Electromagnetic Coil Connection Assembly With Modular Bushings

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Solution Overview

Problem

Existing electromagnetic coil assemblies for viscous clutches face challenges in fabrication complexity, durability under harsh conditions, and compactness, particularly when used with rotatable shafts, leading to reliability issues and increased mass.

Innovation Solution

The electromagnetic coil assembly features a multi-part construction with a coil sub-assembly and a tower sub-assembly, utilizing electrically conductive bushings and fasteners for both mechanical and electrical connections, allowing for easier assembly and reduced component exposure to harsh conditions, while maintaining a compact and lightweight design.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional electromagnetic coil assemblies are used with rotatable shafts, then the coil can be positioned near the shaft, but the assembly requires complex mechanical and electrical attachments that reduce reliability and increase mass

Engineering Contradiction:

ImprovereliabilityVSAvoidcomplexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electromagnetic coil assembly is divided into separate modular components: the coil housing with mounted coil, the tower assembly with electrical connections, and mounting brackets. This segmentation allows each component to be optimized independently and simplifies assembly, reducing the complexity of mechanical and electrical attachments while improving reliability through modular design.

Inventive Principle:

Principle #1Segmentation

2Reliability

Engineering Contradiction:

ImprovereliabilityVSAvoidmass

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The mounting brackets are designed to perform dual functions: mechanically securing the coil assembly to the shaft while also providing electrical connection pathways. This merging of mechanical support and electrical connection functions into single components reduces the number of separate attachments needed, thereby reducing overall assembly mass while maintaining reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If labor-intensive soldering and part-insertion steps are used in fabrication, then electrical connections can be made, but the fabrication process becomes prolonged and complex

Engineering Contradiction:

ImprovedurabilityVSAvoidease of manufacture

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Traditional soldering and complex electrical attachment methods are replaced with a mechanical connection system using conductive mounting brackets and pre-configured electrical terminals. This mechanical substitution simplifies the fabrication process by eliminating labor-intensive soldering steps while maintaining durable electrical connections through robust mechanical interfaces.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Volume of moving object

If the electromagnetic coil assembly is made compact, then the clutch package size is reduced, but the assembly may be more difficult to manufacture and maintain

Engineering Contradiction:

ImprovecompactnessVSAvoidease of manufacture

Core Design Contradiction:

Volume of moving objectVSEase of manufacture

Solution Approach 1:

The tower assembly containing electrical connections and control circuitry is nested within or adjacent to the coil housing, with components arranged in a compact hierarchical structure. This nesting approach achieves space efficiency while maintaining manufacturability through standardized assembly sequences and accessible connection points for maintenance.

Inventive Principle:

Principle #7Nested doll (Nesting)

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

This configuration simplifies the assembly process, enhances durability, and achieves a compact, low-mass electromagnetic coil assembly that is easier to manufacture and maintain, with reduced risk of damage from vibrations and environmental stressors.

Implementation Method 1

Operation of the valve can be controlled by way of magnetic flux generated by an electromagnetic coil (or solenoid)

Methodology Applied

Scientific EffectMagnetic flux generation: Electromagnet

Implementation Method 2

Additionally, viscous clutches can include a Hall effect sensor, or other suitable sensor. Such a sensor can be used to measure clutch output speed

Methodology Applied

Scientific EffectHall effect: Hall Effect

Data Source

PatentEP4239653A1Electromagnetic coil connection assembly and associated method

Publication Date: 2023.09.06 HORTON INC

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AI summary

An electromagnetic coil assembly (34; 134) comprising: a coil winding (72) forming multiple turns; a molded base (74-1; 174-1) having an at least partially annular shape, the molded base positioned adjacent to the coil winding; a mount bushing (76A; 76B; 176; 176A) made of an electrically conductive material and secured to the molded base, wherein the coil winding is electrically connected to the mount bushing; a tower housing (90) positioned adjacent to the molded base; a tower bushing (96A; 96B) secured to the tower housing; and a fastener (98A; 98B) electrically connecting the tower bushing to the mount bushing, wherein the fastener further mechanically secures the tower housing to the molded base.