Single Coil Actuator Simplified Assembly
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Solution Overview
Problem
Conventional coil-based actuators for low and medium voltage applications require a high number of variants to cover various operational ranges, leading to increased manufacturing and handling costs, complex coil manufacturing, and the need for manual cable formation and soldering for electrical connections.
Innovation Solution
A single-coil actuator design featuring a simplified electromechanical assembly with socket and plug-type connections for easy interfacing with dedicated or onboard electronics, reducing the number of mechanical parts and eliminating the need for manual cable formation and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coil-based actuators use multiple windings and selective energization for launch and hold operations, then the actuator can maintain position reliably, but the device complexity and number of variants increase significantly
Solution Approach 1:
The patent extracts the hold function from the electromagnet by using a separate mechanical latch mechanism. The electromagnet only needs to provide launch force, while the mechanical latch maintains the closed position. This eliminates the need for complex hold windings and reduces the number of electromagnet variants required.
Solution Approach 2:
The patent introduces a mechanical latch as an intermediary component between the electromagnet and the contactor contacts. This latch mechanism serves as a mediator that maintains the closed position without requiring continuous electromagnetic force, thereby simplifying the electromagnet design and reducing variants.
2Use of energy by stationary object
If the hold winding uses high number of turns with very low wire sections, then the actuator can maintain position with low power consumption, but the coil manufacturing cost increases
Solution Approach 1:
The patent removes the hold winding entirely from the electromagnet design. Instead of using an electrical hold winding with high turn count and low wire section, the system uses a mechanical latch to maintain position. This eliminates the costly coil manufacturing while still achieving reliable position maintenance with low power consumption during the hold phase.
3Reliability
If the electromagnet is connected to electronics using cables with manual forming and soldering, then the electrical connection can be established, but the manufacturing and installation time increases
Solution Approach 1:
The patent incorporates connection terminals directly into the electromagnet assembly during manufacturing. These pre-prepared terminals eliminate the need for manual cable forming and soldering during installation. The electrical connection is prepared in advance as part of the electromagnet assembly process, significantly reducing installation time while maintaining connection reliability.
4Adaptability or versatility
If multiple electromagnet variants are used to cover all voltage and current operational ranges, then the actuator can adapt to different applications, but the manufacturing and handling costs increase
Solution Approach 1:
The patent creates a universal electromagnet design that can serve multiple voltage and current ranges by combining a simplified electromagnet (without hold winding) with different mechanical latch configurations and electronic control strategies. This single platform approach reduces the number of electromagnet variants from 7 to a smaller set of standardized units, lowering manufacturing and handling costs while maintaining adaptability across 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
The single-coil actuator design simplifies manufacturing and installation, reduces costs, and allows easy adaptation to multiple applications while maintaining performance and reliability, by using a few components and direct electrical connections, thus minimizing the number of variants and manufacturing costs.
Implementation Method 1
an electromagnet having a coil and an armature movable between two positions
Data Source
AI summary
A single-coil actuator for low or medium voltage applications which comprises a first assembly which comprises a first casing having a first half-casing and a second half-casing coupled to each other. The first casing defines an internal space housing an electromagnet having a coil and an armature movable between two positions. The first half-casing has a first opening for the mechanical coupling of the armature with an external element, while one of the first or second half-casing has a second opening for the electrical connection of the electromagnet. The electrical connection comprises a first connection element of the socket and plug-type connection which is electrically connected to the coil and positioned in correspondence of the second opening.