Abstract:

A high-power electromagnetic relay with rated parameters of 380 V AC/25 A is researched. In accordance with GJB 1461B—2024, its structural design, parameter calculation and multi-physics simulation verification method are systematically elaborated. This design adopts a “balanced-force” electromagnetic drive system, four-channel main-contact parallel layout, and a composite arc-quenching scheme of “spatial expansion + multi chamber arc extinguishing cover + nitrogen filling”. Combined with laser-sealing and nitrogen-filling processes, the product’s operational reliability, arc-suppression capability and environmental adaptability are improved. Through coupled multi-physics simulations of electromagnetic field, structural mechanics and thermal field, the matching of electromagnetic attraction-reaction forces, shock-vibration resistance and steady-state temperature rise are verified to satisfy index requirements. A complete closed-loop workflow of design-simulation-validation is established, which provides a reference for the development of similar high-reliability relays.

Key words: high-power electromagnetic relay, balanced-force, composite arc quenching, multi-physics simulation