Spool with Deformable Sleeve for Motor Brake Coil
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Solution Overview
Problem
The manufacturing of spools with winding wires is costly and labor-intensive due to the need for multiple contacts and complex connections, particularly with center taps, which increases effort and expense.
Innovation Solution
A spool design featuring a deformable sleeve made of sheet metal, which allows for cost-effective electrical connections through force-locking and welding, eliminating the need for additional parts and simplifying the manufacturing process by providing deformable regions for clamping and welding the winding wire and stranded conductor, and incorporating a center tap for rapid switchable brakes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a brake coil with center tap is manufactured using conventional methods, then the brake function is achieved, but manufacturing effort and cost increase due to multiple contacts and complex connections
Solution Approach 1:
The patent combines the electrical connection function and mechanical support function into a single integrated spool structure. The winding wire is directly connected to the spool body, eliminating the need for separate connecting pieces and multiple contacts. This merging of functions reduces manufacturing complexity while maintaining the brake coil's operational reliability.
Solution Approach 2:
The spool serves multiple functions simultaneously: it acts as the structural support for the winding wire, provides the electrical connection path, and serves as the mounting element for the brake coil. This multi-functionality eliminates the need for additional specialized parts, reducing both manufacturing effort and component count.
2Reliability
If winding wire is connected by winding around and soldering, then electrical connection is achieved, but manufacturing time and cost increase
Solution Approach 1:
The spool is pre-designed with integrated connection points and conductive paths during the molding process. The winding wire is positioned and connected in a single operation during spool manufacturing, rather than requiring separate winding, positioning, and soldering steps. This preliminary integration of the connection structure dramatically reduces manufacturing time.
Solution Approach 2:
The patent replaces the traditional mechanical soldering process with a direct mechanical and electrical integration through the spool structure. The winding wire is electrically connected through the conductive material in the spool body, eliminating the need for thermal soldering processes and reducing manufacturing time and complexity.
3Strength
If additional connecting pieces with hooks are used to guard against pulling out, then connection security is improved, but manufacturing complexity and effort increase
Solution Approach 1:
The mechanical retention function and electrical connection function are merged into the single spool structure. The spool body itself provides both the electrical conductive path and the mechanical anchoring for the winding wire, eliminating the need for separate connecting pieces with hooks. This integration maintains connection security while reducing structural complexity.
Solution Approach 2:
The spool serves as both the electrical connector and the mechanical retention element. The same structure that provides the electrical path also provides the mechanical strength to prevent pulling out, eliminating the need for additional specialized connecting components and simplifying the overall device structure.
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 spool design reduces manufacturing effort and cost by enabling easy and secure electrical connections, minimizing manufacturing faults, and allowing for high automation in the production of electric motors with cost-effective brake coils.
Implementation Method 1
the sleeve including deformable regions, for producing the electrical connections, a respectively deformable region being deformable such that a force-locking connection is provided
Implementation Method 2
Welded joints are then able to be produced by appropriate heating
Data Source
AI summary
A spool includes at least one bobbin and one winding wire, e.g., a winding wire lacquered for electrical insulation, the bobbin including at least one channel, e.g., one arranged as a pocket, at least one sleeve being electrically connected to the winding wire, the sleeve being electrically connected to an electrical line, e.g., a stranded conductor of a cable, the sleeve including deformable regions, for producing the electrical connections, a respectively deformable region being deformable such that a force-locking connection is provided and welding is able to be carried out.