Filter Structure Welding Fixture Automation
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Solution Overview
Problem
Conventional network boxes with manually wound coils suffer from incorrect winding positions, long manufacturing cycles, and low production efficiency due to the manual winding of conductive wires and pins.
Innovation Solution
A filter structure with a box containing coil components and wiring components, where conductive wires are welded and fixed to positive and negative wiring pins using a welding fixture that automates the process by embedding the wiring section into a wire latch slot and using a spot welding machine, eliminating the need for manual winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual winding of conductive wires and pins is used, then flexibility and adaptability are maintained, but manufacturing precision and productivity deteriorate due to wrong winding positions and low production efficiency
Solution Approach 1:
The patent replaces the manual mechanical winding operation with an automated welding fixture system that uses spot welding machines to automatically weld conductive wires to wiring pins. The fixture includes positioning structures (latch slots, protruding portions) that automatically guide and secure the conductive wires in correct positions, eliminating manual winding operations and ensuring precise positioning through mechanical constraints rather than human skill.
2Productivity
If manual winding of conductive wires and pins is used, then process simplicity is maintained, but productivity deteriorates due to long manufacturing cycle
Solution Approach 1:
The patent implements preliminary action by pre-configuring the welding fixture with positioning structures (latch slots, protruding portions) that automatically guide and secure conductive wires before welding. The wiring pins are pre-embedded in the box with connecting sections that extend outward, ready for immediate welding. This preliminary preparation eliminates time-consuming manual positioning during actual assembly, significantly reducing manufacturing cycle while maintaining process simplicity through standardized fixtures.
Solution Approach 2:
The patent introduces a welding fixture as an intermediary device between the manual operation and the final welded product. The fixture includes latch slots that receive and secure conductive wires, protruding portions that apply pressure to ensure contact, and positioning features that guide wiring pins. This intermediary tool automates the complex coordination required for precise wire positioning and welding, improving productivity without requiring workers to master complex manual winding skills.
3Manufacturing precision
If automated welding fixture is used, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The patent segments the welding fixture into distinct functional modules: latch slots for securing conductive wires, protruding portions for applying pressure, positioning features for guiding wiring pins, and welding areas for spot welding operations. Each component has a specific, simple function. This segmentation allows the complex welding process to be broken down into manageable, independently designed elements, making the overall fixture less complex than a monolithic design while maintaining high precision through coordinated module interactions.
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, shortens manufacturing time, improves production efficiency, and lowers costs by automating the assembly process and ensuring precise wiring connections.
Implementation Method 1
use a spot welding machine to sequentially weld the conductive wire and the positive wiring pin or the negative wiring pin
Implementation Method 2
the conductive wire is contacted with an end of the positive wiring pin or the negative wiring pin
Data Source
AI summary
Disclosed are a filter structure, a welding fixture, and a manufacturing method of the filter structure. The filter structure includes: a box having a cavity; coil components installed in the cavity; and wiring components, each having a positive wiring pin and a negative wiring pin fixed to the box. The conductive wire has conductive wires coupled to both ends of the coil component and welded with the positive and negative wiring pins respectively. After a wiring section of the pins is embedded into a side of a wire latch slot, the conductive wire of the coil is latched into the wire latch slot and welded with the pins by spot welding without the need of manually winding the conductive wire and the pins, so as to reduce labor, expedite assembling, improve production efficiency and save material cost of the conductive wire.