让槽。本发明的这种结构，在线圈架压入底座时，第一挂钩部件装入第一卡孔时，第一挂钩部件的两个钩头向中间方向变形，第二挂钩部件装入第二卡孔时，第二挂钩部件的钩头向触点方向变形，从而可以降低装配时线圈架与底座之间的装配难度和解决装配时的塑料异物产生。
4、本发明由于在第二卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个还设为波浪形壁面。本发明的这种结构，通过将第二卡孔的一侧壁设计成波浪形结构，调整完超行程后对第二挂钩部件进行热熔处理，第二挂钩部件的热熔融物填充波浪形表面，能够实现整体部件在对应于第二卡孔的位置处沿着铁芯安装孔的轴线方向和垂直于铁芯安装孔的轴线的水平方向同时被限位，同时，波浪形的表面可以增加第二卡孔与挂钩的热熔融物的配合面积，增加固定强度。
本发明还提供一种可保证衔铁正常动作的继电器，通过结构改进，避免了衔铁或动簧片被卡死的现象发生，能够保证衔铁或动簧片正常动作，从而确保继电器的正常使用。
本发明的可保证衔铁或动簧片正常动作的继电器，包括外壳、底座、线圈组件、铁芯、轭铁、衔铁和动簧片；线圈组件呈卧式安装在底座上，铁芯装在线圈组件的铁芯安装孔中，铁芯的第一端部端面设为极面；轭铁的第一部分与铁芯的第二端部相固定，轭铁的第二部分适配在线圈组件的上面，动簧片的第一端部与所述轭铁的第二部分相固定，动簧片的第二端部与衔铁相固定，并使衔铁与铁芯的极面相对应以及衔铁的上部适配在轭铁的刀口处，且衔铁的上端高出所述轭铁的第二部分的上面和动簧片，或动簧片的上端位置高出所述轭铁的第二部分的上面和衔铁；所述外壳装在底座上并将所述线圈组件、铁芯、轭铁、衔铁和动簧片容纳在内；在外壳的顶部内侧面中还设有向下突出的能够抵向所述轭铁的第二部分的上表面的凸出部，且所述凸出部的底面与所述轭铁的第二部分的上表面之间的距离小于所述外壳的顶部内侧面与衔铁或动簧片的上端之间的距离，以在外壳向下变形时，利用所述凸出部 抵在所述轭铁的第二部分的上表面，从而保证外壳不会压住衔铁或动簧片。
所述外壳的顶部内侧面的凸出部为三个，并呈三角形分布。
所述外壳中，在对应于线圈组件的铁芯安装孔的轴线的两边的侧壁中，还设有能够适配在所述轭铁的第二部分的两侧边的限位筋，且所述限位筋与所述轭铁的第二部分的对应侧边之间具有预置的间隙，以防止包含轭铁在内的磁路部分在预置方向的窜动。
所述轭铁为L型，轭铁的L型的一边作为所述轭铁的第一部分，该第一部分与所述铁芯的第二端部相固定，轭铁的L型的另一边作为所述轭铁的第二部分，该第二部分适配在所述线圈组件的上侧；所述动簧片为L型，动簧片的L型的一边作为所述动簧片的第一部分，该第一部分在所述轭铁的第二部分的上面与轭铁相固定，动簧片的L型的另一边作为所述动簧片的第二部分，该第二部分与衔铁相固定。
所述轭铁的第二部分的端部的两侧分别向外延伸设有凸柱，两个凸柱之间构成所述轭铁的刀口；所述衔铁的上部的两侧分别设有第一凹槽，所述衔铁的上部的两侧的第一凹槽分别与所述轭铁的第二部分的端部的两个凸柱相配合，使所述衔铁的上部适配在所述轭铁的刀口处。
所述衔铁的顶端设有第二凹槽，所述动簧片的第一部分跨过所述衔铁的顶端的第二凹槽，以使所述衔铁的上端高出所述轭铁的第二部分的上面和动簧片。
所述动簧片的第一部分中，还设有对所述衔铁的顶部进行限位的止挡部，以将所述衔铁的上部限位在所述轭铁的刀口处。
所述轭铁的第二部分的端部的两侧分别向外延伸设有凸柱，两个凸柱之间构成所述轭铁的刀口；所述衔铁的上部的两侧分别设有台肩，所述衔铁的上部的两侧的台肩分别与所述轭铁的第二部分的端部的两个凸柱相配合，使所述衔铁的上部适配在所述轭铁的刀口处。
所述动簧片的第一部分跨过所述衔铁的顶端，以使所述动簧片的上端位置高出所述轭铁的第二部分的上面和衔铁。
与现有技术相比较，本发明的有益效果是：
1、本发明由于在外壳的顶部内侧面中还设有向下突出的能够抵向所述轭铁的第二部分的上表面的凸出部，且所述凸出部的底面与所述轭铁的第二部分的上表面之间的距离小于所述外壳的顶部内侧面与衔铁或动簧片的上端之间的距离。本发明的这种结构，当外壳顶部受力变形时，外壳会同时使凸出部向下发生移动，凸出部会与轭铁先接触，从而避免外壳与衔铁或动簧片接触，卡死衔铁或动簧片，能够保证衔铁或动簧片正常动作，从而确保继电器的正常使用。
2、本发明由于将外壳的顶部内侧面的凸出部设为三个，并呈三角形分布。本发明的这种结构，能够保证外壳顶部受力变形时与轭铁平稳接触，保证了外壳不会与衔铁或动簧片接触，保证衔铁或动簧片正常动作。
3、本发明由于外壳中，在对应于线圈组件的铁芯安装孔的轴线的两边的侧壁中，还设有能够适配在所述轭铁的第二部分的两侧边的限位筋，且所述限位筋与所述轭铁的第二部分的对应侧边之间具有预置的间隙。本发明的这种结构，可以防止包含轭铁在内的磁路部分在预置方向的窜动。
本发明的负载端子带信号监控的大电流继电器，包括机芯部分和底座；所述机芯部分包括磁路部分及其受磁路部分工作而动作的动簧衔铁部分；所述底座包括两个静簧以及将两个静簧相互绝缘地通过注塑方式固定在一起的塑料体；所述静簧设有静触点；所述机芯部分安装在底座上并使机芯部分的动簧衔铁部分的动触点与静簧的静触点相配合，以实现触点闭合时，电流由一个静簧的负载端子流入，从另一个静簧的负载端子流出；两个静簧还分别设有一个向上凸出而没被所述塑料体所遮盖的凸部，所述两个静簧的凸部上还分别连接一信号线，以实现对触点闭合状态以及触点开闭次数的信号进行采集。
所述动簧衔铁部分包括桥接片以及设置于桥接片两端部的动触点；所述静簧为片形结构包括水平埋在所述塑料体的主体部、弯折成露出在塑料体之上的接触部和水平露出在塑料体的侧边以作为负载端子的连接部，所述静触点设于接触部；所述机芯部分的桥接片的两端部分别与两个静簧的接触部相对应；所述凸部设于所述静簧的主体部。
所述信号线与所述静簧的凸部之间还设有金属导电片，所述金属导电片设有第一通孔，所述金属导电片的第一通孔配合在静簧的凸部上，并通过焊接或铆接方式相连接。
所述两条信号线的各一端分别连接对应的金属导电片，两条信号线的各另一端分别与一个连接器相连接，并通过所述连接器与继电器外部的控制模块相连接。
所述静簧的凸部与静簧的主体部为一体结构，且是由静簧的主体部从底面向上拍打形成。
