Universal Magnetic Base for Vertical and Horizontal Assembly
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Solution Overview
Problem
Conventional magnetic assemblies require separate bases for vertical and horizontal types, leading to centralized production, increased space usage, and higher production costs, limiting product standardization and automatic production efficiency.
Innovation Solution
A magnetic assembly and base design featuring a pin base with different types of pins for vertical and horizontal applications, allowing for decentralized production and reduced volume through a frame and pin base configuration with accommodation spaces, enabling easier soldering and assembly with various design requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate bases are used for vertical and horizontal magnetic assemblies, then each base can be optimized for its specific type, but the production scale cannot be decentralized and production costs increase
Solution Approach 1:
The base is designed with a universal structure that can accommodate both vertical and horizontal magnetic assemblies. The pin base includes multiple through holes arranged in different patterns, allowing the same base to support different assembly orientations and types, thereby achieving multi-functionality and eliminating the need for separate base designs.
2Ease of manufacture
If conventional bases are designed to meet winding and solder requirements, then the soldering and assembly can be performed, but the base volume becomes large and occupies much space
Solution Approach 1:
The base design utilizes vertical space by extending pins through the base thickness, allowing windings to be soldered from both top and bottom surfaces. This dimensional approach enables compact base volume while maintaining adequate soldering access and mechanical strength, eliminating the need for large lateral extensions.
3Manufacturing precision
If different base designs are used for vertical and horizontal magnetic assemblies, then each assembly type can be optimized, but automatic production becomes difficult and production efficiency decreases
Solution Approach 1:
The universal base design with standardized through hole patterns and pin configurations enables the same base to accommodate both vertical and horizontal magnetic assemblies. This standardization facilitates automatic production by eliminating the need for different base handling procedures, while maintaining precise assembly capabilities through consistent dimensional tolerances and feature locations.
Data Source
AI summary
A magnetic assembly includes a magnetic core, two windings, and a base. The windings are arranged around the magnetic core, and each of the windings has two leading sections. The base carries the magnetic core, and comprises a frame part, a pin base, and two first pins and two second pins disposed on the pin base. The pin base is connected with the frame part, and has four through holes. Two first pins are disposed in two of the through holes, and two second pins are disposed in the other two of the through holes. Each of the first pins and the second pins has two extending parts extended from the first surface and the second surface respectively, and the leading sections of the windings are connected with the first pins and the second pins respectively. Therefore, the advantages of decreasing the production costs and product standardization are achieved.