Stamping Iron Core Bending Part For EV Relay
Products Description
This Stamping Iron Core Bending Part for EV Relay is a functional stamped magnetic structural component, possessing both electromagnetic and mechanical properties:
Its flat structural design adapts to the compact layout of high-voltage relays.
Integrated stamping and bending avoids structural risks associated with welding or assembly.
Good magnetic circuit continuity facilitates the formation of stable electromagnetic attraction.
High dimensional consistency makes it suitable for automated assembly and mass production applications.
In relays, the flat iron core typically works in conjunction with the coil, armature, and contact system. Its geometric accuracy and magnetic stability are the core foundation for ensuring consistent relay performance.
Core Functions: Precisely Matching the Multi-Dimensional Needs of High-Voltage Relays
High-Efficiency Electromagnetic Conduction
As the Coil Soft Iron Core carrier of the relay's electromagnetic circuit, optimized magnetic field path design reduces leakage flux loss, improves electromagnetic conversion efficiency, and ensures rapid engagement and disengagement of the relay under low power consumption, shortening response time and adapting to the real-time control requirements of high-voltage systems in new energy vehicles.
Stable Structural Support
Combining high strength and dimensional stability, it provides precise positioning and robust support for internal components such as the relay coil, armature, and contacts, preventing component displacement under vibration and ensuring the consistency and reliability of relay switching operations.
Precise Positioning and Guiding Function
The bending structure design is highly compatible with the internal assembly path of the relay, playing a guiding and positioning role, ensuring precise armature movement trajectory, reducing action jamming, minimizing contact wear, and extending the mechanical life of the relay.
Anti-Interference Protection Function
Through the closed magnetic circuit design and material properties, Straight Coil Core effectively shields external electromagnetic interference while preventing its own magnetic field from affecting other precision electronic components in the vehicle, ensuring the stable operation of the entire vehicle's electronic system.
Technical Features
Core Process:
Post-Stamping Stress-Relief Annealing: This is the Cold Heading Pure Iron Core of our technology and the fundamental difference between our products and ordinary stamped parts. During stamping and bending, the crystal lattice of metal is distorted, generating enormous internal stress, which severely degrades its electromagnetic properties. Each of our iron cores undergoes high-temperature annealing in a precisely controlled protective atmosphere after forming. This process eliminates internal stress, restores and optimizes the material's electromagnetic properties, bringing it back to its optimal state.
Precision Dies and Zero-Burst Stamping: We use high-precision carbide dies, combined with an optical alignment system, to ensure smooth, burr-free, and corner-free stamping edges. Burrs not only affect subsequent assembly accuracy but can also become "point discharge points" in the magnetic field, generating eddy currents and localized overheating. Our "zero-burr" process is the microscopic foundation for ensuring performance and reliability.
Detailed Showcase: A Deep Dive into Professional Value
Gradient Hardness Design
We achieve differentiated hardness in different parts of the Relay Core through localized heat treatment. For example, we maintain high toughness in the bending hinge area to prevent breakage, increase hardness in the pole face area to enhance wear resistance, and ensure strength at mounting holes. This level of precision control is impossible with a single heat treatment.
Insulation Coating Integrity Protection
The insulation coating on the surface of the electrical steel is crucial for suppressing inter-laminar eddy currents. Throughout the stamping, bending, and annealing processes, we employ special lubrication and process control to ensure that this thin coating retains over 95% of its integrity after forming, which is key to low iron loss.
Multi-Component Integrated Core
We can integrate two or more magnetically conductive components (such as the stationary Coil Core for Electromagnetic relay and yoke) that traditionally require separate manufacturing and assembly into a single piece of material through ingenious bending design. This eliminates assembly errors, improves the overall integrity of the magnetic circuit, and reduces the number of parts and assembly costs.
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