UI Core Transformer Module for Automated Winding and Soldering
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Solution Overview
Problem
Existing transformer modules are costly and prone to errors due to the need for hand winding and soldering, which introduces weaknesses and stress in the core windings, especially during long-term temperature cycling.
Innovation Solution
A transformer module design featuring a machine-wound bobbin and automated assembly process, including a U-shaped core with integrated bobbins and a surface-mounted header, allowing for pick-and-place assembly and in-line soldering, which enhances winding accuracy and reduces tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If hand winding and hand soldering are used, then flexibility and adaptability are improved, but manufacturing precision and reliability deteriorate due to errors and stress in core windings
Solution Approach 1:
The patent replaces hand winding with automated winding machines and hand soldering with automated soldering equipment. The winding machine winds conductive material around the core in a controlled, repeatable manner, eliminating human error and stress introduced by manual handling. The automated soldering system precisely attaches windings to PCB pads without the mechanical stress of hand soldering, thereby improving manufacturing precision while maintaining production flexibility.
2Adaptability or versatility
If hand processing is used, then adaptability is improved, but reliability deteriorates due to weaknesses and stress in core windings during temperature cycling
Solution Approach 1:
The patent replaces hand processing with automated systems that apply consistent, controlled forces during winding and soldering. This eliminates the variable mechanical stress introduced by manual handling, resulting in more reliable windings that better withstand long-term temperature cycling without developing weaknesses or failures.
Solution Approach 2:
The patent changes the process parameters from manual, variable human operation to controlled, repeatable automated parameters. The winding tension, speed, and soldering temperature are precisely controlled by equipment, ensuring consistent quality and reliability across all produced units, thereby improving overall product reliability.
3Reliability
If encapsulation and hand processing are used, then safety creepage distance is maintained, but productivity and cost-effectiveness deteriorate due to costly manual operations
Solution Approach 1:
The patent replaces costly hand processing with automated winding and soldering equipment, significantly improving productivity. The automated systems can operate continuously at high speed, reducing production time and cost while maintaining the required safety creepage distances through precise, repeatable positioning and spacing of windings relative to the core and PCB.
4Adaptability or versatility
If hand soldering is used, then adaptability is improved, but manufacturing precision and durability deteriorate due to breakage of solder joints during temperature cycling
Solution Approach 1:
The patent replaces hand soldering with automated soldering equipment that provides precise, controlled heat application and solder deposition. This eliminates the mechanical stress and imprecision of manual soldering, creating stronger, more reliable solder joints that better withstand temperature cycling without breaking, while maintaining the adaptability to attach windings to PCB pads.
Data Source
AI summary
A transformer assembly includes a substrate, a surface-mounted header on the substrate, a core on the surface-mounted header and including a U-shaped portion and I-shaped portion, and first and second bobbins on two legs of the U-shaped portion of the core.