Coil with retaining element and electrical connector

Abstract

Coil (1), for example as a magnetic coil in an electromagnet, consisting of a coil former (10) which carries a plurality of turns (20) of a current-conducting wire (2) and wherein the coil former (10) has at least one retaining element (3) for mechanically fixing a wire start (21) and a wire end (22) of the turns (10) and electrical connectors (4, 41, 42) at the wire start (21) and wire end (22) for connecting to an electrical supply and return line (6), wherein the connectors (4, 41, 42) are designed as components separate from the retaining element (3), wherein only one retaining element (3) is provided on the coil former (10) which carries both the wire start (21) and the wire end (22) at a distance from each other, wherein the connectors (4, 41, 42) provided as separate components are bonded or welded to the retaining element (3). or are crimped or wherein the retaining element (3) is designed to clamp the connectors (4, 41,42) to enable on the retaining element (3), wherein a support (30) is provided for the arrangement of the retaining element (3) on the coil (1), from which the retaining element (3) is received, wherein the support (30) connects to the coil (1) on one side and the support (30) carries the retaining element (3) on the side facing away from the coil (1), wherein the support (30) is already provided on the coil body (10) during its manufacture.

Description

[0001] The invention relates to a coil, such as is used, for example, as a magnetic coil in an electromagnet, consisting of a coil body which carries a plurality of turns of a current-conducting wire and wherein the coil body has at least one holding element for the mechanical fixing of a wire start and a wire end of the turns, as well as the electrical connector at the wire start and wire end for connection to an electrical supply or discharge line.

[0002] A two-sided terminal block for an electromagnet is known from US 2010 / 0 259 348 A1. The terminal block comprises a base, a first terminal insertion slot on a first side of the base, a second terminal insertion slot on the second side of the base, a connecting post, and a wire. The wire is routed through both terminal insertion slots. Terminal plugs can be inserted into the terminal block along the coil's length for electrical contact with the wire.

[0003] DE 20 2005 006 010 U1 discloses an actuating magnet with a coil former, wherein the conductor ends are accommodated in a holding device. DE 100 14 738 A1 discloses an electrical coil with a coil former and at least one holder for the coil wire on the front flange. A tongue-shaped insulation displacement contact contacts the coil wire in the holder. DE 35 44 974 A1 teaches an electromagnet with plug connections for the wire ends of the winding. US 2011 / 0 088 252 A1 describes an electrical coil assembly with two-part connecting terminals. WO 2008 / 011 449 A2 discloses an electrical connecting terminal with at least one first welding lug. US 4,728,916 A discloses a magnetically actuated device, wherein terminal elements are inserted into terminal receiving cavities to contact the coil wire. US 4,166,265 A discloses a coil former having recesses spanned by wire.Electrical connections to the ends of the winding wire on the coil body are made by inserting terminals into each of the recesses.

[0004] Conventional coil formers are designed in such a way that they require customized coil formers or retaining elements arranged therein for a wide variety of connectors, geometries, and configurations. This requires that the winding device be modified to suit the specific connectors to be used before the coil formers can be manufactured. In the production of small series, this results in significant conversion costs, coupled with downtime and unsatisfactory machine utilization.

[0005] The object of the present invention is to further develop a generic coil in such a way that the coil can be adapted to the intended use only via the connector.

[0006] This object is achieved by the coil having the features of claim 1. The coil according to the invention is characterized in that the connectors are designed as components separate from the holding element.

[0007] The advantage of the coil according to the invention is that a coil former with standardized essential components and a holding element arranged thereon for mechanically securing a wire start and a wire end is provided and used. The final adaptation of the coil to the planned installation situation or the design specified by the user is achieved by subsequent arrangement of the connectors, which are provided as separate components. One advantage resulting from this is that the coil formers with free wire ends can be manufactured in large numbers as standard components and, for example, stored. In an adaptation step, the respective application-dependent connector is then plugged onto the universal holding element, which holds or supports the free wire start and the free wire end, and in doing so, is conductively connected to the wire ends arranged accordingly on the holding element or to the wire start.The invention also provides for standardized holding elements on coil formers with different sizes, wire gauges, and winding counts, so that when changing production, only the tool or the connectors to be arranged needs to be retooled, while all other (machine) settings can remain the same. This significantly shortens setup times and significantly reduces production costs, for example, for small batches.