所述塑料体中，在对应于所述两个静簧的凸部的周边还分别设有让位区，所述两个静簧的凸部分别套接有弹簧，所述弹簧在对应的让位区中被压缩在所述金属导电片与所述静簧的主体部之间，以利用所述弹簧增加所述金属导电片与所述静簧的电接触面积。
所述静簧的凸部与所述静簧的主体部为分立的零件，所述静簧的凸部为金属铆钉，所述静簧的主体部的对应位置设有第二通孔，所述金属铆钉配合在所述静簧的主体部的第二通孔中，所述金属铆钉的底部与所述静簧的主体部的第二通孔铆接相配合。
所述金属铆钉的顶部设有台阶，所述金属导电片的第一通孔配合在所述金属铆钉的台阶处。
所述信号线为软导线。
与现有技术相比较，本发明的有益效果是：
1、本发明由于采用了在两个静簧的主体部中还分别设有一个向上凸出而没被所述塑料体所遮盖的凸部，所述两个静簧的凸部上还分别连接一信号线，以实现对触点闭合状态以及触点开闭次数的信号进行采集。本发明的这种结构，通过在静簧上增加信号引出线这一简单装置，当触点闭合时，两条信号线也连通，通过采集两条信号线的连通信号，一方面，可以实时监控触点的状态、判断继电器是否正常工作，及时排查风险；另一方面，可对继电器的触点开闭次数进行收集、统计，当达到失效次数时，能自动提醒更换或维修，从而保证继电器的正常应用。本发明使继电器多增加了信号监控功能。
2、本发明由于采用了将静簧的凸部与所述静簧的主体部设为分立的零件，且静簧的凸部为金属铆钉，静簧的主体部的对应位置设有第二通孔，将金属铆钉配合在静簧的主体部的第二通孔中，将金属铆钉的底部与所述静簧的主体部的第二通孔铆接相配合。本发明的这种结构，便于静簧的凸部的工艺制作，且在静簧的凸部与金属导电片相配合时，不会导致塑料体的损坏，由于金属铆钉为实心体，还能提高金属导电片与静簧的凸部的接触的稳定性。
3、本发明由于采用了在金属铆钉的顶部设有台阶，将金属导电片的第一通孔配合在所述金属铆钉的台阶处。本发明的这种结构，可以利用金属铆钉的台阶来增加金属导电片与静簧的导电面积，提高导电可靠性。
4、本发明由于采用了在塑料体中，在对应于所述两个静簧的凸部的周边还分别设有让位区，在两个静簧的凸部分别套接有弹簧，弹簧在对应的让位区中被压缩在所述金属导电片与所述静簧的主体部之间。本发明的这种结构，利用弹簧的可变形性，在弹簧变形后始终与金属导电片、静簧的主体部相接触，从而可以保证信号诊断端子(即金属导电片)与负载端子(即静簧的主体部)之间的可靠连接，进一步保证了诊断信号的传递，从而可以保证系统对监测信号的有效读取。
5、本发明由于采用了信号线为软导线，且信号线的一端连接金属导电片，信号线的另一端与一个连接器相连接，本发明是利用软导线来消除硬连接(金属片与金属片直接连接，容易脱落)之间所产生的应力，从而提高了连接的可靠性。
以下结合附图及实施例对本发明作进一步详细说明；但本发明的一种负载端子带信号监控的大电流继电器不局限于实施例。
本发明还提供一种桥式大电流电磁继电器，通过结构改进，在应用于大电流环境时，可提升载流能力，降低触点处的发热，减小触点分断时的燃弧，从而提升产品的性能。
本发明的桥式大电流电磁继电器，包括底座、安装在底座上的两个具有刚性特征的静簧、呈卧式安装在底座上的线圈以及连接于匹配在线圈的附近的衔铁和轭铁之间的具有柔性特征的动簧片；在动簧片的连接有所述衔铁的一端还固接具有刚性特征 的桥接片，并使桥接片的两端分别与两个静簧相对应；所述每个静簧上分别设有两个静触点，所述桥接片的两端分别设有两个动触点，且四个动触点呈一字型排列，当所述线圈工作而使所述桥接片的两端与两个静簧相接触时，所述桥接片的两端的两个动触点分别与两个静簧上的两个静触点对应相接触。
所述桥接片的两端的两个动触点和两个静簧上的两个静触点分别设为方形结构。
所述桥接片的两端的两个动触点和两个静簧上的两个静触点的触点表面分别设为向外凸出的弧面。
所述轭铁为L型，轭铁的L型的一边为第一部分，该第一部分与铁芯相固定，轭铁的L型的另一边为第二部分，所述第二部分配置在线圈的上面。
所述的两个静簧分别设在所述桥接片与所述线圈之间。
所述的两个静簧分别对称装在底座的两侧。
所述底座中，在对应于桥接片的背向动触点的一面还装有止挡块。
所述止挡块中，还装有缓冲垫。
与现有技术相比较，本发明的有益效果是：
1、本发明在每个静簧上分别设有两个静触点，在所述桥接片的两端分别设有两个动触点，且四个动触点呈一字型排列，当所述线圈工作而使所述桥接片的两端与两个静簧相接触时，所述桥接片的两端的两个动触点分别与两个静簧上的两个静触点对应相接触。本发明的这种结构，是在每个负载端子(即静簧)上同时设有并列的两个触点，这两个触点实现并连，而在动簧片的桥接片上对应设有的四个触点，并让桥接片上的四个触点分别于负载端子上的两个触点两两对应，两个负载端子(即静簧)则通过桥接片实现串联，双触点在负载端子端接通时，双触点并联使得等效的电阻减半(也相当于电流分流，可提升载流能力)，因此在同等电流条件下，功耗量降低至原来的1/2，因此大大降低触点的功耗量，即降低触点处的发热，从而提升产品性能——负载能力更高；两个负载端子借助桥接片串联，实现电流回路的同步双断开也使得出现的电弧能量减半，达到减小触点分断时的燃弧的目的。
2、本发明将桥接片的两端的两个动触点和两个静簧上的两个静触点分别设为方形结构，以及将桥接片的两端的两个动触点和两个静簧上的两个静触点的触点表面分别设为向外凸出的弧面。本发明的这种结构，可以利用方形结构和弧形表面的配合使动静触点间的接触为线接触，从而提高动静触点间接触的可靠性。
3、本发明在动簧片的连接有所述衔铁的一端还固接具有刚性特征的桥接片，并使桥接片的两端分别与两个静簧相对应。本发明的这种结构，使得动簧片只需承担动簧部件的来回运动的机械疲劳强度而不承担载流能力，而桥接片只承担载流能力而不承担载抗机械疲劳能力，在具有相同灭弧能力的情况，能随机选择动簧材料而不需要选择特殊的动簧材料，同时负载回路路程更短(电流只流经桥接片而不经过动簧片)， 即更短的路程则有更小的线路电阻，因此，在相同负载(电流)的条件下，发热量会更小。
本发明中通过以下参照附图对优选实施例的说明，本发明的上述以及其它目的、特征和优点将更加明显。
附图说明
通过参照附图详细描述其示例实施方式，本发明的上述和其它特征及优点将变得更加明显。
图1是本发明继电器线圈组件的实施例一的立体构造示意图；
