Fan Structure Coil Assembly with Winding Columns
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Solution Overview
Problem
The assembly process of coils in fan structures with brushless motors is complex, leading to a high defect rate and increased assembly cost due to the labor-intensive and error-prone process of winding coils and welding them onto the circuit board.
Innovation Solution
The fan structure incorporates a circuit board with annularly arranged positioning holes and winding columns, where conductive wires are wound to form coils, with head ends fixed on fastening columns before being welded onto the circuit board, simplifying the assembly process and reducing the risk of loose connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conventional assembly way of winding coils first and then welding them on the circuit board is used, then the coils can be formed, but the assembly process becomes very complicated and easily causes welding failure
Solution Approach 1:
The patent applies preliminary action by pre-forming the coils on the winding columns before assembling the circuit board. The conductive wires are wound around the winding columns to form coils in advance, and the head ends are positioned in the positioning holes. This preliminary preparation simplifies the subsequent assembly process and reduces welding complexity, directly addressing the technical contradiction between reliability and device complexity.
2Ease of manufacture
If the conventional assembly way is used, then the coils can be assembled, but it spends a lot of labor and time costs resulting in high assembly cost
Solution Approach 1:
The patent implements preliminary action by pre-assembling the coils on the winding columns with the circuit board positioned beforehand. The positioning holes in the circuit board align with the winding columns, allowing the coils to be pre-formed and positioned before final assembly. This reduces labor and time costs during the actual assembly process, effectively lowering assembly cost while maintaining manufacturing quality.
Solution Approach 2:
The patent applies self-service through the self-aligning mechanism between the positioning holes in the circuit board and the winding columns. The structure automatically guides the coils into the correct positions during assembly, reducing the need for manual adjustment and intervention. This self-aligning feature simplifies the manufacturing process and reduces assembly time, directly addressing the ease of manufacture versus assembly time contradiction.
3Manufacturing precision
If the conventional assembly way is used, then the coils can be formed, but the process is labor-intensive and error-prone
Solution Approach 1:
The patent implements self-service through the self-aligning mechanism where the positioning holes in the circuit board automatically guide the winding columns into the correct positions. This self-guiding structure reduces manual intervention and minimizes assembly errors, improving manufacturing precision while maintaining ease of operation. The structure itself performs the alignment function, reducing reliance on operator skill and reducing errors.
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 approach reduces the defect rate and assembly cost by streamlining the coil assembly process, improving the speed and accuracy of wire-winding, and facilitating the welding of coil ends onto the circuit board, thereby enhancing the overall operability and efficiency of the fan structure.
Implementation Method 1
at least one conductive wire is wound on the plurality of winding columns to form a plurality of coils
Implementation Method 2
the fan with brushless motor uses the detection element to detect the variation of a magnetic field of the magnet
Implementation Method 3
the circuit board controls the plurality of coils to generate an alternate magnetic field, to sequentially repel the N magnetic pole and the S magnetic pole of the magnet, thereby driving rotation of the fan
Data Source
AI summary
The present disclosure illustrates a fan structure which includes an outer shell member, a rotating module and a circuit module. The outer shell member has a receiving groove, and an axis part and a fastening part. The fastening part includes winding columns. The rotating module includes the fan, an axis coupling part pivotally connected with the axis part, and a magnetic part disposed on a periphery of the axis coupling part. The circuit module includes a circuit board which has positioning holes formed on and annularly arranged the surface thereof. Position-limiting caps are respectively mounted and fixed on the winding column after the winding columns are inserted through the positioning holes. A conductive wire is wound on the winding columns to form coils, and has two ends welded on the circuit board. Therefore, defect rate and assembly cost of production of fan structure of the present disclosure can be decreased.