Electromagnetic Brake Snap-Fit Coil Assembly for Automated Mounting
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Solution Overview
Problem
Existing electromagnetic brakes are difficult to mount and require complex assembly processes, limiting their automation potential.
Innovation Solution
The electromagnetic brake features a snap-fit connection between the coil unit and housing body, utilizing snap hooks and grooves, along with bayonet-type connections for the friction disk, allowing for simplified assembly and automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coil unit is connected to the housing body by means of injected and cured impregnation material, then the connection is secure, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent replaces the chemical bonding process (injected and cured impregnation material) with a mechanical snap-fit connection system. The coil unit features snap hooks that engage with corresponding grooves in the housing body, eliminating the need for adhesive injection and curing processes while maintaining secure connection.
Solution Approach 2:
The patent extracts and eliminates the impregnation material connection method from the assembly process, replacing it with a purely mechanical snap-fit system. This removes the complex multi-step process of injection and curing, leaving only the simple mechanical engagement of snap hooks with grooves.
2Reliability
If the coil unit is molded into the housing body by means of synthetic resin, then the connection is secure, but the assembly process becomes complex and difficult to automate
Solution Approach 1:
The patent replaces the molding process with synthetic resin with a mechanical snap-fit connection system. The snap hooks on the coil unit engage with grooves in the housing body through simple mechanical engagement, which can be easily performed by robotic assembly systems without requiring complex molding equipment or material injection systems.
3Device complexity
If a snap-fit connection is used between the coil unit and housing body, then the assembly is simplified and automation is enabled, but the connection strength may be reduced
Solution Approach 1:
The connection system is segmented into multiple discrete snap hooks distributed around the coil unit perimeter. This segmentation allows the connection force to be distributed across multiple engagement points, maintaining overall connection strength while enabling simple individual snap-fit engagement at each point.
Solution Approach 2:
The snap hooks are pre-formed as integral features of the coil unit structure, positioned and shaped in advance to engage with the housing body grooves. This preliminary preparation ensures that the connection strength is built into the design geometry rather than requiring additional fastening steps or materials.
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 easy, automated mounting of the electromagnetic brake, reducing assembly complexity and potential for noise and vibration, while maintaining secure connections.
Implementation Method 1
the snap hook can be elastically deformed by applying a force, such that the snap hook can latch into a groove provided on the housing body
Implementation Method 2
coil unit (26), a pole core (31) which can be excited by the coil unit (26)
Data Source
AI summary
An electromagnetic brake with a housing body and a coil unit, wherein the coil unit has a positive connection to the housing body, wherein the coil unit is positively connected to the housing body by means of a snap-fit connection, wherein at least one snap hook of the coil unit is supported on a web of the housing body.