[0008] In a development of the invention considered advantageous, the holding element is designed such that the wire start and end are secured in spatially spaced areas. This avoids the risk of short circuits between the winding start and end.

[0009] In the context of the present invention, it should be noted that the term "turns" can be synonymously replaced by the term "winding" or "windings." The terms "turns" or "windings" refer to a winding of a material in the solid state around an axis. In the context of the coil according to the invention, the current-conducting wire is arranged in the form of turns on a coil body. These turns are achieved by winding the wire onto the coil body.

[0010] The invention provides that only one holding element is provided on the coil body, which holds both the wire start and the wire end at a distance from one another. The free wire areas of the wire start and wire end are guided around extensions, projections, mandrels or domes provided on the holding element and secured by suitable crossing or winding. For example, the winding start and the winding end can be wound once or several times around a so-called winding mandrel or mandrel-like extension on the holding element. A different winding or number of windings or different numbers of windings and wire start and wire end are also possible. The holding element itself can provide a guide for the free wire areas and insulate the wire end and the wire start from each other.

[0011] An advantageous embodiment provides only a single holding element that supports or secures the wire start and wire end in spaced-apart regions. A further development of the invention alternatively provides that the coil has two holding elements, one holding element for the wire start and one for the wire end. The use of two separate holding elements also allows the free wire areas to be secured and connectors adapted to the ultimate use of the coil to be subsequently arranged. The connectors, provided as separate components, are pushed onto the respective holding elements or glued, welded, or caulked to the holding element or elements. The invention provides for clamping of the connectors on the holding element, which is possible depending on the design of the holding element.

[0012] For the arrangement of the holding element, a support is provided on the coil, in particular on a coil flange, which extends radially to the coil former. According to the invention, the holding element is received by this support. This embodiment has the advantage of allowing further standardization of coil former production.

[0013] The conductive wire is first wound onto a single coil former, and the free wire end or beginning is then connected to a retaining element that is held by the carrier. The retaining element then secures the wire beginning and end and is suitable for accommodating or supporting a wide variety of connectors.

[0014] It is considered advantageous if the holding element is designed as a winding mandrel around which the wire end or wire start is at least partially wrapped. A further embodiment is possible in this case, in which the holding element has two winding mandrels, one winding mandrel for the wire end and one winding mandrel for the wire start. First, before winding begins, the winding mandrel assigned to the wire start is wrapped around the wire start. After winding is complete, the other winding mandrel assigned to the wire end is wrapped around the wire end and the turns are then fixed accordingly. The terms mandrel and mandrel are used synonymously in connection with the invention.

[0015] One embodiment of the device according to the invention that is considered advantageous provides that the connector is pushed onto the holding element. The connector, which as initially explained connects the wire start or end to an electrical supply or discharge line, is arranged on the holding element in such a way that the wire end or start is arranged between the connector and the holding element. An alternative embodiment provides that the connector is arranged between the holding element and the wire end or start. The arrangement of the wire start or end is also determined by the way in which the wire start or end wraps around the holding element or a winding mandrel advantageously provided there.

[0016] The holding element itself advantageously has recesses or grooves or the like that allow the connector to be pushed on.

[0017] A further development of the invention considered advantageous proposes that the connector be glued, welded, or caulked to the holding element, or that the connector be held on the holding element by clamping. In any case, it proves advantageous to design the connector as a separate component from the holding element and to attach the connector as needed to a standardized coil body with windings of a current-conducting wire arranged thereon. The aforementioned connection options are suitable for this purpose. All of these connection options have the advantage that they can be carried out automatically, so that the coil according to the invention can also be produced in larger series.

[0018] According to the invention, the carrier connects to the coil on one side and the carrier carries the holding element on the side facing away from the coil. The carrier is already provided on the coil body during its manufacture, thus providing a standardized element that can be functionalized or adapted to the respective requirements of the subsequent use of the coil by selecting a suitable holding element or a connector connected to the holding element.

