Adjustable Winding Form Element for Inductance Precision
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Solution Overview
Problem
Existing windings exhibit a broad spread and deviations from the intended design due to production tolerances, leading to high reject rates, especially when the precise extent, shape, or inductance of the winding is critical.
Innovation Solution
A winding design featuring a form element with adjustable elements on its lateral surface, where the thickness of these elements can be altered along the longitudinal direction to compensate for production tolerances and achieve the intended properties of the winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional windings are manufactured using standard form elements and conductors, then production is straightforward, but the windings exhibit broad spread and deviations from intended design due to production tolerances
Solution Approach 1:
The form element incorporates adjustable elements (such as adjustable rings or segments) that can be dynamically positioned along the longitudinal axis to modify the winding geometry. This dynamic adjustability allows compensation for production tolerances and enables precise control of winding inductance and extent without requiring completely custom-form fitted components for each variation.
Solution Approach 2:
The invention changes geometric parameters of the form element, specifically the position and configuration of adjustable elements along the longitudinal axis. By varying these parameters, the effective winding geometry can be tuned to achieve target inductance values and dimensional specifications, compensating for tolerances in the conductor and manufacturing process.
2Manufacturing precision
If production tolerances are tightened to reduce winding deviations, then winding precision improves, but manufacturing cost and complexity increase significantly
Solution Approach 1:
The adjustable elements are pre-configured on the form element at specific positions along the longitudinal axis before the winding process. This preliminary configuration allows the form element to compensate for anticipated production tolerances, enabling standard manufacturing processes to produce windings within specification without requiring post-manufacturing adjustment or rejection.
Solution Approach 2:
The form element with adjustable elements serves a dual function: it provides the mechanical support for winding while simultaneously acting as a tuning mechanism to achieve precise winding geometry. The adjustable elements self-adjust or are adjusted to compensate for tolerances in the conductor dimensions and winding process, eliminating the need for separate precision-control mechanisms.
3Manufacturing precision
If custom-form fitted windings are manufactured for each application, then winding precision is achieved, but production time and cost increase
Solution Approach 1:
The form element design with adjustable elements provides a universal solution that can accommodate multiple winding specifications and tolerance ranges. A single form element design can be used across different production batches and applications by adjusting the position of the adjustable elements, eliminating the need to manufacture custom form elements for each specific winding requirement while maintaining precision.
Data Source
Figure 1
Figure 2
Figure 3(a)~3(b)
AI summary
A winding (1) is provided, which comprises a form element (2) having a longitudinal axis (LA) defining a longitudinal direction (L) and a radial direction ® perpendicular to the longitudinal axis (L). The form element (2) comprises a core (3) with a lateral surface, and adjustable elements (4) arranged on the lateral surface of the core (3). The adjustable elements (4) are elongated and extend along the longitudinal direction (L). A thickness of the adjustable elements (4) in a radial direction (R) is altered along the longitudinal direction (L). A conductor (5) is wound around the form element (2) along the longitudinal direction (L) forming turns (6) of the winding (1).