First, the contact is loose and cracks
The contact is the electrical contact part of the relay to complete the switching load, and the contact of some products is riveted and pressed, and its main drawbacks are loose contacts, cracked contacts or excessive dimensional position deviation. This will affect the contact reliability of the relay. The loosening of the shoveling point is caused by the unreasonable size of the mating part of the reed and the contact or the improper adjustment of the riveting pressure by the operator. Contact cracking is caused by too much hardness of the material or too much pressure. For the contacts of different materials, different material processes are adopted, and some contact materials with higher hardness should be annealed, and the contacts are manufactured, riveted or spot welded. The contact manufacturing should be careful, because there are tolerances in the material, so the length of each cut should be decided after the trial. The contact manufacturing should not have flash, pad damage and non-fullness. The contact riveting deviation is caused by the operator not touching the mold correctly and touching it up and down misalignment. Contact damage, contamination, oil contamination and iron filings on uncleaned moldings. No matter what kind of disadvantages, it will affect the reliability of the relay. Therefore, in the process of contact manufacturing, riveting or welding, it is necessary to comply with the self-inspection regulations for the intermediate sampling of the first article inspection and the final inspection in order to improve the assembly quality.
Second, the relay parameters are unstable
A considerable part of the parts of the electromagnetic relay are riveted and matched, and the main problem is that the riveting place is loose or the bonding strength is poor. This kind of problem will make the relay parameters unstable, the parameters change greatly at high and low temperatures, and the resistance to mechanical vibration and impact is poor. The main reasons for this problem are the out-of-tolerance of riveted parts, improper placement of parts, unqualified quality of tools or inaccurate installation. Therefore, before riveting and welding, it is necessary to carefully check whether the tool and the riveted parts meet the requirements.
3. Deformation of the riveting parts of the electromagnetic system
After riveting, the parts are bent, twisted, and the pier is thick and black, which causes difficulties in the assembly or adjustment of the next process, and even causes scrap. The main reasons for this problem are that the riveted parts are too long, too short or the force is uneven when riveting, the assembly deviation of the mold or the design size is wrong, and the parts are improperly placed. When riveting, the operator should first check whether the size, appearance and mold of the parts are accurate, if the mold is not in place, it will affect the assembly quality of the electromagnetic system or the deformation of the iron core and the thickness of the pier.
4. Damage to glass insulators
The glass insulator is made of metal prongs and glass sintering, which is easy to bend the prongs during inspection, assembly, adjustment, transportation and cleaning, and the glass insulators fall off and crack, resulting in air leakage and the insulation and voltage resistance are reduced, and the rotation of the prongs will also cause the displacement of the contact reeds, which will affect the reliable on-off of the product. This requires the operator of the assembly to handle with care during the whole process of relay production, the parts should be neatly arranged in the transfer box, and the pins are not allowed to be pulled or twisted when assembling or adjusting.
Fifth, coil failure
There are many kinds of coils used for relays, some are outsourced and some are not outsourced, and the coils should be placed in special appliances separately in a single piece, if they collide and cross-connect, they will cause disconnection when they are separated. When the electromagnetic system is riveted, the pressure adjustment of the lever press and press should be moderate, too much pressure will cause the coil to break or the coil frame to crack, deform, winding breakdown. If the pressure is too small, it will cause the winding to loosen and the magnetic loss to increase. Multi-winding coils are generally headed with different colored leads. When welding, you should pay attention to distinguishing, otherwise it will cause coil welding errors. For coils with a starting and ending requirements, the starting and ending points are generally marked by the method of marking. Care should be taken when assembling and welding, otherwise the relay level will be reversed.
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