[0019] It is advantageous if at least one guide element for the wire, in particular for the wire start and / or end, is provided on the carrier, the coil, or the coil body. This ensures that the wire end or the wire start is kept separate and enables a proper winding process.

[0020] The carrier or the coil flange preferably has a lateral recess spanned by the wire. The connector is then arranged on the carrier or coil flange or the holding element in such a way that an electrically conductive connection to the wire or the wire region spanning the recess is ensured. The wire located in the region of the lateral recess is aligned such that it engages with the connector plugged onto the holding element or the carrier or coil flange. After the connector has been arranged, the wire can be glued, welded, caulked, or clamped to the connector and the connector to the carrier, coil flange, or holding element in order to create a permanent and electrically conductive connection.

[0021] A further development of the invention provides that the coil former, the coil, the holding element, or the carrier carrying the holding element has a clamping slot that can cooperate with a plug-in piece of the connector in a mechanically holding manner. The plug-in piece of the connector can advantageously be inserted into the clamping slot. This advantageously stabilizes the arrangement of the connector. Furthermore, the clamping connection between the holding element or carrier coil or coil former and connector is significantly improved, and an electrically conductive connection is ensured. The clamping slot is preferably aligned perpendicular to the coil former, but can also run parallel to the coil axis or have another orientation considered advantageous.

[0022] Equally of inventive significance is a group of individual, at least partially different connectors that have a contact area that interacts with the wire of a magnetic coil and a connection area that can be connected to the electrical supply or discharge line. The connectors in the group are characterized by the fact that the contact areas of the connectors in all groups are designed identically. This has the advantage that, when the connector configuration is adapted to the coil's area of ​​application, the connection areas are provided with a shape that matches the holding elements on the coil. These are designed in such a way that the same contact point with the coil's wire is always ensured.This provides a standardized contact area that is adapted to standardized coil former designs or retaining element configurations, thus significantly simplifying the assembly of the entire system, consisting of coil or coil former and connector. The group preferably consists of at least two subgroups of connectors, with the connectors of one subgroup being of the same type and the connectors of different subgroups having different connection areas.

[0023] The connectors provided by the embodiment according to the invention can, for example, be designed as connectors that can be connected to the electrical supply line on the one hand and to the electrical discharge line on the other. An embodiment with different arrangement sides can also be provided in this way. The invention thus provides connectors that can be arranged precisely on the coil body and yet are matched to the coil according to the invention, so that assembly can be carried out much more easily.

[0024] The invention also provides a system which, in addition to a coil, for example a coil which can be used as a magnetic coil in an electromagnet, is formed from a coil body which carries a plurality of turns of a current-conducting wire and provides at least one holding element for mechanically securing a wire start and a wire end of the turns, and a connector which is formed separately from the holding element and is connected to the coil body upon completion. The connector contacts either the wire start or the wire end and allows an electrically conductive connection. The system according to the invention furthermore has all of the features described in connection with the coil, individually or in combination.

[0025] Equally of inventive importance is a method for assembling a magnetic coil, for example, for an electromagnet, wherein the magnetic coil has a coil body onto which a conductive wire with a plurality of turns is wound. The method according to the invention provides that the wire start or end is secured to at least one holding element. In a further method step, the magnetic coil is completed with connectors, in particular from a group of partially different connectors. Completion occurs by the connector being conductively connected to the wire in a contact area. The contact area is provided on the connector.The fixing of the wire start or wire end on the holding element is carried out in such a way that the contact area of ​​the connector and the wire start or wire end are brought into contact when the connector is arranged, thus establishing a conductive connection.

[0026] A further development of the method according to the invention provides that the connector, along with the electrical connection, is mechanically connected to the coil body, the coil, the holding element, or the support carrying the holding element. The connection is made, for example, by gluing, welding, or caulking, or by simply plugging the connector onto the holding element. In this case, a clamping connection can also be provided, which is created by engaging the connector with corresponding recesses, grooves, or the like provided on the holding element.

