Air Core Coil Fitting Apparatus for Magnetic Circuit Cores
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Solution Overview
Problem
The manual fitting of air core coils onto cores results in variability and inefficiency due to operator skill dependence, leading to deformation and poor output quality, as gap dimensions are not consistently optimal for magnetic circuit designs.
Innovation Solution
An automated air core coil fitting apparatus with a holding member, coil fitting rod, rod driving member, pushing member, and sending member that allows for precise and automatic fitting of air core coils onto cores, utilizing a sending member with catch pieces to guide the coil along the core's edge and prevent sticking at the middle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual fitting operation is used, then operator flexibility is maintained, but fitting quality and consistency deteriorate due to operator skill dependence
Solution Approach 1:
The patent replaces the manual mechanical fitting operation with an automated mechanical system consisting of a rod driving member, pushing member, and sending member. This substitution eliminates operator skill dependence while maintaining precise control over the fitting process, thereby improving fitting quality consistency without sacrificing operational capability
Solution Approach 2:
The automated fitting apparatus performs the fitting operation autonomously through coordinated action of its components. The system self-regulates the fitting process without requiring continuous human intervention, ensuring consistent quality while maintaining operational efficiency
2Manufacturing precision
If gap dimensions are optimized for magnetic circuit design, then inductance values and magnetic saturation characteristics improve, but coil fitting difficulty increases due to narrow gaps
Solution Approach 1:
The patent introduces a rod driving member as an intermediary tool that bridges the gap between the coil and core. This intermediary mechanism enables precise control during the fitting process, allowing coils to be fitted into narrow gaps without deformation while maintaining the gap dimensions required for optimal magnetic circuit performance
Solution Approach 2:
The pushing member and sending member provide dynamic, controlled force application during the fitting process. This dynamic approach allows the system to adapt to the narrow gap constraints while successfully inserting the coil, resolving the contradiction between maintaining small gap dimensions and enabling easy fitting
3Manufacturing precision
If automated fitting apparatus is implemented, then fitting consistency and quality improve, but device complexity increases
Solution Approach 1:
The automated fitting apparatus is segmented into distinct functional components: a holding member for the core, a rod driving member for positioning, a pushing member for insertion, and a sending member for final placement. This segmentation allows each component to perform its specific function efficiently while keeping the overall system manageable and maintainable
Data Source
AI summary
In order to provide an air core coil fitting apparatus that can automatically fit an air core coil onto a core, an air core coil fitting apparatus includes a holding member, a coil fitting rod, a rod driving member, a pushing member, and a sending member. The holding member holds a core main body that is formed in a ring shape, has a gap extending through the core main body from an inner circumferential face to an outer circumferential face thereof, and allows an air core coil wound in advance to be fitted onto the core main body from one end thereof. On the coil fitting rod, the air core coil that is to be fitted onto the core main body held by the holding member is fitted. The rod driving member brings a front end of the coil fitting rod close to or into contact with the one end of the core main body held by the holding member. The pushing member pushes the air core coil fitted on the coil fitting rod, toward the one end of the core main body. The sending member is disposed at a circumferential edge of the core main body held by the holding member, and pulls the air core coil pushed by the pushing member and fitted onto the core main body, toward another end of the core main body.