AAA Carbon battery.What are the technologies and standards for communication relays?

　　The structure and design of a communication relay

　　Almost 100% of the relays used in modern program-controlled switches are PCB electromagnetic relays with contacts. Structurally, most of the first and second generation communication relays are slap-type magnetic circuit structures, push rod mechanical transmission, and use twin contacts. The material is Agpd alloy. Starting from the second generation, in order to improve its sensitivity, the structure uses permanent magnets of samarium-cobalt high-energy alloy to form a bridge magnetic circuit, but a considerable part of the relays are still made of monostable. However, starting from the third generation, the structural form is completely different from the first and second generations. Almost all of them are made of a double-coil symmetrical balanced rocker magnetic circuit structure containing high-energy permanent magnets. The contacts are spot-welded on the strip and then integrally injection molded. , higher precision requirements, extremely sensitive, very small design margin, and extremely high material requirements.

　　At present, there are many domestic designers and manufacturers of the first, second and third generation communication relays, but no one is interested in the fourth generation communication relays. This illustrates the current overall relay equipment manufacturing level, product design level and production management level of my country's relay industry. There is still a considerable gap compared with international standards. These gaps manifest themselves as:

　　⑴Except for relay design used in aerospace and special applications, civilian and commercial relays lack standard design specifications. It is not an exaggeration to say that the vast majority of domestic relay manufacturers currently only stay at the level of tracking and imitation research;

　　⑵ For various types of ultra-small magnetic circuit structures with permanent magnets, there is a lack of actual factory analysis and calculations. Relay manufacturers are still unable to accurately describe and utilize what kind of magnetic circuit structure forms the best "three-dimensional field". Especially how to effectively utilize magnetic energy when the working air gap is small and there is a large magnetic leakage distribution;

　　⑶No one has conducted in-depth research, analysis and practical application of new edge materials and new processes. Such as ultra-fine electromagnetic wires, high-energy permanent magnets, excellent engineering plastics and relay accessories, etc., the design of communication relays lacks effective technical support.

　　⑷There is a lack of engineering and technical talents who understand both the basic theory, design, and process skills of relays and are familiar with special relay manufacturing equipment. The current situation is: relay product designers and equipment design and manufacturing personnel are two teams, lacking technical integration. Generally speaking, the design and manufacturing of first-, second-, and third-generation communication relays is not a big problem, but it involves the fourth-generation ultra-small communication. I'm afraid relays are not so handy.

　　⑸The vast majority of companies rarely have the ability to manufacture high-speed, efficient, repeatable, and consistent electromechanical production lines. 2. The manufacturing technology of communication relays. Domestic imitation research on communication relays has a long history. The earliest tracking and imitation research work started around the end of the 1970s. The target is ITT's RZ type DIp relay, with a size of 20×10×10 and a point load of 1A30VDC. , the maximum current is 2A. We call it the first generation relay, which is designed and manufactured by hand. The current best level of this type of relay is Ningbo Huigang Electronics, with operating capacity: 900,000 pieces/month (two shifts per day), and the relay is non-polar neutral. The second generation of monostable communication relays with permanent magnets can also be manufactured independently in China, and the operation method is manual. Operating capacity: 20,000 pieces/month (manual), (full imitation of OMRONG6A type), if it is semi-automatic level: Shanghai OMRONG6A, operating capacity: 12Kp/8h1 line/month. Xiamen SiemensD2 operating capacity is 800Kp/second shift, 1 line/month. Almost 100% of the existing third-generation communication relays are operated by automatic machines and are manufactured on production lines composed of special equipment. For a typical production line, see the TX line of Panasonic in Beijing. Production operation characteristics:

　　(1) It is no longer a production model of single-piece production and final assembly.

　　(2) There is almost no manual work in the continuous operation, and it is all completed by special mechanical assembly.

　　(3) Modern technologies such as micro-welding technology, thin wire winding technology, combined plastic compression molding technology, laser welding technology, contact tracking (overtravel OT amount) adjustment technology, small terminal flattening technology, demagnetization, and magnetization are adopted. technology, airtight plastic sealing technology and multi-parameter characteristic comprehensive testing and inspection technology, etc.

　　(4) Operation capacity: 1500Kp/line, second shift,/month. As for the fourth-generation communication relay, we have only seen samples so far, not the manufacturing process. However, from a structural analysis, its operating mode should be similar to that of the third-generation relay.

