Compact Gas Lighting Transformer with Pre-mounted Windings
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Solution Overview
Problem
Existing electronic gas lighting devices for cooking ranges are large in size and difficult to assemble, particularly in terms of length, and lack cost-effectiveness in manufacturing and assembly.
Innovation Solution
The design includes a cup-shaped body with a carrying element and windings pre-mounted on a ferromagnetic core, embedded in insulating resin, with high-voltage outputs and terminal supports protruding from the resin for easy connection and assembly, allowing for automatic assembly and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional transformer structure is used, then technical performance is satisfactory, but device size is large and assembly is difficult
Solution Approach 1:
The transformer is divided into modular components: a pre-assembled transformer unit with primary and secondary windings, and a separate body housing. This segmentation allows the transformer to be manufactured and tested independently, then easily integrated into the gas lighting device body, reducing overall assembly complexity while maintaining technical performance.
Solution Approach 2:
The transformer is pre-mounted and pre-assembled as a complete unit before integration into the gas lighting device body. This preliminary action consolidates multiple assembly steps into a single operation, significantly reducing assembly difficulty and time while ensuring proper positioning of all transformer components.
2Reliability
If traditional transformer structure is used, then technical performance is satisfactory, but device length is large
Solution Approach 1:
The transformer unit is nested within the body housing, with the carrying element positioned inside the body's internal concavity. This nesting arrangement optimizes space utilization and reduces the overall length of the gas lighting device while maintaining the transformer's technical performance.
Solution Approach 2:
The transformer design transitions from a linear arrangement to a compact three-dimensional configuration within the body housing. The primary winding, secondary winding, and carrying element are arranged in multiple dimensions, allowing the transformer to fit within a smaller footprint and reducing device length.
3Ease of operation
If manual assembly is used, then assembly flexibility is high, but manufacturing cost is high and productivity is low
Solution Approach 1:
The device is segmented into a pre-assembled transformer unit and a body housing with integrated high-voltage outputs. This segmentation enables the transformer to be manufactured and tested separately using automated processes, then simply integrated into the body, combining automation efficiency with assembly flexibility.
Solution Approach 2:
The transformer is pre-assembled and pre-tested as a complete unit before final integration into the gas lighting device body. This preliminary action allows automated manufacturing processes to be used for the transformer, improving productivity while maintaining the flexibility to adapt to different body configurations.
4Manufacturing precision
If extensive assembly operations are required, then assembly precision can be controlled, but manufacturing cost increases
Solution Approach 1:
The transformer is designed as a separate, pre-assembled unit with integrated windings and carrying element. This segmentation reduces the number of assembly operations required for the overall device, as the transformer unit is installed as a complete component, thereby reducing manufacturing costs while maintaining assembly precision through dedicated transformer manufacturing processes.
Solution Approach 2:
The transformer is pre-assembled and pre-positioned with precise alignment features before integration into the body. This preliminary action ensures assembly precision is achieved during the simpler transformer manufacturing process rather than during final device assembly, reducing overall manufacturing costs while maintaining precision.
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
This design results in a compact, easily assembled gas lighting device with reduced length and lower manufacturing costs, enabling efficient assembly using pre-mounted parts and automatic machines without altering existing systems.
Implementation Method 1
a transformer accommodated in the body and in turn comprising a primary winding wound about and carried by a ferromagnetic material core
Data Source
AI summary
A gas lighting device including: a body formed by an electrically insulating material and carrying a plurality of high-voltage outputs for the connection to spark generating means; a transformer accommodated in the body and including a primary winding wound about and carried by a ferromagnetic material core, a carrying element formed by an electrically insulating material and designed to contain within a tubular drum thereof the primary winding, and a secondary winding consisting of a plurality of coils externally carried by the drum of the carrying element, electrically insulated from the primary winding and essentially coaxial with the latter; the core is bar-shaped and accommodated inside the carrying element and the drum directly supports also the high-voltage outputs, which are integrally obtained on the drum so as to form therewith the carrying element and laterally overhangingly protrude from the drum.