Electromagnetic relay assembly with a linear motor

• US 6,320,485 B1
• Filed: 10/13/1999
• Issued: 11/20/2001
• Est. Priority Date: 04/07/1999
• Status: Expired due to Term

• Current Assignee: Xiamen Hongfa Electric Power Controls Co., Ltd
• Original Assignee: Klaus A. Gruner
• Inventors: Gruner, Klaus A.
• Primary Examiner(s): Donovan, Lincoln
• Assistant Examiner(s): NGUYEN, TUYEN T
• Application Number:
  US09/416,988
• Time in Patent Office: 769 Days
• Field of Search: 335/78-85, 335/124, 335/128, 335/185-190, 335/250, 335/251, 335/257, 335/132
• US Class Current: 335/78
• CPC Class Codes: H01H 2051/2218 having at least one movable permanent magnet
• CPC Class Codes: H01H 50/546 for contactors having bridging contacts
• CPC Class Codes: H01H 50/644 having more than one rotating or pivoting part
• CPC Class Codes: H01H 51/2209 with rectilinearly movable armature
• CPC Class Codes: H01H 51/2227 in which the movable part comprises at least one permanent magnet, sandwiched between pole-plates, each forming an active air-gap with parts of the stationary magnetic circuit H01H51/2209 takes precedence

Abstract

The present invention is an electromagnetic relay capable of transferring currents of greater than 100 amps for use in regulating the transfer of electricity or in other applications requiring the switching of currents of greater than 100 amps. A relay motor assembly has an elongated coil bobbin with an axially extending cavity therein. An excitation coil is wound around the bobbin. A generally U shaped ferromagnetic frame has a core section disposed in and extending through the axially extending cavity in the elongated coil bobbin. Two contact sections extend generally perpendicularly to the core section and rises above the motor assembly. An actuator assembly is magnetically coupled to the relay motor assembly. The actuator assembly is comprised of an actuator frame operatively coupled to a first and a second generally U-shaped ferromagnetic pole pieces, and a permanent magnet. A contact bridge made of a sheet of conductive material copper is operatively coupled to the actuator assembly.

Claims

1. An electromagnetic relay comprising:

a relay motor comprising a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a U-shaped ferromagnetic frame, said U-shaped ferromagnetic frame having a first contact section, a second contact section and a middle section, said middle section disposed in and extending through the axially extending cavity in the bobbin, and said first and said second contact section extending perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending perpendicularly from the first contact section and above the bobbin, the second contact section having a second and third tongue portions extending perpendicularly from the second contact section and above the bobbin, the second tongue portion lying below the third tongue portion;

a motor actuator having an actuator frame, the actuator frame having a first side and a second side, the first side having a first cam and a second cam, the second side having a third cam and a fourth cam, the first cam being identical to the third cam, and the second cam being identical to the fourth cam;

a movable contacts assembly, the movable contacts assembly comprising a spring housing, a first L-shaped lever, a second L-shaped lever, a first side-actuator and a second side-actuator, the first L-shaped lever being identical to the second L-shaped lever, both the first L-shaped lever and the second L-shaped lever being symmetrical, the spring housing having a top spring housing and a bottom spring housing, the top spring housing being identical to the bottom spring housing, the top spring housing having a first pivot hole, a second pivot hole, a third pivot hole, a fourth pivot hole, a first actuator slot, a second actuator slot, a first spring cavity, a second spring cavity, a third spring cavity, a fourth spring cavity, the top spring housing being symmetrical across the first slot and the second slot, the bottom spring housing having a fifth pivot hole, a sixth pivot hole, a seventh pivot hole, a eighth pivot hole, a third actuator slot, a fourth actuator slot, a fifth spring cavity, a sixth spring cavity, a seventh spring cavity, a fourth spring cavity, the bottom spring housing being symmetrical across the third slot and the fourth slot, the top spring housing being positioned as a mirror image of the bottom spring housing, the first pivot hole being in line with the seventh pivot, the second pivot being in line with the eighth pivot, the third pivot being in line with the fifth pivot, the fourth pivot being in line with the sixth pivot, the first actuator slot facing the third actuator slot, and the second actuator slot facing the fourth actuator slot, the first L-shaped lever having a first arm with a first end, a second arm with a second end, a first bearing shaft and a second bearing shaft, the first L-shaped lever rotatively positioned with its first shaft in the fourth pivot hole and its second shaft in the sixth pivot hole, the second L-shaped lever having a third arm with a third end, a fourth arm with a fourth end, a third bearing shaft and a fourth bearing shaft, the second L-shaped lever rotatively positioned with its third shaft in the first pivot hole and its fourth shaft in the seventh pivot hole, the first end operatively coupled to the first cam and the third end operatively couple to the fourth cam, or the first L-shaped lever rotatively positioned with its first bearing shaft in the third pivot hole and its second bearing shaft in the fifth pivot hole, the second L-shaped lever rotatively positioned with its third bearing shaft in the second pivot hole and its fourth bearing shaft in the eighth pivot hole, the second end operatively coupled to the second cam and the fourth end operatively couple to the third cam, the first side-actuator having a first lever nesting, a first contact-bridge-arm, and a second contact-bridge-arm, the second side-actuator having a second lever nesting, a third contact-bridge-arm, and a fourth contact-bridge-arm, the first lever nesting operatively coupled to the second end of the first L-shaped lever and the second lever nesting operatively coupled to the fourth end of the second L-shaped lever, or the second lever nesting operatively coupled to the first end of the first L-shaped lever, and the first lever nesting operatively coupled to the third end of the second lever;

