Gradient Coil Winding with Segmented Carrier
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing magnetic field gradient coil manufacturing methods are limited by the minimum spacing between conductor turns due to the wall thickness of the mold or carrier, which restricts the close packing of windings and maximum current carrying capacity, especially in high-precision MR imaging systems.
Innovation Solution
The use of an electrically insulating carrier with pre-formed openings for precise alignment of conductor turns and a keying feature on the conductor or mold to achieve arbitrarily close spacing between windings, allowing for closer-packed windings and improved manufacturing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional mold or carrier wall thickness is used to manufacture gradient coils, then the manufacturing process is simple, but the spacing between conductor turns cannot be minimized, limiting current carrying capacity
Solution Approach 1:
The carrier is segmented with multiple openings along its surface, each opening serving as a precise定位 feature for conductor turns. This segmentation allows the conductor to be positioned in discrete, closely-spaced locations without requiring thick carrier walls, thereby minimizing spacing between turns while maintaining manufacturing feasibility.
Solution Approach 2:
The openings are pre-formed in the carrier before the conductor is installed. This preliminary action establishes precise positioning features in advance, allowing the conductor to be accurately placed at predetermined locations with minimal spacing, eliminating the need for thick walls that would otherwise be required to maintain structural integrity during assembly.
2Quantity of substance
If conductor turns are spaced closely together to maximize current carrying capacity, then the gradient coil performance improves, but the manufacturing complexity increases due to precision requirements
Solution Approach 1:
The openings in the carrier serve as intermediary positioning features between the manufacturing process and the final conductor arrangement. These openings act as physical guides that automatically ensure precise spacing and alignment of conductor turns, transforming a potentially complex precision assembly task into a straightforward installation process where the carrier itself provides the positioning function.
3Ease of manufacture
If thick carrier walls are used to maintain structural integrity during manufacturing, then the manufacturing process is robust, but the spacing between conductor turns is increased, reducing current carrying capacity
Solution Approach 1:
Rather than using thick continuous walls, the carrier employs a segmented structure with discrete openings. This segmentation allows the carrier to maintain sufficient structural integrity through the distributed pattern of openings while providing the precise positioning features needed for closely-spaced conductor turns, thereby maximizing current carrying capacity without sacrificing manufacturing robustness.
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 enables magnetic field gradient coils with closer-packed windings, higher current carrying capacity, and easier mold removal, enhancing the performance and manufacturing efficiency of magnetic field gradient coils.
Implementation Method 1
Magnetic field gradient coils generate spatially varying magnetic fields over the examination region of a magnetic resonance (MR) imaging system
Data Source
AI summary
A magnetic field z-gradient coil is manufactured by inserting elements (38) into openings (36) on an outside of an insulating carrier (32), wrapping an electrical conductor turn (34) around the outside of the insulating carrier with one side of the wrapped electrical conductor alongside elements inserted into openings on the outside of the insulating carrier, removing the elements alongside the one side of the wrapped electrical conductor from the openings, and repeating to wrap conductor turns of a z-gradient coil (20) around the electrically insulating carrier. A transverse magnetic field gradient coil is manufactured by laying electrical conductor (44) onto a mold (50) with a keying feature (46, 46a) extending along the conductor engaging a mating keying feature (52, 52a) of the mold that defines a winding pattern (56), attaching an insulating back plate (58) to the resulting coil section opposite from the mold, and removing the mold.