[0027] In a preferred embodiment, the method according to the invention provides that the completion of the magnetic coil with connectors takes place spatially and / or temporally separately from the winding process of the magnetic coil. This embodiment allows the provision of a standardized, prepared coil or coil body carrying the current-conducting wire and the subsequent, adapted arrangement of correspondingly functionalized connectors. For this purpose, the wound magnetic coil can, for example, be manufactured in large numbers from standardized components and then stored. In a completion order, the connectors are then arranged on the prepared coils or coil bodies, thus completing the coil. This results in significantly shortened setup times, which more than compensate for the storage costs incurred during storage.In addition, it is possible to respond to small series production orders with little effort without having to completely adapt all the tools and machines for producing the coils, especially when coil bodies of different sizes always have the same holding elements.

[0028] In this context, it is particularly noted that all features and properties described with reference to the device, as well as procedures, are also transferable mutatis mutandis with regard to the formulation of the inventive method and can be used within the meaning of the invention and are deemed to be disclosed. The same applies in reverse, meaning that structural, i.e., device-related, features mentioned only with reference to the method can also be considered and claimed within the scope of the device claims and are also considered part of the invention and disclosure.

[0029] The invention is illustrated schematically in the drawing, particularly in one embodiment. Shown are: Fig. 1a a coil in plan view; Fig. 1b the holding element of the coil according to the invention in side view; Fig. 2a a coil according to the invention with arranged connectors in plan view; Fig. 2b the coil Fig. 2a in side view.

[0030] In the figures, identical or corresponding elements are designated by the same reference numerals and will therefore not be described again unless appropriate.

[0031] Fig. Figure 1a shows a plan view of a coil 1 according to the invention. This shows a coil body (cf. Fig. 1b) adjoining coil flange, which is connected to the holding element 3. The coil 1 carries windings 20 of a current-conducting wire 2. Of this wire 2, Fig. 1a, only the wire start 21 and the wire end 22 are visible, which wrap around the holding element 3. The connectors 4 are shown separately from the holding element 3. A first connector 41 serves to make contact with the wire start 21, while a second connector 42 is connected to the wire end 22. The connectors 4 serve to connect to an electrical supply or discharge line to the coil 1. The coil 1 shown here or its coil body 10 can be provided as a standardized element and is completed to form an overall system by arranging it, for example, by plugging, gluing, welding, or otherwise connecting it to the connectors 41, 42. The connectors 4 have a plug-in piece 43 matched to the design of the holding element 3.Regardless of the final design of the section of the connectors 41, 42 connected to the electrical supply or discharge line, the plug-in piece 43 is matched to the retaining element 3 and can thus be universally connected to a standardized retaining element. The final matching of the connectors 4, 41, 42 is then achieved via the sections of the connectors 41, 42, 4 that adjoin the plug-in piece 43.

[0032] In the exemplary embodiment, the holding element 3 provides a total of two winding mandrels 31, 32, which are wrapped around the wire beginning 21 and the wire end 22, respectively, thus securing the wire 3. A contact area (not shown) is provided on the connector 4 itself, which establishes an electrical connection after contacting the wire 2.

[0033] The holding element 3 is in the embodiment of the Fig. 1a on the coil flange 11, which extends radially from the coil body 10 (cf. Fig. 1b). A corresponding extension is, for example, molded, injected, or subsequently added.

[0034] The coil flange 11 itself has a guide slot 12 (cf. Fig. 1b), via which the wire 2, for example the wire beginning 21 or the wire end 22, is guided towards the holding element 3.

[0035] The embodiment of the coil 1 according to the invention shown here makes it possible to provide a standardized component with a simplified configuration and thus a high-volume production capability. The actual adaptation of the coil 1 to the final intended use is achieved by the arrangement of the connectors 4, which carry the connection elements suitable for the respective application.

[0036] This makes it possible to respond quickly and easily to small series requirements using an element that is available in large numbers, without having to take up setup times in order to adapt the entire winding machine or production device.

[0037] Fig. Figure 1b shows a side view of a coil 1 according to the invention. Shown here is only a section of the coil body 10, which carries the windings 20 of the current-conducting wire 2. The windings 20 are shown schematically. Also visible is the coil flange 11, which adjoins the actual coil body 10 and, in the exemplary embodiment, Fig. 1b provides a support 30 for the holding element 3. The holding element 3 has already been described in connection with the Fig. 1a. The coil flange 11 simultaneously serves as a guide for the wire start 21 and the wire end 22 and ensures that the wire start 21 and the wire end 22 are kept separate to prevent short circuits.

