Additive Gradient Coil Assembly Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for manufacturing gradient coil assemblies in MRI systems are prone to structural weaknesses and manufacturing defects due to manual processes, which can lead to reduced durability and increased susceptibility to errors.
Innovation Solution
The use of additive manufacturing techniques, such as electron beam deposition, laser powder deposition, or ultrasonic consolidation, to automate the construction of gradient coil assemblies, allowing for precise control and integration of various components like spacers, windings, and cooling channels without manual assembly, thereby enhancing precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual processes are used for manufacturing gradient coil assemblies, then flexibility in assembly is maintained, but manufacturing precision and reliability deteriorate due to manufacturer error and uncertainty
Solution Approach 1:
The patent replaces manual mechanical assembly processes with automated deposition systems. The additive manufacturing system automatically deposits conductor material, spacers, dielectric insulators, and other layers onto the cylindrical former without manual intervention, eliminating manufacturer error and uncertainty while maintaining flexibility through programmable control.
Solution Approach 2:
The system enables self-aligned deposition where each layer automatically positions itself relative to previous layers through the controlled deposition process. The cylindrical former serves as a self-aligning platform that guides the placement of spacers, conductor material, and insulators without requiring manual alignment adjustments.
2Strength
If conventional winding methods are used to form gradient coils, then manufacturing simplicity is maintained, but structural strength deteriorates due to stress from bending coils to desired shape
Solution Approach 1:
The patent applies preliminary action by depositing conductor material in its final desired configuration directly onto the cylindrical former, rather than winding and then bending the material. The conductor material is deposited layer by layer in the exact shape needed, eliminating subsequent bending operations that would introduce stress and reduce durability.
Solution Approach 2:
The manufacturing process changes the fundamental parameter of material formation from post-forming (winding then bending) to in-situ formation (direct deposition). This parameter change allows the conductor material to be created in its final stress-free configuration, significantly improving structural strength while managing process complexity through automation.
3Adaptability or versatility
If additional features like soldering pads and connecting leads are brazed onto gradient boards, then functionality is enhanced, but reliability deteriorates due to introduced weak points
Solution Approach 1:
The patent merges the formation of soldering pads, connecting leads, and other features into the single additive manufacturing process. All these features are deposited concurrently with the main coil structure using the same automated system, eliminating separate brazing operations and the weak points they introduce while maintaining full functionality.
Solution Approach 2:
The system uses composite material deposition where conductor material, dielectric insulators, spacers, and other components are integrated into a unified structure through layered deposition. This composite approach creates inherent bonding between features without requiring additional joining processes like brazing, thereby improving structural integrity while maintaining adaptability.
4Productivity
If hand-performed manufacturing processes are used, then process flexibility is maintained, but productivity deteriorates due to time-consuming manual operations
Solution Approach 1:
The patent replaces all manual mechanical operations with an automated additive manufacturing system. The system automatically deposits multiple layers of different materials, forms complex three-dimensional structures, and completes the entire gradient coil assembly without manual intervention, dramatically increasing manufacturing speed while maintaining flexibility through programmable control.
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 approach reduces manufacturing time, enhances precision, and minimizes structural instabilities and defects, resulting in more reliable and durable gradient coil assemblies for MRI systems.
Implementation Method 1
The use of additive manufacturing techniques, such as electron beam deposition, laser powder deposition, or ultrasonic consolidation
Implementation Method 2
The use of additive manufacturing techniques, such as electron beam deposition, laser powder deposition, or ultrasonic consolidation
Data Source
AI summary
The embodiments disclosed herein relate generally to magnetic resonance imaging systems and, more specifically, to the manufacturing of a gradient coil assembly for magnetic resonance imaging (MRI) systems. For example, in one embodiment, a method of manufacturing a gradient coil assembly for a magnetic resonance imaging system includes depositing a first layer comprising a base material onto a surface to form a substrate and depositing a second layer onto the first layer. The second layer may enable bonding between a conductor material and the substrate. The method also includes depositing a third layer onto the second layer using a consolidation process. The consolidation process uses the conductor material to form at least a portion of a gradient coil.