Electromagnetic Coil Terminal Line Using Copper Intermediary
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Solution Overview
Problem
The existing wire connection structure in electromagnetic coupling devices fails to maintain electric continuity when using aluminum wire windings due to the higher coefficient of thermal expansion of aluminum compared to brass terminal members, leading to gaps and disconnection as temperature changes.
Innovation Solution
The design incorporates a terminal casing with grooves and connection pieces made of brass, where the terminal lines and connection pieces have similar coefficients of thermal expansion, ensuring stable electric continuity by press-fitting the aluminum winding ends into slits within the terminal members, which are made of the same metal material as the connection pieces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum wire is used for the electromagnetic coil winding to reduce weight, then the weight of the electromagnetic coupling device is reduced, but the electric continuity between the terminal member and the winding is lost due to different thermal expansion coefficients
Solution Approach 1:
A terminal line made of copper (same material type as the original copper winding) is introduced as an intermediary component between the aluminum winding and the brass terminal member. This terminal line serves as a mediator that maintains electric continuity while allowing the winding to be made of lighter aluminum material. The terminal line is press-fitted into grooves of the terminal member and also press-fitted to the aluminum winding, creating a reliable electrical connection path.
Solution Approach 2:
The invention changes the material parameter of the connection component (terminal line) to match the thermal expansion characteristics of the original copper winding rather than the aluminum winding. By selecting copper or copper-alloy terminal lines, the system compensates for the thermal expansion mismatch between aluminum and brass, ensuring stable electric continuity across temperature variations while maintaining the weight reduction benefit of aluminum windings.
2Reliability
If copper wire is used for the electromagnetic coil winding, then electric continuity is maintained with brass terminal members, but the weight of the electromagnetic coupling device increases
Solution Approach 1:
The connection system is segmented into three distinct parts: the aluminum winding, the copper terminal line, and the brass terminal member. This segmentation allows each component to be optimized for its specific function - the aluminum winding for light weight, the copper terminal line for electrical conductivity and thermal expansion compatibility, and the brass terminal member for structural support and connection. This segmentation resolves the contradiction by separating the weight-critical winding from the connection-critical terminal line.
3Stability of the object's composition
If a terminal member made of brass is used, then structural stability is maintained, but electric continuity is lost when connected to aluminum windings due to thermal expansion differences
Solution Approach 1:
The copper terminal line acts as an intermediary that decouples the thermal expansion characteristics of the brass terminal member from the aluminum winding. The terminal line is press-fitted into grooves of the terminal member, maintaining the structural stability of the brass component, while simultaneously being press-fitted to the aluminum winding, ensuring electrical continuity. This intermediary structure allows the terminal member to maintain its optimal material properties without directly contacting the aluminum winding.
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 maintains stable electric continuity across temperature changes, reduces the weight of the electromagnetic coupling device by using aluminum, and simplifies the connection process while ensuring reliable electrical conductivity.
Implementation Method 1
the terminal line and the connection piece are made of the same kind of metal materials, and the winding of the electromagnetic coil is made of the metal material different in kind from that forming the terminal line and the connection piece
Data Source
AI summary
The present invention relates to an electromagnetic coupling device. In the electromagnetic coupling device according to the present invention, ends (5a and 5b) of a winding of an electromagnetic coil (5) are fitted to grooves of a terminal casing, and terminal members (19a and 19b) are press-fitted to a groove crossing the abovementioned groove, so that lead wires (18a and 18b) held by the terminal members (19a and 19b) are electrically connected to the ends (5a and 5b) of the winding. Terminal lines (51a and 51b) made of enameled copper wires are connected to the opposite ends of the winding of the electromagnetic coil (5) made of an aluminum wire, and the terminal lines (51a and 51b) handled as the ends (5a and 5b) of the winding are connected to brass-made connection pieces (29a and 29b) of the terminal members (19a and 19b).