电磁继电器额定寿命优化设计

Optimization of the rated life of electromagnetic relay

电磁继电器额定寿命指标是继电器能否满足整机需求的关键,直接影响着系统运行的可靠性.针对电磁继电器额定寿命能力批次间差异大这一问题,对影响电磁继电器额定寿命的机理进行分析和研究,确定影响电磁继电器额定寿命失效的主要因素是触点接触面积、触点间接触压力、触点间隙及触点材料.在不改变电磁继电器结构设计及触点材料的情况下,为提升电磁继电器额定寿命能力及一致性,采用DOE优化设计方法,针对相应的影响因子进行了DOE试验设计,最终得出合理的触点间隙、常闭触点压力及超程值;再利用容差设计方法,优化触点间隙、常闭触点压力及超程的控制范围,提升额定寿命的一致性.研究结果表明:通过DOE试验可找到电磁继电器的影响因子优化方案,利用容差设计可以优化各影响因子的控制范围,有效提升了继电器额定寿命能力及一致性,提升产品质量.

The rated life of an electromagnetic relay is the key to meet the requirements of the whole machine, which has a direct influence on the reliability of the system. According to the large endurance discrepancy between different batches, we analyzed the mechanism that affects the rated life of electromagnetic relays and found that the life failure of electromagnetic relays is mainly caused by contact area, contact pressure, contact gap, and the material of contactors. Without changing the structural design and the materials of contactors, the test design instructed by design of experiment ( DOE) for the related influencing factors was carried out to improve the rated life and its consistency, and obtained reasonable contact gap, constant contact pressure, and overrun. Besides, the contact gap, constant contact pressure, and the control range of overrun were optimized by using the tolerance design to enhance the consistency of rated life. The result indicates that the DOE test can disclose the optimization scheme of the factors that influence electromagnetic relays and the control range of the influencing factors can be optimized through tolerance design, which can effectively enhance the rated life and its consistency, thus improve product quality.