Simulation Analysis And Optimal Design Of Differential Polarized Relays With Double Permanent Magnets

Differential polarized relay with double permanent magnets has many advantages, such as high sensitivity, small size, fast motion and high thermal stability. It has a broad application prospect on missiles, space launch vehicles. However, domestic products compared with foreign products in terms of quality consistency are not ideal. Optimization design of this type of relay is required to be carried out and it’s important to improve analysis methods and ideas in the relay design. This paper took the differential polarized relay with double permanent magnets as the research object and discussed deeply the load test, quality characteristics, simulation models, structure optimization and robust optimization method to aim at improving the reliability of products.Firstly, for differential polarized relay products with double permanent magnets, constant resistance load and surge load test were conducted respectively. The failure mode of the products was determined by compaing the test results. The process capability of key size and process parameters was evaluated through the statistic analysis of the key output characteristics. The anslysis above provided the optimal direction for the following products optimization design.Secondly, the relay assembly prototype model was built by using the three dimensional modeling software UG. Characteristics of relay’s static attractive force and the mechanical force were calculated by using ANSYS and ADAMS. Based on the static data tables of static simulation, the dynamic characteristics of relay were obtained through MATLAB/Simulink models to complete virtual prototyping platforms. Then based on magnetic circuit method, the deformation energy method and runge-kutta method of order 4, the fast calculation models of static and dynamic characteristics were established to provide the simulation analysis platforms.Thirdly, considering the failure mechanism, three kinds of optimal schemes were proposed by using the optimization design platform. First of all, the key parameters of the original structure were optimized. The influence on the output characteristics by the parameters was analyzed. What’s more, the optimization parameters were given and the optimization results were evaluated. Then, clamptype pusher’s contact system is returned by the armature driver to restrain contact bounce, this paper took this structure into the relay design and obtained the optimal clamp-type pusher. Finally, in order to improve the breaking velocity of contacts, the new contact system structure was established. This feasibility of this scheme to improve product life was verified by the simulation analysis of virtual prototyping platforms and test analysis of product samples.Lastly, the best optimization structure was chosen and the robust optimization design was done to reduce the dispersion of the products. By using the dual response surface model, the mean value and variance of the critical static attractive force point were fitted. At the same time, the fitting effects of Latin Hypercube Sampling and Uniform Design were compared. The multi-objective particle swarm algorithm was used to optimize the dual response surface model and the algorithm feasibility was vefified. Finally, the optimization parameter values were obtained. The tolerance design of electromagnetic system and contact system was done. The significant factors were determined by the contribution rates and the optimization goal of improving the product consistency was achieved through the tolerance redistribution.