Bobbin With Staggered Notches For Terminal Routing
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Solution Overview
Problem
Automatic winding machines face issues with overlapping or detaching outlet terminals of winding coils, leading to potential short-circuits and hindering the assembly of magnetic core assemblies, which are labor-intensive and costly to resolve.
Innovation Solution
A bobbin design with staggered notches and pins on the second lateral plate, allowing for non-overlapping and secure fixation of outlet terminals, enabling complete automation of the winding process and preventing terminal detachment during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the winding task is performed by an automatic winding machine along a linear direction, then the labor cost is saved and the production performance is enhanced, but the outlet terminals of the winding coil may overlap with each other causing short-circuited problems
Solution Approach 1:
The patent introduces a U-shaped channel structure that guides the outlet terminals along a curved path instead of a linear direction. The channel includes a first section extending in a first direction and a second section extending in a second direction perpendicular to the first direction, creating a two-dimensional routing path that prevents terminal overlap while maintaining automated winding capability
Solution Approach 2:
The U-shaped channel acts as an intermediary structure between the automatic winding machine and the outlet terminals. It provides a predetermined routing path that mediates the linear motion of the winding machine and the spatial arrangement of terminals, ensuring they do not overlap while maintaining automation
2Reliability
If tubes or tapes are used to cover the outlet terminals to prevent short-circuits, then the terminals are effectively isolated from each other, but the steps become labor-intensive and time-consuming and increase the material cost
Solution Approach 1:
The U-shaped channel structure provides built-in terminal management functionality. The channel's geometry automatically guides and separates the outlet terminals along its curved path, eliminating the need for external tubes or tapes. The structure serves its own terminal routing function, reducing labor and material requirements
Solution Approach 2:
The patent merges the terminal routing function with the structural support function by integrating the U-shaped channel into the bobbin body. This combines multiple functions (structural support, terminal guidance, short-circuit prevention) into a single integrated component, eliminating the need for separate covering materials
3Extent of automation
If the outlet terminal is detached from the wire-managing notch after the winding task, then the winding task can be completed automatically, but the assembly of the magnetic core assembly with the bobbin is hindered
Solution Approach 1:
The U-shaped channel is pre-formed as an integral part of the bobbin structure before the winding process. This preliminary structural preparation provides a predetermined routing path that guides the terminals during automated winding, ensuring they remain properly positioned and do not detach, thereby facilitating subsequent assembly operations
Data Source
AI summary
A bobbin includes a first lateral plate, a second lateral plate, a winding section, a channel, a plurality of first pins and a plurality of second pins. A plurality of first protrusion structures are protruded externally from an edge of the second lateral plate. Each of the first protrusion structures includes an inner wall and a first notch. The inner walls of two adjacent first protrusion structures face each other and are separated from each other by a specified distance. The first notches of the first protrusion structures are respectively formed in the corresponding inner walls and staggered relative to each other. The first pins are disposed on the first protrusion structures, respectively. The second pins are disposed on the first protrusion structures, respectively. The first pins and the second pins are perpendicular to bottom surfaces of respective first protrusion structures.