Magnetic Base Coil Connections Without Soldering
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Solution Overview
Problem
The existing magnetic bases for electric machine tools, such as magnetic core drilling machines, face challenges in connecting coil windings to connecting cables due to complex and unreliable soldering processes, which limits process reliability and mechanical durability.
Innovation Solution
The use of mechanical connection aids like crimp connectors, splices, and wire end ferrules for connecting coil winding end sections to connecting cables, eliminating the need for soldering and ensuring reliable and reproducible electrical contact, along with a receptacle system for secure accommodation and insulation to prevent short circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldering is used to connect coil winding end sections to connecting cables, then electrical contact is established, but the process becomes complicated and process reliability decreases
Solution Approach 1:
The patent replaces the soldering process (thermal/chemical connection method) with a mechanical connection system consisting of connection aids, clamps, and pressing elements. This mechanical substitution eliminates the need for soldering operations, heat-shrink tubing, and manual soldering skills, thereby simplifying the process and improving reliability through consistent mechanical fastening.
Solution Approach 2:
The patent introduces connection aids as intermediary components between the coil winding end sections and connecting cables. These connection aids include clamps and pressing elements that mechanically secure the connection, serving as a mediator that ensures reliable electrical and mechanical contact without requiring direct soldering between the components.
2Strength
If hand soldering is used to connect coil windings, then electrical contact is achieved, but mechanical load capacity is limited and reproducibility is poor
Solution Approach 1:
The patent replaces hand soldering with a mechanical connection system using clamps and pressing elements that can be applied with consistent force. This mechanical system provides superior mechanical load capacity compared to solder joints and ensures reproducible connections through standardized application procedures rather than manual skill-dependent processes.
Solution Approach 2:
The patent changes the connection method from thermal/chemical (soldering) to mechanical (pressing/clamping), fundamentally altering the connection parameters. This parameter change enables the connection to withstand higher mechanical loads and achieves consistent reproducibility through controlled pressing forces and standardized connection aid dimensions.
3Ease of manufacture
If insulation is stripped from coil winding end sections, then electrical connection is possible, but the process becomes more complex and time-consuming
Solution Approach 1:
The connection aids serve as intermediaries that can accommodate the insulated end sections of the coil windings directly, eliminating the need for insulation stripping. The mechanical connection system is designed to work with the insulated wire, thereby simplifying the manufacturing process and reducing preparation time while maintaining reliable electrical connection through the conductive path established by the mechanical contact.
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 approach simplifies the manufacturing process, enhances reliability, and improves mechanical durability by providing a secure, reproducible, and insulated electrical connection, reducing the risk of short circuits and mechanical failure.
Implementation Method 1
two components are connected to one another through plastic deformation of the connecting element, for example through clinching, squeezing, pinching together, or folding
Implementation Method 2
at least one first magnet coil constituting an electromagnet
Data Source
AI summary
A magnetic base for an electric machine tool, in particular for a magnetic core drilling machine. A body that is accommodated in a receiving space. At least one first magnet coil constituting an electromagnet, a coil winding of the at least one first magnet coil being wound on a bobbin and a magnetic force of which is switchable between a maximum resultant holding force and a minimum resultant holding force. The coil winding of the magnet coil has two end sections that are each connected to a connecting cable that serves to make electrical contact between the magnetic coil and the electric machine tool. The body has a first side adapted to be coupled to the electric machine tool and has an opposite second side adapted to be placed on a workpiece that is to be processed. End sections of the coil winding are connected to the connecting cables.