关键词: 平衡衔铁式, 接触系统, 数字模型, 质量一致性

Abstract:

The main failure mode of balanced armature relays during operation is contact ablation in the contact system, which is caused by large dispersion in the pull-in speed during the relay’s pull-in process. Excessively high pull-in speed can lead to contact bounce, while excessively low pull-in speed can result in poor pull-in. Taking a certain type of product as the research object, a method for consistent parameter design and tolerance design based on digital models is proposed. By establishing an electromagnetic-mechanical co-simulation model of the entire machine, the influence laws of key parameters such as contact gap and initial pressure on the pull-in speed are analyzed. After optimization, the average pull-in speed is reduced to 0.3224 m/s, and the standard deviation is decreased by 17.9%. Through tolerance design, the standard deviation is further reduced by 34.3%. The tests show that the proposed method can effectively suppress contact bounce and arcing phenomena, and improve the product quality consistency.

Key words: balanced armature, contact system, digital model, quality consistency