图2是图1中的A部放大示意图；
图3是本发明的实施例一的线圈架与线圈引脚相配合的示意图；
图4是图3中的B部放大示意图；
图5是本发明的实施例一的线圈引脚的立体构造示意图；
图6是本发明的实施例一的线圈架、漆包线与线圈引脚相配合的示意图；
图7是图6中的C部放大示意图；
图8是本发明的实施例一的信号线装入线圈引脚的过程示意图一；
图9是本发明的实施例一的信号线装入线圈引脚的过程示意图二；
图10是本发明的实施例一的信号线装入线圈引脚的过程示意图三；
图11是本发明的实施例一的电子元件的构造示意图；
图12是本发明的实施例一的电子元件与线圈引脚相配合的示意图；
图13是本发明继电器线圈组件的实施例二的线圈引脚的立体构造示意图；
图14是本发明可调整超行程的大电流继电器实施例的立体构造分解示意图；
图15是本发明的实施例的主视图(未含外壳)；
图16是本发明的实施例的仰视图(未含外壳)；
图17是沿图16中A-A线的剖视图；
图18是图17中的D部的放大示意图；
图19是图17中的E部的放大示意图；
图20是本发明的实施例的仰视图(未含外壳且转动一个角度)；
图21是沿图20中D-D线的剖视图；
图22是本发明的实施例的线圈架、动簧衔铁部件和轭铁的配合示意图；
图23是本发明的实施例的线圈架、动簧衔铁部件和轭铁的配合示意图(翻转一个角度)；
图24是本发明的实施例的底座和静簧的配合示意图；
图25是图24中的F部的放大示意图；
图26是本发明的实施例的(未含外壳且底部翻转)立体构造示意图；
图27是图26中的G部的放大示意图；
图28是本发明保证衔铁或动簧片正常动作的继电器实施例一(未装外壳)的立体构造示意图；
图29是本发明的实施例一(未装外壳)的立体构造示意图(转动一个角度)；
图30是本发明的实施例一的俯视图；
图31是沿图30中的B-B线的剖视图；
图32是图31中的H部的部分结构的放大示意图(外壳的凸出部与轭铁未接触)；
图33是图31中的H部的部分结构的放大示意图(外壳的凸出部与轭铁接触)；
图34是本发明的实施例一的外壳的立体构造示意图；
图35是本发明的实施例一的外壳(翻转状态)的立体构造示意图；
图36是本发明的实施例一的外壳的仰视图；
图37是本发明的实施例一的外壳与轭铁配合状态的示意图；
图38是本发明的实施例二(未装外壳)的立体构造示意图；
图39是本发明的实施例二的俯视图；
图40是沿图39中的C-C线的剖视图；
图41是图40中的J部的部分结构的放大示意图(外壳的凸出部与轭铁未接触)；
图42是图40中的J部的部分结构的放大示意图(外壳的凸出部与轭铁接触)；
图43是本发明负载端子带信号监控的大电流继电器的实施例一的立体构造示意图；
图44是本发明的实施例一的立体构造分解示意图；
[根据细则91更正 09.06.2020]　
图45是本发明的实施例一的底座部分的立体构造示意图；
[根据细则91更正 09.06.2020]　
图46是本发明的实施例一的底座部分的俯视图；
图47是本发明的实施例一的底座部分的翻转一面的示意图；
图48是本发明的实施例一的静簧部分与信号线相配合的示意图；
图49是本发明的实施例一的静簧部分与信号线相配合的分解示意图；
图50是本发明的实施例一的静簧部分与信号线相配合的俯视图；
图51是本发明的实施例一的静簧部分与信号线相配合的翻转一面的示意图；
图52是沿图51中E-E线的剖视图；
图53是沿图51中F-F线的剖视图(铆接前)；
图54是沿图51中F-F线的剖视图(铆接后)；
图55是本发明的实施例二的静簧部分与信号线相配合的分解示意图；
图56是本发明的实施例二的静簧部分与信号线相配合的翻转一面的示意图；
图57是沿图56中P-P线的剖视图；
图58是沿图56中Q-Q线的剖视图；
图59是本发明的实施例三的静簧部分与信号线相配合的示意图；
图60是本发明的实施例三的静簧部分与信号线相配合的分解示意图；
图61是本发明的实施例三的静簧部分与信号线相配合的翻转一面的示意图；
图62是沿图61中M-M线的剖视图；
图63是沿图61中N-N线的剖视图；
图64是本发明的实施例的立体构造分解示意图；
图65是本发明的实施例的立体构造示意图(不含外壳)；
图66是本发明的实施例的桥接片的立体构造示意图；
图67是本发明的实施例的静簧的立体构造示意图；
图68是本发明的实施例的安装于底座的静簧与桥接片相配合的示意图；
图69是本发明的实施例的安装于底座的静簧与桥接片相配合的俯视图。
具体实施方式
现在将参考附图更全面地描述示例实施方式。然而，示例实施方式能够以多种形式实施，且不应被理解为限于在此阐述的实施方式。虽然本说明书中使用相对性的用语，例如“上”、“下”来描述图标的一个组件对于另一组件的相对关系，但是这些术语用于本说明书中仅出于方便，例如根据附图中所述的示例的方向。能理解的是，如果将图标的装置翻转使其上下颠倒，则所叙述在“上”的组件将会成为在“下”的组件。其他相对性的用语，例如“顶”、“底”等也作具有类似含义。当某结构在其它结构“上”时，有可能是指某结构一体形成于其它结构上，或指某结构“直接”设置在其它结构上，或指某结构通过另一结构“间接”设置在其它结构上。
用语“一个”、“一”、“该”和“所述”用以表示存在一个或多个要素/组成部分/等；用语“包括”和“具有”用以表示开放式的包括在内的意思并且是指除了列出的要素/组成部分/等之外还可存在另外的要素/组成部分/等；用语“第一”、“第二”等仅作为标记使用，不是对其对象的数量限制。
继电器线圈组件实施例一
参见图1至图12所示，本发明的一种继电器线圈组件，包括线圈架1、漆包线200、线圈引脚3和信号线400；所述线圈架1的两端分别设有凸缘11，两凸缘11之间构成线圈架的绕线窗口12，所述漆包线200缠绕在所述绕线窗口12中；所述线圈引脚3包括插接部31、漆包线固定部32和信号线固定部33，所述线圈引脚3通过插接部31插装于 所述线圈架1的其中一端的凸缘11；所述信号线固定部33设有开口向下的第一卡槽331；所述信号线400卡接在所述第一卡槽331中；所述第一卡槽331的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩332，所述第一卡槽331的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段333，以在对设有倒钩332的一侧槽壁的外部施力时利用所述斜面段333将所述信号线400挤压在所述第一卡槽331内，并利用所述倒钩332防止所述信号线400从第一卡槽331脱出。
