Robust Design for Consistency in Balanced Force Relay Considering Process Data

With the rapid development of manned spaceflight technology, the performance requirements of aerospace relays have become increasingly stringent. However, there are still large inconsistencies in the electrical parameters of relays, and manufacturing process errors continue to affect their performance. To address the problem that the pull-in and release voltage of a typical aerospace relay exhibit excessive dispersion and fail to meet specification, this paper firstly summarizes the research status of the dynamic characteristics of the relay. Secondly, an establishes the electromagnetic system model and reaction force model of the relay are established. Parametric modeling is employed to simulate deviations in the manufacturing process. Comparison between the simulation results and experimental data confirms that the simulation error is less than 5%, meeting the required accuracy. Using orthogonal experiment design with five-factor, three-level orthogonal array, key parameter levels are determined through signal-to-noise ratio and sensitivity analysis. Based on these results, an optimization scheme is proposed to adjust critical parameters. Specifically, improving the precision of the vertical height fixture for the long yoke iron is recommended to enhance consistency in the relay manufacturing process.