Wire Gap Spacers for Precise Electro-Magnetic Core Assembly
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Solution Overview
Problem
Existing electro-magnetic assemblies with gap spacers made of non-magnetic, electrically nonconductive materials face challenges such as tedious manual labor, tight tolerance issues, and increased errors due to limited thickness options and susceptibility to folding or creasing.
Innovation Solution
The use of wires as gap spacers in electro-magnetic assemblies, which allows for precise adjustment of gap thickness by selecting wires of different gauges, eliminates the need for manual placement and reduces errors, enabling automation of the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-magnetic, electrically nonconductive materials are used as gap spacers, then the gap can be formed in the electro-magnetic assembly, but the materials are susceptible to folding or creasing and require tedious manual placement
Solution Approach 1:
The patent changes the material parameter from traditional nonconductive materials (paper, Nomex) to wire materials with different physical properties. Wires are inherently resistant to folding and creasing compared to sheet materials, eliminating the reliability issue while enabling automated placement through standard wire handling mechanisms.
Solution Approach 2:
The patent replaces the manual mechanical placement process with an automated wire placement system. Wires can be automatically positioned and secured using clamps or adhesives, eliminating the tedious manual labor previously required for placing gap spacers.
2Manufacturing precision
If non-magnetic, electrically nonconductive materials are used as gap spacers, then the gap can be formed, but tight tolerance issues and increased errors occur due to limited thickness options
Solution Approach 1:
The patent changes the gap spacer from sheet material with fixed thickness to wire material where thickness is determined by wire gauge. This provides continuous adjustability of the gap thickness parameter, allowing precise control and multiple thickness options by simply selecting different wire gauges, thereby improving both manufacturing precision and adaptability.
3Manufacturing precision
If wires are used as gap spacers, then precise adjustment of gap thickness is enabled by selecting wires of different gauges, but eddy current losses may occur in AC signals
Solution Approach 1:
The patent introduces an intermediary non-conductive coating on the wire surface. This coating acts as a barrier that prevents eddy current formation while allowing the wire to maintain its function as a gap spacer. The coating mediates between the need for precise gap control using wires and the need to minimize energy losses in AC applications.
Data Source
AI summary
An electro-magnetic assembly is provided. The electro-magnetic assembly includes a core including a core base and a core top, the core defining a depression sized to receive a winding. The electro-magnetic assembly further includes a gap spacer including one or more wires positioned between the core base and a core top.