本实施例中，所述信号线400卡接在所述线圈引脚3的第一卡槽331后还通过焊接方式使信号线400与线圈引脚3固定。
本实施例中，所述第一卡槽331中，设有斜面段333的槽壁与设有倒钩332的槽壁为同一侧槽壁，所述第一卡槽331的另一侧槽壁设为直面形壁。
本实施例中，所述倒钩332为两个，所述两个倒钩332由开口边沿向内呈顺序排列。
进一步的，所述线圈引脚3还包括电子元件固定部34，电子元件500为电阻或二极管；所述电子元件固定部34设有开口向下的第二卡槽341；且所述第二卡槽341设在所述第一卡槽331的侧边。
本实施例中，所述第一卡槽331的直面形壁比第一卡槽331的斜面段333的槽壁更加靠近所述第二卡槽341。
本实施例中，所述线圈引脚3为片形结构；线圈架1的铁芯安装孔13的轴线Z(见图6)呈水平设置；所述线圈引脚3的中上部为所述插接部31并配合在线圈架1的其中一端的凸缘11的配合槽14中；所述线圈引脚3的下部为信号线固定部33和电子元件固定部34；所述线圈引脚3的中部向一侧延伸构成所述漆包线固定部32，并在线圈引脚3插装于所述线圈架1后弯向线圈架的绕线窗口12。
本实施例中，所述线圈引脚3的漆包线固定部32还设有便于定位及缠绕漆包线的第一齿形结构321。
本实施例中，所述线圈引脚3的插接部31中还设有用来与线圈架的配合槽实现过盈配合的第二齿形结构311。
与现有技术相比较，本发明的有益效果是：
本发明的一种继电器线圈组件，在线圈引脚3的第一卡槽331的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩332，所述第一卡槽331的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段333，以在对设有倒钩的所述的其中一侧槽壁的外部施力时利用所述斜面段333将所述信号线挤压在所述第一卡槽331内，并利用所述倒钩332防止所述信号线400脱出。本发明的这种结构，通过在第一卡槽331内设置斜面，相当于形成一个三角区，柔性信号线从第一卡槽的开口处沿着倒钩332边缘位置处压入第一卡槽331内后，通过对第一卡槽331的具有倒钩的一侧槽壁的外部进行挤压，使该侧槽壁的倒钩332向另一侧槽壁方向发生变形，使槽内空间变小，信号线400与第一卡槽331呈过盈配合，从而实现将信号线400卡住， 使之不容易脱落。
本发明的一种继电器线圈组件，信号线400卡接在所述线圈引脚3的第一卡槽331后，还通过焊接方式使信号线400与线圈引脚3固定。本发明的这种结构，形成卡接加焊接的双重保险，不会出现虚焊，使信号线与线圈引脚的连接更可靠。
本发明的一种继电器线圈组件，在线圈引脚3的漆包线固定部32还设有便于定位及缠绕漆包线的第一齿形结构321。本发明的这种结构，利用第一齿形结构321来控制第一圈漆包线的起始位置，在绕好漆包线200后再折弯时，可以避免漆包线200与线圈架1相重叠，防止漆包线200被卡住。
继电器线圈组件实施例二
参见图13所示，本发明的一种继电器线圈组件，与实施例一的不同之处在于，所述倒钩332仅为一个。
可调整超行程的大电流继电器实施例
参见图14至图27所示，本发明的一种可调整超行程的大电流继电器，包括外壳2、线圈架1、动簧衔铁部件15和底座300；线圈架1的铁芯安装孔13的轴线呈水平设置，铁芯安装孔13装有铁芯，线圈架1的两端分别设有凸缘11，两凸缘11之间构成绕线窗口，绕线窗口缠绕漆包线；所述动簧衔铁部件15与线圈架1装配在一起，并使动簧衔铁部件15的动触点150在线圈架1的一端的外侧与静触点41呈配合状态，静触点41设在静簧4上，静簧4是装在底座300上；所述线圈架1的一端的凸缘11向下延伸设有第一挂钩部件5(见图19-21)，底座300的对应位置设有第一卡孔310，线圈架1的第一挂钩部件5配合在底座300的第一卡孔310中，使包含有线圈架和动簧衔铁部件的整体部件(整体部件还包括轭铁、铁芯、漆包线等)在对应于第一卡孔的位置处沿着竖向被限位和沿着垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第一间隙H1，以铁芯的轴线为Z轴，以竖向为X轴，以垂直于铁芯安装孔的轴线的水平方向为Y轴，则线圈架的第一挂钩部件5与底座300的第一卡孔310的配合，在对应于第一卡孔的位置处，整体部件不能相对于底座300沿着X轴的正反方向移动，整体部件也不能相对于底座300沿着Y轴的正反方向移动，但是，沿着Z轴，整体部件可以相对于底座300移动第一间隙的距离；所述线圈架1的另一端的凸缘11向下延伸设有第二挂钩部件6，底座300的对应位置设有第二卡孔320，所述线圈架1的第二挂钩部件6配合在底座的第二卡孔320中，使所述整体部件在对应于第二卡孔的位置处沿着竖向被限位和沿着垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第二间隙H2，这样，线圈架1的第二挂钩部件6与底座300的第二卡孔320的配合，整体部件不能相对于底座300沿着X轴的正反方向移动，整体部件也不能相对于底座300沿着Y轴的正反方向移动，但是，沿着Z轴，整体部件可以相对于底座300移动第二间隙的距离；从而可以利用所述第一间隙H1和第二间隙H2实现 触点超行程的调节；第一间隙H1和第二间隙H2是相等的。
本实施例中，所述第一挂钩部件5为一个，第一挂钩部件5设在所述铁芯安装孔13的轴线Z的正下方；所述第二挂钩部件6为两个，两个第二挂钩部件6对称设在所述铁芯安装孔13的轴线Z的正下方的两侧。
参见图21-23，本实施例中，所述第一挂钩部件包括两个朝向相反的挂钩51、52和位于两个挂钩51、52之间的一个使挂钩能够弹性摆动的第一避让槽53；所述两个挂钩51、52的钩头50分别朝向所述铁芯安装孔的轴线Z的正下方的两侧。
