Electromagnetic Switch Bobbin Segmentation for Starter Coil Stability

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Solution Overview

Problem

Conventional electromagnetic switch devices for starters face issues with winding fluctuations and varying coil resistances due to different wire diameters, leading to instability in electric current requirements and increased manufacturing costs.

Innovation Solution

The electromagnetic switch device employs a bobbin with separated winding portions using flange portions and notch portions to guide coils, allowing multiple coils with different wire diameters to be wound separately, preventing winding fluctuations and enabling cost-effective production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If coils with different wire diameters are overlapped and wound around a single bobbin, then the device can be compact, but winding fluctuation occurs and coil resistance varies

Engineering Contradiction:

Improvedevice sizeVSAvoidwinding consistency

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The single bobbin is divided into multiple separate bobbins, each dedicated to winding a specific coil with a particular wire diameter. This segmentation prevents winding fluctuation by providing dedicated winding spaces for each coil type, while maintaining compactness through the coaxial arrangement of the divided bobbins.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If coils with different wire diameters are wound around different bobbins, then winding fluctuation is prevented, but the number of components increases and manufacturing cost increases

Engineering Contradiction:

Improvewinding consistencyVSAvoidnumber of components

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Multiple separate bobbins are merged into a single integrated bobbin structure with distinct winding portions. Each winding portion is dedicated to a specific coil type, preventing winding fluctuation, while the unified structure reduces the number of components compared to completely separate bobbins and lowers manufacturing cost.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If coils with different wire diameters are wound around different bobbins, then winding fluctuation is prevented, but manufacturing cost increases

Engineering Contradiction:

Improvewinding consistencyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

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 design stabilizes the electric current required for the starter, reduces manufacturing costs, and prevents winding fluctuations, allowing for a downsized and cost-effective electromagnetic switch device.

Implementation Method 1

an electromagnetic switch device for a starter, which generates an ignition magnetic force, by which a plunger is aspirated

Methodology Applied

Scientific EffectElectromagnetic force: Lorentz Force

Data Source

PatentUS11450497B2Electromagnetic switch device for starter

Publication Date: 2022.09.20 MITSUBISHI ELECTRIC CORP

AI summary

Provide an electromagnetic switch device for a starter, by which a winding fluctuation of a plurality of coils, of which wire diameters are different from each other, is prevented, which can be downsized and can be produced with a low cost. A bobbin, at which winding portions are separated by using a first flange portion which includes a first notch portion, second notch portions, and third notch portions, by which coils are led out, and a first separation wall and a second separation wall, which include the second notch portions and the third notch portions, by which coils are led out, is included, and a main aspiration holding coil, a sub-aspiration holding coil, and a resistance coil, of which wire diameters are different from each other, which are respectively wound around a first winding portion, a second winding portion, and a third winding portion, which are separated, are provided.