Electromagnetic Switch Diode Orientation for Vibration Resistance
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Solution Overview
Problem
Conventional electromagnetic switches for engine starters in motor vehicles face durability issues due to high vibration and mechanical shock, particularly affecting the diode connected in parallel with the electromagnetic coil, which can lead to damage from inductive current and wear during energization interruption.
Innovation Solution
The electromagnetic switch design includes a diode connected in parallel with the electromagnetic coil, with leads arranged parallel to the movement direction of the movable core, and a bobbin with a diode mounting portion to minimize mechanical shock and vibration, ensuring the diode is securely fixed and protected from damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diode is disposed within the electromagnetic switch, then the inductive current can be circulated to protect the energization interrupting means, but the diode may receive mechanical shock from the movement of the movable core
Solution Approach 1:
The diode is extracted from the internal structure of the electromagnetic switch and mounted on the external surface of the bobbin. This separation removes the diode from the high-vibration zone where the movable core operates, eliminating the mechanical shock problem while preserving the diode's electrical function of circulating inductive current.
Solution Approach 2:
The bobbin serves as an intermediary mounting platform for the diode. By placing the diode on the bobbin's external surface rather than inside the electromagnetic switch housing, the bobbin acts as a mediator that isolates the diode from mechanical shocks while maintaining electrical connectivity through the diode's leads connected to the electromagnetic coil.
2Reliability
If the diode is mounted on the electromagnetic switch, then it can protect against inductive current damage, but the diode and its leads are vulnerable to damage from high vibration and mechanical shock
Solution Approach 1:
The diode is extracted from the vulnerable internal environment and relocated to the external surface of the bobbin. This positioning reduces exposure to high-vibration zones and mechanical shock paths, thereby strengthening the mechanical integrity of the diode and its leads while maintaining electrical protection functionality.
3Device complexity
If the lead arrangement direction of the diode is perpendicular to the movement direction of the movable core, then the diode structure is simpler, but the diode receives greater mechanical shock load
Solution Approach 1:
The lead arrangement direction is specifically optimized to be parallel to the movement direction of the movable core. This local directional arrangement ensures that the leads align with the shock trajectory, distributing mechanical stress along the lead length rather than creating bending moments, thereby reducing the mechanical shock load on the diode body.
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 effectively reduces the load on the diode and its leads during mechanical shock and vibration, preventing damage and ensuring reliable operation, while also minimizing the current flowing through the energization interrupting means, thus enhancing the durability of the switch.
Implementation Method 1
an electromagnetic coil (3), a fixed core (4), a movable core (5)... The electromagnetic coil is configured to form an electromagnet when energized. The fixed core is arranged to be magnetized by the electromagnet.
Implementation Method 2
when the energization of the electromagnetic coil is interrupted by an energization interrupting means, some damage may be made to the energization interrupting means due to the inductance of the electromagnetic coil... a diode is electrically connected in parallel with the electromagnetic coil... at least part of the electric current, which is caused by the inductance of the electromagnetic coil, can be made to circulate within a closed circuit formed by the electromagnetic coil and the diode
Data Source
AI summary
An electromagnetic switch includes an electromagnetic coil, a fixed core, a movable core, and a diode. The electromagnetic coil is configured to form an electromagnet when energized. The fixed core is arranged to be magnetized by the electromagnet. The movable core is arranged to be attracted by the magnetized fixed core to move in a movement direction toward the fixed core. The diode is electrically connected in parallel with the electromagnetic coil. The diode includes a main body and has a pair of leads respectively extending from a pair of ends of the main body which are opposite to each other in a lead arrangement direction of the diode. The lead arrangement direction of the diode is parallel to the movement direction of the movable contact.