Optimization Design for Quality Consistency of Balanced Armature Relay Contact System Based on Digital Model

doi:10.16628/j.cnki.2095-8188.2025.07.001

Abstract

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

CLC Number:

TM581

CHEN Dongxu, LI Jianping, XU Le. Optimization Design for Quality Consistency of Balanced Armature Relay Contact System Based on Digital Model[J]. LOW VOLTAGE APPARATUS, 2025, 0(7): 1-8.

Figures/Tables 31

References 16

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序号	筛选参数	中心值及上下限
1	动簧片宽度/mm	2.2±0.30
2	动簧片长度/mm	14.4±0.05
3	初压力/mN	80±8
4	超程/mm	0.06±0.02
5	触点间隙/mm	0.295±0.015
6	自由程/mm	0.25±0.02
7	触点垂直度/(°)	0±5

水平	触点间隙A/mm	触点初压力B/mN	触点垂直度C/(°)	超程 D/mm
1	0.270	70	-5	0.036
2	0.295	80	0	0.060
3	0.320	90	5	0.084

内表方案号	内表设计因素
内表方案号	A/mm	B/mN	C/(°)	D/mm
1	0.270	70	-5	0.036
2	0.270	80	0	0.060
3	0.270	90	5	0.084
4	0.295	70	-5	0.060
5	0.295	80	0	0.084
6	0.295	90	5	0.036
7	0.320	70	0	0.036
8	0.320	80	5	0.060
9	0.320	90	-5	0.084
10	0.270	70	5	0.084
11	0.270	80	-5	0.036
12	0.270	90	0	0.060
13	0.295	70	0	0.084
14	0.295	80	5	0.036
15	0.295	90	-5	0.060
16	0.320	70	5	0.060
17	0.320	80	-5	0.084
18	0.320	90	0	0.036

误差因素	公差范围
触点间隙A/mm	±0.015
触点初压力B/mN	±8
触点垂直度C/(°)	±5
超程D/mm	±0.02
温度E/℃	30±95

水平	触点间隙A/mm	触点初压力B/mN	触点垂直度C/(°)	超程 D/mm	温度 E/℃
1	A_n-0.015	B_n-8	C_n-5	D_n-0.02	-65
2	A_n	B_n	C_n	D_n	30
3	A_n+0.015	B_n+8	C_n+5	D_n+0.02	125