a first group of contact bridge assemblies, the first group of contact bridge assemblies having a first contact bridge assembly and a second contact bridge assembly, said first contact bridge assembly having a first contact bridge, a first pressure spring and a second pressure spring, the first pressure spring disposed within the first spring cavity, the second pressure spring disposed within the second spring cavity, both the first pressure spring and the second pressure spring connected to the first contact bridge, the first contact bridge operatively engaged by the first contact-bridge-arm of the first side actuator, the first contact bridge being movable between a first position wherein the first contact bridge not in contact with two first contact points positioned directly opposite the first contact bridge and a second position wherein the first contact bridge in contact with the two first contact points, the first contact bridge serving as a conductive pathway between the two first contact points, the motor actuator acting on the movable contacts assembly, the first cam of the motor actuator driving the first L-shaped lever, the first L-shaped lever driving the first side actuator, the first contact-bridge-arm of the first side actuator pulling the first contact bridge assembly into the first position and compressing both the first pressure spring and the second pressure spring attached thereto, in the second position the first contact-bridge-arm of the first side actuator applying no pulling force allowing both the first pressure spring and the second pressure spring to decompress driving the first contact bridge assembly into contact with the two first contact points,

said second contact bridge assembly having a second contact bridge, a third pressure spring and a fourth pressure spring, the third pressure spring disposed within fifth spring cavity, the fourth pressure spring disposed within sixth spring cavity, both the third pressure spring and the fourth pressure spring connected to the second contact bridge, the second contact bridge operatively engaged by the second contact-bridge-arm of the first side actuator, the second contact bridge being movable between a third position wherein the second contact bridge not in contact with two second contact points positioned directly opposite the second contact bridge and a fourth position wherein the second contact bridge in contact with the two second contact points, the second contact bridge serving as a conductive pathway between the two second contact points, the motor actuator acting on the movable contacts assembly, the first cam of the motor actuator driving the first L-shaped lever, the first L-shaped lever driving the first side actuator, the second contact-bridge-arm of the first side actuator pulling the second contact bridge assembly into the third position and compressing both the third pressure spring and the fourth pressure spring attached thereto, in the fourth position the second contact-bridge-arm of the first side actuator applying no pulling force allowing both the third pressure spring and the fourth pressure spring to decompress driving the second contact bridge assembly into contact with the two second contact points; and

a second group of contact bridge assemblies, the second group of contact bridge assemblies having a third contact bridge assembly and a fourth contact bridge assembly, said third contact bridge assembly having a third contact bridge, a fifth pressure spring and a sixth pressure spring, the fifth pressure spring disposed within the third spring cavity, the sixth pressure spring disposed within the fourth spring cavity, both the fifth pressure spring and the sixth pressure spring connected to the third contact bridge, the third contact bridge operatively engaged by the third contact-bridge-arm of the second side actuator, the third contact bridge being movable between a fifth position wherein the third contact bridge not in contact with two third contact points positioned directly opposite the third contact bridge and a sixth position wherein the third contact bridge in contact with the two third contact points, the third contact bridge serving as a conductive pathway between the two third contact points, the motor actuator acting on the movable contact s assembly, the second cam of the motor actuator driving the second L-shaped lever, the second L-shaped lever driving the second side actuator, the third contact-bridge-arm of the second side actuator pulling the third contact bridge assembly into the fifth position and compressing both the fifth pressure spring and the sixth pressure spring attached thereto, in the sixth position the third contact-bridge-arm of the second side actuator applying no pulling force allowing both the fifth pressure spring and the sixth pressure spring to decompress driving the third contact bridge assembly into contact with the two third contact points,