[0038] The holding element 3 has in the embodiment of the Fig. 1b has a clamping slot 33. The plug-in piece 43 of the connector 4 is inserted into this. The connector 4 is thus held in the clamping fit and contacts the wire end 22 or the wire beginning 21 in the lateral area of ​​the holding element 3. Here, the wire 2 spans a recess in the holding element 3, as is the case, for example, in Fig. 1a. In this spanning section, the contact area of ​​the connector 4 engages the wire 2 and establishes an electrically conductive connection. Fig. 1b shows the coil 1 according to the invention in an unassembled state, i.e. without connectors 4 arranged.

[0039] Fig. Figure 2a shows the assembled state of the coil 1 according to the invention. Here, the connectors 41, 42 were attached to the side of the holding element 3 and inserted into the clamping slots 33 provided there. The contact areas on the connectors 41, 42 engage around the wire 20 stretched on the holding element 3 and contact it. This creates an electrically conductive connection. The supply and discharge lines 6 are connected to the connectors 41, 42. This is particularly important in Fig. 2b. Here, the supply and discharge lines 6 have an angled portion, which can be used, for example, to establish a plug connection with a power source. Fig. 2a and Fig. 2b shows that the coil 1 can be adapted to the respective application areas by appropriately selecting the supply or discharge lines 6 or their configuration on the connectors 41, 42. The geometry and size, shape, or design of the supply or discharge line 6 can be freely selected, while the coil 1 or the holding element 3, as well as the wire start 21 or wire end 22 defined there, provide a standardized element. Coil 1, coil body 10, and carrier 30 or holding element 3 can thus be provided as a standardized system element. The final adaptation of the entire coil 1 is achieved by the shape of the connectors 4 or their supply or discharge lines 6.

[0040] In the embodiment of the Fig. 2a, the connector 4 is pushed onto the holding element 3. The wire beginning 21 runs on the side of the holding element 3 facing away from the plug-in piece 43. The wire end 22, however, runs between the holding element 3 and the connector 4 and is thus partially covered by the plug-in piece 43.

[0041] The wire end 22 or the wire beginning 21 wrap around the winding mandrels 31, 32 of the holding element 3. In the embodiment of the Fig. 1a and Fig.2a, the wire start 21 only has half a wrap around the winding mandrel 31, while the wire end 22 wraps twice around the winding mandrel 32 assigned to it. Depending on the diameter of the wire 2 used, a higher or lower number of wraps is necessary to ensure a secure hold of the wire start 21 or wire end 22. The arrangement is realized by the friction existing between the wire 2 and the holding element 3. Overall, however, depending on the ultimate use of the coil 1, it is also possible to provide more than one wrap. The connection area, i.e. the plug-in piece 43 of the connector 4, projects into the carrier 30 or the holding element 3. The actual contact of the connector 4 with the wire start 21 or wire end 22 is made via the contact piece or a contact area provided there.Here, it is possible to make a clamping connection between wire 2, i.e. wire end 22 or wire beginning 21, and connector 4 in the contact area by clamping wire 2.

[0042] The supply and / or discharge line 6 or the supply or discharge area of ​​the connector 4 can have various embodiments, which depend on the final use or the intended purpose of the coil 1 according to the invention.

[0043] The spool flange 11 guides the wire start 21 or wire end 22 through suitable grooves or recesses to the intended position on the holding element 3 and enables lateral guidance of the wire 2 on the holding element 3. In addition, the spool flange 11 also ensures that the wire start 21 and wire end 22 are kept separate until corresponding connectors 4 are arranged on the spool 1.

[0044] The claims filed now with the application and subsequently are without prejudice to the attainment of further protection.

[0045] Should a closer examination, particularly of the relevant prior art, reveal that one or another feature is beneficial to the purpose of the invention but not crucially important, then, of course, a formulation will be sought that no longer contains such a feature, particularly in the main claim. Such a subcombination is also covered by the disclosure of this application.

[0046] It should also be noted that the embodiments and variants of the invention described in the various embodiments and shown in the figures can be combined with one another as desired. Individual or multiple features are interchangeable. These feature combinations are also disclosed.

