Rail Vehicle Coil Device Pinch Connection for Electromagnetic Brake
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Solution Overview
Problem
Existing electromagnetic track brakes for rail vehicles face challenges in efficiently connecting coil winding wires to connection cables, leading to increased installation space, component usage, and potential thermal hazards due to cohesive connections like soldering or welding.
Innovation Solution
A coil device with a winding wire having a first end for a direct electrical connection to a connection cable using a pinch or crimp connection, minimizing installation space and reducing failure potential by avoiding thermal hazards, and utilizing pinch sleeves and shrink tubes for reliable and insulated connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (metal sheet, connection pin, cable shoe) are used to connect coil winding wire to connection cable, then reliable electrical connection is achieved, but installation space increases and device complexity increases
Solution Approach 1:
The patent combines multiple connection components (metal sheet, connection pin, cable shoe) into a single integrated connection element. The winding wire is directly connected to the connection cable through a unified structure that eliminates the need for separate metal sheets, connection pins, and cable shoes, thereby reducing installation space while maintaining electrical connection reliability.
Solution Approach 2:
The connection element serves multiple functions simultaneously: it provides electrical connection, mechanical support, and structural integration. This multi-functional design allows a single component to replace the traditional multi-component assembly, reducing the overall volume required for the coil device.
2Reliability
If cohesive connections (soldering or welding) are used to connect coil winding wire to connection cable, then reliable electrical connection is achieved, but thermal damage hazards increase
Solution Approach 1:
The patent replaces thermal connection methods (soldering or welding) with a mechanical connection system. The winding wire is mechanically secured to the connection cable through a crimping or pressing mechanism, eliminating the need for heat application and associated thermal damage risks while maintaining reliable electrical connection.
3Reliability
If traditional connection components are used, then electrical connection is established, but manufacturing cost and part quantity increase
Solution Approach 1:
The patent merges multiple separate components (metal sheet, connection pin, cable shoe) into a single integrated connection element. This reduces the total number of parts that need to be manufactured, stored, and assembled, thereby simplifying the manufacturing process and reducing production costs while maintaining reliable electrical connection.
4Reliability
If multiple connection components are used, then reliable electrical connection is achieved, but device complexity increases
Solution Approach 1:
The patent integrates multiple connection functions into a single unified structure, eliminating the need for separate metal sheets, connection pins, and cable shoes. This simplification reduces the complexity of the connection structure while maintaining reliable electrical connection through the integrated design.
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
The solution provides a simplified, reduced-size coil connection that enhances the braking effect of electromagnetic track brakes, reduces electrical transfer resistance, and minimizes thermal damage risks while ensuring reliable and efficient electrical connections.
Implementation Method 1
the first end of the winding wire is formed as a first coil connection for establishing an electrically conductive joining connection to a first connection cable
Data Source
AI summary
The invention relates to a coil device for an electromagnetic track brake for a rail vehicle. The coil device has a winding wire, which has a first end and a second end. The coil device is the first end of the winding wire is formed as a first coil connection for establishing an electrically conductive joint connection to a first connection cable and/or the second end of the winding wire is formed as a second coil connection for establishing an electrically conductive joint connection to a second connection cable.