Electromagnet Spool Carrier Design for Brake Assembly
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Solution Overview
Problem
The existing manufacturing process for electromagnets in electromagnetic brakes is labor-intensive due to the need for laborious coil insertion into a metallic magnetic body, and the prior art requires an undercut in the armature disk for demagnetization, which complicates the assembly.
Innovation Solution
An electromagnet design featuring a coil carrier with a projecting edge and a magnetic body comprising an inner and outer magnetizable parts with a gap, allowing easy coil insertion and eliminating the need for an undercut, facilitating simplified assembly and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metallic magnetic body is used with laborious coil insertion, then the structural strength is improved, but the manufacturing complexity increases
Solution Approach 1:
The magnetic body is divided into an inner part and an outer part that can be assembled separately. The coil is first inserted into the inner part, then the outer part is attached to complete the electromagnet. This segmentation allows easy coil insertion while maintaining structural integrity through the combined assembly of both parts.
2Reliability
If an undercut in the armature disk is created for demagnetization, then the demagnetization function is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The demagnetization air gap is extracted from the armature disk structure and relocated to the magnetic body assembly. Instead of creating an undercut in the armature disk, the gap is formed by the spacing between the inner and outer parts of the magnetic body, eliminating the need for precise undercut machining while maintaining the demagnetization function.
3Stability of the object's composition
If the coil is inserted into a complete magnetic body, then the structural integrity is improved, but the assembly time increases
Solution Approach 1:
The coil is preliminarily inserted into the inner part of the magnetic body before the outer part is attached. This preliminary action allows the coil to be positioned and secured in place while the magnetic body is still in a partially assembled state, reducing the overall assembly time while maintaining the structural integrity of the complete electromagnet.
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 simplifies the manufacturing of electromagnets by enabling straightforward coil placement and demagnetization air gap creation, reducing assembly complexity and costs while maintaining effective braking functionality.
Implementation Method 1
an armature disk is pretensioned with compression springs against a friction lining carrier, so that a braking effect is ensured without current being supplied to the electromagnets of the brake
Implementation Method 2
Switching on the excitation current of the electromagnet causes the armature disk to release the friction lining carrier and the brake is released
Data Source
Figure 1a
Figure 1b
Figure 1c
AI summary
The electromagnet has an armature, a magnetic body made of magnetizable material, and a coil that is arranged in the body, where the body includes internal and external parts (1, 2) made of magnetizable material. The internal part is arranged in an opening of the external part. The parts are dimensioned in such a manner that a gap remains between the parts. The parts are in the shape of reciprocally opened cylinders, and are centered with each other. The external and/or the internal part have front sided through-holes (3), blind holes and/or internal threads. An independent claim is also included for a method for manufacturing electromagnets.