Electromagnet Coil Core Guiding Profiles for Compact Assembly
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Solution Overview
Problem
Existing electromagnets face challenges in achieving easy assembly and high operational reliability while maintaining a compact design, as they often require a safety distance between the wire coil and the coil core to prevent damage during assembly, which can compromise the magnetic flux conduction properties.
Innovation Solution
The electromagnet design features a rectangular envelope curve with inwardly projecting profiles and corresponding depressions on the coil core, allowing for reliable guidance and reduced safety distances between the coil core and windings, ensuring easy assembly and operational reliability through precise profiling and indentation design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a safety distance is maintained between the wire coil and the coil core, then operational reliability is improved, but the electromagnet size increases and compact design is compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming guiding profiles on the coil body and corresponding recesses on the coil core before assembly. These pre-formed features guide the coil core during insertion, ensuring proper positioning and preventing lateral displacement that could damage the wire coil insulation, thereby maintaining operational reliability without requiring excessive safety distances
Solution Approach 2:
The patent applies local quality by creating localized guiding profiles and recesses at specific locations on the coil body and coil core. These localized features provide precise guidance and positioning only where needed during assembly, allowing minimal safety distances in critical areas while maintaining compact overall dimensions
2Ease of operation
If the coil core is precisely guided during assembly, then ease of assembly is improved, but device complexity increases due to additional profiling features
Solution Approach 1:
The guiding profiles and recesses are pre-formed during the manufacturing of the coil body and coil core components, respectively. This preliminary action ensures that when assembly occurs, the components self-align and guide each other into the correct position, greatly simplifying the assembly process without requiring complex assembly mechanisms
Solution Approach 2:
The coil body and coil core are designed to be self-guiding through the interaction of profiles and recesses. During assembly, the profiled features automatically guide the coil core into proper alignment with the wire coil, eliminating the need for external guiding mechanisms or complex alignment procedures
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 ensures reliable assembly and high operational safety by maintaining a compact form factor without compromising magnetic flux conduction, as the profiling and indentations guide the coil core effectively and reduce stress on the connecting webs, enhancing the overall performance and durability of the electromagnet.
Implementation Method 1
an electromagnet (1) with at least one wire coil (2, 3) and at least one coil core (4)
Data Source
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AI summary
The invention relates to an electromagnet, comprising at least one wire coil (2, 3) and at least one coil core (4; 14; 52), wherein the at least one wire coil (2, 3) is accommodated on a coil former (6; 46) and comprises a large number of windings (40), which surround the at least one coil core (4; 14; 52) and define a winding axis (32), wherein the coil former (6; 46) comprises end pieces (28, 39; 59, 60) spaced apart along the winding axis (32) and axially bounding the at least one wire coil (2, 3), which end pieces are connected to each other by at least two connecting webs (30, 31; 49, 50) extending along the winding axis (32). According to the invention, the accommodating space (11; 51) is bounded by a rectangular envelope (12; 62) having at least one profile (35, 36, 37, 38; 47, 48) protruding inward, and the coil core (4; 14; 52) has a recess (21; 53, 54), which extends along the winding axis (32) at least in some segments and which corresponds to the profile (35, 36, 37, 38; 47, 48).