Electromagnetic Switch Terminal Vibration Resistance
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Solution Overview
Problem
Conventional electromagnetic switches for starters face challenges in suppressing vibration of plate-like terminals under large vibrational loads, leading to potential breakage of lead wires connected to excitation coils, and require additional parts for fixation, complicating waterproofing and increasing parts count.
Innovation Solution
The electromagnetic switch incorporates a male and female terminal configuration where the male terminal is insert-molded in a resin mold cover and the female terminal is fixed to the coil bobbin, with a fitting section for electrical connection and a guide section to reduce vibration, eliminating gaps and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plate-like terminal is inserted into the mold cover through an insertion hole, then the terminal can be electrically connected, but the terminal vibrates under large vibrational loads leading to lead wire breakage
Solution Approach 1:
The patent merges the terminal fixation function with the mold cover structure itself. The insert-molded male terminal becomes an integral part of the mold cover, eliminating the need for separate fixation components like cup washers or nuts. This integration provides robust vibration resistance while maintaining electrical connection reliability.
Solution Approach 2:
The male terminal is pre-fixed to the mold cover through insert molding before final assembly. This preliminary fixation ensures the terminal is securely positioned and cannot vibrate during operation, preventing lead wire breakage while maintaining electrical connectivity.
2Stability of the object's composition
If a bolt is used as the 50 terminal and tightly fastened with cup washer or nut, then vibration resistance is improved, but the parts count increases and waterproofing becomes more difficult
Solution Approach 1:
The patent combines multiple functions into the mold cover structure: the mold cover itself serves as both the housing and the terminal fixation mechanism. The insert-molded male terminal is directly integrated into the mold cover, eliminating the need for separate fixation parts like cup washers, nuts, and additional terminals, thus reducing parts count while maintaining fixation stability.
Solution Approach 2:
The mold cover is designed to perform multiple functions: it houses the excitation coil, provides structural support, and serves as the fixation mechanism for the energization terminal. This multi-functionality reduces the need for separate components and simplifies the overall structure while maintaining vibration resistance.
3Strength
If a bolt is used as the 50 terminal, then fixation strength is improved, but the shape cannot be made waterproof coupler-like
Solution Approach 1:
The male terminal is designed with a plate-like shape that can be locally optimized for both fixation strength and waterproof coupler form factor. The insert-molding process allows the terminal to have different structural characteristics at different locations: a robust fixed portion integrated with the mold cover and a flexible connection portion for the lead wire, achieving both strength and shape requirements.
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 enhances vibration resistance, reduces parts count, and facilitates easy electrical connection while maintaining waterproof integrity, preventing lead wire breakage and simplifying assembly.
Implementation Method 1
an excitation coil; an energization terminal through which a current is supplied to the excitation coil from an external battery
Data Source
AI summary
The electromagnetic switch for use in a starter includes a solenoid including an excitation coil and a plunger, and an energization terminal through which a current is supplied to the excitation coil from an external battery. The excitation coil generating, when applied with the current, a magnetic attraction force to move the plunger in order to close a main contact of the starter to thereby energize a motor of the starter. The energization terminal is constituted by a male terminal having a plate-like shape and insert-molded in the mold cover, and a female terminal fixed to a coil bobbin of the excitation coil and connected with a lead wire of the excitation coil, the female terminal being provided with a fitting section to which the male terminal is fitted so that the male and female terminals are electrically connected to each other.