Electromagnetic Coil With Partial Windings For Rapid Release
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Solution Overview
Problem
Existing electromagnetic brake and clutch systems face challenges in achieving rapid and low-loss release, with complex and expensive production methods due to the need for split coils and high current handling, which can lead to coil destruction.
Innovation Solution
A coil design featuring multiple partial windings with different wire diameters, connected via contacting elements and center taps, allowing for cost-effective and simplified manufacturing, with the option to use stranded wires and resistance welding for secure connections, enabling efficient magnetic attraction and thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If a split coil design with acceleration coil and hold coil is used to achieve rapid release, then the release speed is improved, but the manufacturing complexity and cost increase due to center tap requirements
Solution Approach 1:
The coil is divided into multiple independent partial windings (first partial winding, second partial winding, third partial winding) with different wire diameters, each capable of being manufactured and connected separately through contacting elements, eliminating the need for complex center tap integration in a single coil structure
Solution Approach 2:
Contacting elements serve as intermediary components that connect the multiple partial windings with different wire diameters, simplifying the manufacturing process by allowing separate production and assembly of coil sections rather than requiring complex integrated center tap structures
2Speed
If high current values are applied to the acceleration coil for rapid release, then the release dynamics are improved, but the risk of coil destruction increases
Solution Approach 1:
Different partial windings have different wire diameters optimized for their specific functions: the first partial winding has a larger wire diameter to handle high surge currents during acceleration, while the second and third partial windings have smaller diameters suitable for holding current, allowing each section to operate within safe current limits
Solution Approach 2:
The wire diameter parameter is varied across different partial windings to match the current requirements of each function, with the first partial winding using a larger diameter to withstand high instantaneous currents without destruction while smaller diameter wires are used for the hold coil sections
3Power
If multiple partial windings with different wire diameters are used, then the magnetic attraction torque and thermal load requirements are optimized, but the manufacturing complexity increases
Solution Approach 1:
The coil is segmented into multiple partial windings that can be manufactured separately and connected via contacting elements, allowing each section to be optimized for specific power and thermal requirements while maintaining manufacturing simplicity through modular assembly
Solution Approach 2:
The contacting elements serve multiple functions: they electrically connect partial windings with different wire diameters, provide mechanical support, and facilitate modular assembly, thereby simplifying the overall manufacturing process despite the complexity of having multiple wire sizes
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 design enables rapid and low-loss release of the brake or clutch, reduces production costs, and prevents coil damage by managing high currents effectively, while allowing for adaptable current handling and efficient heat dissipation.
Implementation Method 1
a coil (1; 100), in particular for brakes or clutches (10; 200) that can be actuated electromagnetically
Implementation Method 2
Material-locking connections can be produced between the winding or connection wires and the contacting element by means of a resistance welding process
Data Source
Figure 1
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Figure 3
AI summary
A coil, in particular for electromagnetically controlled brakes or clutches, has two or more part-windings and associated taps. A first part-winding comprises a winding wire having a first diameter, and a second part-winding comprises a winding wire having a different diameter.