Electrohydraulic Actuator PCB Wiring for Automated Coil Connection
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Solution Overview
Problem
Existing electro-hydraulic actuators face challenges in automated production due to the difficulty of reliably and efficiently connecting the thin, limp coil winding of an electromagnet to a circuit board, as conventional methods are complex and space-consuming.
Innovation Solution
A wire guide element with a threading opening is attached to the circuit board, allowing the connecting wire of the coil winding to be easily passed through and soldered into a contact opening, simplifying the electrical connection process and enabling reliable assembly in automated systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional through-hole mounting method is used to connect coil winding to circuit board, then electrical connection is achieved, but the process is complex and difficult to automate due to the thin and limp nature of the connecting wire
Solution Approach 1:
A wire guide element is introduced as an intermediary component between the circuit board and the connecting wire. This wire guide element features a threading opening that receives and guides the thin connecting wire from the coil winding onto the circuit board, making the wire visible and manageable during automated assembly processes
Solution Approach 2:
The wire guide element extends in a direction perpendicular to the circuit board surface, creating a third dimension for wire routing. This vertical extension allows the thin wire to be guided through space in a controlled manner, making it accessible to automated picking and placing equipment without requiring complex planar manipulation
2Reliability
If elaborate interconnecting means are used to achieve reliable contact, then connection reliability is improved, but installation space and device complexity increase considerably
Solution Approach 1:
The wire guide element serves as a simple intermediary that provides mechanical guidance and positioning for the connecting wire. It features a threading opening that receives the wire and guides it to the contact opening on the circuit board, ensuring reliable electrical connection without requiring complex interconnecting mechanisms
Solution Approach 2:
The connection system is segmented into distinct functional components: the coil winding with its connecting wire, the wire guide element with threading opening, and the circuit board with contact opening. This segmentation allows each component to be optimized independently while simplifying the overall assembly process
3Reliability
If spring-loaded contact elements are used to press against circuit board, then reliable contact is achieved, but a considerable amount of installation space is required
Solution Approach 1:
The spring-loaded contact elements and their associated complex mechanisms are extracted and replaced with a simpler wire guide element. The wire guide element provides reliable wire positioning and contact through its threading opening design, eliminating the need for space-consuming spring mechanisms while maintaining connection reliability
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 solution provides a cost-effective and easy-to-use method for integrating a control circuit into the actuator, ensuring secure and reliable electrical connections for the coil winding, facilitating the integration of a control device directly within the actuator, and simplifying the assembly process.
Implementation Method 1
an electromagnet with a coil winding (23)
Implementation Method 2
soldered into a contact opening (41) of the circuit board (1)
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an electrohydraulic actuator (3) comprising a valve part (6), an electromagnet (5) with a coil winding (23), a magnetic armature (52) movably mounted in the electromagnet (5), and a valve element (61) actuated by the magnetic armature (52) and arranged in the valve part (6). It is proposed that at least one printed circuit board (1) be arranged on the electrohydraulic actuator (3), wherein the printed circuit board (1) has a wire guide element (8) mounted on the printed circuit board (1) on a side facing the electromagnet (5), wherein the wire guide element (8) has at least one threading opening (81), and wherein a contact section (21) of a connecting wire (2) of the coil winding (23) is passed through the threading opening (81) of the wire guide element (8) and soldered into a contact opening (41) of the printed circuit board (1).Furthermore, the invention relates to a method for manufacturing such an electrohydraulic actuator (3).