A novel optimization method for dynamic response analysis of HSERs via a field-circuit coupling mathematical model

In the aerospace sector, the soft magnetic materials of Hermetically Sealed Electromagnetic Relays (HSERs) are critical in forming magnetic circuits. Conventional soft magnetic materials, primarily magnetic iron, have been unable to meet the development trend of fast-response, miniaturized, and lightweight aerospace and aviation systems. This paper applies circuit theory and electromagnetics theory to establish a Field-Circuit Coupling Mathematical Model (FCCMM) for dynamic response analysis of HSERs. This model centers on inductance calculation, with the core’s permeability and saturation magnetic flux density as critical parameters. Based on this model, for a specific type of HSER, this paper introduced three alloys with key parameters different from magnetic iron, then tested the magnetic characteristic curves of these four soft magnetic materials, followed by simulations to obtain the electromagnetic characteristics of digital mock-ups corresponding to these four materials, compared and validated the dynamic responses corresponding to these four soft magnetic materials finally. Based on the theoretical model analysis results, this paper designed a lightweight coil to minimize response time, made prototypes, set up test systems, and tested dynamic characteristics. The experimental results indicate that the nanocrystalline alloy 1K107B exhibits the most significant optimization, reducing the closing time by 40.48% and achieving a weight reduction of 6.53%.