Relay Moving Contact
Products Description
Relay Moving Contacts are functional elements mounted on the moving reed of a relay, achieving a "dynamic contact-disconnect" action under electromagnetic force or thermal actuation. They must possess:
Excellent conductivity
High anti-welding properties
Stable mechanical fatigue resistance
Resistance to arc erosion
Long-term contact impedance stability
Compared to ordinary silver contacts, Moving Silver Contact utilise a multi-material composite structure, employing different welding and forming processes to maintain stable performance even under high-frequency operation, high-current surges, and high-temperature climbing environments.
Manufacturing Process: The Journey from a Roll of Wire to a Dynamic Actuator
Material Refining and Forming
High-purity copper and silver alloy wires are selected and processed into the base material and silver contacts of the Silver Moving Contacts through multi-station cold heading or precision stamping.
01
Automated Composite Riveting
The base material and silver contacts are precisely fed into a specialised riveting machine via a vibratory feeder and robotic arm, achieving high-energy composite bonding in an instant.
02
Heat Treatment and Stress Relief
The Electrical Moving Contacts undergo precise vacuum annealing to eliminate internal stress generated during riveting and forming, restoring and optimising the elastic properties of the base material.
03
Surface Treatment and Sorting
The copper base material is electroplated (e.g., tin plating, silver plating) as needed to enhance solderability or oxidation resistance. Finally, 100% appearance and size sorting is performed using an AOI system.
04
Final Inspection and Packaging
Sampling inspections are conducted on the finished products for key dimensions, bonding strength, elasticity, and electrical properties. Then, professional anti-static and shockproof packaging is used to ensure the Silver Alloy Moving Contact arrives in perfect condition.
05
Design Advantages and Details
Micro-bump Array on Contact Surface
Electron microscopy reveals a unique micro-bump distribution on the Silver Contact for Switch surface: uniform 0.5μm bumps spaced 1.5μm apart. These bumps are not random but precisely designed through dynamic contact simulation optimisation, ensuring stable point contact during movement and preventing large-area wear.
Stress-Free Movement Guide Groove
Considering the precision of installation and movement, the Silver Alloy Moving Contact features a unique movement guide groove. Micro-guide grooves at the contact edge ensure uniform pressure distribution during movement, preventing contact surface damage due to improper movement. This design improves movement accuracy by 40% while ensuring optimal contact performance.
Dynamic Arc-Guiding Gradient Zone
A dynamic arc-guiding gradient zone is designed at the contact separation end. This gradient zone is not static but dynamically adjusted according to the movement speed, effectively suppressing arc formation in its early stages. High-speed photography shows that the arc is guided to a safe path at the moment of separation, without spark generation.
Balance between Standardisation and Customisation
We offer standard-size series to meet mainstream relay needs, while also supporting customised designs. Our engineering team can quickly respond to special application scenarios, such as ultra-high-speed switching or extreme environmental conditions, ensuring a perfect match between the Electrical Moving Contacts and the customer's relay system.
Application Scenarios: In which key control areas is reliable operation defined?
| New Energy Vehicles and Charging Systems | Main contactors, pre-charge relays, Battery Management System (BMS) relays: Resisting high-voltage DC interruption challenges, frequent operation, and vehicle vibration, requiring extremely high arc resistance and mechanical lifespan. |
| Smart Homes and Building Automation | Smart circuit breakers, Air Conditioning/Underfloor Heating Control Relays: Requires safe and reliable load control within compact spaces, demanding low Silver Moving Contact resistance, low heat generation, and long lifespan. |
| Industrial Control and Safety Systems | Safety relays, PLC output modules, Motor starters: In industrial environments with vibration and dust, absolute reliability of signal or power switching must be guaranteed, with operation cycles reaching millions of times. |
| Communications and Energy Infrastructure | Base station power control, internal relays of photovoltaic inverters: Need to withstand outdoor temperature cycling and maintain stable performance under high surge currents. |
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