ElectricalEngineeringResearchVolume2,2014

DesignofElectromagneticRelay
ThePlunger
HomayoonMeshginkelk,MohammadrezaShiravi*,MajidAlambeigi,MinaFazli
DepartmentofElectricalEngineering,UniversityofTafresh,Tafresh,Iran
*mohammadreza.shiravi@yahoo.com

Received16August,2013;Revised20October,2013;Accepted5November,2013;Published20January,2014
2014ScienceandEngineeringPublishingCompany

Abstract
Relaysareusedindustriallyinawidevarietyofapplications.
Traditional mechanical relays are large, slow, noisy devices,
but are still widely used in various machines and processes
forcontrolpurposes.Inthispapercrosssectionofamoving
electromagneticrelayis A;canbeinsidetheexternalvertical
holemagneticchamber.Gapbetweenthetwoisnegligible.r
is the resistance in ohms, and the coil has N turns. Once a
potentialsourcevvoltDCandagain,ACpowerisappliedto
theendsofthecoil.Magneticmaterialcanbeassumedtobe
ideal up to saturation flux density of 1.6T. Regardless of
efflorescence flux in the air gap. The force exerted on the
movingpartsiscomputedasafunctionoftheairgapy.Next,
effectofthedynamicequationsisalsochecked.
Keywords
ElectromagneticRelay;Plunger;FiniteElementMethods

Introduction
Two key factors in selecting an actuation mechanism
are reliability and cost. In terms of reliability,
eelectromagneticactuatorscanbecontrolledwithlow
cost electronics. In terms of reliability, relay design
requires the creation of executable models for both
features, the elastic spring and the tension generated
by electromagnets during the performance measure
the relative energies associated with both,
displacement coil and magnetic attraction for each
component,Thananother,providesarangeofdesign.
Solving nonlinear ordinary differential equations with
two couples Accurately simulates the dynamic
responsecharacteristicsoftheinstrument.Here,lessis
studied to the elastic spring. And more, the
electromagnetic equations, force calculation, and then
examinesthedynamicequations.
Thestudiesdoneonthisfieldincluding:(1)Inductance
of a plungertype magnet: In this paper, a method for

the evaluation of this function, using Mathcad, is

proposed and two verifications of the formula are
performed: using a finite element method and
experimentaldeterminationsofthetotalinductancefor
large range of the gap variation. The experimental
values are compared with the sum of internal
inductance, calculated with formula and external
inductance calculated with finite element method
[Cividjianetal.(1998)].(2)Insecondpaper:Equations
derivedfromthecontinuumdesignsensitivityanalysis
(CDSA), in conjunction with the material derivatives
for a continuous medium and using the energybased
approach, have been successfully applied to the
calculation of both total force and force distributions.
The resultant expressions are similar to the Maxwell
Stress Tensor, Magnetic Charge method, and Virtual
Work Method but have several advantages over the
traditional approaches. Numerical implementation of
theschemeleadstoefficientcalculationsandimproved
accuracy [Kim et al. (2007)]. (3) The third paper: It
present a novel movingiron, highpressure, high
speedelectromagneticactuatorthatutilizespermanent
magnet(PM)shieldingforincreasingairgapflux.We
analyzeitsstaticanddynamiccharacteristicsbyusing
the finiteelement method, taking into account the
nonlinear characteristics and the eddycurrent loss of
themagneticmaterial.Theexperimentalandsimulated
results agree well and show that the actuator has a
displacement of 0.6 mm, closing time of 2.24 ms, and
openingtimeof7.78mswithoutlatchingforce[Manet
al. (2010)]. Therefore, in this paper, tried that,
Precautionsbefollowed.
Calculations of the Electromagnetic Force
The mechanical attractive force generated by passing
current through a solenoid can be determined using

13

ElectricalEngineeringResearchVolume2,2014

Ampere and Faradays laws of magnetism. Amperes

law stipulates that the integration of magnetic field
intensity, H, around a closed contour of length l is
equal to the net current crossing the surface of the
closedcontour:

H .dl Ni (1)
where iis the applied current and Nis the number of
timesthecurrentencirclesthecontour.Theintegralof
the field intensity in the contour is equal to the total
magneticflux, ,dividedbythecrosssectionalarea,A,
andthemagneticpermeability, ,ofthematerial:

(2)
A

acrossthecoilandcanbederivedas:
d ( x, i )
d Ni
N (8)
K s ( x, i ) N
dx
dx Rg
Assuming no electrical power loss in the coil, the
changeinworkdoneasthetotalfluxchangesis:
1
W i.d ( N ) R .d iN (9)
2
Theforceactingonthesecondmagneticelementis:
dW
Ni d
(10)

