Apparatus and method for assembling, testing, labeling, inspecting and packaging a low profile magnetic component

Abstract

An apparatus for manufacturing a low profile magnetic component, a method of manufacturing an apparatus for manufacturing low profile magnetic components, and a method of manufacturing a low profile magnetic component. In one embodiment, the apparatus includes a frame with a fixture adapted to hold a magnetic core. The apparatus includes a loading station coupled to the frame that is adapted to load the magnetic core onto the fixture. Also coupled to the frame is a wire feeding and cutting station configured to feed and cut a wire and form a conductive element having a particular configuration. The wire feeding and cutting station also positions the conductive element for mounting on the magnetic core. The embodiment includes a clamping station coupled to the frame for clamping and mounting the conductive element on the magnetic core.

What is claimed is:  
     
         1 . A apparatus for manufacturing a low profile magnetic component, comprising: 
 a frame;    a fixture couplable to said frame and adapted to hold a magnetic core;    a loading station coupled to said frame and adapted to load said magnetic core onto said fixture;    a wire feeding and cutting station coupled to said frame and adapted to feed and cut a wire to form a conductive element having a particular configuration and position said conductive element for mounting on said magnetic core; and    a clamping station coupled to said frame for clamping and thereby mounting said conductive element on said magnetic core.    
     
     
         2 . The apparatus as recited in  claim 1  further comprising a first video inspection station coupled to said frame to inspect said magnetic component for conformity with certain specifications.  
     
     
         3 . The apparatus as recited in  claim 1  further comprising an electrical test station coupled to said frame to test certain electrical characteristics of said magnetic component.  
     
     
         4 . The apparatus as recited in  claim 1  further comprising a labeling station coupled to said frame adapted to print and place a label on said magnetic component.  
     
     
         5 . The apparatus as recited in  claim 4  further comprising a second video inspection station coupled to said frame to inspect said label for conformity with certain specifications.  
     
     
         6 . The apparatus as recited in  claim 1  further comprising a packaging station coupled to said frame adapted to package said magnetic component.  
     
     
         7 . The apparatus as recited in  claim 6  wherein said loading station is configured to remove said magnetic core from a receiving package and said packaging station is adapted to package said magnetic component in a shipping package identical to said receiving package.  
     
     
         8 . The apparatus as recited in  claim 1  wherein said wire feeding and cutting station is adapted to form a plurality of said conductive element.  
     
     
         9 . The apparatus as recited in  claim 8  wherein said clamping station is adapted to clamp and thereby mount said plurality on said magnetic core.  
     
     
         10 . A method of manufacturing a low profile magnetic component manufacturing apparatus, comprising: 
 forming a frame;    coupling a fixture to said frame, said fixture adapted to hold a magnetic core;    coupling a loading station to said frame, said loading station adapted to load said magnetic core onto said fixture;    coupling a wire feeding and cutting station to said frame, said wire feeding and cutting station adapted to feed and cut a wire to form a conductive element having a particular configuration and position said conductive element for mounting on said magnetic core; and    coupling a clamping station to said frame, said clamping station adapted for clamping and thereby mounting said conductive element on said magnetic core.    
     
     
         11 . The method as recited in  claim 10  further comprising coupling a first video inspection station to said frame, said first video inspection station adapted to inspect said magnetic component for conformity with certain specifications.  
     
     
         12 . The method as recited in  claim 10  further comprising coupling an electrical test station to said frame, said electrical test station adapted to test certain electrical characteristics of said magnetic component.  
     
     
         13 . The method as recited in  claim 10  further comprising coupling a labeling station to said frame, said labeling station adapted to print and place a label on said magnetic component.  
     
     
         14 . The method as recited in  claim 13  further comprising coupling a second video inspection station to said frame, said second video inspection station adapted to inspect said label for conformity with certain specifications.  
     
     
         15 . The method as recited in  claim 10  further comprising coupling a packaging station to said frame, said packaging station adapted to package said magnetic component.  
     
     
         16 . The method as recited in  claim 15  wherein said packaging station is configured to remove said magnetic core from a receiving package and said packaging station is configured to package said magnetic component in a shipping package identical to said receiving package.  
     
     
         17 . The method as recited in  claim 10  wherein said wire feeding and cutting station is adapted to form a plurality of said conductive element.  
     
     
         18 . The method as recited in  claim 17  wherein said clamping station is adapted to clamp and thereby mount said plurality on said magnetic core.  
     
     
         19 . A method of manufacturing a magnetic component using a magnetic component manufacturing apparatus, comprising: 
 placing a magnetic core in a fixture with a loading station coupled to a frame of a magnetic component manufacturing apparatus;    feeding and cutting a wire to form a conductive element having a particular configuration and positioning said conductive element for mounting on said magnetic core with a wire feeding and cutting station coupled to said frame; and    clamping and mounting said conductive element on said magnetic core with a clamping station coupled to said frame.    
     
     
         20 . The method as recited in  claim 19  further comprising inspecting said magnetic component for conformity with certain specifications with a first video inspection station coupled to said frame.  
     
     
         21 . The method as recited in  claim 19  further comprising testing certain electrical characteristics of said magnetic component with an electrical test station coupled to said frame.  
     
     
         22 . The method as recited in  claim 19  further comprising printing and placing a label on said magnetic component with a labeling station coupled to said frame.  
     
     
         23 . The method as recited in  claim 22  further comprising inspecting said label for conformity with certain specifications with a second video inspection station coupled to said frame.  
     
     
         24 . The method as recited in  claim 19  further comprising packaging said magnetic component with a packaging station coupled to said frame.  
     
     
         25 . The method as recited in  claim 24  further comprising configuring said loading station to remove said magnetic core from a receiving package and configuring said packaging station to package said magnetic component in a shipping package identical to said receiving package.  
     
     
         26 . The method as recited in  claim 19  further comprising forming a plurality of said conductive element with said wire feeding and cutting station.  
     
     
         27 . The method as recited in  claim 26  further comprising clamping and mounting said plurality on said magnetic core with said clamping station.