said fourth contact bridge assembly having a fourth contact bridge, a seventh pressure spring and an eighth pressure spring, the seventh pressure spring disposed within the seventh spring cavity, the eighth pressure spring disposed with the eighth spring cavity, both the seventh pressure spring and the eighth pressure spring connected to the fourth contact bridge, the fourth contact bridge operatively engaged by the fourth contact-bridge-arm of the second side actuator, the fourth contact bridge being movable between a seventh position wherein the fourth contact bridge not in contact with two fourth contact points positioned directly opposite the fourth contact bridge and an eighth position wherein the fourth contact bridge in contact with the two fourth contact points, the fourth contact bridge serving as a conductive pathway between the two fourth contact points, the motor actuator acting on the movable contacts assembly, the second cam of the motor actuator driving the second L-shaped lever, the second L-shaped lever driving the second side actuator the fourth contact-bridge-arm of the second side actuator pulling the fourth contact bridge assembly into the seventh position and compressing both the seventh pressure spring and the eighth pressure spring attached thereto, in the eighth position the fourth contact-bridge-arm of the second side actuator applying no pulling force allowing the seventh pressure spring and eighth pressure spring to decompress driving the fourth contact bridge assembly into contact with the two fourth contact points,

the first group of contact bridge assemblies and the second group of contact bridge assemblies together capable of creating double normally open contact arrangements, double normally close contact arrangements, and/or one normally open contact arrangement and one normally close contact arrangement.

2. The electromagnetic relay in claim 1 further comprising a relay housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the motor actuator, the movable contacts assembly, the first group of contact bridge assemblies and the second group of contact bridge assemblies being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6 mm separating the contact bridge and each contact point.

3. The electromagnetic relay in claim 1 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter.

4. An electromagnetic relay assembly comprising:

a relay motor;

a motor actuator;

a movable contacts assembly, the movable contacts assembly operatively engaged to the motor actuator, the movable contacts assembly comprising a first and a second L-shaped lever and a first and a second side-actuator, both said first and said second L-shaped lever being symmetrical, both said first and said second L-shaped lever having a first portion with a first end, and a second portion with a second end, the first end operatively engaged to the motor actuator, the side-actuator having a lever nesting, a first contact-bridge-arm, and a second contact-bridge-arm, the lever nesting operatively coupled to the second end of the L-shaped lever; and

a first group of contact bridge assemblies, the first group of contact bridge assemblies having a first contact bridge assembly and a second contact bridge assembly, said first contact bridge assembly comprising a first contact bridge and a plurality of pressure springs, the pressure springs connected to the first contact bridge, the first contact bridge operatively engaged by the first contact-bridge-arm of the first side actuator, the first contact bridge being movable between a first position wherein the first contact bridge not in contact with two first contact points positioned directly opposite the first contact bridge, the pressure springs being compressed by the first side actuator, and a second position wherein the first contact bridge in contact with the two first contact points, the pressure springs not being compressed by the first side actuator, the first contact bridge serving as a conductive pathway between the two first contact points, the motor actuator driving the first L-shaped lever, the first L-shaped lever driving the first side actuator, the first contact-bridge-arm of the first side actuator pulling the first contact bridge assembly into the first position and compressing the pressure springs attached thereto, in the second position the first contact-bridge-arm of the first side actuator applying no pulling force allowing the pressure springs to decompress driving the first contact bridge assembly into contact with the two first contact points,

said second contact bridge assembly having a second contact bridge and a plurality of pressure springs, the pressure springs connected to the second contact bridge, the second contact bridge operatively engaged by the second contact-bridge-arm of the first side actuator, the second contact bridge being movable between a third position wherein the second contact bridge not in contact with two second contact points positioned directly opposite the second contact bridge, the pressure springs being compressed by the first side actuator, and a fourth position wherein the second contact bridge in contact with the two second contact points, the pressure springs being decompressed by the first side actuator, the second contact bridge serving as a conductive pathway between the two second contact points, the motor actuator driving the first L-shaped lever, the first L-shaped lever driving the first side actuator, the second contact-bridge-arm of the first side actuator pulling the second contact bridge assembly into the third position and compressing the pressure springs attached thereto, in the fourth position the second contact-bridge-arm of the first side actuator applying no pulling force allowing the pressure springs to decompress driving the second contact bridge assembly into contact with the two second contact points; and

