Information
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Patent Grant
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6798323
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Patent Number
6,798,323
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Date Filed
Thursday, September 20, 200123 years ago
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Date Issued
Tuesday, September 28, 200420 years ago
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Inventors
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Original Assignees
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Examiners
- Donovan; Lincoln
- Rojas; Bernard
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CPC
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US Classifications
Field of Search
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International Classifications
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Abstract
An electromagnetically actuable device has a magnetic core proximate an armature and a coil selectively energized to draw the armature to the magnetic core. The armature and magnetic core are of laminated magnetic steel and have mating surfaces. At least one of the armature and magnetic core includes conductive weld or braze lines for integrally securing laminations together to define a conductive path proximate the mating surface to provide a shading coil.
Description
TECHNICAL FIELD OF THE INVENTION
This invention relates to electromagnetically actuable devices and, more particularly, to an electromagnet incorporating a shading coil.
BACKGROUND OF THE INVENTION
A typical electromagnetically actuable device has a magnetic core proximate an armature. A coil is selectively energized to draw the armature to the magnetic core. The device may be a solenoid, a contactor, a motor starter, or the like. The armature is operatively associated with a movable device such as movable contacts or an actuator. In many instances the coil is selectively energized from an AC power source. With AC-operated electromagnets, elimination or control of noise is a prime concern. To minimize noise the surface interface of the magnetic core and armature of each device must be matched to provide minimal magnetic “air gap” and a stable interface surface. The minimal air gap assures sufficient force to prevent movement and the stable surface interface prevents movements due to the widely changing forces in the AC-operated device. Particularly, a spring provides a constant force between the magnetic core and the armature. Energization of the coil counteracts the spring force to draw the armature toward the magnetic core. However, with an AC power source operating at, for example, 60 Hz, there are 120 zero crossings each second during energization. At each zero crossing the spring force may overcome the magnetic force causing the armature to be pushed away and then drawn back again. This can produce a noisy electromagnet.
Conventional shading coils have been used without success to address this problem. A conventional shading coil drives the formation of a small shaded magnetic pole formed on the interface or mating surface of the core or armature. The conventional shading coil is typically a conductive alloy in a stamped ring that is attached to the laminations of the AC electromagnet. These conventional coils routinely break and therefore are costly to produce and assemble. Also, the laminations of conventional coils are often held together with rivets that add costs to producing the electromagnets. The rivets provide points of failure. Accordingly, the inherent weakness of the rivets and the conventional shading coils typically limit the mechanical life of the electromagnet.
SUMMARY OF THE INVENTION
In accordance with the invention, a shading coil is formed in an electromagnet by welding or brazing or the like.
Broadly, there is disclosed herein an electromagnetically actuable device having a magnetic core proximate an armature and a coil selectively energized to draw the armature to the magnetic core. The device comprises the armature and magnetic core being of laminated magnetic steel and having mating surfaces. At least one of the armature and magnetic core includes means for integrally securing laminations together to define a conductive path proximate the mating surface to provide a shading coil.
It is a feature of the invention that the securing means comprises weld connections between adjacent laminations of the at least one of the armature and magnetic core.
It is another feature of the invention that the securing means comprises braze connections between adjacent laminations of the at least one of the armature and magnetic core. The braze connections may use a conductive alloy such as copper.
It is still another feature of the invention that the securing means comprises the sole means for securing the laminations together.
It is a further feature of the invention that a single conductive line is provided on the mating surface transverse to the laminations and a plurality of conductive lines are provided below the mating surface transverse to the laminations. It is a further feature of the invention that the single conductive line is of greater depth than the plurality of conductive lines.
There is disclosed in accordance with another aspect of the invention an electromagnetically actuable device having a magnetic core proximate an armature and a coil selectively energized to draw the armature to the magnetic core. The device comprises the armature and magnetic core including laminations of magnetic steel and having mating surfaces and at least one of the armature and one of the magnetic core including conductive areas formed integrally with the laminations to define a conductive path proximate the mating surface to provide a shading coil.
There is disclosed in accordance with still another aspect of the invention the method of forming an electromagnet having a magnetic core and an armature. The method comprises providing an armature and magnetic core formed of lamination of magnetic steel and having a mating surface and integrally securing the laminations together to define a conductive path proximate the mating surface to provide a shading coil.
