Integrated Inductance Pressure Pad for Magnetic Core Assembly
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Solution Overview
Problem
The complex and expensive screw connection of multiple inductance pressure pieces required for assembling inductive components, such as chokes, complicates the manufacturing process and increases costs.
Innovation Solution
The use of inductance pressure pieces with multiple finger sections that can be nested and manufactured efficiently, allowing for simplified assembly by pushing them through coil formers and bracing at corner points, reducing the need for screwing in the middle section and enabling cost-effective production using stamped sheet metal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple individual pressure pieces are used for each leg of the magnetic core, then mechanical stability is achieved, but the screw connection becomes complex and expensive
Solution Approach 1:
Multiple individual pressure pieces are merged into a single integrated pressure piece with multiple arms. Each arm corresponds to a leg of the magnetic core, allowing all legs to be secured simultaneously with one piece instead of requiring multiple separate pieces and their associated screw connections.
Solution Approach 2:
The single pressure piece serves multiple functions by having multiple arms that can simultaneously engage with multiple legs of the magnetic core. This multi-functional design eliminates the need for separate pressure pieces for each leg, reducing assembly complexity while maintaining mechanical stability.
2Reliability
If multiple pressure pieces are screwed together at the yoke and main section areas, then the magnetic core is securely held, but manufacturing cost increases
Solution Approach 1:
Multiple pressure pieces are combined into one integrated component, reducing the total number of parts that need to be manufactured, stored, and assembled. This consolidation lowers manufacturing costs while maintaining the same holding reliability through the multi-arm design.
Solution Approach 2:
The single pressure piece is segmented into multiple arms, each independently positioned to engage with a specific leg of the magnetic core. This segmentation allows the piece to function as multiple individual pressure pieces would, but with the cost benefits of being a single manufactured component.
3Manufacturing precision
If six pressure pieces are used for a three-leg magnetic core, then complete coverage is achieved, but the assembly process becomes time-consuming
Solution Approach 1:
Six separate pressure pieces are merged into a single pressure piece with six arms (or appropriate number based on core configuration). This allows all arms to be positioned and secured simultaneously in one assembly operation, rather than requiring six separate operations, thereby dramatically improving assembly speed while maintaining complete coverage.
Solution Approach 2:
The pressure piece is pre-configured with all necessary arms in their correct positions and orientations before assembly. This preliminary preparation ensures that when the piece is installed, all legs of the magnetic core are immediately and correctly covered, eliminating the need for sequential adjustment and positioning during assembly.
Data Source
Figure 1~1b
Figure 2~2b
Figure 3
AI summary
The pad (1) has a flat body made of metal and/or non-metallic material such as punched sheet metal, and finger sections (4, 6) extending from an elongated main section (2) and transverse to the elongated main section in a direction. The main section and finger sections are rest in a flat or slightly curved plane, and are integrally formed as single-piece, where width of the finger sections is increased to the main section. A clearance is formed between the finger sections by the width of adjacent finger sections.