Polarized DC Electromagnetic Device Spool Assembly
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Solution Overview
Problem
The assembly efficiency of polarized DC electromagnetic devices is hindered by the time-consuming attachment of an outer yoke, leading to decreased efficiency and increased size due to the need for wider terminal blocks.
Innovation Solution
A configuration featuring a spool with radially protruding flange portions, a coil terminal attachment portion, and a separate coil terminal attachment mechanism, allowing the outer yoke to be attached before the coil terminal, improving assembly efficiency without increasing device size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the terminal block width is increased to improve assembly efficiency, then the assembly efficiency improves, but the electromagnetic device size increases
Solution Approach 1:
The invention divides the attachment process into two independent stages: first attaching the outer yoke to the spool, then attaching the coil terminal to the spool. This segmentation allows each component to be attached separately without interfering with each other, improving assembly efficiency without requiring an increased terminal block width.
Solution Approach 2:
The outer yoke is attached to the spool before the coil terminal is attached. This preliminary action of attaching the outer yoke first creates space and access for subsequent coil terminal attachment, enabling efficient assembly without increasing the overall device size.
2Ease of operation
If the terminal block width is increased to attach the outer yoke, then the outer yoke attachment becomes easier, but the electromagnetic device size increases
Solution Approach 1:
The invention segments the attachment operations by providing a dedicated coil terminal attachment portion on the spool that is separate from the outer yoke attachment area. This allows the outer yoke to be attached to the spool body while the coil terminal is attached to the dedicated portion, making both operations easier without increasing overall size.
Solution Approach 2:
The coil terminal attachment portion acts as an intermediary structure on the spool that facilitates the attachment of the coil terminal without requiring the terminal block to be wider. This intermediary structure enables easy attachment while maintaining compact dimensions.
3Ease of operation
If the terminal block is integrally formed with the coil winding frame, then the movable core attachment becomes easier, but the outer yoke attachment becomes time-consuming
Solution Approach 1:
The invention segments the attachment functions by providing a dedicated coil terminal attachment portion on the spool that is separate from the outer yoke attachment area. This segmentation allows the outer yoke to be attached to the spool body while the coil terminal is attached to the dedicated portion, making both operations easier without increasing overall size.
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 configuration enhances assembly efficiency by allowing the outer yoke to be attached first, reducing the size of the polarized DC electromagnetic device and improving the assembly process, while maintaining equivalent performance to alternating-current devices.
Implementation Method 1
a permanent magnet disposed between the outer yoke and the inner yoke
Implementation Method 2
an excitation coil is wound around a spool
Data Source
AI summary
A polarized DC electromagnetic device and electromagnetic contactor using same to improve assembly efficiency without size increase of the electromagnetic device. The device includes a plunger inserted through a cylindrical portion of a spool around which an excitation coil is wound and having a first armature and a second armature attached to both ends, an outer yoke attracting the first armature and the second armature, an inner yoke disposed inside the outer yoke and attracting the second armature, and a permanent magnet disposed between the outer yoke and the inner yoke. The spool includes radially protruding flange portions respectively formed at both ends of the cylindrical portion, a coil terminal attachment portion formed in the flange portion on the first armature side, and a coil terminal attached to the coil terminal attachment portion.