Electromagnetic Coupling Terminal Block Design
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Solution Overview
Problem
The existing electromagnetic coupling devices, such as clutches and brakes, face a dead space issue due to the positioning of lead wires between the electromagnetic coil and the field core, leading to an oversized field core and reduced coil turns.
Innovation Solution
An electromagnetic coupling device design that incorporates a terminal block with through holes allowing the magnet wire ends to project and be soldered outside the field core, eliminating the need for internal lead wire connections and minimizing dead space, thereby downsizing the field core or increasing coil turns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If lead wires are positioned between the electromagnetic coil and the field core, then the electromagnetic coupling device can be assembled, but a dead space is generated in the field core causing it to upsize in the axial direction
Solution Approach 1:
The patent extracts the lead wire connection function from the field core interior to an external terminal block. The terminal block is positioned outside the field core, and lead wires are routed through holes in the terminal block rather than occupying space within the field core. This extraction eliminates the dead space in the field core while maintaining the electrical connection function.
Solution Approach 2:
The terminal block serves as an intermediary component that facilitates the connection between the electromagnetic coil and external circuits. It provides a dedicated structure for lead wire connections outside the field core, acting as a mediator that resolves the spatial conflict between connection requirements and compact field core design.
2Reliability
If lead wires are positioned between the electromagnetic coil and the field core, then electrical connections can be established, but the number of turns of the electromagnetic coil decreases
Solution Approach 1:
The patent extracts the electrical connection function from the field core interior to an external terminal block. By routing lead wires through holes in the terminal block and making connections outside the field core, the design eliminates the dead space that would otherwise reduce the number of coil turns, thereby maintaining or increasing the coil turns while ensuring reliable electrical connections.
3Ease of manufacture
If the field core is upsized to accommodate lead wire positioning, then assembly is simplified, but the overall device size increases
Solution Approach 1:
The patent extracts the connection structure from the field core to an external terminal block, eliminating the need to enlarge the field core for lead wire accommodation. The terminal block is positioned outside the field core, allowing compact field core design while maintaining assembly simplicity through the structured connection interface provided by the terminal block.
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 dead space within the field core, enabling a smaller axial size or more coil turns, simplifies insulation processing, and enhances soldering reliability by guiding lead wires directly to terminals.
Implementation Method 1
an electromagnetic coil (17) contained in an annular groove (31)
Implementation Method 2
the winding start end (34a) passes through the first through hole (47a), projects from the first terminal (44a), and is soldered to the first terminal (44a) together with the first lead wire (56)
Data Source
AI summary
An electromagnetic coupling device includes an electromagnetic coil, a field core including a recessed portion containing the electromagnetic coil, and a terminal block inserted in a hole passing through the wall of the recessed portion. The terminal block includes a terminal portion projecting outside the field core, a pair of terminals provided at the terminal portion, and a pair of through holes passing through the terminal block via the pair of terminals. The winding start end and winding termination end of the electromagnetic coil pass through the pair of through holes, project from the pair of terminals, and are soldered to the pair of terminals together with a pair of external connection lead wires.