Electromagnetic Switch Connector Assembly for Starter Motor
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Solution Overview
Problem
Conventional electromagnetic switch devices for starters in large-displacement engines face challenges with increased coil resistance due to larger solenoid coil development length, leading to insufficient current supply and increased manufacturing costs, while protruding auxiliary relays compromise vehicle mountability and vibration resistance.
Innovation Solution
An electromagnetic switch device with a connector assembly formed by stamping conductive material, integrating connectors to form motor and electric circuits, and a resin member to fix these connectors, which reduces the device's size and improves assembly, mountability, and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the auxiliary relay is provided with the solenoid coil wound around the outer circumference of the movable contact, then the auxiliary relay can be integrated into the electromagnetic switch device, but the development length of the coil is increased causing increased coil resistance and insufficient current supply
Solution Approach 1:
The patent changes the spatial arrangement by providing the auxiliary relay in the axial direction of the movable contact rather than wrapping around its outer circumference. This dimensional change reduces the coil's development length and resistance while maintaining integration within the electromagnetic switch device structure.
Solution Approach 2:
The patent modifies the geometric parameters of the solenoid coil by reducing its development length through the axial placement configuration. This parameter change directly addresses the coil resistance issue while preserving the auxiliary relay's current supply function.
2Reliability
If the auxiliary relay is provided with a larger solenoid coil to reduce coil resistance, then sufficient current can be supplied, but the size of the solenoid coil is enlarged increasing manufacturing cost
Solution Approach 1:
By repositioning the auxiliary relay in the axial direction, the patent achieves the same current supply capability with a more compact coil configuration, avoiding the need for larger, more expensive coils while maintaining sufficient current delivery.
3Ease of manufacture
If the auxiliary relay protrudes in the axial direction to reduce coil size, then manufacturing cost is reduced, but vehicle mountability is deteriorated
Solution Approach 1:
The patent merges the auxiliary relay with the electromagnetic switch device structure, providing it in the axial direction where it can be integrated into the terminal block assembly. This combination allows compact packaging that maintains vehicle mountability while reducing manufacturing costs.
4Ease of manufacture
If the auxiliary relay is located away from the engine attachment surface to accommodate the reduced coil size, then manufacturing cost is reduced, but vibration response is increased causing deteriorated vibration resistance
Solution Approach 1:
The patent combines the auxiliary relay with the electromagnetic switch device housing and terminal block structure, positioning it at the engine attachment surface. This integrated positioning ensures the auxiliary relay remains close to the mounting surface, maintaining vibration resistance while achieving cost reduction through the compact axial configuration.
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 solution facilitates easier assembly and connection, downsizes the device, enhances vehicle mountability, and improves vibration resistance by minimizing the sub coil's size and eliminating axial protrusions.
Implementation Method 1
an electromagnetic switch which includes a pair of main fixed contacts, a main movable contact, an attraction coil, and a holding coil and which opens and closes an electric circuit for a motor via the pair of main fixed contacts, and when the attraction coil and the holding coil are energized, moves an overrunning clutch via a shift lever
Implementation Method 2
an auxiliary relay which includes a pair of sub fixed contacts, a sub movable contact, and a sub coil, the pair of sub fixed contacts being connected to the attraction coil and the holding coil of the electromagnetic switch, the auxiliary relay energizing the attraction coil and the holding coil of the electromagnetic switch via the pair of sub fixed contacts in response to a starting signal
Data Source
AI summary
An electromagnetic switch device for starter includes a connector assembly which has a plurality of connectors formed by stamping a conductive material and which forms a motor electric circuit and an electric circuit for supplying power to an attraction coil and a holding coil, wherein the connector assembly includes: a connector (A) connecting one of a pair of sub fixed contacts and a battery terminal; a connector (B) connecting the other one of the pair of sub fixed contacts, and one end of the attraction coil and one end of the holding coil; a connector (C) connecting the other end of the attraction coil and a motor terminal; a connector (D) connecting one end of a sub coil and an S terminal; and a resin member integrally fixing at least one pair of the connector (A), the connector (B), the connector (C), and the connector (D).