Reactor Assembly Positioning via Segmented Bobbin Engagement
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Solution Overview
Problem
Conventional reactors used in vehicle-mounted DC-DC converters face difficulties in assembly due to the precise positioning requirements of bulging portions and grooves, which reduces productivity as the difference in width between these features becomes smaller, making it harder to accurately position the assembly within the case.
Innovation Solution
A reactor design with two positioning positions and two escaping positions on the frame-shaped bobbins or case, utilizing projecting pieces and engaging grooves to facilitate easier assembly, allowing the assembly to be positioned at two predetermined positions rather than four, thereby simplifying the assembly process and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If four positioning positions (bulging portions and grooves) are used to fix the assembly in the case, then the assembly is securely positioned, but the assembly operation becomes more difficult and productivity decreases
Solution Approach 1:
The positioning function is segmented into two types: positioning positions (with engaging grooves) and escaping positions (without engaging grooves). This segmentation allows the assembly to be easily inserted through escaping positions while being securely positioned at positioning positions, resolving the contradiction between secure positioning and assembly ease.
Solution Approach 2:
Instead of requiring engagement at all four positions, the design uses partial engagement at only two positioning positions. The other two positions serve as escaping positions that allow easy insertion. This partial action approach maintains positioning accuracy while significantly improving assembly ease.
2Manufacturing precision
If the difference in width between bulging portions and grooves is made smaller for tighter engagement, then positioning precision is improved, but assembly difficulty increases
Solution Approach 1:
The four positions are segmented into positioning positions and escaping positions. At positioning positions, tight engagement with small width difference ensures high positioning precision. At escaping positions, larger width difference allows easy insertion. This segmentation resolves the contradiction between positioning precision and assembly speed.
Solution Approach 2:
Different local qualities are applied at different positions: tight engagement structure at positioning positions for precision, and loose engagement structure at escaping positions for speed. This local differentiation allows both high precision and high productivity to coexist in the overall assembly system.
Data Source
AI summary
A reactor in which an assembly is easily assembled into a case and which is excellent in productivity is provided. In this reactor, two positions out of a total of four positions near opposite widthwise end parts of frame-shaped bobbins when an assembly accommodated in a case is viewed from above serve as positioning positions and the remaining two positions serve as escaping positions. At the positioning positions, projecting pieces provided on the frame-shaped bobbin are engaged with engaging grooves provided on the case. On the other hand, at the escaping positions, projecting pieces provided on the frame-shaped bobbin are allowed to escape in escaping portions (escaping grooves) provided on the case.