Magnetic Flux Detection for Laminated Capacitor Electrode Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for detecting the stacking direction of internal electrodes in laminated capacitors are inaccurate due to downsizing, which makes it difficult to align the electrodes correctly in series of taped electronic components, leading to manufacturing challenges.
Innovation Solution
An apparatus and method that utilize a magnetic generator and magnetic flux density detector to identify the stacking direction of internal electrodes in laminated capacitors, combined with a conveying mechanism and sorter to ensure alignment, and an imaging device for defect detection, ensuring accurate sorting and alignment of capacitors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If magnetic flux density measurement is used to detect stacking direction of internal electrodes, then detection can be performed, but detection accuracy deteriorates due to downsizing of internal electrodes
Solution Approach 1:
The patent applies preliminary action by fixing the positional relationship between the laminated capacitor and the magnetic generator/detector before measurement. The capacitor is positioned at a predetermined location on the conveyance table, and the magnetic generator and detector are arranged at fixed positions above and below the table. This preliminary positioning ensures that the measurement is performed under controlled conditions, eliminating positional misalignment as a source of error and enabling accurate detection even of the small magnetic forces generated by downsized internal electrodes.
2Ease of manufacture
If magnetic flux density measurement is used without fixed positioning, then measurement can be performed, but detection accuracy deteriorates due to positional misalignment
Solution Approach 1:
The patent implements preliminary action by pre-establishing the positional relationship between the measurement system and the capacitor. The conveyance table is designed with a specific structure that positions the capacitor at a predetermined location, and the magnetic generator and detector are mounted at fixed positions above and below the table. This preliminary setup ensures that when measurement is performed, the capacitor is automatically in the correct position, eliminating the need for complex real-time positioning adjustments while maintaining high measurement accuracy.
Solution Approach 2:
The patent introduces the conveyance table as an intermediary element between the capacitor and the measurement system. The table serves as a mediator that establishes and maintains the predetermined positional relationship. By using this intermediary structure, the system achieves both ease of manufacture (the table provides a simple mechanical solution) and high measurement precision (the table ensures consistent positioning), resolving the contradiction between these two requirements.
3Volume of moving object
If internal electrodes are downsized, then component size is reduced, but magnetic force difference becomes smaller and harder to detect
Solution Approach 1:
The patent applies preliminary action by establishing optimal measurement conditions before detection. The magnetic generator and detector are positioned at predetermined distances from the capacitor, and the measurement is performed when the capacitor is in a specific position on the conveyance table. This preliminary setup maximizes the detection sensitivity for the small magnetic forces generated by downsized internal electrodes, enabling accurate measurement despite the reduced force magnitude.
Solution Approach 2:
The patent replaces direct mechanical contact or complex mechanical positioning systems with a magnetic field-based measurement system. Instead of using mechanical means to detect or manipulate the internal electrodes, the system uses magnetic flux density measurement. This substitution allows for non-contact, high-precision detection of the stacking direction, which is particularly effective for downsized components where mechanical approaches would be too intrusive or imprecise.
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
The solution effectively aligns the stacking directions of internal electrodes with high certainty, improving the manufacturing process by enhancing detection accuracy and reducing positional misalignment issues, resulting in a series of taped electronic components with consistent electrode orientation.
Implementation Method 1
a magnetic generator (35a) that generates a magnetic force
Implementation Method 2
a magnetic flux density detector (35b) that detects magnetic flux density
Data Source
AI summary
A controller identifies a stacking direction of internal electrodes in an electronic component, based on magnetic flux density detected by a magnetic flux density detector when the electronic component passes between a magnetic generator and the magnetic flux density detector. The controller instructs a sorter to sort out, based on the identified stacking direction of the internal electrodes, the electronic component in which the stacking direction of the internal electrodes is consistent with a predetermined direction. A conveying mechanism includes a conveying table with a plurality of concave portions, and conveys electronic component fixed in position in the concave portions.