Further features and advantages of the invention will be readily apparent from the specification and from the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1
is an exploded, perspective view of an electromagnetically actuable device in the form of a contactor including an electromagnet in accordance with the invention;
FIG. 2
is a perspective view of an armature or magnetic core of an electromagnet in accordance with the invention during an initial stage of assembly;
FIG. 3
is a view similar to
FIG. 2
of the electromagnet after conductive areas are formed therein;
FIG. 4
is a view similar to
FIGS. 2 and 3
of the electromagnet after grinding a mating surface; and
FIG. 5
is a side elevation view of the electromagnet of FIG.
4
.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring initially to
FIG. 1
, an electromagnetically actuable device in the form of an electrical contactor
18
is illustrated in exploded form. The contactor
18
includes a base
20
, a housing
22
, an electromagnet
24
, a coil
26
an actuator assembly
28
and a cover plate
30
. The electromagnet
24
includes an armature
48
and a magnetic core
50
. The housing
22
is mounted to the base
20
and encloses the coil
26
and the magnetic core
50
. The magnetic core
50
is fixedly mounted in the housing
22
. The magnetic core
50
is made of laminated magnetic steel, as is well known. The coil
26
includes a conventional bobbin, winding and terminal assembly and is located within the housing
22
and on the magnetic core
40
. The armature
48
is also of laminated magnetic steel and is associated with movable contacts
32
carried on a contact carrier
34
moveable mounted in the housing
22
. Particularly, the contact carrier
34
moves with the armature
48
. The housing
22
also supports stationary contacts
36
positioned in proximity with the moveable contacts
32
.
When the coil
26
is energized, the movable armature
48
is drawn toward the magnetic core
50
in a conventional manner. The movement of the armature
48
toward the magnetic core
50
causes the moveable contacts
32
to selectively open or close an electrical circuit with the stationary contacts
36
, as is known.
While this application illustrates an electromagnetically actuable device in the form of a contactor, the teachings of the invention can similarly be applied to other electromagnetically actuable devices such as AC solenoids, electromagnetic actuators, motor starters, or the like.
In accordance with the invention, the electromagnet
24
uses weld penetration areas as conductive sections to replace conventional shading coils and structurally hold the laminations together as an assembly. Conductive alloys may optionally be added to the weld or braze areas to improve the conductivity of the resulting shading coil zone, as the resistivity of the lamination material is not extremely low.
FIGS. 2-4
illustrate an assembly sequence for the magnetic core
50
in accordance with the invention. Additionally, the method described can be used to produce the armature
48
with a shading coil, or both an armature and magnetic core for use in an electromagnet, as will be apparent to those skilled in the art.
Referring initially to
FIG. 2
, a plurality of “E-shaped” laminations
52
are stacked with each lamination
52
being aligned with the other laminations
52
. The laminations
52
are temporarily held together by any known means, represented by a bracket
54
, during initial stages of the assembly process. The laminations
52
are typically formed of a material such as silicon steel having approximately 6% silicon. However, the laminations
52
could be cold rolled steel or most other types of steel, except annealed stainless steel. The use of laminations is intended to prevent electrical currents from being conducted between laminations. The assembled laminations
52
define interface first and second opposite end mating surfaces
56
and
57
and a center mating surface
58
to be associated with corresponding mating surfaces of an associated armature, or magnetic core, as the case may be, as with the contactor
18
of FIG.
1
.
Referring to
FIGS. 3 and 5
, the laminations
52
are integrally secured together by welding a plurality of weld lines across or transverse to the stack of laminations
52
. Owing to conductivity of the lamination material and/or an alloy used for welding, the weld lines comprise conductive lines that define conductive paths between laminations
52
. Particularly, a single conductive line
60
is provided on the first end mating surface
56
. Three parallel conductive lines
62
are provided just below the first end mating surface
56
. The use of three conductive weld lines
62
provides as much conductivity as possible between the laminations
52
. However, there may be room for only a single conductive weld line
60
on the mating surface
56
itself. In accordance with the invention, the depth of the single conductive weld line
60
may be greater than the three conductive weld lines
62
. As is apparent, the conductive weld lines
60
and
62
in combination with the outermost laminations
52
form a continuous conductive path. This conductive path provides the function of a shading coil. Additionally, the weld lines
60
and
62
provide structural connections between the laminations
52
.