本实施例中，所述第一卡孔310的底部的对应于钩头50的位置分别设有台阶面朝下的第一台阶311；所述第一挂钩部件5的上部两侧设有用来防止过压的翼片54，当第一挂钩部件5配合在第一卡孔310时，第一挂钩部件5的两个挂钩51、52的钩头50分别钩在第一卡孔的第一台阶311处，第一挂钩部件5的两侧的翼片54抵在第一卡孔310的边沿的底座上，从而使所述整体部件在对应于第一卡孔的位置处沿着竖向被限位。
本实施例中，所述第一挂钩部件5与所述第一卡孔310的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁之间呈过渡配合，使所述整体部件在对应于第一卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向被限位。
本实施例中，所述第二挂钩部件6包括一个钩头60朝向线圈架外的挂钩61和设在挂钩61旁边使所述挂钩61能够向线圈架内方向弹性摆动的第二避让槽62。
本实施例中，所述第二卡孔320的底部的对应于钩头60的位置设有台阶面朝下的第二台阶321；所述第二挂钩部件6的上部设有用来防止过压的且是台阶面朝下的第三台阶63，当第二挂钩部件6配合在第二卡孔320时，第二挂钩部件6的钩头60钩在第二卡孔320的第二台阶321处，第二挂钩部件6的第三台阶63抵在第二卡孔320的边沿的底座上，从而使所述整体部件在对应于第二卡孔的位置处沿着竖向被限位。
本实施例中，所述第二挂钩部件6与所述第二卡孔320的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁之间呈过渡配合，使所述整体部件在对应于第二卡孔320的位置处沿着垂直于铁芯安装孔的轴线的水平方向被限位；所述第二卡孔的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个还设为波浪形壁面322，以在利用所述第一间隙和第二间隙实现触点超行程的调节后，对第二卡孔320的波浪形壁面322和第二挂钩部件之间的热融处理，使第二挂钩部件6与底座300固定在一起，使所述整体部件在对应于第二卡孔的位置处沿着铁芯安装孔的轴线方向和垂直于铁芯安装孔的轴线的水平方向同时被限位，并利用波浪形壁面322实现整体部件在对应于第二卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向的微调整；也就是说，由于第二卡孔320有波浪形壁面322，第二卡孔320的波浪形壁面322与第二挂钩部件6热融处理后，线圈架(以及整体部件)在对应于第二 卡孔的位置处沿着垂直于铁芯安装孔的轴线的水平方向有微小的移动。
进一步的，本发明的大电流继电器还包括轭铁7，所述轭铁7设有安装脚70，所述轭铁7的安装脚70与所述第二挂钩部件6一起配合在所述第二卡孔320中，且所述轭铁的安装脚70相对于所述第二挂钩部件6更加靠近所述铁芯安装孔的轴线的正下方；所述第二卡孔320的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个相对于另一个更加远离所述铁芯安装孔的轴线的正下方。
本发明的一种可调整超行程的大电流继电器，在线圈架1的一端的凸缘11向下设有第一挂钩部件5，底座300的对应位置设有第一卡孔310，线圈架的第一挂钩部件5配合在底座的第一卡孔310中，使包含有线圈架和动簧衔铁部件的整体部件在对应于第一卡孔310的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第一间隙；在线圈架1的另一端的凸缘11向下延伸设有第二挂钩部件6，底座300的对应位置设有第二卡孔320，所述线圈架的第二挂钩部件6配合在底座的第二卡孔320中，使所述整体部件在对应于第二卡孔的位置处沿着竖向和垂直于铁芯安装孔的轴线的水平方向被限位，而沿着铁芯安装孔的轴线方向存在可移动的第二间隙；从而利用所述第一间隙和第二间隙实现触点超行程的调节。本发明的这种结构，既实现了线圈架1与底座300之间的钩挂固定，避免了现有技术采用劈铆固定所带来的弊端，而且还能够实现大电流继电器的超行程调整。
本发明的一种可调整超行程的大电流继电器，第一挂钩部件5设为一个，且第一挂钩部件5设在所述铁芯安装孔的轴线的正下方；第二挂钩部件6设为两个，两个第二挂钩部件6对称设在所述铁芯安装孔的轴线的正下方的两侧。本发明的这种结构，通过线圈架1与底座300之间的三点配合，使得线圈架与底座之间能够获得稳固的连接。
本发明的一种可调整超行程的大电流继电器，将第一挂钩部件5设计成包括两个朝向相反的挂钩51、52和两个挂钩51、52之间的一个使对应的挂钩能够弹性摆动的第一避让槽53；所述两个挂钩51、52的钩头50分别朝向所述铁芯安装孔的轴线的正下方的两侧；将第二挂钩部件6设计成包括一个钩头60朝向线圈架外的挂钩61和设在挂钩旁边使所述挂钩能够向线圈架内方向弹性摆动的第二避让槽62。本发明的这种结构，在线圈架1压入底座300时，第一挂钩部件5装入第一卡孔310时，第一挂钩部件5的两个钩头50向中间方向变形，第二挂钩部件6装入第二卡孔320时，第二挂钩部件6的钩头60向触点方向变形，从而可以降低装配时线圈架与底座之间的装配难度和解决装配时的塑料异物产生。
本发明的一种可调整超行程的大电流继电器，在第二卡孔320的沿着垂直于铁芯安装孔的轴线的水平方向的两个相对的孔壁中的其中一个还设为波浪形壁面322。本发明的这种结构，通过将第二卡孔320的一侧壁设计成波浪形结构，调整完超行程后对第二挂钩部 件6进行热熔处理，第二挂钩部件6的热熔融物填充波浪形表面322，能够实现整体部件在对应于第二卡孔的位置处沿着铁芯安装孔的轴线方向和垂直于铁芯安装孔的轴线的水平方向同时被限位，同时，波浪形的表面可以增加第二卡孔320与挂钩61的热熔融物的配合面积，增加固定强度。
可保证衔铁或动簧片正常动作的继电器实施例一
