Analysis and Optimization of Adjust-Free Rate of Balanced Force Relay Contact System

The balance force relay has excellent performance and high reliability. Because of its complex structure and difficult assembling process, its qualification rates of contact system parameters are extremely low after final assembly. Aiming at this, firstly, based on the random matching process between the electromagnetic and the contact system, analyze the adjust-free rate of the contact system. The contact pressure simulation model is established, and the key factors affecting the adjust-free rate of the contact system are determined. The parameter design is carried out for the contact pressure, and the optimal level combination of the parameters relate to armature travel is determined. The tolerance design is carried out to improve the consistency of the armature travel, and the tolerance optimization scheme is determined. Based on the assignment problem, the mathematical model of the optimal matching problem is established. The optimal solution is obtained by the Hungarian algorithm, which realizes the improvement of the consistency of the contact gap. Based on this, an adjust-free optimization strategy of contact system based on neural network prediction model is proposed. According to the expected value of contact pressure, the ideal bending angle of static contact is predicted reversely, and the contact system is pre-adjusted by automation equipment before final assembly. Produce the actual products, and the contact pressure and contact gap are tested after final assembly, which verifies the effectiveness of the scheme.