Segmented Soft Magnetic Core for Automated Common Mode Filter Assembly
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Solution Overview
Problem
Conventional power circuit common mode filters with one-piece soft ferrite cores are complex and inefficient, leading to low production efficiency and unstable product quality due to manual threading and susceptibility to internal short circuits.
Innovation Solution
A power circuit common mode filter with a combined structure of a U-shaped soft magnetic core and two cylindrical soft magnetic cores, where the cylindrical cores are movably installed in the U-shaped core with recessed grooves and covered with high-voltage-resist insulating material, allowing for automated coil winding and assembly, reducing the risk of damage and improving stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a one-piece soft ferrite core is used with manual threading, then the structure is simple, but production efficiency is extremely low and product quality is unstable
Solution Approach 1:
The one-piece soft ferrite core is divided into multiple segments: a U-shaped soft magnetic core and two cylindrical soft magnetic cores. This segmentation allows each part to be manufactured and assembled separately, enabling automated production while maintaining structural functionality. The U-shaped core provides the main magnetic path, and the cylindrical cores fit into recessed grooves to complete the magnetic circuit.
Solution Approach 2:
The insulating layers are pre-formed on the soft magnetic cores before coil winding. The recessed grooves are pre-created in the U-shaped core to receive the cylindrical cores. These preliminary actions enable subsequent automated assembly operations to proceed efficiently without manual intervention for positioning and insulation protection.
2Reliability
If manual threading is used, then the process is simple to implement, but the insulating layer is easily scratched causing internal short circuits
Solution Approach 1:
Insulating layers are applied beforehand to the soft magnetic cores before any threading or coil winding operations. These insulating layers (made of materials like epoxy resin or polyimide) provide protective cushioning that prevents scratching of the core surfaces during subsequent automated assembly operations, thereby preventing internal short circuits and improving product reliability.
Solution Approach 2:
Manual threading operations are replaced with automated coil winding machines. The mechanical substitution eliminates human hand operations that cause scratching, using controlled automated systems to perform the threading with precision and consistency, thereby improving both reliability and manufacturing efficiency.
3Productivity
If automated coil winding is enabled, then production efficiency increases, but the coil coating film may be damaged
Solution Approach 1:
The insulating layers are applied to the soft magnetic cores before automated coil winding. These layers serve as a protective cushioning layer that prevents the automated winding machine's tools from directly contacting and damaging the coil coating film, thereby maintaining coil integrity while enabling high-speed automated production.
4Extent of automation
If the cylindrical cores are assembled with coils before assembly with the U-shaped core, then automated assembly is enabled, but the positioning precision must be maintained
Solution Approach 1:
The cylindrical soft magnetic cores are pre-assembled with their respective coils before being installed into the U-shaped core. The recessed grooves in the U-shaped core are designed with precise dimensions to receive these pre-assembled units. This preliminary assembly approach, combined with precision-engineered recessed grooves, enables automated assembly while maintaining the required positioning precision for optimal magnetic coupling and electrical performance.
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 production efficiency, reduces costs, and improves product quality by enabling automated assembly and preventing coil damage, resulting in a more reliable and efficient manufacturing process.
Implementation Method 1
a coil is set on each of the two cylindrical soft magnetic cores in the U-shaped soft magnetic core
Implementation Method 2
the U-shaped soft magnetic core and the two cylindrical soft magnetic cores are both covered with a high-voltage-resist insulating material to form insulating layers
Data Source
AI summary
A power circuit common mode filter includes: a U-shaped soft magnetic core and two cylindrical soft magnetic cores, wherein recessed grooves are provided at tops of two side walls of the U-shaped soft magnetic core, and the two cylindrical soft magnetic cores are movably installed in the U-shaped soft magnetic core; two ends of each of the cylindrical soft magnetic cores are embedded in the corresponding recessed grooves, and a coil is set on each of the two cylindrical soft magnetic cores in the U-shaped soft magnetic core; the U-shaped soft magnetic core and the cylindrical soft magnetic cores are both covered with a high-voltage-resist insulating material to form insulating layers; surfaces of the insulating layers at the recessed grooves are provided with electrode layers, and ends of the coil is fixedly connected to the electrode layers through soldering tin.