F
2 dx
dx
Substituting for the reluctance in the solution of the
magneticflux,theforceprovidedbytheelectromagnet
onthemagneticplungercanbewrittenas:

A .dl Ni (3)
where the flux can be separated from the integral by
defining a term for the magnetic resistance called the
reluctance, R. Amperes law can then be rewritten in
terms of the magnetic flux and resistance through a
materialas:
R Ni (4)

Fmag

Ni

20 A xgap x 2

0 A

(11)

The Exact Dimensions of the Model

Dimensions of the simulation model in the software
MaxwellPresentedasfollows:

Thereluctanceofairgap:
xgap x
(5)
R
A
Thereluctanceoftheairgapwithpermeability, 0,is
defined by the displacement of the spring, x, from its
initialgapdistance,xgap.Ampereslawwasdeveloped
for time invariant fields. Thus when considering only
Ampereslaw,x=0andthereluctanceremainsconstant.
TABLEIPHYSICALCONSTANTSFORELECTROMAGNETDESIGN

Physicalconstants

value

AppliedCurrent(A)

NumberofTurns(N)

100

PermeabilityofFreeSpace( 0 )
PermeabilityofNickel( )

4 10 7 N / A2
800 0

Areacrossplunger(m2)

3.8*104

Initialairgap(mm)

0.5

The flux linkage is defined as the number of turns in

the coil multiplied by the magnetic flux passing
throughthecrosssectionalareaofthecoil.Thevoltage
maythenbederivedas:
d N ( N ) di ( N ) dx
V

(6)
dt
di dt
dx dt
Equation (6) can be rewritten using the inductance, L,
ofthecircuittimesthecurrent,andthespeedance,Ks,
ofthecircuittimesthevelocityoftheplunger:
di
dx
V L x, i . K s ( x, i ). (7)
dt
dt
The speedance is the coefficient of motional EMF

14

FIG.1PLUNGERMODEL
TABLEIIDIMENSIONSOFTHESIMULATEDMODEL

Var.

mm

Var.

mm

Var.

Mm

40

2.5

9.5

2.5

R
a

40

10.5

Lt

h b

39

10

d1

0.5

0.5

h1

10

D2

0.5

0.5

h2

10

d3

0.5

h4

60.5

4.8

60

L1

10

60

L2

10

Analysis and Simulation

Inthissectionplungersimulatedbytwostate.

ElectricalEngineeringResearchVolume2,2014

For example, we have applied sinusoidal voltage

V (t ) 100 2 cos(120 t ) . displacement to 1mm we

calculate amount of force applied to the piston,
Currentis:

100 2 cos120 t

i (t )

N 2 0 A
2x

1002 4 107 380 106 120

1.80
1103

100 2 cos120 t
4 (1.8)
2

In the figure 4, peak current is In the shape about

34.27A.Withcalculatedamount32.21A,adifferenceof
about6%.
30.00

100 2
cos120 t
4.39

1 100 2 cos120 t 2
f (
) ...
2
4.39
1002 4 107 3.8 104 1
6
2
10
1 cos 240 t
f 1238 89 cos 2 120 t 1238 89

f av 619 445 N

0.00

-10.00

0.06
20.00
0.04
10.00
0.02
0.00

-20.00

-30.00

Maxwell2DDesign1

0.00
-10.00

-20.00

M o v in g 1 .P o s itio n [m m ]

0.40
0.20
4.00
Time [ms]

6.00

8.00

FIG.2DISPLACEMENTONEMMMOVINGPARTS
Maxwell2DDesign1
Force
600.00
Curve Info

9.51

Time [ms]

6.00

8.00

10.00

-0.04

Ni

100 3
N2
.0439 106 L
0.228H
4
R
6.08 10

2.1 105 0.021mm

f

1 2 1002 4 107 3.8 10 4

(3 )
2
106

21.488 N

This means that that for every y <.021 mm, the force
exertedonthepistonduetothesaturationofmagnetic
material, is fixed. The gap is greater, R is greater
reluctance,Lislessinductance,Bisless;thenmagnetic
materialisnotsaturated.Andviceversa.

f [n e w to n ]