参见图28至图42所示，本发明的一种可保证衔铁或动簧片正常动作的继电器，包括外壳2、底座300、线圈组件100、铁芯49、轭铁7、衔铁67和动簧片8；线圈组件100包括线圈架1、漆包线200和线圈引脚3，线圈组件100呈卧式安装在底座300上，铁芯49装在线圈组件100的线圈架1的铁芯安装孔中，铁芯49的第一端部的端面设为极面；轭铁7的第一部分71与铁芯49的第二端部相固定，轭铁7的第二部分72适配在线圈组件100的上面，动簧片8的第一部分81与所述轭铁7的第二部分72相固定，动簧片8的第二端部82与衔铁67相固定，并使衔铁67与铁芯49的极面相对应以及衔铁67的上部适配在轭铁7的刀口处，且衔铁67的上端高出所述轭铁7的第二部分72的上面和所述动簧片8的第一部分81的上面；所述外壳2装在底座300上并将所述线圈组件100、铁芯49、轭铁7、衔铁67和动簧片8容纳在内；在外壳2的顶部内侧面中还设有向下突出的能够抵向所述轭铁的第二部分72的上表面的凸出部21，且所述凸出部21的底面与所述轭铁的第二部分72的上表面之间的距离D1小于所述外壳2的顶部内侧面与衔铁67的上端之间的距离D2，以在外壳2向下变形时，利用所述凸出部21抵在所述轭铁的第二部分72的上表面，从而保证外壳2不会压住衔铁67。凸出部为扁圆柱，也可以为筋条等其他类似结构。
本实施例中，所述外壳2的顶部内侧面的凸出部21为三个，并呈三角形分布。
本实施例中，所述外壳2中，在对应于线圈组件100的铁芯安装孔的轴线的两边的侧壁中，还设有能够适配在所述轭铁的第二部分72的两侧边的限位筋22，且所述限位筋22与所述轭铁的第二部分72的对应侧边之间具有预置的间隙，以防止包含轭铁在内的磁路部分在预置方向的窜动。
本实施例中，所述轭铁7为L型，轭铁7的L型的一边作为所述轭铁的第一部分71，该第一部分71与所述铁芯49的第二端部相固定，轭铁的L型的另一边作为所述轭铁的第二部分72，该第二部分72适配在所述线圈组件100的上侧；所述动簧片8为L型，动簧片的L型的一边作为所述动簧片的第一部分81，该第一部分81在所述轭铁7的第二部分72的上面与轭铁7相固定，动簧片8的L型的另一边作为所述动簧片的第二部分82，该第二部分82与衔铁67相固定。
本实施例中，所述轭铁的第二部分72的端部的两侧分别向外延伸设有凸柱721，两个凸柱721之间构成所述轭铁的刀口；所述衔铁67的上部的两侧分别设有第一凹槽671，所述衔铁67的上部的两侧的第一凹槽671分别与所述轭铁的第二部分72的端部的两个凸柱721相配合，使所述衔铁67的上部适配在所述轭铁7的刀口 处。
本实施例中，所述衔铁67的顶端设有第二凹槽672，所述动簧片8的第一部分81跨过所述衔铁67的顶端的第二凹槽672，以使所述衔铁67的顶端高出所述轭铁7的第二部分72的上面和动簧片8的第一部分81的上面。
本实施例中，所述动簧片8的第一部分81中，还设有对所述衔铁的顶部进行限位的止挡部811，以将所述衔铁67的上部限位在所述轭铁7的刀口处。
本发明的一种可保证衔铁或动簧片正常动作的继电器，在外壳2的顶部内侧面中还设有向下突出的能够抵向所述轭铁的第二部分的上表面的凸出部21，且所述凸出部21的底面与所述轭铁的第二部分的上表面之间的距离D1小于所述外壳的顶部内侧面与衔铁的上端之间的距离D2。本发明的这种结构，当外壳2顶部受力变形时，外壳2会同时使凸出部21向下发生移动，凸出部21会与轭铁7先接触，从而避免外壳2与衔铁67接触，卡死衔铁67，能够保证衔铁67正常动作，从而确保继电器的正常使用。
本发明的可保证衔铁或动簧片正常动作的继电器，将外壳2的顶部内侧面的凸出部21设为三个，并呈三角形分布。本发明的这种结构，能够保证外壳2顶部受力变形时与轭铁7平稳接触，保证了外壳2不会与衔铁67接触，保证衔铁67正常动作。
本发明的一种可保证衔铁或动簧片正常动作的继电器，外壳2的在对应于线圈组件的铁芯安装孔的轴线的两边的侧壁中，还设有能够适配在所述轭铁的第二部分的两侧边的限位筋22，且所述限位筋22与所述轭铁的第二部分72的对应侧边之间具有预置的间隙。本发明的这种结构，可以防止包含轭铁在内的磁路部分在预置方向的窜动。
可保证衔铁或动簧片正常动作的继电器实施例二
参见图34至图42所示，本发明的一种可保证衔铁或动簧片正常动作的继电器，与实施例一的不同之处在于，所述衔铁67的上部的两侧分别设有台肩673，所述衔铁的上部的两侧的台肩673分别与所述轭铁的第二部分72的端部的两个凸柱721相配合，使所述衔铁67的上部适配在所述轭铁7的刀口处。
所述动簧片8的第一部分81跨过所述衔铁67的顶端，以使所述动簧片8的上端位置高出所述轭铁的第二部分72的上面和衔铁。
所述凸出部21的底面与所述轭铁的第二部分72的上表面之间的距离D1小于所述外壳2的顶部内侧面与动簧片8的上端之间的距离D3。
当外壳2顶部受力变形时，外壳2会同时使凸出部21向下发生移动，凸出部21会与轭铁7先接触，从而避免外壳2与动簧片8接触，卡死动簧片8，能够保证动簧片8正常动作，从而确保继电器的正常使用。
负载端子带信号监控的大电流继电器实施例一
参见图43至图54所示，本发明的一种负载端子带信号监控的大电流继电器， 包括外壳2、机芯部分8和底座300；外壳2装在底座300上并将机芯部分8容纳在内，所述机芯部分8包括磁路部分81及其受磁路部分工作而动作的动簧衔铁部分15；所述动簧衔铁部分15包括桥接片78以及设置于桥接片78两端部的动触点150；本实施例的动触点150为单独的零件而固定在桥接片78上，当然，动触点也可以由桥接片78一体形成的凸出，或者是由桥接片78的端部直接构成动触点；所述底座300包括两个静簧4以及将两个静簧4相互绝缘地通过注塑方式固定在一起的塑料体92；所述静簧4为片形结构包括水平埋在所述塑料体的主体部911、弯折成露出在塑料体之上的接触部912和水平露出在塑料体92的侧边以作为负载端子的连接部913，接触部912设有静触点914，本实施例的静触点914为单独的零件而固定在静簧4的接触部912上，当然，静触点也可以由静簧4的接触部912一体形成的凸出，或者是由静簧4的接触部912直接构成静触点；所述机芯部分8安装在底座300上并使机芯部分8的桥接片78的两端部分别与两个静簧4的接触部912相对应，以实现触点闭合(即桥接片78的两端部的动触点150与两个静簧4的接触部912的静触点41对应相接触)时，电流由一个静簧的负载端子流入，从另一个静簧的负载端子流出；在两个静簧4的主体部911中还分别设有一个向上凸出而没被所述塑料体92所遮盖的凸部42，所述两个静簧4的凸部42上还分别连接一信号线400，以实现对触点闭合状态以及触点开闭次数的信号进行采集。
