Compound Line Filter Gear Nesting for Axial Size Reduction
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Solution Overview
Problem
The existing compound line filters face challenges in downsizing due to the gear being positioned outward of the outer flange parts in the axial direction, which hinders size reduction.
Innovation Solution
A compound line filter design where the gear is positioned between the coils in the axial direction, and the secondary magnetic path part extends from the closed magnetic path part, allowing the gear to overlap with partition plates, thereby eliminating the need for additional axial space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the gear is provided outward of the outer flange parts in the axial direction, then the gear can be properly positioned for winding operations, but the axial size of the line filter increases
Solution Approach 1:
The gear is repositioned from the outer axial direction to the radial direction between the coils. This dimensional change allows the gear to overlap with partition plates in the radial view, eliminating the need for additional axial space while maintaining functionality for winding operations.
Solution Approach 2:
The gear is nested within the space between the coils, overlapping with the partition plates when viewed radially. This nesting arrangement allows the gear to share space with existing structural elements, reducing the overall axial dimension without compromising the winding operation capability.
2Length of moving object
If the gear is positioned between the coils in the axial direction, then the axial size is reduced, but the gear may interfere with coil winding operations
Solution Approach 1:
The gear positioning is changed from axial to radial arrangement, allowing it to be located between coils without interfering with the winding path. The overlapping configuration in radial view ensures the gear occupies space that does not conflict with coil placement during manufacturing.
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 configuration reduces the axial size of the line filter by eliminating the space required for the gear, while maintaining the necessary magnetic properties for both common and normal modes.
Implementation Method 1
The magnetic core includes a closed magnetic path part and a secondary magnetic path part
Implementation Method 2
Two of the windings are disposed between two of the outer flange parts and the middle flange part, respectively
Data Source
AI summary
A compound line filter includes a bobbin, two coils and a magnetic core. The coils are wound on the bobbin in a state of being separated from each other in an axial direction. The magnetic core includes a closed magnetic path part and a secondary magnetic path part. The bobbin is attached to the closed magnetic path part. The secondary magnetic path part extends from the closed magnetic path part in a direction intersecting with the axial direction and is positioned between the coils in the axial direction. The bobbin includes at least one gear, and the gear is positioned between the coils in the axial direction.