Multiconnection Coil Structure for Magnetic Clamping
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Solution Overview
Problem
Existing permanent magnet clamping apparatuses for ferrous workpieces face issues with manual soldering and crimping of electric connections, leading to potential short-circuits, high setup times, reliability dependence on operator skill, increased costs, and significant space requirements due to multiple cables.
Innovation Solution
A multiconnection coil structure with non-conductive polymer support and thin metal conductor windings, featuring equipotential electric terminals that eliminate the need for manual soldering and crimping, allowing for quick connections and reduced cable usage by using Faston terminals for power distribution across multiple coils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering and crimping are used to establish electric connections, then electric connections can be made between coils and power source, but the process requires long time (about five hours for forty pole units) and high operator skill
Solution Approach 1:
The patent applies preliminary action by pre-attaching electric connection elements to the coil windings during the coil manufacturing process, rather than establishing connections after coil installation. This preliminary preparation eliminates the need for time-consuming manual soldering and crimping during apparatus assembly, reducing connection establishment time from five hours to a fraction of that time while ensuring consistent, high-quality connections through automated manufacturing processes.
Solution Approach 2:
The coil structure is designed to be self-sufficient with integrated electric connection elements that are automatically positioned and connected during coil winding. The support structure includes built-in features that guide and secure the connection elements, eliminating the need for external manual intervention and high-skill operations during assembly.
2Power
If multiple electric cables are laid in the frame for electric connections, then power can be distributed to multiple coils, but a large volume is occupied by the electric connections
Solution Approach 1:
The patent merges multiple electric connection functions into a single integrated coil structure. By incorporating multiple electric connection elements directly on the coil support, the design eliminates the need for separate cables to connect each coil to the power source. This consolidation reduces the volume occupied by electric connections while maintaining full power distribution capability to all coils.
Solution Approach 2:
The coil structure with integrated electric connection elements serves multiple functions simultaneously: it generates the magnetic field through winding and provides multiple electric connections for power distribution. This multi-functionality eliminates the need for separate cable infrastructure, reducing overall space requirements while maintaining power distribution to multiple coils.
3Ease of manufacture
If manual soldering and crimping processes are used, then electric connections can be established, but the quality and reliability are strictly dependent on operator ability
Solution Approach 1:
The coil structure is designed to be self-sufficient with integrated electric connection elements that are automatically positioned and connected during coil winding. The support structure includes built-in features that guide and secure the connection elements, eliminating the need for external manual intervention and high-skill operations during assembly.
Solution Approach 2:
The patent replaces manual mechanical processes (soldering and crimping) with an automated integration process where connection elements are attached to the coil windings during manufacturing. This substitution of manual operations with automated manufacturing ensures consistent quality and reliability independent of operator skill level.
4Power
If separate cables are used for each coil connection, then power can be supplied to individual coils, but the fabrication costs increase proportionally with the number of coils
Solution Approach 1:
The patent merges multiple electric connection functions into a single integrated coil structure. By incorporating multiple electric connection elements directly on the coil support, the design eliminates the need for separate cables to connect each coil to the power source. This consolidation reduces the volume occupied by electric connections while maintaining full power distribution capability.
Solution Approach 2:
The coil structure with integrated electric connection elements serves multiple functions simultaneously: it generates the magnetic field through winding and provides multiple electric connections for power distribution. This multi-functionality eliminates the need for separate cable infrastructure, reducing overall space requirements while maintaining power distribution to multiple coils.
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
Ensures perfect insulation, reduces fabrication time and costs, minimizes storage space, and enhances reliability by eliminating the need for manual connection processes while maintaining efficient power distribution across multiple coils.
Implementation Method 1
a coil, having a bobbin on which an electric conductor is wound to form a winding, said coil being placed around each main magnetic core to activate and/or deactivate each pole unit of the clamping surface
Implementation Method 2
a main magnetic core formed of a magnetically reversible permanent magnet
Implementation Method 3
a ferromagnetic frame adapted to contain a plurality of pole units
Data Source
AI summary
The present invention relates to a multiconnection coil structure (1) comprising a support (2) of predetermined profile (2A) and at least one electric conductor (3) wound on said support (2) to form a winding (4). The multiconnection coil structure (1) has for each winding (4) at least two (5, 6) electric conductor means, each extending between a first (7) and a second (8) points of said profile (2A). Further, each conductor means (5, 6) are electrically connected to one of the terminal ends of the conductor (3), and include at least two distinct electric connection elements (5A, 5B, 6A, 6B), so that when one connection element (5A, 5B) of each conductor means (5, 6) is connected to a power source (V), said power source (V) is also applied to at least another connection element (6A, 6B) of each conductor means (5, 6).