Similarly, a single conductive weld line
64
is provided on the second end mating surface
57
, while three conductive weld lines
66
are provided below the second end mating surface
57
. The conductive lines
64
and
66
along with the outermost laminations
52
again form a shading coil. In accordance with the invention, the conductive weld lines
60
,
62
,
64
and
66
may comprise the sole means for securing the laminations
52
together. Additionally, a structural weld line
68
can be provided transversely in the central mating surface
58
, with a similar structural weld line
70
opposite thereto.
Referring to
FIG. 4
, as a final manufacturing step, the mating surfaces
56
,
57
and
58
may be subjected to a grinding operation to provide relatively smooth surfaces for a minimal magnetic air gap. In so doing, the single conductive weld lines
60
,
64
and
68
may not be readily visible, but are still present as represented by the dashed lines.
As described above, conductive weld lines are used to define shading coils and to provide structural connections. Alternatively, conductive lines may be provided by conventional brazing techniques rather than welding. Moreover, conductive alloys may be added to the weld or braze lines to improve the conductivity of the shading coil. Copper would be a suitable alloy. As described, a shading coil is formed from either the base material of the laminations or an alternative welding material that is holding the laminations together. This avoids the addition of parts to the magnetic core or armature in order to hold it together and provide a shading coil. More particularly, the described solution replaces the separate pieces with conductive areas that are formed by weld or braze operations. These conductive areas may be structurally superior to rivet connections and also less expensive.
It can therefore be appreciated that a new and novel system and method for forming a shading coil within an electromagnet has been described. It will be appreciated by those skilled in the art that, given the teaching herein, numerous alternatives and equivalent will be seen to exist which incorporate the disclosed invention. As a result, the invention is not to be limited by the foregoing exemplary embodiments, but only by the following claims.
Claims
- 1. An electromagnetically actuable device having a magnetic core proximate an armature and a coil selectively energized to draw the armature to the magnetic core, comprising:the armature and magnetic core being of laminated magnetic steel and having mating surfaces and at least one of the armature and magnetic core including means for integrally securing laminations together to define a conductive path proximate the mating surface to provide a shading coil, wherein the securing means comprises the sole means for securing the laminations together.
- 2. The electromagnetically actuable device of claim 1 wherein the securing means comprises weld connections between adjacent laminations of the at least one of the armature and magnetic core.
- 3. The electromagnetically actuable device of claim 1 wherein the securing means comprises braze connections between adjacent laminations of the at least one of the armature and magnetic core.
- 4. The electromagnetically actuable device of claim 3 wherein the braze connections use a conductive alloy.
- 5. The elctromagnetically actuable device of claim 3 wherein the braze connections use copper.
- 6. The electromagnetically actuable device of claim 1 wherein a single conductive line is provided on the mating surface transverse to the laminations and a plurality of conductive lines are provided below the mating surface transverse to the laminations.
- 7. The electromagnetically actuable device of claim 6 wherein the single conductive line is of a greater depth than the plurality of conductive lines.
- 8. An electromagnetically actuable device having a magnetic core proximate an armature and a coil selectively energized to draw the armature to the magnetic core, comprising:the armature and magnetic core including laminations of magnetic steel and having mating surfaces and at least one of the armature and magnetic core including conductive areas formed integrally with the laminations to define a conductive path proximate the mating surface to provide a shading coil, wherein the conductive areas are defined by securing means comprising the sole means for securing the laminations together.
- 9. The electromagnetically actuable device of claim 8 wherein the at least one of the armature and magnetic core comprises weld connections between adjacent laminations to define the conductive path.
- 10. The electromagnetically actuable device of claim 8 wherein the at least one of the armature and magnetic core comprises braze connections between adjacent laminations to define the conductive path.
- 11. The electromagnetically actuable device of claim 10 wherein the braze connections use a conductive alloy.
- 12. The electromagnetically actuable device of claim 10 wherein the braze connections use copper.
- 13. The electromagnetically actuable device of claim 8 wherein a single conductive line is provided on the mating surface transverse to the laminations and a plurality of conductive lines are provided below the mating surface transverse to the laminations to define the conductive areas.
- 14. The electromagnetically actuable device of claim 13 wherein the single conductive line is of a greater depth than the plurality of conductive lines.
US Referenced Citations (5)