Clamshell Inductor Winding Assembly for Precise Automated Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing inductors are time-consuming and prone to errors, leading to variations in inductance and increased manufacturing costs, particularly due to the need for precise winding of metal wires around preformed cores and manual alignment of leads during assembly.
Innovation Solution
The use of a clamshell casing with symmetric portions that form continuous inductive windings, eliminating the need for individual wire winding and enabling automated, high-volume production with precise alignment and joining of conductive segments to form inductor windings around an inductor core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional wire winding methods are used to form inductor windings, then the inductor can be manufactured with basic functionality, but the manufacturing time and labor cost increase significantly
Solution Approach 1:
The inductor winding structure is segmented into multiple discrete conductive segments that can be independently formed and then assembled. Each segment corresponds to a portion of the final winding, allowing parallel manufacturing and reducing overall cycle time compared to traditional sequential wire winding.
Solution Approach 2:
The conductive segments are pre-formed and pre-positioned in their final locations before the actual winding assembly process. This preliminary formation of segments allows for automated manufacturing and eliminates the time-consuming manual wire winding operation.
2Manufacturing precision
If manual wire winding is performed around preformed cores, then inductor windings can be created, but manufacturing precision and consistency of inductance values deteriorate
Solution Approach 1:
By dividing the winding into discrete segments that are precisely formed and positioned, the patent achieves better control over each segment's geometry and electrical properties. This segmentation allows for tighter tolerances and more consistent inductance values across production batches.
Solution Approach 2:
The patent replaces the mechanical wire winding process with an automated system that forms and positions conductive segments using controlled deposition or assembly mechanisms. This substitution eliminates manual variability and achieves higher precision in winding geometry and inductance consistency.
3Productivity
If conventional winding machines are used for high-volume production, then basic manufacturing capacity is achieved, but the complexity of lead alignment and assembly increases
Solution Approach 1:
The winding structure is divided into segments that are pre-formed with integrated lead structures. This segmentation allows leads to be automatically positioned and connected during assembly, reducing the complexity of manual lead alignment and enabling high-volume automated production.
Solution Approach 2:
The patent merges the winding formation and lead creation processes into a single integrated step when forming the conductive segments. This consolidation eliminates separate lead formation and alignment operations, reducing assembly complexity while maintaining high production capacity.
4Ease of manufacture
If hand-winding or conventional winding methods are employed, then inductor windings can be formed, but manufacturing costs increase due to labor and time requirements
Solution Approach 1:
Conductive segments are pre-formed using automated processes before final assembly. This preliminary action enables high-volume production with reduced labor costs, as the time-intensive wire winding operation is replaced with more efficient segment formation and assembly processes.
Data Source
AI summary
A structure for forming inductor windings includes a first portion and a second portion of a clamshell casing. The first portion includes a first set of electrically conductive segments, a first inner carrier, and a first outer carrier. The second portion includes a second set of electrically conductive segments, a second inner carrier, and a second outer carrier. An inductor core is mountable between the first inner carrier and the first outer carrier within the first portion. A control assembly aligns and joins the first portion to the second portion of the clamshell casing such that the first set of electrically conductive segments arranged in the first pattern that correspond to first half-turns of the inductor windings, are attached to the second set of electrically conductive segments arranged in the second pattern that correspond to second half-turns of the inductor windings, to form continuous turns around the inductor core.