400.00
300.00
200.00
100.00
0.00 0.00

4.00

y R 0 A .0439 106 4 107 3.8 104

ANSOFT

Force1.Force_mag
Setup1 : Transient
Moving1.Force_mag
Setup1 : Transient

500.00

2.00

FIG.4THEREDISCURRENT

R
2.00

0.00

For a voltage VDC=12V, and the flux density of 1.6T

assuming that the magnetic material is ideal. To
calculate the amount of force to Displacement 1mm,
Currentsteadystateisasfollows:
V 12
i
3A
r
4
BA 1.6 3.8 10 4 6.08 10 4 wb

0.60

0.00

-0.02

DCVoltage

ANSOFT

Curve Info
Moving1.Position
Setup1 : Transient

0.80

0.00

ANSOFT

0.10

Curve Info
Current(Winding1)
Setup1 : Transient
FluxLinkage(Winding1)
0.08
Setup1 : Transient
InducedVoltage(Winding1)
Setup1 : Transient

10.00

-40.00

Position

Maxwell2DDesign1

30.00

Inthefigure2,Displacementonemmmovingpartsis
shown.

1.00

Winding

40.00

20.00

In d u c e d V o lta g e (W in d in g 1 ) [V ]

r 2 ( L ) 2

C u rre n t(W in d in g 1 ) [A ]

i (t ) V (zt )

In the figure 3, the peak power is 532.8N with the

calculatedvalue619.44Nisabout14%difference.This
large variation due to the reluctance of the fixed and
removablenozzlegapisnegligible.Soitisbettertobe
considered. Positive sign, because it is also the size of
theforce,theplothere.

F lu x L in k a g e (W in d in g 1 ) [W b ]

SinusoidalVoltage

2.00

4.00

Time [ms]

6.00

8.00

10.00

FIG.3ELECTROMAGNETICFORCE,FORASINUSOIDAL
VOLTAGE V (t ) 100 2 cos(120 t )

Figure 5 compares the calculated value of the force

difference is the difference between taking the spring
constantKoccurinsoftware.
We see in Figure 6, the peak current is 3A. And is
accordancewithcalculatedvalue.

15

ElectricalEngineeringResearchVolume2,2014

Force

4.50

Maxwell2DDesign1

ANSOFT

ThesethreeequationsaresolvedinMATLABusingthe
solverODE45.

Curve Info
Force1.Force_mag
Setup1 : Transient
Moving1.Force_mag
Setup1 : Transient

4.00

Inthefigure7,afterconnectingthepowerpistonmay
fluctuate.Andintheendprovedtobethe.1mm,But
thepositionisnotzero.

Y 1 [n e w to n ]

3.00

2.00

Inthefigure8,thepistonisfixedandhavenospeed.

1.00

In the figure 9, Current, according to calculations at

steadystate,isfixedtothe3A.
2.00

4.00

Time [ms]

6.00

8.00

10.00

FIG.5FORCETOPISTON
12.00

3.00

10.00

2.50

Winding

Maxwell2DDesign1

ANSOFT

0.008

Curve Info
Current(Winding1)
Setup1 : Transient
0.007
FluxLinkage(Winding1)
Setup1 : Transient
InducedVoltage(Winding1)
Setup1 : Transient

4.00

F lu x L in k a g e (W in d in g 1 ) [W b ]

6.00

2.00

C u rre n t(W in d in g 1 ) [A ]

In d u c e d V o lta g e (W in d in g 1 ) [V ]

0.006

8.00

0.005

1.50

0.004

0.003

1.00

0.002
2.00

0.50
0.001

0.00

0.00

0.00

2.00

4.00

Time [ms]

6.00

8.00

10.00

0.000

FIG.6THEREDCOLORREPRESENTSTHECURRENT

Dynamic Equations
Using equations previously described, Coupled set of
first order nonlinear differential equations can be
developedtomakeacompletelymodeltool.
dx
v
dt
dv
m. Fg K .x b( x, i ).v K s ( x, i ).i (12)
dt
di
L( x, i ). Va K s ( x, i ).v R..i
dt

But, with a alternating source Position changed

oscillatory. Due to the structure Plunger, here is
unacceptable. But it can be use in a tool as a Moser
machinethatisassmallfluctuations,butthetwosides
are allowed to fluctuations reciprocating this AC
voltageisapplied.NotetoFigures8to10.Ofcourse,in
theory, be made condition on the position that never
becomes negative but this condition also affects the
othertwostatevariables.
Inthefigure11,atthemoment,connectthesource;in
piston speed, several peak occurs. This is not too far
fromexpectation.
The coefficients of the equations were estimated. To
achieve more accurate response parameter should be
calculated as the exact Ks. Formalin calculate
parametersuchasb,alsoareapproximate.Otherstate
variablesliketheelectromagneticforce,energyfieldor
flux linkage can be added into the state equation. But
we could directlyuse Rungkuta format to solve the
equations.Again,thismethodisbasedonODE45.
-4

x 10

5
4
3
position:m

0.00 0.00

2
1
0

Which,bisthedampingcoefficientofviscosity,andK
ismechanicalspringconstant.

