Adjustable Winding Form for Inductance Tolerance Compensation
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Solution Overview
Problem
Windings exhibit significant deviations in inductance and shape due to production tolerances and manufacturing uncertainties, leading to high rejection rates, especially in critical applications.
Innovation Solution
A winding design featuring a form element with adjustable elongated elements along its longitudinal axis, allowing for thickness alteration in the radial direction to compensate for production tolerances, with the conductor wound around these elements to achieve precise inductance and shape control, and optionally using spacer elements for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional windings are manufactured using standard form elements and conductors, then production is simple and fast, but the inductance and shape exhibit significant deviations due to production tolerances
Solution Approach 1:
The form element incorporates adjustable elements that can be dynamically modified to alter the radial thickness of the form element. This dynamic adjustability allows compensation for production tolerances and achieves precise inductance values while maintaining a relatively simple base structure.
Solution Approach 2:
The invention changes the physical parameter of the form element by altering the radial thickness of adjustable elements. This parameter modification enables precise control over the winding shape and inductance, resolving the contradiction between manufacturing simplicity and precision.
2Manufacturing precision
If the thickness of adjustable elements is altered to compensate for production tolerances, then inductance precision is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The form element is segmented into a core and multiple adjustable elements that can be independently modified. This segmentation allows selective adjustment of specific regions to compensate for local production tolerances without requiring complete remanufacturing of the entire form element.
Solution Approach 2:
The adjustable elements are pre-configured on the form element before winding the conductor. This preliminary arrangement allows for easy adjustment and optimization of the form element geometry prior to the final winding process, simplifying the overall manufacturing workflow.
3Stability of the object's composition
If adjustable elements are arranged uniformly on the lateral surface, then force distribution is even and winding stability is improved, but the device structure becomes more complex
Solution Approach 1:
The adjustable elements are distributed uniformly around the lateral surface of the form element, creating local adjustment capabilities at multiple positions. This uniform distribution ensures even force distribution and stabilizes the winding while maintaining rotational symmetry, balancing structural complexity with performance benefits.
Data Source
AI summary
A winding is provided, which comprises a form element having a longitudinal axis defining a longitudinal direction and a radial direction perpendicular to the longitudinal axis. The form element comprises a core with a lateral surface, and adjustable elements arranged on the lateral surface of the core. The adjustable elements are elongated and extend along the longitudinal direction. A thickness of the adjustable elements in a radial direction is altered along the longitudinal direction. A conductor is wound around the form element along the longitudinal direction forming turns of the winding.