Coil Assembly Radial Pin Arrangement for Relay Compactness
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Solution Overview
Problem
Existing coil assemblies in relays have an extended overall length due to the lateral arrangement of connection pins, which hinders a narrow design and efficient use of installation space, particularly when the connection pins protrude beyond the coil axis.
Innovation Solution
A method for producing a coil assembly with an insulating coil body and a connection block where the terminal block is pivotally attached to the coil flange, allowing connection pins to be bent over and arranged parallel to the coil axis, reducing the overall length and optimizing space usage by embedding pins in an insulating block body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If connection pins are arranged laterally beyond the coil axis, then electrical connection is achieved, but the overall length of the coil assembly increases
Solution Approach 1:
The connection pins are arranged radially outward from the coil flange rather than extending axially beyond the coil ends. This dimensional change from axial to radial arrangement allows electrical connection while maintaining a compact overall length, as the pins extend perpendicular to the coil axis rather than parallel to it.
Solution Approach 2:
The connection pins are pre-positioned in the coil flange before the coil is wound and assembled. This preliminary arrangement ensures that the pins are already in their optimal radial positions, eliminating the need for axial extensions and allowing the coil assembly to maintain its compact length while still providing proper electrical connection points.
2Ease of operation
If connection pins extend beyond the coil axis, then electrical connection is provided, but installation space is not efficiently used
Solution Approach 1:
By changing the orientation of connection pins from axial extension to radial extension from the coil flange, the design utilizes the radial dimension more effectively. This allows the coil assembly to have a compact axial length while providing adequate space for electrical connections in the radial direction, thus optimizing the overall installation space.
3Length of moving object
If the coil assembly is shortened, then space efficiency is improved, but connection pin arrangement becomes more difficult
Solution Approach 1:
The connection pins are integrated into the coil flange structure before the coil winding process. This preliminary integration ensures that the pins are precisely positioned in the radial direction and are securely held, simplifying the manufacturing process despite the compact dimensions. The pins are ready for connection without requiring additional axial space.
Solution Approach 2:
The connection pins are merged with the coil flange as an integrated structure rather than being separate components attached afterward. This merging simplifies the manufacturing process by reducing the number of assembly steps, as the pins are already in their final positions when the coil is wound and assembled, despite the shortened overall length.
Data Source
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AI summary
The invention relates to a coil assembly, comprising a coil former (1), a coil (2), and a connection block (3), which is pivotably fastened to the coil former (1). The coil (2) is wound while the connection block (3) is pivoted away, the winding wire ends are soldered onto the connection pins (35, 36), and the connection block (3) is pivoted close to the coil (2).