　　2. Communication relay standard

　　Due to the particularity of communication relays, the relay standards are also different depending on the installed machine (switch). In recent years, IEC has new regulations on communication relays used in switches. Its standard system is also derived from four basic relay standards such as IEC255-7. See Table 1 for details. Domestic switch manufacturers produce different types of switches and have different requirements for relays. For application considerations, the former leaders of the Ministry of Posts and Telecommunications compiled a standard for program-controlled switches. However, due to difficulties in implementation, the Posts and Telecommunications standard has not yet been promulgated. At present, all complete machine manufacturers require communication relay supply units to supply according to their own corporate standards, such as the component procurement specifications for 04 machines, the component subscription standards for C&C08, etc.

　　three. Communication relay discussion

　　1Is it necessary to use relays in switches? According to those who design and manufacture switches, at least for now, small PCB relays must be used in switches.

　　(1) Function of electromagnetic relay in switch a. The gate circuit output of the user board; b. The input and output lines of the relay board relay signals; c. Power supply board power cut d. Change; e. Monitor the ring current output of the board. Generally, at least three relays are used per line in office switches.

　　(2) The irreplaceable advantages of electromagnetic relays are fully utilized in switches. These advantages are: a. High insulation input-output impedance ratio; b. The contact load can vary over a very wide range, c. Generally from 10mV10mA to 50V2A/DC, d. And can carry cable load; e. Small power consumption: generally only 0.15W and at most 0.2W, f. This is absolutely necessary to save power for power supplies that use electromechanical components in large quantities; g. cheap, h. It is particularly competitive as the cost of each switch has dropped from 100$/line to 20$/line.

　　Of course, it is said that switches that do not have contact relays at all are also being tested, but it will take some time before they can be put into practical use. Therefore, it can be considered that in the first one to twenty years of this century, it is absolutely necessary to use low-cost small and ultra-small DIL and SMD communication relays in program-controlled switches. 2How long can the market life of electromagnetic relays last?

　　Table 2 shows the service life of relays once used in telephone switches: The author believes that the third and fourth generation products will generally not be eliminated in program-controlled switches between 2005 and 20.

　　3How far are we from independently producing third and fourth generation relays? (1) See Table 4 for the current situation

　　(2) Conditions for developing fourth-generation relays

　　a. After reform and opening up, the overall level and process technology of my country's manufacturing relays are basically in line with international standards. There are a group of professional engineering and technical personnel who understand technology, expertise, and management.

　　b. Have considerable economic strength, c. Such as capital, factory buildings, tooling manufacturing capabilities, special equipment, d. manufacturing capabilities, etc.

　　e. Have ready-made successful experiences and failure lessons from abroad.

　　d. Have market demand and cost competitiveness

　　(3) The main difficulties in developing fourth-generation communication relays: Table 5 gives the main difficulties in manufacturing such relays. in conclusion

　　(1) Communication relay is definitely a promising component, especially for wired communication applications, and it will not change in the 10 to 15 years since the beginning of this century. Relevant experts predict that by 2005, a single office switch will require nearly 1 billion third-generation/fourth-generation communication relays, which shows the vastness of the market. (2) From the perspective of professional relay production technology, many large domestic manufacturers have the ability to develop or develop third-generation or even fourth-generation communication relays with the help of foreign professional manufacturers. Xiamen Hongfa has already started work in this area, and they have independently The third generation communication relay developed is expected to enter small batch production in 2005. (3) Peripheral supporting and assisting manufacturers have become very large, such as Dalian Fuji and Zhuhai Rongsheng, which specialize in enameled wires, and Rite Machinery, which specializes in multi-axis high-speed winding machines (this is a company with great research on the tension control of the wire in the winding process). manufacturer). Sumitomo Corporation provides excellent injection molding technology and equipment, as well as manufacturers that can provide various joint comprehensive testing instruments, etc. (4) If Chinese relay manufacturers were still wandering around the periphery of communication relays 10 years ago, it can be said with certainty now that this situation will never exist, and will be replaced by a vigorous attitude and a pragmatic approach to high-end manufacturing. to join the manufacturing ranks of precision, high-tech quality ultra-small (SDT) (DIL) communication relays.

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