Adjustable Spacer Assembly for EMC Lead Spacing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for electromagnetic compatibility (EMC) testing, such as using tape to secure leads above a ground plane, are inefficient and prone to errors due to lead movement and variability, leading to time-consuming setups and low repeatability of tests.
Innovation Solution
An adjustable spacer assembly with a body, guide, and movably coupled spacer elements that allow for precise spacing and height adjustment of electrically-conductive elements, ensuring consistent alignment and spacing according to EMC testing criteria, reducing the need for tape and facilitating faster setup and reconfiguration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tape is used to secure leads on a non-conductive sheet, then leads can be positioned above the ground plane, but leads are difficult to maintain in parallel at proper separation and lead placement is time consuming
Solution Approach 1:
The spacer assembly is designed to self-align and maintain leads in parallel at proper separation without requiring continuous manual adjustment or extensive tape application. The guide structure with grooves automatically positions leads as they are placed, and the spacer elements maintain spacing without active control
Solution Approach 2:
The spacer assembly is pre-configured with guide grooves and spacer elements at the correct spacing before leads are placed. This preliminary preparation eliminates the need for real-time measurement and adjustment during lead placement, allowing technicians to simply place leads into the pre-positioned guides
2Reliability
If leads are secured with tape to maintain spacing, then leads can be held in position, but changing wiring setup requires tape removal and reinstallation which is slow
Solution Approach 1:
The spacer assembly allows leads to be easily inserted and removed from the guide grooves while maintaining position stability during testing. The design transitions from a static taped configuration to a dynamic system where leads can be quickly reconfigured by simply moving them along the guide or removing them entirely
Solution Approach 2:
The wiring setup is segmented into modular components where individual leads can be independently positioned and adjusted in the guide grooves without affecting other leads. This modular approach allows selective reconfiguration of specific leads or groups of leads without requiring complete disassembly
3Manufacturing precision
If rigid EMC testing criteria are specified for lead arrangement, then testing standards are met, but variability in testing setup makes compliance difficult
Solution Approach 1:
The spacer assembly incorporates adjustable spacer elements that can be moved along the guide to change the spacing parameters. This allows the same physical device to accommodate different EMC testing standards by adjusting the position of spacer elements, thereby changing the geometric parameters of lead arrangement without requiring different equipment
Data Source
AI summary
A novel spacer assembly includes a body defining a bottom surface and a top surface opposite the bottom surface, a guide coupled to the top surface and extending along an axis, and a plurality of spacer elements movably coupled to the guide along the axis and being configured to receive a plurality of electrical leads therebetween. Each of the spacer elements extends above the top surface of the body and defines a predetermined width along the axis. When the leads are placed between the spacer elements, a spacing between adjacent ones of the leads corresponds to the predetermined width of the interposing spacer element. The predetermined width corresponds to a predefined electromagnetic compatibility (EMC) testing criteria. The spacer assembly facilitates rapid placement and accurate spacing of leads during initial EMC test setup or reconfiguration.