[0047] The references cited in the dependent claims indicate the further development of the subject matter of the main claim through the features of the respective subclaim. However, these are not to be understood as a waiver of independent, objective protection for the features of the referenced subclaims.

[0048] Features that were only disclosed in the description, or individual features from claims that comprise a plurality of features, can at any time be incorporated into the independent claim(s) as being of essential importance to the invention in order to distinguish them from the prior art, even if such features were mentioned in connection with other features or achieve particularly favorable results in connection with other features.

Claims

[1] Coil (1), for example as a magnetic coil in an electromagnet, consisting of a coil body (10) which carries a plurality of turns (20) of a current-conducting wire (2), and wherein the coil body (10) has at least one holding element (3) for mechanically securing a wire start (21) and a wire end (22) of the turns (10), as well as electrical connectors (4, 41, 42) at the wire start (21) and wire end (22) for connecting to an electrical supply and discharge line (6), wherein the connectors (4, 41, 42) are designed as components separate from the holding element (3), wherein only one holding element (3) is provided on the coil body (10), which carries both the wire start (21) and the wire end (22) at a distance from one another, wherein the connectors (4, 41, 42) provided as a separate component are connected to the holding element (3) glued, welded or caulked or wherein the holding element (3) is designed to clamp the connectors (4, 41,42) on the holding element (3), wherein a carrier (30) is provided for the arrangement of the holding element (3) on the coil (1), by which carrier the holding element (3) is received, wherein the carrier (30) adjoins the coil (1) on one side and the carrier (30) carries the holding element (3) on the side facing away from the coil (1), wherein the carrier (30) is already provided on the coil body (10) during its manufacture. [2] Coil (1) according to claim 1, characterized by that at least one guide element (12) for the wire (2), in particular for the wire start (21) and / or for the wire end (22), is provided on the carrier (30), the coil (1) or the coil body (10). [3] Coil (1) according to one of the preceding claims, characterized by that the holding element (3) is designed as a winding mandrel (31, 32) around which the wire end (22) or the wire beginning (21) wraps at least partially. [4] Coil (1) according to one of the preceding claims, characterized by that the carrier (30) or the coil flange (11) has a lateral recess which is spanned by the wire (2) and the connector (4, 41, 42) is electrically conductively connected to the wire (2), in particular in the region of the recess, and / or the coil body (10), the coil (1), the holding element (3) or the carrier (30) carrying the holding element (3) has a plug-in slot (33) which is able to cooperate, in particular in a mechanically holding manner, with a plug-in piece (43) of the connector (4, 41, 42) which can be plugged into the plug-in slot (33). [5] Method for assembling a coil (1), for example a magnetic coil for an electromagnet, wherein the coil (1) has a coil body (10) onto which a current-conducting wire (2) with a plurality of turns (20) is wound, and wherein the wire start (21) or the wire end (22) is fixed to at least one holding element (3), and subsequently the coil (1) is completed with connectors (4, 41, 42), in particular from a group of partially different connectors (4, 41, 42), by the connector (4, 41, 42) being conductively connected to the wire (2) in a contact area, wherein only one holding element (3) is provided on the coil body (10), which carries both the wire start (21) and the wire end (22) at a distance from one another, wherein the connectors (4, 41, 42) provided as a separate component are connected to the holding element (3) glued,are welded or caulked or wherein the holding element (3) is designed to enable clamping of the connectors (4, 41, 42) on the holding element (3), wherein for the arrangement of the holding element (3) on the coil (1) a carrier (30) is provided, by which the holding element (3) is received, wherein the carrier (30) adjoins the coil (1) on one side and the carrier (30) carries the holding element (3) on the side facing away from the coil (1), wherein the carrier (30) is already provided on the coil body (10) during its manufacture. [6] Method according to claim 5, characterized by that the connector (4, 41, 42) is mechanically connected to the coil body (10), the coil (1), the holding element (3) or the carrier (30) carrying the holding element (3) together with the electrical connection. [7] A method according to any one of claims 5 and 6, characterized bythat the completion of the coil (1) with connector (4, 41, 42) takes place spatially and / or temporally separately from a winding process of the coil (1), in particular wherein the wound coil (1) is stored before completion.

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