Products Description
Unlike traditional industrial control relays, EV Relay Core has stringent requirements for spatial layout and instantaneous engagement force.
Flat, Low Center of Gravity Design: The unique flat geometry not only compresses the overall height of the relay but also facilitates high-density integration within a compact battery pack, while enhancing stability against multi-axis vibrations (X-Y-Z axes).
High Saturation Magnetic Induction: Achieving powerful electromagnetic attraction within a small volume ensures rapid contact opening or closing under high voltage and high current conditions, effectively suppressing arcing.
Low Residual Magnetism Interference: Optimized material formulation ensures that the core instantly releases the armature after the drive current disappears, avoiding the risk of contact sticking due to residual magnetism.
Material Advantages: Microscopic Balance Between High Saturation and Low Loss
1. Selection of High-Performance Soft Magnetic Alloys
Considering the limited space and enormous current characteristics of electric vehicle high-voltage systems, we select high-grade non-oriented silicon steel or iron-nickel soft magnetic alloys with high saturation magnetic induction.
High Saturation Magnetic Induction: Our core materials typically have a saturation magnetic induction of 1.8T - 2.0T or higher. This means that even with limited coil turns and volume, the Flat Core for EV Relay can still generate strong electromagnetic attraction, ensuring reliable relay engagement even at extremely low temperatures (battery performance degradation) or voltage fluctuations, eliminating the risk of overheating from "lackluster connections."
Low Coercivity: This is crucial for safety. Extremely low coercivity means the Stamping Iron Core Bending Part for EV Relay is "soft" and demagnetizes rapidly. When the coil is de-energized, the magnetic field inside the core disappears instantly, and there is no residual magnetism attracting the armature. This is the physical basis for millisecond-level response speeds in electric vehicles that require rapid interruption of fault currents (such as short circuits).
2. Superior Frequency Characteristics and Lamination Technology
To address the eddy current heating generated during high-current switching, our flat iron core (especially for high-frequency applications) employs a high-insulation-coated silicon steel sheet lamination process. The insulating coating between the sheets effectively cuts off the eddy current path, significantly reducing iron losses and temperature rise. This improved temperature control capability effectively suppresses coil temperature rise under continuous high-current conditions, extending the product's electrical life.
Key Functions and Design Advantages: Performance for Space
| Magnetic Circuit Centrality | Constructs a low-impedance magnetic flux loop, converting the coil's ampere-turn potential into mechanical attraction. |
| Heat Conduction Path | The flat, large-area structure makes it an excellent heat conductor, quickly transferring heat generated by the coil to the outer casing for heat dissipation, preventing overheating failure. |
| Contact Drive | Precisely controls the armature's stroke and attraction characteristics, ensuring constant contact pressure when the moving and stationary contacts close, reducing contact resistance. |
| Flat Integrated Design | The flat structure perfectly fits the limited space of the battery pack or PDU (Power Distribution Unit), achieving highly integrated installation. Compared to a cylindrical iron core, its height dimension is significantly reduced, leaving valuable energy space for the battery module. |
| Optimized Electromagnetic Force | The wide pole face design makes the electromagnetic attraction curve smoother. At the critical point of the attraction process, it provides a larger reserve of attraction force, effectively overcoming the sticky force after contact welding, ensuring the reliability of the next disconnection. |
| Easy-to-assemble positioning features | We have designed precise positioning holes, bosses or slots on the Pure Iron Core for EV Relay, which enables "blind assembly" and self-alignment on automated assembly lines, greatly improving the assembly efficiency and accuracy of downstream customers. |
Why Choose Our Engineering Capabilities?
Engineering Support
We have a team led by PhDs specializing in magnetic materials research, capable of providing electromagnetic simulation and reliability analysis, shortening your R&D cycle.
Automotive-Grade Quality System
We strictly adhere to the IATF 16949 quality management system, ensuring that every Cold Heading Pure Iron Core undergoes rigorous testing for reliability.
Agile Supply and Customization
For the emerging 800V high-voltage platform, we have mature solutions for special material Relay Cores.
contact us
For further evaluation of samples, verification of magnetic performance matching, or collaboration on new platform projects, please submit your technical parameters and project requirements. We will provide you with a systematic support solution based on our engineering matching and mass production delivery capabilities.
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