Electromagnet Integrated Armature Spring Design

Solution Overview

Problem

Conventional electromagnets with separate spiral springs require additional components and increased size, leading to higher production costs and larger dimensions, which are disadvantageous for switching speeds and assembly complexity.

Innovation Solution

An electromagnet design where the armature spring is integrated as a flat or leaf spring attached to the armature, allowing for a compact assembly and reduced volume consumption, with a magnetizable fastening disk guiding the magnetic field, enabling smaller, lighter, and faster-switching devices with lower costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a discrete spiral spring is used as the armature spring, then the armature can be returned to its starting position when de-energized, but the electromagnet requires additional components and increased size, leading to higher production costs and larger dimensions

Engineering Contradiction:

Improvearmature return functionVSAvoidnumber of components

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The armature spring is integrated directly into the armature as a monolithic component, combining the armature and spring into a single piece. This eliminates the need for separate spring components and their associated mounting structures, thereby reducing device complexity while maintaining the armature return function.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If a discrete spiral spring is used as the armature spring, then the armature can be returned to its starting position when de-energized, but the electromagnet has larger dimensions and requires larger coils, increasing overall size and production costs

Engineering Contradiction:

Improvearmature return functionVSAvoidelectromagnet size

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The armature spring is integrated directly into the armature as a monolithic component, combining the armature and spring into a single piece. This eliminates the need for separate spring components and their associated mounting structures, thereby reducing device complexity while maintaining the armature return function.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If a discrete spiral spring is used as the armature spring, then the armature can be returned to its starting position when de-energized, but the assembly process requires mounting additional filigree components, increasing assembly effort and complexity

Engineering Contradiction:

Improvearmature return functionVSAvoidassembly effort

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The armature spring is integrated directly into the armature as a monolithic component, combining the armature and spring into a single piece. This eliminates the need for separate spring components and their associated mounting structures, thereby reducing device complexity while maintaining the armature return function.

Inventive Principle:

Principle #5Merging (Combining)

4Device complexity

If the armature spring is designed as a flat spring attached to the armature, then the assembly process is simplified and volume consumption is reduced, but the magnetic field guidance requires additional consideration

Engineering Contradiction:

Improveassembly complexityVSAvoidmagnetic field guidance

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

A fastening disc made of magnetizable material is introduced as an intermediary component between the flat spring and the coil body. This disc serves dual purposes: mechanically securing the flat spring to the armature and guiding the magnetic field, thereby resolving both the assembly simplification and magnetic field guidance requirements.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 integrated armature spring design simplifies assembly, reduces material usage, and enhances switching characteristics by allowing a more effective magnetic field interaction, resulting in smaller, lighter, and more efficient electromagnets with improved switching speeds and lower production costs.

Implementation Method 1

a coil body with a wire winding which can be charged with current and which at least partially surrounds the armature

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

an armature spring, by means of which the armature is moved back to its starting position when it is de-energized

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 3

the fastening disk is formed from a different material, namely a magnetizable material. This also serves to guide the magnetic field

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Data Source

PatentEP2600360B1Electromagnet

Publication Date: 2017.04.12 SVM SCHULTZ VERWALTUNGS GMBH & CO KG

AI summary

The electromagnet (I) comprises a cylinder arranged in a sleeve (3), a coil main portion (4) formed partially around an armature (1), and an armature spring through which the armature is moved in the currentless state in its initial position. The armature spring is formed as a flat spring (2) and is attached to the armature. The outer diameter of the flat spring corresponds to the internal diameter (d4) of the sleeve and/or the taper portion (3.1) formed in the sleeve.