a second group of contact bridge assemblies, the second group of contact bridge assemblies having a third contact bridge assembly and a fourth contact bridge assembly, said third contact bridge assembly having a third contact bridge and a plurality of pressure springs, the pressure springs connected to the third contact bridge, the third contact bridge operatively engaged by the third contact-bridge-arm of the second side actuator, the third contact bridge being movable between a fifth position wherein the third contact bridge not in contact with two third contact points positioned directly opposite the third contact bridge, the pressure springs being compressed by the second side actuator, and a sixth position wherein the third contact bridge in contact with the two third contact points, the pressure springs being decompressed by the second side actuator the third contact bridge serving as a conductive pathway between the two third contact points, the motor actuator driving the second L-shaped lever, the second L-shaped lever driving the second side actuator, the third contact-bridge-arm of the second side actuator pulling the third contact bridge assembly into the fifth position and compressing the pressure springs attached thereto, in the sixth position the third contact-bridge-arm of the second side actuator applying no pulling force allowing the pressure springs to decompress driving the third contact bridge assembly into contact with the two third contact points,

said fourth contact bridge assembly having a fourth contact bridge and a plurality of pressure springs, the pressure springs connected to the fourth contact bridge, the fourth contact bridge operatively engaged by the fourth contact-bridge-arm of the second side actuator, the fourth contact bridge being movable between a seventh position wherein the fourth contact bridge not in contact with two fourth contact points positioned directly opposite the fourth contact bridge, the pressure springs being compressed by the second side actuator, and an eighth position wherein the fourth contact bridge in contact with the two fourth contact points, the pressure springs being decompressed by the second side actuator, the fourth contact bridge serving as a conductive pathway between the two fourth contact points, the motor actuator driving the second L-shaped lever, the second L-shaped lever driving the second side actuator, the fourth contact-bridge-arm of the second side actuator pulling the fourth contact bridge assembly into the seventh position and compressing the pressure springs attached thereto, in the eighth position the fourth contact-bridge-arm of the second side actuator applying no pulling force allowing the pressure springs to decompress driving the fourth contact bridge assembly into contact with the two fourth contact points,

the first group of contact bridge assemblies and the second group of contact bridge assemblies together capable of creating double normally open contact arrangements, double normally close contact arrangements, and one normally open contact arrangement and one normally close contact arrangement.

5. The electromagnetic relay in claim 4 wherein the movable contacts assembly is comprised of an upper spring housing and a lower spring housing, a pair of side actuators, and a pair of L-shaped levers, the upper spring housing overlaying the lower spring housing, a first actuator slot and a second actuator slot extending in the upper and lower spring housing, the side actuator disposed within the first actuator slot and the second actuator slot, a bottom side of the L-shaped levers rotatably mounted atop the lower spring housing, each L-shaped lever operatively engaged to a side actuator, the lower and upper spring housing each having a pair of contact bridge assemblies attached thereto, each side actuator operatively engaging a contact bridge on the upper spring housing and a contact bridge on the lower spring housing.

6. The electromagnetic relay in claim 4 wherein the movable contacts assembly is comprised of a housing, an L-shaped lever and a side actuator, the housing having a plurality of actuator slots and a plurality of lever attachment points alongside the actuator slots, the L-shaped lever rotatively mounted onto a lever attachment point, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the motor actuator and the second portion operatively engaged to the side actuator, the side actuator disposed within the channel.

7. The electromagnetic relay in claim 4 wherein further comprising a housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the motor actuator, the movable contacts assembly and a plurality of the contact bridge assemblies being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6 mm separating the contact bridge and each contact point.