所述信号线400与所述静簧的凸部42之间还设有金属导电片65，所述金属导电片65设有第一通孔610，所述金属导电片65的第一通孔610配合在静簧4的凸部42上，并通过焊接或铆接方式相连接。
本实施例中，所述两条信号线400的各一端分别连接对应的金属导电片65，两条信号线400的各另一端分别与一个连接器700相连接，并通过所述连接器700与继电器外部的控制模块相连接。
本实施例中，所述静簧的凸部42与所述静簧的主体部911为分立的零件，所述静簧的凸部42为金属铆钉，所述静簧的主体部911的对应位置设有第二通孔915，所述金属铆钉配合在所述静簧的主体部911的第二通孔915中，所述金属铆钉的底部与所述静簧的主体部911的第二通孔915铆接相配合。
本实施例中，所述金属铆钉的顶部设有台阶421，所述金属导电片65的第一通孔610配合在所述金属铆钉的台阶421处，并通过铆接方式相固定。
本实施例中，所述信号线400为软导线。
本发明的一种负载端子带信号监控的大电流继电器，采用了在两个静簧4的主体部911中还分别设有一个向上凸出而没被所述塑料体所遮盖的凸部42，所述两个静簧4的凸部42上还分别连接一信号线400，以实现对触点闭合状态以及触点开闭次数的信号进行采集。本发明的这种结构，通过在静簧4上增加信号线400这一简单装置，当触点闭合时，两条信号线也连通，通过采集两条信号线的连通信号，一方面， 可以实时监控触点的状态、判断继电器是否正常工作，及时排查风险；另一方面，可对继电器的触点开闭次数进行收集、统计，当达到失效次数时，能自动提醒更换或维修，从而保证继电器的正常应用。本发明使继电器多增加了信号监控功能。
本发明的一种负载端子带信号监控的大电流继电器，采用了将静簧的凸部42与所述静簧的主体部911设为分立的零件，且静簧的凸部42为金属铆钉，静簧的主体部911的对应位置设有第二通孔915，将金属铆钉配合在静簧的主体部911的第二通孔915中，将金属铆钉的底部与所述静簧的主体部911的第二通孔915铆接相配合。本发明的这种结构，便于静簧的凸部的工艺制作，且在静簧的凸部与金属导电片相配合时，不会导致塑料体的损坏，由于金属铆钉为实心体，还能提高金属导电片与静簧的凸部的接触的稳定性。
本发明的一种负载端子带信号监控的大电流继电器，采用了在金属铆钉的顶部设有台阶421，将金属导电片65的第一通孔610配合在所述金属铆钉的台阶421处。本发明的这种结构，可以利用金属铆钉的台阶421来增加金属导电片65与静簧4的导电面积，提高导电可靠性。
本发明的一种负载端子带信号监控的大电流继电器，采用了信号线400为软导线，且信号线400的一端连接金属导电片65，信号线400的另一端与一个连接器700相连接，本发明是利用软导线来消除硬连接(金属片与金属片直接连接，容易脱落)之间所产生的应力，从而提高了连接的可靠性。
负载端子带信号监控的大电流继电器实施例二
参见图55至图58所示，本发明的一种负载端子带信号监控的大电流继电器，与实施例一的不同之处在于，静簧的凸部的形成不相同，本实施例中，静簧的凸部42与静簧的主体部911为一体结构，且是由静簧的主体部911从底面向上拍打形成。
实负载端子带信号监控的大电流继电器施例三
参见图59至图63所示，本发明的一种负载端子带信号监控的大电流继电器，与实施例二的不同之处在于，所述塑料体92中，在对应于所述两个静簧的凸部42的周边还分别设有让位区，也就是在对两个静簧4注塑形成底座300时，塑料没有包到凸部42的地方，凸部42的旁边还有一圈是没有塑料，使这个位置的静簧的主体部911也露出来，所述两个静簧的凸部42分别套接有弹簧95，所述弹簧95在对应的让位区中被压缩在所述金属导电片65与所述静簧的主体部911之间，以利用所述弹簧95增加所述金属导电片65与所述静簧4的电接触面积；弹簧95是起着连通负载端子(即静簧4)和信号线连接端子(即金属导电片65)的作用。
本发明的一种负载端子带信号监控的大电流继电器，采用了在塑料体92中，在对应于所述两个静簧4的凸部42的周边还分别设有让位区，在两个静簧的凸部分别套接有弹簧95，弹簧95在对应的让位区中被压缩在所述金属导电片65与所述静簧的主体部911之间。本发明的这种结构，利用弹簧95的可变形性，在弹簧95变形后 始终与金属导电片65、静簧的主体部911相接触，从而可以保证信号诊断端子(即金属导电片)与负载端子(即静簧的主体部)之间的可靠连接，进一步保证了诊断信号的传递，从而可以保证系统对监测信号的有效读取。
桥式大电流电磁继电器实施例
参见图64至图69所示，本发明的一种桥式大电流电磁继电器，包括外壳2、底座300、安装在底座300上的两个具有刚性特征的静簧4、呈卧式安装在底座300上的线圈201以及匹配在线圈201的附近的衔铁67和轭铁7之间的具有柔性特征的动簧片8；在动簧片8的连接有所述衔铁67的一端还固接具有刚性特征的桥接片78，并使桥接片78的两端分别与两个静簧4相对应；所述每个静簧4上分别设有两个静触点41，所述桥接片78的两端分别设有两个动触点150，且四个动触点150呈水平一字型排列，静簧4上的两个静触点41也呈水平排列，铁芯49的一端设为极面，铁芯49的另一端与轭铁7相固定。
轭铁7为L型，轭铁7的L型的一边为第一部分71，该第一部分71与铁芯49的另一端相固定外，轭铁7的L型的另一边为第二部分72，该第二部分72配置在线圈的旁边(即线圈架的绕线窗口外)，本实施例中，轭铁7的第二部分72是配置在线圈201的上面，轭铁7的第二部分72的端头作为轭铁7的刀口用来配合衔铁67。
具有柔性特征的动簧片8也弯成大致L型，动簧片8的L型的一边为第一部分81，该第一部分81与轭铁7的第二部分72相固定，动簧片8的另一边为第二部分82，该第二部分82与衔铁67相固定，使得衔铁67能够以轭铁7的刀口为转轴吸向4的极面。当所述线圈201工作，使衔铁67吸向铁芯49的极面，衔铁67带动动簧片8的第二部分82摆动，动簧片8的第二部分82再带动桥接片78移动，使所述桥接片78的两端与两个静簧点41相接触，所述桥接片78的两端的两个动触点150分别与两个静簧4上的两个静触点41对应相接触。
本实施例中，所述桥接片78的两端的两个动触点150和两个静簧4上的两个静触点41分别设为方形结构。
