Opposite-Wound Coil Assembly for Simpler Magnetic Actuator Manufacturing
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Solution Overview
Problem
Existing manufacturing and assembling methods for small electromagnetic actuators are complex and costly, limiting their application in cost-sensitive technological fields.
Innovation Solution
A coil assembly for magnetic actuators is designed with two or more winding areas, allowing for a tubular coil holder with central and outer circular rims to accommodate a coil wound in opposite directions, enhancing manufacturing simplicity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional manufacturing and assembling methods are used for small electromagnetic actuators, then manufacturing precision and reliability are maintained, but device complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges multiple separate components (coil holder, coil, magnets, pole pieces) into a single integrated coil assembly where the coil is pre-mounted on the coil holder forming a unified structure. This combination simplifies the manufacturing process by reducing the number of separate assembly steps while maintaining the functional integrity and precision of each component.
Solution Approach 2:
The coil is pre-mounted on the coil holder in a preliminary assembly step before the entire coil assembly is installed into the actuator. This preliminary action allows the coil and holder to be manufactured and prepared separately with high precision, then easily integrated into the final assembly, reducing overall device complexity and manufacturing cost.
2Productivity
If traditional assembly methods are used, then component reliability is maintained, but productivity and production quantity capability decrease
Solution Approach 1:
The actuator is divided into distinct modules: the coil assembly (coil holder with pre-mounted coil), the magnet assembly (magnets with pole pieces), and the housing. Each module can be manufactured independently with high reliability, then quickly assembled together. This segmentation enables parallel production of multiple units, significantly increasing productivity while maintaining assembly reliability through standardized interfaces.
Solution Approach 2:
The coil assembly design with the coil pre-mounted on the coil holder creates a universal module that can be used across different actuator configurations and production batches. This standardized module approach allows for mass production with consistent quality and reliability, as the same proven design can be replicated efficiently.
3Adaptability or versatility
If multiple separate components are used, then functional versatility is improved, but manufacturing cost and assembly complexity increase
Solution Approach 1:
The coil holder is designed to integrate multiple functions: it serves as the structural support for the coil, provides magnetic shielding, defines the air gap geometry, and acts as a mounting platform. By merging these functions into a single component, the patent reduces the total number of parts, lowering manufacturing cost while maintaining the functional versatility needed for different actuator applications.
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 process, reduces costs, and enables the production of electromagnetic actuators suitable for larger quantities, improving their applicability in cost-sensitive fields while maintaining mechanical stability and accuracy.
Implementation Method 1
The coil assembly comprises a coil and a magnet assembly... when electricity is applied to the coil, the coil assembly moves along an axial direction of the magnetic actuator
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3
AI summary
A coil assembly for a magnetic actuator is described, the coil assembly comprising: - a tubular coil holder (100) comprising a first (110) and second open distal end (120); - the first open distal end comprising an outer circular rim (112) and an inner circular rim (114) separated by a circular groove (116); - the second open distal end comprising an outer circular rim (122); the tubular coil holder further comprising a central circular rim (130) arranged substantially halfway between the inner circular rim of the first open distal end and the outer circular rim of the second open distal end; - a coil (140) formed of a single wire (150), the coil comprising a first coil section (142) arranged in a first winding area (144) between the inner circular rim of the first open distal end and the central circular rim, and a second coil section (146) in a second winding area (148) between the central circular rim and the outer circular rim of the second distal end; the first coil section and the second coil section being wound about the tubular coil holder in opposite directions; whereby a first end (152) and a second end (154) of the single wire are arranged in the circular groove; the inner circular rim comprising a longitudinal groove (114.1) to extend the first end and the second end of the single wire from the circular groove to the first winding area; the central circular rim comprising a longitudinal groove (130.1) to extend the single wire form the first winding area to the second winding area and vice versa; - an external connection (160) comprising a first conductor (162) and a second conductor (164); whereby an end of the first conductor is electrically connected to the first end of the single wire so as to form a first electrical connection (166) arranged in the circular groove and an end of the second conductor is electrically connected to the second end of the single wire so as to form a second electrical connection (168) in the circular groove and wherein the first and second conductor extend through the outer circular rim via a longitudinal groove (112.1) of the outer circular rim.