Transformer Movable Pin for Automated Assembly

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Solution Overview

Problem

The miniaturization of electronic products has led to reduced space between primary and secondary components in transformers, making manual welding of secondary windings necessary, which increases labor costs and reduces assembly efficiency and production yields due to the lack of automated production processes.

Innovation Solution

The introduction of a transformer design with a movable pin and latch system that allows for automated assembly, where the movable pin is positioned at different levels to facilitate the assembly of the iron core set and winding onto the bobbin, enabling the use of robot arms for assembly, thereby reducing labor costs and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the adapter is downsized to meet miniaturization trends, then the size of the adapter is reduced, but the space for welding the secondary winding is reduced, making automated production impossible and requiring manual welding

Engineering Contradiction:

Improvesize of adapterVSAvoidautomated production capability

Core Design Contradiction:

Volume of moving objectVSExtent of automation

Solution Approach 1:

The patent divides the transformer into modular components: a bobbin with side walls, a magnetic core set, primary and secondary windings, and connection pins. This segmentation allows each component to be independently manufactured and positioned, enabling automated assembly despite the compact overall size of the adapter.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent introduces connection pins as intermediary elements that extend from the bobbin to the circuit board, providing automated electrical connections. These pins serve as mediators between the transformer windings and the circuit board, replacing manual welding processes and enabling robotic assembly in the downsized adapter configuration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If manual welding is used for the secondary winding, then the adapter can be assembled, but labor costs increase and assembly efficiency decreases

Engineering Contradiction:

Improveassembly capabilityVSAvoidassembly efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical welding process with an automated mechanical insertion system. Connection pins are designed to be inserted through holes in the circuit board using automated equipment, substituting the manual welding operation and thereby increasing assembly efficiency while maintaining manufacturing capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If manual welding is used for the secondary winding, then the adapter can be assembled, but production yields decrease

Engineering Contradiction:

Improveassembly capabilityVSAvoidproduction yields

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The connection pins are designed with self-positioning features that include locating protrusions fitting into corresponding recesses on the circuit board. This self-service mechanism ensures accurate alignment and consistent positioning during automated insertion, improving assembly precision and production yields by eliminating the variability associated with manual welding operations.

Inventive Principle:

Principle #25Self-service

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 solution enables the transformer to be assembled in an automated process, reducing labor costs and enhancing assembly efficiency and production yields while maintaining sufficient insulation distance between primary and secondary components.

Implementation Method 1

The movable pin includes a first latch portion and a second latch portion, the movable pin is movably disposed in the through hole, the second latch portion is disposed above the first latch portion

Methodology Applied

Scientific EffectMechanical Fastener: Mechanical Fastener

Implementation Method 2

Generally, the phenomenon of electromagnetic induction of the magnetic core set creates a voltage at the secondary winding due to a voltage inputted from the primary winding

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS11488771B2Adapter and transformer thereof

Publication Date: 2022.11.01 CHICONY POWER TECH CO LTD

AI summary

An adapter is provided and having a circuit board, primary components and secondary components installed on the circuit board, a shielding plate disposed between the primary components and the secondary components, and a transformer installed on the circuit board. The transformer has a bobbin, an iron core set assembled with the bobbin, at least one movable pin, at least one first winding, and at least one second winding. The movable pin is able to be positioned at an upper position for allowing the iron core set to be assembled with the bobbin or for allowing the first winding and the second winding to be wound onto the winding portion, and the movable pin is able to be positioned at a lower position when the transformer is installed onto the circuit board. Thereby, the adapter can be assembled in an automated process with improved assembly efficiency and high production yields.