Automated Connected Coil Assembly Mounting for Magnetic Resolvers
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Solution Overview
Problem
Conventional magnetic resolvers with patterned film coils face issues with poor affixing and limited coil turns, leading to increased labor costs and variations in product quality due to manual assembly of connected coil assemblies around projections.
Innovation Solution
An apparatus and method that includes a grip unit, a connected coil assembly forming unit, and a coil mounting unit to automate the process of forming and mounting connected coil assemblies directly around projections, using a winding shaft and chuck mechanism to wind and mount single coils sequentially on projections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If film coils are used to reduce thickness, then the thickness is reduced, but the affixing quality deteriorates and the number of turns cannot be increased
Solution Approach 1:
The film coil is divided into multiple separate film coil pieces, each corresponding to a specific projection. This segmentation allows each piece to be precisely positioned and affixed to its designated projection, improving affixing quality while maintaining the thickness advantages of film coils.
Solution Approach 2:
The film coil pieces are pre-assembled on a temporary carrier in the correct positions before being transferred to the projections. This preliminary arrangement ensures proper positioning and affixing quality during the final mounting process, eliminating the need for manual adjustment.
2Reliability
If wire is wound onto projections to improve resolver property, then the number of turns can be increased, but manual labor is required which increases cost and variations
Solution Approach 1:
Multiple single coils are pre-assembled into a connected coil assembly on a temporary carrier before being transferred to the projections. This preliminary assembly enables automated or semi-automated mounting processes, reducing manual labor while maintaining the high turn count advantages of wound wire coils.
Solution Approach 2:
Multiple single coils are combined into a single connected coil assembly that can be mounted as one unit. This merging reduces the number of separate mounting operations required, improving manufacturing efficiency and reducing variations caused by manual assembly of individual coils.
3Reliability
If connected coil assembly is manually fitted around projections, then the resolver property can be improved, but labor cost increases and product variations occur
Solution Approach 1:
The connected coil assembly is pre-positioned on a temporary carrier with all coils in their correct relative positions before being transferred to the projections. This preliminary setup simplifies the final assembly process, enabling automated mounting while maintaining the improved resolver properties achieved through proper coil positioning.
Solution Approach 2:
A temporary carrier serves as an intermediary structure that holds the connected coil assembly in the correct configuration during manufacturing. This mediator enables precise positioning and transfer of the coil assembly to the projections, reducing assembly complexity and eliminating the need for complex manual fitting procedures.
Data Source
AI summary
An apparatus for manufacturing an electronic component includes a grip unit configured to grip an electronic member having a plurality of projections arranged thereon, a connected coil assembly forming unit configured to form a connected coil assembly in which a plurality of single coils are connected to one another, and a coil mounting unit configured to sequentially mount the plurality of single coils of the connected coil assembly on the plurality of projections.