Contactor Electromagnetic Unit Assembly With Plug-In Coil Connections
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Solution Overview
Problem
Existing large-scale AC contactors face challenges due to space constraints, leading to insufficient attraction force and increased assembly complexity, with manual connections prone to wire breakage and instability, resulting in high costs and reduced reliability.
Innovation Solution
An electromagnetic system with a base and electromagnetic units, featuring lug plates and plug-in terminals for secure connections, automated wire fixing, and a protective cover to enhance stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If two electromagnetic system components are connected in series to form an electromagnetic system assembly, then the attraction force is improved, but the assembly complexity increases and reliability decreases due to manual wire connections
Solution Approach 1:
The electromagnetic system is divided into multiple electromagnetic system components, each with its own coil, that can be independently assembled and then connected through standardized terminal blocks. This segmentation allows for simplified assembly while maintaining the required attraction force through series connection of the components.
Solution Approach 2:
The connection method is changed from manual wire twisting and welding to standardized terminal block connections. This parameter change in the connection approach reduces assembly complexity and improves reliability while maintaining the electrical series connection necessary for the desired attraction force.
2Ease of manufacture
If manual twisting and welding of wire ends is used to connect coils, then the electromagnetic system assembly is formed, but the risk of wire breakage and insufficient soldering increases
Solution Approach 1:
Terminal blocks are introduced as intermediary components between the coil wires. These terminal blocks provide a standardized, reliable connection point that eliminates the need for manual twisting and welding, thereby reducing the risk of wire breakage and insufficient soldering while maintaining ease of assembly.
3Ease of manufacture
If adhesive tape is used to temporarily fix enameled wire ends, then the coils can be wound, but the connection stability decreases and rework is required
Solution Approach 1:
Wire guides are provided that allow enameled wire ends to be properly positioned and fixed before the winding process begins. This preliminary action ensures that the wire ends are correctly aligned and secured, eliminating the need for temporary adhesive tape fixation and ensuring connection stability from the start.
4Adaptability or versatility
If the electromagnetic system assembly relies only on coil wire connections without overall limiting fixation, then the structure is flexible, but the connecting wires are easily loosened or broken during installation
Solution Approach 1:
The coil wires are merged with the terminal blocks and the terminal blocks are integrated into the electromagnetic system components. This merging creates a unified structure where the connecting wires are securely fixed through the terminal blocks, preventing loosening or breakage during installation while maintaining the necessary structural flexibility.
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 stable and reliable connections, reduces assembly complexity, and lowers manufacturing costs by enabling automated wire fixing and preventing wire breakage, while maintaining dielectric performance and protecting against external interference.
Implementation Method 1
the electromagnetic system includes a moving iron core, a static iron core, a coil winding, etc.
Data Source
AI summary
Disclosed are an electromagnetic system and a contactor. The electromagnetic system includes a base and at least two electromagnetic units arranged inside the base. The base includes a wall forming an installation space for installing the electromagnetic units. Each electromagnetic unit includes a coil support used for winding a coil. A lug plate is arranged at a wire inlet end and a wire outlet end on one side, corresponding to the wall, of the coil support respectively. Each lug plate includes a connecting part. Openings are set in positions of the wall corresponding to the connecting parts of the electromagnetic units. The two electromagnetic units penetrate into the installation space from the openings through connecting wires arranged outside the wall and are connected to the connecting parts to form a connection. According to the present invention, the reliability of the product can be improved.