Brake Coil Assembly Structure for 3-Axis Tolerance Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing coil assemblies for vehicle braking systems face challenges in reducing manufacturing costs and achieving a 3-axis degree of freedom without using deep drawing methods, which increases material and process costs and can lead to height tolerance deviations and noise in ECU performance.
Innovation Solution
A coil assembly design featuring a hollow bobbin with engagement protrusions, lead pins, pin assembly units, and a hollow case with engagement holes and step differences, allowing for assembly without deep drawing, and incorporating a valve assembly to control oil flow paths, enabling 3-axis freedom through injection-molded components and elastic deformations for heat dissipation and interference prevention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deep drawing methods are used to manufacture the coil assembly, then the structural strength and shape precision are improved, but the manufacturing cost increases and height tolerance deviations occur
Solution Approach 1:
The patent replaces expensive deep drawing processes with injection molding, which is a more cost-effective manufacturing method. The bobbin and case are manufactured using injection molding technology, eliminating the need for costly deep drawing operations while maintaining adequate structural integrity for the application.
Solution Approach 2:
The patent changes the manufacturing parameters and methods from deep drawing to injection molding. This parameter change allows for better control of height tolerances through mold design while significantly reducing manufacturing costs. The injection molding process enables precise dimensional control without the high costs associated with deep drawing.
2Strength
If deep drawing methods are used to manufacture the coil assembly, then the structural integrity is improved, but noise in ECU performance increases
Solution Approach 1:
The patent eliminates the deep drawing process in favor of injection molding, which produces less noise and vibration. The injection-molded components generate fewer harmful factors such as noise that could interfere with ECU performance, while still providing sufficient structural integrity for the coil assembly application.
3Manufacturing precision
If engagement protrusions and holes are designed for assembly, then the assembly precision is improved, but the device complexity increases
Solution Approach 1:
The patent combines the engagement features directly into the injection-molded bobbin and case structures. The engagement protrusions and holes are integrated into the basic component geometry during the molding process, rather than being added as separate features. This merging approach maintains assembly precision while minimizing additional structural complexity.
Solution Approach 2:
The engagement protrusions and holes serve multiple functions: they provide precise positioning during assembly, structural connection between components, and alignment features. By designing these features to fulfill multiple roles, the patent achieves high assembly precision without proportionally increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces manufacturing costs and ensures a 3-axis degree of freedom for the coil assembly, minimizing height tolerance deviations and noise, while maintaining effective heat dissipation and preventing interference during assembly.
Implementation Method 1
a coil assembly for vehicle braking including a hollow type bobbin configured to allow a coil to be wound along an outer circumferential surface thereof
Implementation Method 2
an elastic portion extending in a diagonal direction with respect to the first direction from the fixing portion
Data Source
AI summary
A coil assembly for vehicle braking includes a hollow bobbin configured to allow a coil to be wound along an outer circumferential surface thereof, and having at least one engagement protrusion formed on an upper surface and/or a lower surface, a plurality of lead pins coupled with the bobbin to supply current to the coil, a plurality of pin assembly units formed on two side ends of the bobbin to fix the lead pins and connect the lead pins to the coil and a hollow case configured to surround at least a portion of the bobbin, and formed to be bent in the upper and lower portions in a first direction to be attached to the upper and lower surfaces of the bobbin.