What is the Relay Yoke for Electric Vehicle Charging?
Relay Yoke for Electric Vehicle Charging is a stamped pure iron component used in the magnetic circuit of a relay or DC contactor assembly. Production can be arranged around customer drawings, material requirements, forming geometry and inspection criteria. The current product page identifies pure iron and precision stamping as the main material and manufacturing features, but does not publish a specific material grade, magnetic-property values or dimensional tolerances. These details should be confirmed before tooling approval and batch production.
Key Manufacturing Technologies of Electromagnetic Relay Yoke Frame
High-Speed Progressive Die Stamping
Multi-station progressive tooling stamps the relay yoke geometry from continuous DT4C coils in a single automated process. Punching, notch shearing, coining, and multi-stage 90° bending are executed at speeds up to 200 strokes per minute. Precision guiding pillars maintain punch-to-die alignment within 0.003 mm, ensuring burr heights remain strictly below 0.02 mm to prevent air gap variations inside assembled EV charging contactors.
Controlled-Atmosphere Magnetic Annealing
Post-stamping mechanical strain introduces dislocations into the iron crystal lattice, degrading magnetic permeability and increasing coercivity. All stamped yokes undergo continuous belt-furnace hydrogen/nitrogen atmosphere annealing at 850°C to 880°C. This process stress-relieves the material, promotes grain growth, and lowers coercive force (Hc) below 60 A/m, restoring optimal soft magnetic performance.
In-Line Optical & Force Monitoring
Every production batch passes through an integrated vision inspection unit that verifies hole centers, slot widths, and surface flatness across 100% of the stamped parts. Automated sensor arrays detect pitch drift or tool wear in real time, stopping the press automatically if key dimensions exceed the ±0.015 mm tolerance band, eliminating out-of-spec yokes before surface treatment.
Electrolytic Surface Passivation & Plating
To resist corrosion caused by outdoor moisture and wide ambient temperature swings inside charging piles, the yokes receive barrel-plated zinc or nickel finishes with trivalent chromium passivation. Plating thickness is verified via X-ray fluorescence (XRF) spectrometry. Salt spray resistance testing confirms zero white rust at 96 hours and zero red rust at 240 hours.
Technical Specifications & Materials of Relay Iron Yoke Bracket
| Parameter / Technical Metric | Specification Value / Operational Standard |
|---|---|
| Chemical Composition | C ≤ 0.008%, P ≤ 0.015%, S ≤ 0.012% |
| Electrical Conductivity | 10.2% - 10.8% IACS |
| Coercive Force (Hc) | ≤ 60 A/m (After Decarburization Annealing) |
| Saturation Magnetic Flux Density (Bs) | 1.95 - 2.10 T |
| Mechanical Hardness | 85 - 110 HV (Post-Annealed State) |
Typical Application Scenarios of Pure Iron Stamped Relay Yoke
800V DC Fast Charging Station Contactors
Serves as the structural and magnetic guide frame in main high-voltage DC contactors. The low residual magnetism prevents contact sticking or delayed breaking when switching off continuous charging currents exceeding 350A at 800V DC.
AC Level 2 Wallbox Latching Relays
Integrated into single-phase and three-phase residential EVSE latching mechanisms. High magnetic permeability minimizes coil drive power requirements, suppressing thermal dissipation during extended multi-hour charging sessions.
Automotive On-Board Charger (OBC) Relays
Acts as the magnetic core retainer in compact vehicle power conversion units. High mechanical yield strength withstands continuous powertrain vibrations and thermal cycling from -40°C to +125°C without physical distortion.
Photovoltaic-to-EV Storage Interface Switches
Functions in bi-directional DC transfer switches connecting solar energy storage units directly to EV charging infrastructure. Precise magnetic symmetry ensures consistent pull-in voltages across millions of actuation cycles.
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