Induction Component Manufacturing via Isostatic Pressing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing induction components often result in low-quality components and are complex, lacking in efficiency and ease of production.
Innovation Solution
The method involves winding individual coils of any desired shape and cross-section, embedding them in a ferromagnetic substrate block with predefined orientation, followed by isostatic pressing to achieve homogeneity and spatial fixation, and then dividing the block into induction components with exposed winding ends for easy connection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If coils are embedded in a ferromagnetic substrate block with predefined orientation and subjected to isostatic pressing, then manufacturing precision and homogeneity are improved, but device complexity increases
Solution Approach 1:
The marking is applied to the plate before the pressing operation, so that the orientation information is pre-established. During isostatic pressing, the marking is automatically transferred to the block, ensuring precise coil orientation without requiring complex post-processing or alignment procedures.
Solution Approach 2:
The marking on the plate serves as a template or copy that is transferred to the block during pressing. This copying mechanism ensures that the orientation information is accurately replicated from the plate to the block, maintaining manufacturing precision while using a simple transfer process rather than complex measurement and adjustment systems.
2Stability of the object's composition
If isostatic pressing is used to compact the substrate, then homogeneity and crack-free structure are improved, but manufacturing time and energy consumption increase
Solution Approach 1:
Isostatic pressing uses hydraulic or pneumatic pressure transmission through a fluid medium to apply uniform pressure from all directions simultaneously. This allows the substrate to be compacted homogeneously and free of cracks in a single operation, achieving high structural stability without requiring multiple sequential pressing steps or prolonged processing times.
3Productivity
If the block is divided into induction components after pressing, then productivity is improved, but manufacturing precision may be compromised
Solution Approach 1:
The block is divided into multiple induction components after the pressing operation has established uniform density and structural integrity. The segmentation is performed along predetermined lines that do not compromise the internal homogeneity achieved during pressing, allowing high-volume production while maintaining the positioning accuracy established during the pressing process.
Solution Approach 2:
The markings are applied before pressing, and the block is pressed while intact to ensure homogeneous structure. The division into components occurs after pressing, when the structural integrity is already established. This preliminary establishment of orientation and structure before segmentation ensures that productivity gains from batch processing do not compromise positioning accuracy.
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 method produces high-quality, easy-to-assemble induction components with precise orientation and positioning, ensuring reliable electrical contact and improved manufacturing efficiency.
Implementation Method 1
A pre-pressing operation then takes place in order to produce a certain level of homogeneity within the block and to fix the coils spatially within the block. The pre-pressing operation can take place isostatically, in order to compact the substrate of the block in as homogenous and crack-free a manner as possible.
Data Source
AI summary
The invention proposes a method of producing induction components. A plurality of coils are embedded, with predetermined orientation of the coil ends, in a block made of in particular pulverulent substrate. The block is positioned on a plate having a marking for each coil. The combination made up of block and plate is pressed. The winding ends are exposed by milling and provided with contacts. The block is then sawn up mechanically into individual elements each containing a coil.