Loudspeaker Voice Coil Loop Wiring for Faster Terminal Assembly
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Solution Overview
Problem
The assembly of loudspeakers is challenging due to the unpredictable positioning of flexible lead wires, which requires manual manipulation and additional components like nylon rods, increasing complexity and cost.
Innovation Solution
A method involving a loop of flexible wire attached to both ends of the voice coil former, which is easier to manipulate and connect to electrical terminals, reducing assembly time and cost by using a single length of wire and a manipulation tool to apply tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate free wire ends are used for lead wires, then the lead wires can be flexible and durable, but locating and positioning the wire ends becomes unpredictable and time-consuming
Solution Approach 1:
The lead wires are pre-formed into a loop configuration with predetermined geometry before assembly. This preliminary shaping allows the wire ends to be positioned predictably, eliminating the time-consuming manual locating and positioning step during assembly while maintaining the flexibility needed for durable operation.
Solution Approach 2:
The lead wires are configured as a closed loop structure rather than separate linear ends. This dimensional change from 1D linear wires to a 2D/3D loop configuration provides predictable spatial relationships between connection points, enabling automated or simplified assembly processes.
2Adaptability or versatility
If separate free wire ends are used, then the lead wires maintain flexibility, but the assembly process becomes complex and requires manual manipulation
Solution Approach 1:
The loop configuration is prepared in advance during wire manufacturing, transforming a complex assembly task into a simple connection operation. This preliminary action reduces the assembly process from multiple manual manipulation steps to a single attachment operation.
Solution Approach 2:
The loop structure acts as an intermediary form that simplifies the connection process. Instead of directly manipulating separate wire ends and their positions, the loop provides a standardized interface that can be attached as a single unit, reducing procedural complexity.
3Ease of operation
If a loop of wire is used instead of separate wire ends, then locating and positioning becomes easier, but additional manufacturing steps are required to form the loop
Solution Approach 1:
The wire is formed into a loop configuration, changing its geometric parameters from linear dimensions to a closed-loop shape with predetermined radius and orientation. This parameter change enables easier positioning during assembly while the looping process can be integrated into standard wire manufacturing operations.
4Reliability
If the loop of wire is attached at two locations, then reliable electrical connection is achieved, but the attachment process requires positioning at multiple points
Solution Approach 1:
The loop configuration is designed with predetermined attachment points that are optimally positioned for reliable electrical connection. This preliminary design ensures that when the loop is attached, the connection points are automatically in the correct positions, reducing the time required for multi-point attachment while maintaining connection reliability.
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
Facilitates efficient and reliable loudspeaker assembly by simplifying the connection of lead wires to terminals, reducing manufacturing time and complexity, and allowing for automated processes.
Implementation Method 1
a first end of a flexible wire is attached to the voice coil former and electrically connected to a first end of the voice coil, and a second end of the flexible wire is attached to the voice coil former and electrically connected to a second end of the voice coil
Implementation Method 2
the voice coil is energized (e.g. by having the electrical signal pass through it) to produce a magnetic field which interacts with the magnetic field produced by the magnet unit. This causes the voice coil (and therefore the diaphragm) to move relative to the magnet unit
Data Source
AI summary
A method of assembling a loudspeaker including providing a precursor loudspeaker. The precursor loudspeaker includes a chassis and a voice coil former. The chassis includes a first electrical terminal and a second electrical terminal. A voice coil is mounted on the voice coil former. A first end of a flexible wire is attached to the voice coil former and electrically connected to a first end of the voice coil, and a second end of the flexible wire is attached to the voice coil former and electrically connected to a second end of the voice coil such that the flexible wire forms the loop of wire which extends outwardly from the voice coil former. The method further includes attaching the loop of wire to the first electrical terminal at a first location on the loop of wire and attaching the loop of wire to the second electrical terminal at a second location on the loop of wire.