-1
-2
-3
0

3.v. A2
b
(13)
2. .( xgap x)3
b 2.872 N .s / m .

0.1

0.15
time:ms

0.2

0.25

0.3

FIG.7PISTONPOSITIONCHANGES
0.15
0.1
0.05
0
speed:m/s

Which, v 1.583 10 5 kg / ( m.s ) , A 3.8 104 m2 then

0.05

-0.05
-0.1
-0.15
-0.2

Inserting values with K s .2 , K 5335 , L .228 , Va

-0.25
-0.3
0

12vDC , m .009kg , Fg 0.09 N and writing equations

in the form of stateequations and solve it insoftware
obtainstherequiredwaveforms.
1
(0.09 5335.x1 2.87.x2 0.2.x3 ) (14)
.009
1
(12 0.2.x2 4.x3 )
x3
0.228
x2

16

0.1

0.15
time:ms

0.2

0.25

0.3

2.5

2
i:A

x1 x2

0.05

FIG.8PISTONSPEEDCHANGES

1.5

0.5

0.05

0.1

0.15

0.2

0.25

time:ms

FIG.9CURRENTINTHECOIL

0.3

0.35

ElectricalEngineeringResearchVolume2,2014

-4

dynamic and the electromagnetic equations causes to

solvetherangeofproblemanddesign.

x 10

5
4

position:m

ACKNOWLEDGEMENTS

2
1
0

Thanks to my father for his patience, my mother for

herkindness,andmybrotherforhisassistance.

-1
-2
0

0.05

0.1

0.15

0.2

0.25

0.3

FIG.10PISTONPOSITIONCHANGES

REFERENCES

0.15

Cathey, Jimmie J., Electriacal Machines Analysis And

0.1
0.05

DesignApplingMATLAB,McGrawHill,Vol.2001.

s peed:m /s

Cividjian, G. A. et al., Inductance of a plungertype

-0.05
-0.1

magnet,IEEETrans.onMagnetics,vol.34,no.5,Sept.

-0.15
-0.2

1998,pp.36953688.

-0.25
-0.3
0

0.05

0.1

0.15

0.2

0.25

0.3

Dolan, AlinIulian, Contributions to modeling of the fields

and of the transient regimes in electrical equipments,

FIG.11PISTONSPEEDCHANGES

AbstractOfPhdThesis,UniversityOfCraiova,Craiova,

2009.

1.5
1

Hunt,BrianR.,DifferentialEquationsWithMATLAB,JOHN

i:A

0.5

WILEY&SONSINC,2005.

0
-0.5

Kim,DongHun,Lowther,DavidA.,andSykulski,JanK.,

-1

Efficient Global and Local Force Calculations Based on

-1.5
-2
0

0.05

0.1

0.15

0.2

0.25

0.3

FIG.12CURRENTINTHECOIL

Conclusions
Seen,thecalculatedvaluesandsimulationvalueswere
somewhat close together, If, in the calculation,
regardlessoftheapproximation,theaccuracyishigher.
But the possibility of lack of convergence, also not
unexpectedthecorrectanswerinMaxwellSoftware.In
the analysis of the dynamical equations we assumed
constanttheLandR.Ideally,ofcourse,willmeanthat
B=1.6T. But in the General state changes of R and L,
alsochangestheequation.Thecurrentformwillhave
minor changes in the transient state. Dependence of

ContinuumSensitivityAnalysis,IEEETRANSACTIONS
ONMAGNETICS,VOL.43,NO.4,APRIL2007.
Krause, Paul C., Wasynczuk, Oleg, Sudhoff, Scott D.,
AnalysisofElectricMachineryanddriveSystems,2th
Edition,JOHNWILEY&SONSINC,2002.
Man,Jun,Ding,Fan,Li,Qipeng,andDa,Jing,NovelHigh
SpeedElectromagneticActuatorWithPermanentMagnet
Shielding

for

HighPressure

Applications,

IEEE

TRANSACTIONS ON MAGNETICS, VOL. 46, NO. 12,

DECEMBER2010.

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