8. The electromagnetic relay in claim 4 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter.

9. An electromagnetic relay assembly comprising:

a relay motor;

a motor actuator having an actuator frame, the actuator frame having a first side and a second side, the first side having a first cam and a second cam, the second side having a third cam and a fourth cam, the first cam being identical to the third cam, and the second cam being identical to the fourth cam;

a movable contacts assembly, the movable contacts assembly comprising a housing, a first L-shaped lever, a second L-shaped lever, a first side actuator and a second side-actuator, the first L-shaped lever being identical to the second L-shaped lever, both the first L-shaped lever and the second L-shaped lever being symmetrical, the housing having a plurality of lever attachment points, a first actuator slot and a second actuator slot, both the L-shaped lever rotatively mounted onto a lever attachment point, the first L-shaped lever having a first portion with a first end and a second portion with a second end, the second L-shaped lever having a third portion with a third end and a fourth portion with a fourth end, the first portion operatively engaged to either the first cam or second cam of the motor actuator and the second portion operatively engaged to the first lever-nesting of the first side-actuator, the third portion operatively engaged to either the third cam or the fourth cam of the motor actuator and the fourth portion operatively engaged to the second lever-nesting of the second side-actuator, the first side-actuator disposed within the first actuator slot and the second side-actuator disposed within the second actuator slot; and

a contact bridge assembly, the contact bridge assembly comprising a contact bridge and a plurality of pressure springs, the pressure spring disposed within the housing and connected to the contact bridge, the contact bridge operatively engaged by the either the first side actuator or the second side actuator, the contact bridge being movable between a first position wherein the contact bridge not in contact with two contact points positioned directly opposite the contact bridge and a second position wherein the contact bridge in contact with the contact points, the contact bridge serving as a conductive pathway between the two contact points, the motor actuator acting on both said first L-shaped lever and said second L-shaped lever, said first L-shaped lever driving said first side actuator and said second L-shaped lever driving said second side actuator, either the first side actuator or the second side actuator pulling the contact bridge assembly into the first position and compressing the pressure springs attached thereto, in the second position the side actuator applying no pulling force allowing the pressure springs to decompress driving the contact bridge assembly into contact with the two contact points.

10. The electromagnetic relay in claim 9 wherein the movable contacts assembly is comprised of an upper string housing and a lower spring housing, a pair of side actuators, and a pair of L-shaped levers, the upper spring housing overlaying the lower spring housing, a first actuator slot and a second actuator slot within the upper and lower spring housing, a side actuator disposed within the first and the second actuator slot, the L-shaped levers rotatably mounted onto a lever attachment point located atop the lower spring housing each L-shaped lever operatively engaged to a side actuator, the lower and upper spring housing each having a pair of contact bridge assemblies attached thereto, each side actuator operatively engaging a contact bridge on the upper spring housing and a contact bridge on the lower spring housing.

11. The electromagnetic relay in claim 9 wherein further comprising a housing with a plurality of contact terminal assemblies attached thereto and extending through a wall of the housing, the relay motor, the motor actuator, the movable contact assembly and a plurality of the contact bridges being disposed within the housing, the contact terminal assembly having two isolated contact points positioned across the contact bridge, a gap of at least 1.6 mm separating the contact bridge and each contact point.

12. The electromagnetic relay in claim 9 wherein the contact bridge is made of copper and has a width of 10 millimeters and a thickness of 1 millimeter.

13. An electromagnetic relay assembly comprising:

a ready motor comprising a bobbin having an axially extending cavity therethrough and a conductive coil wound therearound, a U-shaped ferromagnetic frame, said U-shaped ferromagnetic frame having a first contact section, a second contact section and a plurality of core sections, said plurality of core sections disposed in and extending through the axially extending cavity in the bobbin, said first and second contact section extending perpendicularly from opposite ends of the core section and rising above the bobbin, the first contact section having a first tongue portion extending perpendicularly from the first contact section and above the bobbin, the second contact section having a second and portion extending perpendicularly from the second contact section and above the bobbin;

means for conductive contact, the means for conductive contact coupled to the relay motor; and

an actuator assembly, the actuator assembly operatively engaged to the means for conductive contact by way of a movable contacts assembly, the movable contacts assembly comprising a housing, an L-shaped lever and a side actuator, the housing having a plurality of lever attachment points and a plurality of actuator slots, the L-shaped lever rotatively mounted onto a lever attachment point, the L-shaped lever having a first portion and a second portion, the first portion operatively engaged to the actuator assembly and the second portion operatively engaged to the side actuator, the side actuator disposed within the actuator slot and operatively coupled to the means for conductive contact, said means for conductive contact being driven by said side actuator, said side actuator being driven by said L-shaped lever, said L-shaped lever being driven by said actuator assembly.

14. The electromagnetic relay in claim 13 wherein the means for conductive contact is a contact bridge assembly, the contact bridge assembly comprising a contact bridge and a plurality of contact springs.