Magnetic Inductor Assembly Using Involute Laminations
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Solution Overview
Problem
The manufacturing of magnetic inductors for annular electromagnetic pumps is complex due to the need for managing different sizes of flat magnetic plates, resulting in poorly optimized density and alignment issues, which can lead to cavities and electrical insulation problems.
Innovation Solution
A method involving the assembly of identical magnetic plates with a circular involute cross-section, where the plates are interlocked to form a tubular inductor core, and notches for elementary coils are cut subsequently, eliminating misalignment risks and simplifying the manufacturing process while maintaining optimized density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If flat magnetic plates of variable dimensions are used to manufacture the inductor core, then the manufacturing process becomes more complex due to managing different sizes and alignment, but the inductor core can be formed with basic structural requirements
Solution Approach 1:
The patent applies homogeneity by using magnetic plates with identical dimensions and identical circular involute cross-sections. This eliminates the complexity of managing different plate sizes and ensures consistent alignment during assembly, as all plates are interchangeable and have uniform geometric properties for precise fitting.
Solution Approach 2:
The patent uses circular involute cross-sections for the magnetic plates instead of flat surfaces. This curved geometry enables precise interlocking and alignment when plates are assembled axially, eliminating alignment issues while maintaining manufacturing simplicity through standardized curved profiles.
2Quantity of substance
If magnetic plates are arranged with orifices for elementary coil housings before shaping into involute of a circle, then the inductor core density is improved, but the shaping becomes imperfect and orifices interfere with interlocking
Solution Approach 1:
The patent applies preliminary action by first shaping the magnetic plates into circular involute cross-sections to achieve perfect geometry and dense packing, then subsequently creating the orifices for elementary coil housings. This sequence ensures optimal shaping precision before introducing features that could interfere with the interlocking mechanism.
3Ease of manufacture
If orifices are drilled in magnetic plates before assembly, then elementary coil housings can be formed, but interlocking difficulties occur and plates may be damaged
Solution Approach 1:
The patent performs the shaping of magnetic plates into circular involute cross-sections as a preliminary action before drilling orifices. This ensures that the critical interlocking geometry is established first with maximum precision, and the subsequent orifice drilling does not compromise the structural integrity or interlocking capability of the plates.
4Manufacturing precision
If misalignment between orifices occurs, then correction of elementary coil housing is required, but this correction can be detrimental to electrical insulation
Solution Approach 1:
The patent uses magnetic plates with identical dimensions and identical circular involute cross-sections, ensuring that orifices are positioned consistently across all plates. This homogeneity eliminates misalignment issues during assembly, removing the need for corrective actions that could compromise electrical insulation.
Solution Approach 2:
The circular involute cross-section geometry provides inherent alignment features that guide precise positioning of magnetic plates during assembly. This curved geometry ensures orifices align correctly without requiring corrective adjustments, protecting electrical insulation integrity.
Data Source
AI summary
A method for assembling a magnetic inductor for an electromagnetic pump comprising the following steps: providing a plurality of magnetic laminations having a cross section of an involute of a circle; assembling the plurality of magnetic laminations by fitting same into an inductor core; cutting out at least one housing for an elementary coil; providing and placing an elementary coil inside each housing formed in the cutting step and thereby forming the magnetic inductor. Further, a magnetic inductor formed by implementing such a method and an electromagnetic pump including at least one magnetic inductor.