Electromagnetic Actuator With Through-Slot Coil Winding
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Solution Overview
Problem
The existing electromagnetic differential relays require separate manufacturing and storage of different types to accommodate varying coil impedances, leading to inefficient manufacturing and storage practices due to the coil being the primary differentiator between types.
Innovation Solution
A unified manufacturing approach for the electromagnetic actuator, excluding the coil, which is added on demand at the end of assembly, utilizing a casing with a through window for coil winding, and a coil support system that allows for flexible and efficient coil installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different types of relays are manufactured separately to accommodate varying coil impedances, then the relays can meet different market demands, but the manufacturing complexity and storage requirements increase significantly
Solution Approach 1:
The patent creates a universal actuator platform with a standardized magnetic circuit, pallet, spring, and rod assembly that can accommodate different coil impedances. The casing includes a window that allows various coils to be mounted on the same actuator body, enabling one base design to serve multiple relay types (A, AC, G, S) with different impedance requirements.
Solution Approach 2:
The patent segments the relay into two parts: a standardized actuator body that remains constant across different relay types, and variable coils that can be separately selected and mounted. This segmentation allows the coil to be chosen and installed after the main actuator assembly is completed, simplifying manufacturing and inventory management.
2Productivity
If multiple types of relays are produced and kept in stock, then all product variants are available for immediate delivery, but manufacturing efficiency and storage costs decrease
Solution Approach 1:
The actuator body is fully assembled in advance with all components except the coil, which is the variable element. This preliminary assembly of the standardized portion allows efficient production and storage of the base unit, while the specific coil type is selected and installed later based on the customer's impedance requirements, eliminating the need to pre-assemble and store multiple complete relay variants.
3Reliability
If the coil is mounted early in the assembly process, then the relay can be fully tested and quality controlled, but the flexibility to choose coils on demand is lost
Solution Approach 1:
The actuator body is prepared in advance with the magnetic circuit, pallet, spring, and rod assembly completed and tested. The coil mounting is deferred to a later stage when the specific impedance requirements are known, allowing both quality control of the standardized components and flexibility in coil selection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the efficient and cost-effective production and storage of relays by allowing the coil to be installed just in time, simplifying the industrialization process and reducing the need for multiple coil types in stock.
Implementation Method 1
a permanent magnet for biasing the magnetic circuit, arranged between the legs of the armature and creating a permanent magnetic force of attraction of the pallet towards the polar surfaces
Implementation Method 2
an induction coil surrounding the magnetic circuit, connected for example to a circuit to be controlled, in order to modify the initial balance between the magnetic force and the return force of the spring
Implementation Method 3
the flux created on this occasion in the magnetic circuit by the coil combines with the flux generated by the permanent magnet. The combination of the fluxes induced by the magnet on the one hand and by the current appearing in the coil on the other destroys the initial mechanical equilibrium and causes the pallet to rotate
Data Source
Figure 1~2
AI summary
The invention relates to an electromagnetic actuator comprising a magnetic circuit consisting of a stationary magnetic armature and a blade, said blade being movable in opposition to a spring and capable of moving a mechanical actuating member, and an induction coil arranged about an arm of the armature, the assembly being inserted into a housing from which the mechanical member extends. The housing comprises a through-slot located inside a magnetic circuit, in which through-slot the coil is wound once the housing is closed.