What are the common situations and solutions for relay modules

Common problems and solutions for relay modules:

1. Loose or cracked contacts

Contact points are electrical contact components used by relays to switch loads. Some products have contacts that are pressed in through riveting. The main disadvantages are loose contacts, cracks in the contacts, or significant deviations in size and position. This will affect the contact reliability of the relay. The loosening of the disassembly point is caused by the unreasonable size of the spring fitting part and contact area, or improper adjustment of the riveting pressure by the operator. Contact cracks are caused by excessive material hardness or pressure. Different materials are used for contacts made of different materials. For some contact materials with higher hardness, annealing treatment should be carried out, and contact manufacturing, riveting or spot welding should be carried out. Attention should be paid to the manufacturing of contacts, as the material has tolerances, so the length of each cut should be determined after trial contact. The manufacturing of contacts should not remove edges, solder pads, and incompleteness. Contact riveting is caused by the operator's misalignment of the contact tool and the misalignment of the upper and lower contacts. Contact damage and contamination are caused by oil stains and iron filings on unclean contact tools. No matter what kind of malfunction occurs, it will affect the reliability of the relay. Therefore, in the process of contact manufacturing, riveting, or welding, it is necessary to follow the self inspection regulations of intermediate sampling and first piece inspection for final inspection to improve assembly quality. Contact riveting is caused by the operator's misalignment of the contact tool and the misalignment of the upper and lower contacts. Contact damage and contamination are caused by oil stains and iron filings on unclean contact tools. No matter what kind of malfunction occurs, it will affect the reliability of the relay. Therefore, in the process of contact manufacturing, riveting, or welding, it is necessary to follow the self inspection regulations of intermediate sampling and first piece inspection for final inspection to improve assembly quality.

2、 The relay parameters are not chaotic
The parts of electromagnetic relays are riveted together, and the main problem is loose riveting or poor bonding strength. This type of fault will keep the relay parameters unchanged, with large parameter changes at high and low temperatures, and poor resistance to mechanical vibration and impact. The main reasons for this problem are excessive tolerance of riveted parts, improper placement of parts, inconsistent quality of fixtures and tools, or improper installation. Therefore, before riveting, it is necessary to carefully check whether the tools and riveted parts meet the requirements.

3、 Deformation of electromagnetic system riveting components

After riveting, the parts may bend, tilt, become rough, or turn black, which can cause problems in the assembly or adjustment of the next process, and even lead to scrap. The main reasons for this problem are that the riveted parts are too long, too short, or subjected to uneven force during riveting, mold assembly deviations or design size errors, and improper placement of parts. When riveting, the operator should first check the size, appearance, and fixture of the components. If the fixture is not installed in place, it will affect the assembly quality of the electromagnetic system or cause deformation of the iron core and roughness of the pier.

4、 Glass insulator damage

Glass insulators are made by sintering metal pins and glass. Pins that are prone to bending during inspection, assembly, adjustment, transportation, and cleaning can cause glass insulators to detach and break, resulting in air leakage and reduced insulation and voltage resistance. The rolling of the pin can also cause displacement of the contact spring, affecting the reliable on/off of the product. This requires the assembly operator to carefully operate the relay throughout the entire production process, and the parts should be neatly arranged inside the transfer case. When assembling or adjusting, do not pull or twist the lead out feet.

5、 Coil malfunction

There are many types of coils used in relays, some are outsourced and others are outsourced. The coils should be placed separately in specialized equipment. If they collide with each other, they will break when they separate. When riveting electromagnetic systems, the pressure adjustment of the handle should be moderate. Excessive pressure can cause coil breakage or coil frame cracking, deformation, and winding breakdown. If the pressure is too low, the winding will loosen and the magnetic loss will increase. Multi winding coils are generally made of leads of different colors. Attention should be paid to differentiation during welding, otherwise it may cause coil welding errors. Coils with starting and ending requirements are generally used as a marking method to indicate the starting and ending points.