Abstract: A method of detecting and attempting to correct a relay tack weld failure of its contacts is presented. This method senses the failure of a relay's contacts to open once it has been commanded to trip. This sensing may directly sense relay conditions, or may indirectly determine the failure by sensing a system parameter that shows the effects of the failure. Once the failure of the relay to open has been determined, the relay is again energized in an attempt to break loose the relay tack weld. If the relay fails to open after this first attempt, the relay may again be repulsed. Preferably a relay check timer is utilized to ensure that the system has stabilized before a repulse is attempted. A relay pulse timer may be used to control the pulse duration during these attempts. The number of attempts may also be limited.

Abstract: The cutting or crushing of electrical wire during a tang termination process is avoided by the method that includes the steps of providing a post (28) of a thermoplastic material in adjacency to a terminal mounting structure (22, 24) wrapping an electrical conductor (34, 40) forming part of the winding (20) around the post (28), mounting a metal terminal (42) having a tang (52) on the mounting structure (22, 24) so that the tang (52) extends at least partially about the post (28), and closing the tang (52) about the post (28) with sufficient heat to destroy the insulation, if any, on the electrical conductor and establish a fused electrical connection between the tang (52) and/or terminal (42) and the conductor (34, 40).

Abstract: The cutting or crushing of electrical wire during a tang termination process is avoided by the method that includes the steps of providing a post (28) of a thermoplastic material in adjacency to a terminal mounting structure (22, 24) wrapping an electrical conductor (34, 40) forming part of the winding (20) around the post (28), mounting a metal terminal (42) having a tang (52) on the mounting structure (22, 24) so that the tang (52) extends at least partially about the post (28), and closing the tang (52) about the post (28) with sufficient heat to destroy the insulation, if any, on the electrical conductor and establish a fused electrical connection between the tang (52) and/or terminal (42) and the conductor (34, 40).

Abstract: The manufacture of an electrical contactor is simplified by a construction including a base 22, a contactor assembly 20 including at least one movable contact 32 mounted on the base, a magnetic core 26 mounted on the base 22 in proximity to the contactor assembly 20, and a bobbin 28 mounted on the magnetic core 26 and having spaced flanges 112, 114 defining a peripheral winding receiving recess 118 wherein the flange 112 has terminal receiving recesses 122 in an edge 120 thereof. Metallic pins 132 have one end captured in the edge 120 and receive the ends 164 of an electrical winding on the bobbin 126 in wrapped around fashion. A plurality of metallic terminal pieces 128 are provided, one for each of the recesses 122 and include a finger 156 crimped about the corresponding pin 132 and the winding end 164 wrapped thereabout.

Abstract: An electrical contactor including a generally U-shaped base 12 having a bight 44 and parallel upstanding legs 22 terminating in mounting flanges 50, a contactor assembly 10 including an insulator 28 abutting the flanges 50 and having a movably mounted electrical contact 22, and a plastic shell 14 disposed between the legs 42 and sandwiched between the bight 44 and the insulator 28. A magnetic core 16, an electrical coil 48 and an armature 20 are included in the assembly.