Research On Optimization Techniques Of Anti-mechanical Performance Consistency Of Elctromagnetic Relay

Electromagnetic relay is an automatic long-distance electric controlled device, which is widely used in different kinds of electrical automation systems. In practical application, electromagnetic relay must have enough mechanical environmental load endurance to prove the whole system’s reliability as mechanical force exists, such as vibration, impact, noise and so on. Current relay products has the problem that products in batches are inconsistent and reject rate is high, thus it’s of importance to improve product performance and prove the reliability of the system that the consistency of mechanical environmental load endurance is deeply studied.Firstly, this paper analyzes mechanical environmental load endurance and failure mechanism of some type electromagnetic relay. The relay consists of magnetic system and spring system. Kinetic model is used to build the piecewise linear equivalent mechanical model respectively. The FEM model of relay is built in Msc.Patran. Modal analysis is studied to determine inherent frequency and vibration mode of the relay. Frequency response analysis is studied to determine vibration transfer path of the relay and a reasonable criterion of vibration failure should be given. Vibration experiment is conducted to verify correctness and rationality of the model.Secondly, the key factors affecting the anti-mechanical performance of the relay are identified. There are lots of machine parts in the relay. Preliminarily selecting input parameters based on the failure mechanism and establishing local parametric model can greatly improve the computational efficiency; programing the single factor test and analyzing the impact of disturbance within the tolerance range of parameters on output results can filter the Significant factors; thus,the key factors affecting the anti-mechanical performance of the relay can be determined by implementing the orthogonal experiment which can draw the contribution of significant factors.In addition, approximate model based on Kriging method and Griddata method is established to compute quality characteristic distribution of relay and the improved Kriging model is propose. Considering the key parameters determined in the orthogonal experiment as input factors and taking the response amplitude of resonant frequency as well as spring force as output result, Kriging model and Griddata model are built. Compared with the theory and results of two models, modified Kriging model is put forward and the accuracy is improved, which aims to solve the problem that Griddata modle may lose precision in boundary value.At last, the consistency optimization program is put forward which is based on tolerance design. The fast calculation model is used to compute the quality characteristic distribution of mechanical environmental load endurance as well as the qualified rate. The new tolerance distribution program is achieved based on the calculation of contribution rate. The effect of optimized program is verified while comparing the quality characteristic distribution and qualified rate before and after optimization.The study can supplement and perfect the consistency design theory of antimechanical performance of electromagnetic relays. Meanwhile, the theory and method can also make contribution to consistency on mechanical environmental load endurance optimization of other electromechanical products.