Ethernet Magnetics Wire Termination Automation
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Solution Overview
Problem
The manual process of attaching wires to common mode chokes in electronic surface mount packages is labor-intensive and prone to errors, particularly due to the close proximity of wires, which complicates reliable soldering and can lead to broken wires and electrical open circuits.
Innovation Solution
An apparatus comprising a common mode choke base with terminal contacts, a support member, and an adjustable tensioner that aligns and secures wires, using a non-contact energy source to weld the wires to the terminal contacts, minimizing copper wire diameter reduction and preventing wire breakage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual wire winding and soldering is used, then wire connections can be made, but labor intensity increases and connection reliability decreases
Solution Approach 1:
The patent replaces manual mechanical wire winding and soldering operations with an automated wire wrapping machine that performs wire formation, wrapping, and welding through mechanical automation. This substitution eliminates manual labor while ensuring consistent wire placement and connection quality, directly resolving the contradiction between manufacturing ease and connection reliability.
Solution Approach 2:
The wire wrapping machine performs multiple operations automatically including wire feeding, wrapping around terminals, insulation stripping, and welding without requiring manual intervention. The system serves itself by completing the entire wire connection process through automated mechanisms, reducing labor intensity while maintaining high connection reliability through precise mechanical control.
2Area of stationary object
If wires are placed close together to save space, then package density increases, but soldering difficulty and wire breakage risk increase
Solution Approach 1:
The automated wire wrapping machine uses precision mechanical guides and positioning systems to route wires between closely spaced terminals with accuracy that manual operations cannot achieve. The automated welding system applies controlled heat and pressure to create reliable connections even when wires are tightly packed, enabling space-efficient packaging without compromising connection reliability.
Solution Approach 2:
The patent employs controlled welding parameters including temperature, pressure, and duration to create strong wire-to-terminal bonds. The automated system adjusts these parameters to account for the reduced clearance between wires, ensuring reliable connections in compact configurations where manual soldering would be difficult or impossible.
3Ease of manufacture
If manual insulation stripping and soldering is performed, then wire connections can be made, but errors and broken wires increase
Solution Approach 1:
The wire wrapping machine incorporates automated insulation stripping mechanisms with precision-controlled cutting and stripping actions that eliminate the variability and errors associated with manual stripping. The automated wire feeding and positioning systems ensure precise wire placement and termination, achieving manufacturing precision that far exceeds manual capabilities while maintaining process simplicity through integration.
Solution Approach 2:
The integrated wire wrapping machine performs insulation stripping, wire forming, wrapping, and welding in a continuous automated sequence without requiring separate manual operations. This self-service approach eliminates errors that occur during manual transitions between operations and ensures consistent precision throughout the entire wire termination process.
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 solution reduces labor intensity and enhances the reliability of wire connections, preventing wire breakage and ensuring secure electrical contacts, thereby improving the manufacturing efficiency and quality of electronic surface mount packages.
Implementation Method 1
using a non-contact energy source to weld the wires to the terminal contacts
Implementation Method 2
non-contact energy source
Data Source
AI summary
In one implementation, an apparatus is configured to aid in the manufacturing or assembling of electronic surface mount packages. The apparatus includes a common mode choke base configured to support a common mode choke. The apparatus includes terminal contacts coupled to the common mode choke base. The terminal contacts are aligned with wires connected to the common mode choke. The apparatus includes a support member including a wire supporting portion aligned with the wires connected to the common mode choke and a central portion configured to support the common mode choke base.