基于数字样机模型的平衡力式继电器电寿命提升

doi:10.16628/j.cnki.2095-8188.2026.01.004

摘要/Abstract

摘要：

针对某厂家某型号1/2 in³(1 in³≈16.387 cm³)平衡力式继电器产品质量一致性差、电寿命不达标问题,开展平衡力式继电器电寿命提升研究。首先对电寿命失效产品进行失效机理分析,通过燃弧时间、动作过程及吸反力匹配分析,确定继电器寿命终止的根本原因。然后建立继电器数字样机模型,完成吸力与反力静态特性仿真;在此基础上,对电磁系统与触簧系统的关键参数进行优化,使吸反力匹配良好。最后对优化后的继电器样机进行高温电寿命试验,试验结果表明,优化后的产品电寿命显著提升,达到优化目标。

关键词: 平衡力式电磁继电器, 电寿命, 仿真分析, 数字样机模型

Abstract:

Aiming to address poor consistency and short electrical life of a 1/2 in³ balanced force relay of a manufacturer,research on improving the electrical life of balanced force relays is conducted.Firstly,the failure mechanism of products with electrical life failure is analyzed,and the root cause of relay life termination is determined through the analysis of arcing time,action process and suction-reaction force matching.Then,a digital prototype of the relay is established to realize the static characteristic simulation of suction and reaction force;on this basis,the key parameters of the electromagnetic system and contact spring system are optimized to achieve good suction-reaction force matching.Finally,high-temperature electrical life tests are conducted on the optimized relay prototypes.The test results show that the electrical life of the optimized products is effectively improved,and the optimization goal is achieved.

Key words: balance force electromagnetic relay, electrical life, simulation analysis, digital prototype model

中图分类号:

TM58

李欣妍, 武江涛, 韩滢竹, 梁慧敏, 宋琪. 基于数字样机模型的平衡力式继电器电寿命提升[J]. 电器与能效管理技术, 2026, 0(1): 25-31.

LI Xinyan, WU Jiangtao, HAN Yingzhu, LIANG Huimin, SONG Qi. Electrical Life Improvement of Balanced Force Relay Based on Digital Prototype Model[J]. LOW VOLTAGE APPARATUS, 2026, 0(1): 25-31.

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触点	1组	2组
静合触点	0.308	0.618
动合触点	0.344	0.596

参数	参数范围/mm	位置1的电磁吸力/N	位置2的电磁吸力/N
衔铁厚度	1.27~1.35	9.63~10.12	-0.89~1.11
小轭铁厚度	1.20~1.33	4.82~12.48	-0.93~0.90

继电器序号	静合触点		动合触点
继电器序号	1组	2组	1组	2组
1	0.24	0.30	0.27	0.23
2	0.26	0.22	0.28	0.29
3	0.35	0.25	0.28	0.22
4	0.38	0.30	0.37	0.32
5	0.31	0.30	0.29	0.26