Electromagnetic Switch Lead Wire Retainer for Engine Starter
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Solution Overview
Problem
The existing electromagnetic switch designs for engine starters with tandem solenoids face challenges in ease of assembly and stability due to increased lead wire length and adverse magnetic effects, leading to wear and noise issues.
Innovation Solution
The design incorporates lead-wire retainers that extend from the first bobbin to the air gap of the second solenoid, minimizing lead wire deflection and exposure to magnetic forces, thereby enhancing assembly ease and reducing wear and noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the first coil lead wire is routed radially outside the second coil, then the air gap between the second coil and frame can be minimized for better heat dissipation, but the lead wire length increases causing assembly difficulty and magnetic force interference
Solution Approach 1:
The patent introduces a lead wire guide as an intermediary component that channels the first coil lead wire through the second bobbin's lead wire outlet. This mediator allows the lead wire to pass through the magnetic circuit air gap region without being exposed to harmful magnetic forces, while maintaining the minimal air gap configuration for optimal heat dissipation from the second coil.
Solution Approach 2:
The patent extracts the lead wire routing path from the radial exterior of the second coil and redirects it through the lead wire outlet in the second bobbin. This extraction removes the lead wire from the harmful magnetic field region while preserving the compact air gap design between the second coil and frame for efficient heat dissipation.
2Adaptability or versatility
If the first coil lead wire extends outside the second bobbin without proper retention, then routing flexibility is improved, but the lead wire is exposed to magnetic forces causing wear and noise
Solution Approach 1:
The lead wire guide acts as a protective intermediary that channels the first coil lead wire through the second bobbin's lead wire outlet. This intermediary structure allows the lead wire to pass through the magnetic circuit air gap region without being exposed to harmful magnetic forces, while maintaining the minimal air gap configuration for optimal heat dissipation from the second coil.
Solution Approach 2:
The patent applies preliminary anti-action by pre-retaining the first coil lead wire through the lead wire outlet before the harmful magnetic forces from the second coil can act on it. This preventive measure counteracts the potential wear and noise issues that would otherwise occur from magnetic force interference during operation.
3Ease of manufacture
If the lead wire outlet does not extend radially inside the second coil, then manufacturing simplicity is maintained, but the lead wire length increases reducing workability
Solution Approach 1:
The lead wire guide serves as a mediator that enables the lead wire to be retained and guided through the second bobbin's lead wire outlet without requiring the outlet to extend radially inside the second coil. This intermediary structure maintains manufacturing simplicity while improving workability by providing proper lead wire retention and routing.
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 stabilizes the lead wires during assembly and operation, reducing wear and noise, and minimizing the adverse effects of magnetic forces, thus improving the reliability and longevity of the solenoids.
Implementation Method 1
a first solenoid which includes a first coil which is wound around a first bobbin... the first coil working to produce a magnetic force to move a pinion of a starter toward a ring gear of an engine
Implementation Method 2
a second solenoid which includes a second coil which is wound around a second bobbin... the second coil working to produce a magnetic force to close main contacts installed in a power supply circuit
Implementation Method 3
a magnetic force is exerted on the first coil lead wire by interaction of the electric current flowing through the first coil lead wire and the magnetic field crated by the second coil
Data Source
AI summary
An electromagnetic switch includes a first and a second solenoid arranged in alignment in an axial direction of a housing and brings a pinion into mesh with a ring gear of an engine and close main contacts in a power supply circuit for an electric motor which cranks the engine. A retainer is provided which extends from a first bobbin of the first solenoid at least to a location of an air gap formed in a magnetic circuit of the second solenoid. The retainer holds a portion of a lead wire extending from a bobbin of the first solenoid at least in a range between the bobbin and the air gap, thereby minimizing inclination or deflection of the lead wire when the first and second solenoids are fabricated within the housing, thus facilitating the ease with which the first and second solenoids are mounted in place in the housing.