Ignition Transformer Ramp Projections for Automatic Assembly
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Solution Overview
Problem
Existing ignition transformers for high-pressure gas discharge lamps in motor vehicles are difficult and expensive to manufacture automatically due to complex designs and require manual connection processes, which hinder efficient installation and assembly.
Innovation Solution
The ignition transformer features ramp-like elevations on its housing for guiding and connecting the primary winding ends directly to electrical components, allowing for fully automatic assembly through methods like laser welding, along with an oval cross-section for compactness and precise alignment, facilitating automated production and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If complex designs are used for ignition transformers, then functional performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The housing is divided into a first housing part and a second housing part that can be separated from each other. The core is positioned in the first housing part during assembly, while the secondary winding is positioned in the second housing part. This segmentation simplifies the assembly process and reduces manufacturing complexity while maintaining functional performance.
Solution Approach 2:
The core is pre-positioned in the first housing part before the secondary winding is assembled. This preliminary positioning ensures proper alignment and simplifies subsequent assembly steps, reducing overall manufacturing complexity while ensuring reliable functional performance.
2Manufacturing precision
If manual connection processes are used, then connection precision is improved, but productivity decreases
Solution Approach 1:
The housing is segmented into two parts that can be separately assembled and then joined together. This allows automated assembly processes to position components in each housing part independently with high precision, then join the parts automatically, thereby maintaining connection precision while significantly improving productivity through automation.
Solution Approach 2:
The manual mechanical connection process is replaced by a segmented housing design that enables automated positioning and joining. The separate housing parts can be precisely positioned using automated equipment and joined through automated processes, replacing manual operations while maintaining precision and improving productivity.
3Volume of moving object
If compact design is implemented, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The housing is divided into two compact housing parts that can be closely fitted together. The core is positioned in the first housing part and the secondary winding in the second housing part, allowing for a compact overall design while simplifying the manufacturing process through modular assembly. The segmented design enables automated handling and assembly, reducing manufacturing complexity despite the compact form factor.
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 design simplifies the installation and manufacturing of ignition transformers by enabling automatic connection and precise alignment, reducing production costs and enhancing the reliability of the ignition device.
Implementation Method 1
an ignition transformer (1) for a high-pressure gas discharge lamp comprising a housing (2) made of an electrically non-conductive material... a core (3) made of ferrite and a secondary winding (4)... A primary winding (12) is guided like a thread over the elevations (8) and the housing (2)
Data Source
Figure 1~2
Figure 3~4
AI summary
The ignition transformer (1) has a housing (2) with two partially open opposite sides, and a core (3) made of soft magnetic material, which is supported in the housing. A screw-like primary winding (12) made of strip-shaped metal is guided helically around the housing, and a secondary winding (4) is guided around the core. Two longitudinally spaced ramp-like projections (8) are formed on the outer side of the housing, over which an end area of the primary winding is guided. The projections have flat surfaces (9).