Electromagnet Pin Positioning via Guide Piece and Welded Connection
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Solution Overview
Problem
Existing electromagnets are expensive to produce and assemble due to complex soldered connections, which are also unreliable in vibrating environments.
Innovation Solution
The use of a guide piece to position and stabilize pins for a welded connection between the coil connector and the plug contact, replacing soldering with resistance welding or laser spot welding, and designing the coil connector as a stamped part to facilitate cost-effective and reliable assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used to connect the coil and connection area, then the connection is relatively vibration-resistant and reliable, but the production process becomes complex and expensive
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical joining method) with a mechanical connection system consisting of a connection element with connection arms that mechanically engage with the coil and connection area. This substitution eliminates the complex soldering process while maintaining connection reliability through the mechanical interlocking structure.
2Reliability
If soldered connections are used to connect the coil and connection area, then the connection is vibration-resistant, but the production time and cost increase
Solution Approach 1:
The connection element is pre-assembled with the coil and connection area during the coil winding process, before the final assembly stage. The connection arms are positioned and pre-fixed to the coil, so that only a final simple connection to the connection area is needed. This preliminary action significantly reduces production time while maintaining vibration resistance.
Solution Approach 2:
The connection system is divided into separate functional elements: the connection element with multiple connection arms, the coil with integrated connection portions, and the connection area. This segmentation allows each component to be manufactured and prepared independently, then quickly assembled together, improving production speed while maintaining connection integrity.
3Reliability
If stranded wires are soldered to connect the plug and coil, then the connection is reliable in oscillating arrangements, but the assembly process becomes laborious and expensive
Solution Approach 1:
The patent replaces the soldered wire connection system with a mechanical connection element that has connection arms designed to mechanically engage with the coil and connection area. This mechanical system eliminates the need for soldering operations, making assembly much easier and less labor-intensive while maintaining connection stability in oscillating arrangements through the robust mechanical interlocking design.
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 method reduces production costs and enhances reliability by enabling automated, high-precision welding and stabilizing the connection against vibrations, ensuring a stable and efficient electromagnet.
Implementation Method 1
an electromagnet consisting of a coil that generates a magnetic field when electric current flows through it
Implementation Method 2
The welded connection is implemented, for example, by means of resistance welding or as laser spot welding
Implementation Method 3
The welded connection is implemented, for example, by means of resistance welding or as laser spot welding
Data Source
Figure 1a~3
AI summary
The solenoid (1) has a coil generating a magnetic field while passing electric current, and a conducting pin (4) arranged at a connection region (3). The pin is in connection with a rigid coil connector i.e. stamped bent part, through a welding joint, where the coil connector is connected with the coil. The pin is positioned at an end opposite to the connection region by a guiding piece (7) i.e. plastic injection molding part, that slides on the pin. The connection region is arranged in a housing (10), and the guiding piece is supported at the housing. An independent claim is also included for a method for manufacturing a solenoid.