Electromagnetic Coil Solid End Portions
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Solution Overview
Problem
Conventional electromagnetic coils with braided or litz wires face issues with large coil end portions, leading to increased resistance, eddy current generation, and mechanical vibrations, as well as wire disconnection and strain during manufacturing due to the bending of conductive wires.
Innovation Solution
The electromagnetic coil design features a solid conductive member for the coil end portions and uses braided conductive wires only in the effective coil portions, allowing for a compact configuration with reduced eddy current generation and eliminating manufacturing-related issues by crimping the solid conductive members to the conductive wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If braided conductive wires are used in coil end portions, then flexibility and ease of winding is improved, but coil end portion length increases and resistance increases
Solution Approach 1:
The coil is segmented into two distinct parts: the effective coil portion uses braided conductive wires for flexibility during winding, while the coil end portions use solid conductive members for compactness. This segmentation allows each part to have optimized properties for its specific function, resolving the contradiction between ease of winding and coil end portion length.
Solution Approach 2:
Different materials are applied to different locations of the coil. The effective coil portion (where bending is needed) uses braided wires, while the coil end portions (where compactness is needed) use solid conductive members. This local differentiation of material properties resolves the contradiction by applying the right material quality to the right location.
2Adaptability or versatility
If braided conductive wires are bent at winding direction switching portions, then winding can be changed, but wire disconnection and wire diameter strain occur
Solution Approach 1:
The coil structure is segmented so that the effective coil portion (where winding direction switching occurs) uses flexible braided wires that can bend without damage, while the coil end portions use rigid solid conductive members that maintain structural integrity. This segmentation prevents wire disconnection and strain by placing each material type in the appropriate location.
Solution Approach 2:
Instead of using braided wires throughout the entire coil (including end portions), the invention inverts the approach by using solid conductive members for the coil end portions and braided wires only for the effective coil portion. This inversion prevents the reliability issues that would occur if braided wires were bent at the coil end portions.
3Length of stationary object
If solid conductive members are used for coil end portions, then coil end portion length is reduced and resistance decreases, but connection to conductive wires must be made
Solution Approach 1:
The solid conductive members are designed with predetermined connection structures (such as crimping portions or attachment features) that facilitate easy connection to the conductive wires. This preliminary design of the connection interface reduces the actual connection process complexity while maintaining the benefits of reduced coil end portion length and resistance.
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 design reduces the size of coil end portions, decreases resistance, and prevents wire disconnection and strain, enhancing the electromagnetic coil's efficiency and productivity while maintaining stable insulation characteristics.
Implementation Method 1
an electromagnetic coil in which a conductive member is wound around an air core region
Implementation Method 2
used in a coreless electromechanical device
Data Source
AI summary
An electromagnetic coil where a conductive member is wound so as to surround an air core region includes an effective coil portion, a first coil end portion, and a second coil end portion. The effective coil portion is formed of a coil-use conductive wire formed by bundling a plurality of conductive base members, the first coil end portion is formed of a first end member that is made of a solid conductive material, and the second coil end portion is formed of a second end member made of a solid conductive material. In the air core region of “one magnetic material” to which an electric current of a first phase is supplied, the effective coil portion of “the other electromagnetic coil” to which an electric current of a second phase is supplied is fitted.