本实施例中，所述桥接片78的两端的两个动触点150和两个静簧4上的两个静触点41的触点表面分别设为向外凸出的弧面。
本实施例中，所述的两个静簧4分别设在所述桥接片78与所述线圈201之间。
本实施例中，所述的两个静簧4分别对称装在底座300的两侧。
本实施例中，所述底座300中，在对应于桥接片78的背向动触点的一面还装有止挡块85；止挡块85也是两个。本实施例的止挡块85为单独的零件，装在底座300上，当然，止挡块85也可以由底座一体形成。
本实施例中，所述止挡块85中，还装有缓冲垫851。缓冲垫851是用来降低继电器释放时的噪音，继电器释放时，桥接片78会随衔铁67的释放而靠向止挡块85，由于止挡块85有缓冲垫851，可以缓冲桥接片78的撞击力，从而降低撞击产生的噪 声。
本发明的一种桥式大电流电磁继电器，在每个静簧4上分别设有两个静触点41，在所述桥接片78的两端分别设有两个动触点150，且四个动触点150呈一字型排列，当所述线圈201工作而使所述桥接片78的两端与两个静簧4相接触时，所述桥接片78的两端的两个动触点150分别与两个静簧4上的两个静触点41对应相接触。本发明的这种结构，是在每个负载端子(即静簧)上同时设有并列的两个触点，这两个触点实现并连，而在动簧片的桥接片上对应设有的四个触点，并让桥接片上的四个触点分别于负载端子上的两个触点两两对应，两个负载端子(即静簧)则通过桥接片实现串联，双触点在负载端子端接通时，双触点并联使得等效的电阻减半(也相当于电流分流，可提升载流能力)，因此在同等电流条件下，功耗量降低至原来的1/2，因此大大降低触点的功耗量，即降低触点处的发热，从而提升产品性能——负载能力更高；两个负载端子借助桥接片串联，实现电流回路的同步双断开也使得出现的电弧能量减半，达到减小触点分断时的燃弧的目的。从另一方面来说，双触点在负载端接通时，双触点起到分流作用，因此单触点的承担的电流为原来的1/2，根据Q＝I2RT原理，同等电流条件下，发热量降低至原来的1/4，因此大大降低触点的发热量，从而提升产品性能。
本发明的一种桥式大电流电磁继电器，将桥接片78的两端的两个动触点150和两个静簧4上的两个静触点41分别设为方形结构，以及将桥接片78的两端的两个动触点150和两个静簧4上的两个静触点41的触点表面分别设为向外凸出的弧面。本发明的这种结构，可以利用方形结构和弧形表面的配合使动静触点间的接触为线接触，从而提高动静触点间接触的可靠性。
本发明的一种桥式大电流电磁继电器，在动簧片2的连接有所述衔铁67的一端还固接具有刚性特征的桥接片78，并使桥接片78的两端分别与两个静簧4相对应。本发明的这种结构，使得动簧片2只需承担动簧部件的来回运动的机械疲劳强度而不承担载流能力，而桥接片78只承担载流能力而不承担载抗机械疲劳能力，在具有相同灭弧能力的情况，能随机选择动簧材料而不需要选择特殊的动簧材料，同时负载回路路程更短(电流只流经桥接片78而不经过动簧片2)，即更短的路程则有更小的线路电阻，因此，在相同负载(电流)的条件下，发热量会更小。
应可理解的是，本发明不将其应用限制到本说明书提出的部件的详细结构和布置方式。本发明能够具有其他实施方式，并且能够以多种方式实现并且执行。前述变形形式和修改形式落在本发明的范围内。应可理解的是，本说明书公开和限定的本发明延伸到文中和/或附图中提到或明显的两个或两个以上单独特征的所有可替代组合。所有这些不同的组合构成本发明的多个可替代方面。本说明书所述的实施方式说明了已知用于实现本发明的最佳方式，并且将使本领域技术人员能够利用本发明。

Claims (10)

  1. 一种继电器线圈组件，包括线圈架、漆包线、线圈引脚和信号线；所述线圈架的两端分别设有凸缘，两凸缘之间构成线圈架的绕线窗口，所述漆包线缠绕在所述绕线窗口中；所述线圈引脚包括插接部、漆包线固定部和信号线固定部，所述线圈引脚通过插接部插装于所述线圈架的其中一端的凸缘；所述信号线固定部设有开口向下的第一卡槽；所述信号线卡接在所述第一卡槽中；其特征在于：所述第一卡槽的两侧槽壁中的其中一侧槽壁的靠近开口边沿设有倒钩，所述第一卡槽的两侧槽壁中的其中一侧槽壁的对应于信号线的配合位置处还设为由内向外使开口呈逐渐增大的斜面段，以在对设有倒钩的所述的其中一侧槽壁的外部施力时利用所述斜面段将所述信号线挤压在所述第一卡槽内并利用所述倒钩防止所述信号线脱出。
  2. 根据权利要求1所述的继电器线圈组件，其特征在于：所述信号线卡接在所述线圈引脚的第一卡槽后还通过焊接方式使信号线与线圈引脚固定。
  3. 根据权利要求1或2所述的继电器线圈组件，其特征在于：所述第一卡槽中，设有所述斜面段的槽壁与设有所述倒钩的槽壁为同一侧槽壁，所述第一卡槽的另一侧槽壁设为直面形壁。
  4. 根据权利要求3所述的继电器线圈组件，其特征在于：所述倒钩为一个。
  5. 根据权利要求3所述的继电器线圈组件，其特征在于：所述倒钩为两个或两个以上，所述两个或两个以上的所述倒钩由开口边沿向内呈顺序排列。
  6. 根据权利要求3所述的继电器线圈组件，其特征在于：所述线圈引脚还包括电子元件固定部，所述电子元件固定部设有开口向下的第二卡槽，且所述第二卡槽设在所述第一卡槽的侧边。
  7. 根据权利要求6所述的继电器线圈组件，其特征在于：所述第一卡槽的直面形壁比第一卡槽的斜面段的槽壁更加靠近所述第二卡槽。
  8. 根据权利要求6所述的继电器线圈组件，其特征在于：所述线圈引脚为片形结构；线圈架的铁芯安装孔的轴线呈水平设置；所述线圈引脚的中上部为所述插接部并配合在线圈架的其中一端的凸缘的配合槽中；所述线圈引脚的下部为所述信号线固定部和所述电子元件固定部；所述线圈引脚的中部向一侧延伸构成所述漆包线固定部，所述漆包线固定部在线圈引脚插装于所述线圈架后弯向线圈架的绕线窗口。
  9. 根据权利要求8所述的继电器线圈组件，其特征在于：所述线圈引脚的漆包线固定部还设有便于定位及缠绕所述漆包线的第一齿形结构。
  10. 根据权利要求8所述的继电器线圈组件，其特征在于：所述线圈引脚的插接部中还设有用来与所述线圈架的配合槽实现过盈配合的第二齿形结构。
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