Optimization Design Of Anti-surge Ability Of Crystal Relays Under Overload Condition

As a typical product of military electromagnetic relays,crystal dome relays have stable performance,reliability,standardization,and high degree of serialization.Because of their compatibility with ICs,they are used in a large number of markets and dominate.They are the key development direction of relay products.The rapid development of the market puts forward a higher demand for relays.The existing design methods and production methods can no longer form a good match with users.The lack of relays with small size and large overload capacity has become the main bottleneck for development.This article takes the 1/2 crystal cover and four sets of relays as the research object.Through the use of virtual prototype technology,its structure is optimized.By studying the relevant parameters that affect the overload factors,a set of feasible design optimization methods are formed to achieve Improve the load capacity of the product.First of all,a touch-down test was conducted for products with crystalenclosure sealed electromagnetic relays.Electrical parameter testing,mechanical parameter testing,and load capacity testing tests were conducted.Through the analysis of the test results,the main failure modes of the products were determined;The time,contact breaking speed,contact rebound and contact ablation after load were analyzed and studied,which indicated the direction for the subsequent product optimization and laid the foundation for the improvement of overload capacity.Secondly,using finite element simulation technology to accurately calculate the static and dynamic electromagnetic attraction characteristics of the relay electromagnetic system,using the multi-body dynamics analysis software ADAMS to accurately calculate the static and dynamic mechanical reaction characteristics of the relay mechanical system,using ADAMS software and The joint simulation method of Matlab/Simulink software is used to solve the dynamic output characteristics of the relay.Through the joint analysis of theory and simulation,the design defects and weak links of the relay are determined,and an analysis platform is provided for subsequent optimization.Then,for the load-related actuators,the contact spring system has been improved,and a concept based on split kinetic energy has been proposed to improve the breaking speed.At the same time,it compares with the typical solution based on the speed of reaction.At the same time,the ultimate capability of the electromagnetic system was evaluated and analyzed from the aspects of the coil ampoule and the yoke iron armature.Through the analysis and determination of the improved program,and through the virtual prototype technology simulation to verify the feasibility and rationality of the improved program.Finally,the physical prototype assembly of the product improvement program was carried out.In view of the poor consistency of the electromagnetic suction force during the assembly process,the factors affecting the suction characteristics during the assembly process were studied,and the assembly positions and special requirements of the armature needed to be controlled were obtained.The key parameters of the heat treatment process can effectively ensure the stability of the suction characteristics.By testing the improved product,the effectiveness of the improvement was verified..