Compressor Electromagnetic Clutch Field Coil Assembly
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Solution Overview
Problem
The existing field coil assembly of electromagnetic clutches for compressors faces issues such as wire damage during injection molding, increased manufacturing costs due to additional protective members, and difficulty in adjusting wire length, primarily because of the complex injection molding process and the need for separate components.
Innovation Solution
The assembly uses upper and lower holders to connect the terminal and electric wire, which are then engaged through insert molding, simplifying the manufacturing process, eliminating the need for protective members, and allowing easy length adjustment of the electric wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If injection molding is used to form the sleeve and connect the terminal to the electric wire, then the assembly is integrated and protected, but the electric wire may be damaged during the molding process and manufacturing costs increase due to the complexity
Solution Approach 1:
The patent divides the originally integrated injection-molded sleeve into two separate components: a protective sleeve and a holder. The holder is formed separately and provides structural support for assembling the terminal and electric wire, while the sleeve provides protection. This segmentation eliminates wire damage during molding and simplifies the manufacturing process.
Solution Approach 2:
The holder is pre-formed with specific structures (through-holes, grooves, ribs) that enable subsequent assembly of the terminal and electric wire without requiring complex injection molding operations. This preliminary preparation of the holder structure simplifies the overall manufacturing process and prevents wire damage.
2Reliability
If separate protective members are added to protect the electric wire, then wire protection is improved, but device complexity and manufacturing costs increase
Solution Approach 1:
The patent combines the protective function (sleeve) and the assembly function (holder) into a coordinated two-component system. The holder integrates the terminal and electric wire assembly, while the sleeve provides protection. This merging of functions into just two components avoids the complexity of adding multiple separate protective members while maintaining reliable wire protection.
3Ease of manufacture
If the electric wire length is fixed during injection molding, then the assembly is simplified, but the ability to adjust wire length is lost
Solution Approach 1:
By separating the holder (assembly structure) from the protective sleeve, the patent enables the electric wire to extend freely from the holder without being constrained by the molding process. The sleeve can be sized independently to provide protection while allowing wire length adjustment, thus maintaining assembly simplicity while gaining adaptability.
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 approach reduces manufacturing expenses, prevents wire damage, and simplifies the assembly process by eliminating the need for separate protective components while enabling flexible wire length adjustments.
Implementation Method 1
producing a magnetic field by means of electromagnetic induction of an electromagnetic coil at the time of the supply of the electric power
Data Source
AI summary
The present invention relates to a field coil assembly of an electromagnetic clutch for a compressor, more particularly, a field coil assembly of an electromagnetic clutch for a compressor, in which a terminal electrically connected with a field coil portion, and an electric wire are assembled to each other by means of upper and lower holders, and then finally engaged with together by means of an insert molding, thereby simplifying a manufacturing process to reduce manufacturing expense, removing a need for a separate member for protecting an electric wire, and easily adjusting the length of the electric wire.