Modular Coil Assembly for Consistent Electromagnetic Localizers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The formation of electromagnetic field localizers for tracking devices in navigation systems, such as those used in surgical navigation, involves complex manufacturing processes due to inconsistencies and variances in coil placements, number of windings, coil sizes, and spacing, necessitating lengthy calibration procedures.
Innovation Solution
The use of modular coil assemblies formed from individually manufactured coil groups, each comprising three orthogonally positioned coils, which are assembled to minimize manufacturing steps and reduce the need for calibration by ensuring consistent field generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coil assembly methods are used with manual placement and formatting, then flexibility in coil design is maintained, but manufacturing precision and consistency deteriorate due to variances in coil placements, windings, sizes, and spacing
Solution Approach 1:
The coil array is divided into multiple modular coil assemblies, each containing a specific number of coils (e.g., three coils per assembly). These modular units can be manufactured independently with consistent precision using automated formatting equipment, then assembled into the complete array. This segmentation allows each module to be formatted with high precision while simplifying the overall manufacturing process.
Solution Approach 2:
A formatting tool or fixture acts as an intermediary device that precisely positions and formats coils during assembly. This intermediary equipment ensures consistent coil placement, spacing, and winding characteristics without requiring complex manual adjustment procedures, thereby improving manufacturing precision while keeping the assembly process manageable.
2Adaptability or versatility
If multiple forming and processing steps are used to create the localizer array, then coil configuration flexibility is improved, but productivity deteriorates due to lengthy calibration procedures and complex manufacturing
Solution Approach 1:
Coil assemblies are pre-formatted with predetermined configurations using automated formatting equipment before final assembly into the localizer array. This preliminary action ensures that each coil assembly is already precisely configured with the correct number of windings, spacing, and orientation, eliminating the need for time-consuming calibration procedures during final assembly and significantly improving productivity.
Solution Approach 2:
The invention allows for standardized parameters (such as coil spacing, winding count, and assembly geometry) to be defined and maintained across all coil assemblies. By establishing these standardized parameters, the system achieves both configuration flexibility (through modular design) and high productivity (through automated manufacturing and assembly processes that work with these standard parameters).
3Measurement precision
If calibration procedures are extended to account for manufacturing variances, then measurement precision is improved, but loss of time increases due to lengthy calibration requirements
Solution Approach 1:
The manufacturing process incorporates built-in precision features and tolerance compensation mechanisms that cushion against potential variances before they affect measurement accuracy. By designing the coil assemblies with precise mechanical features and consistent formatting, the system pre-compensates for manufacturing variations, ensuring measurement precision without requiring extensive post-manufacturing calibration procedures.
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 approach enhances electromagnetic navigation by reducing calibration time and ensuring consistent field generation, thereby improving the precision and efficiency of tracking devices in navigation systems.
Implementation Method 1
The localizer device may be formed to include a coil of wire to generate the electromagnetic field once a current is driven through the coil of wire
Data Source
AI summary
In various specific embodiments, a localizer can include a plurality of coil groups, where each coil group includes three coils that are formed around a single center. Each of the three coils can be formed around separate jigs and the jigs can be interconnected to form the coil group. The jigs need not be annular, but may be formed in any appropriate configuration of shape or geometry for forming the final coil group.