Coils Manufacture TRIZ Cases

Separate magnetic-core and coil substrates are stacked to tune inductance while keeping composite micro-inductors compact and precise.

A dancer-roller tensioning setup keeps 50-200 μm wire stable during fast coil winding, reducing breakage, stoppages, and operator intervention.

Pre-corrected wire length keeps coil start and end terminals round and correctly positioned despite winding target variation.

A ribbed cover plate and coil housing hold Thomson coil turns during epoxy injection or potting to keep insulation uniform and windings level.

Parallel winding stations keep coil production running when thin wire breaks, reducing standstills while maintaining output.

Redundant winding stations share coil production at lower speed to cut thin-wire breakage and keep output running during station downtime.

A needle roller, deflecting roller, and baffle plate wind small toroidal cores with thicker wire while preventing crossovers and excess residual wire.

Thin wire is wound directly around a component at high speed by allocating most cycle time to gentle winding, reducing breakage and stoppages.

A conveyor machine reorients components between winding stations to produce multiple coils faster without sacrificing winding quality.

A rotating winding assembly wraps foil and insulation directly on the iron core post to cut coil-core gaps, tooling cost, and production time.

Through-wiring formed by electrolytic plating creates a 3D solenoid coil that cuts parasitic capacitance and raises inductor self-resonance.

Interlaced conductor turns reshape coil voltage distribution to cut electric field intensity and peripheral nerve stimulation during fast MRI switching.

A guide member near the core steers twisted wires to the target winding position, improving coil manufacturing accuracy over longer nozzle distances.

Pre-marked foil intervals and layer-length checks keep transformer coils compact, reducing gaps, deformation, and short-circuit risk.

A 3-axis forming arm and translating hook automate toroidal coil winding, improving precision and productivity while reducing operator dependence.

A conveyor with separate winding and handling stations reorients components between coils to raise output while cutting faulty pieces.

A buffer and etch stop around a ferromagnetic-core inductor manage stress, cut signal loss, and improve wafer-level package yield.

Coordinated tension, clamping pressure, and core rotation keep flat wire tight on iron cores, improving heat dissipation without gaps or deformation.

A gear-driven cylinder winds foil or insulation around an iron core post, simplifying transformer winding while reducing tooling cost and skill demands.

Panel-level plated windings and embedded magnetic cores enable compact coupled inductors with low DC resistance and reduced flux leakage.

Bending coil leads onto the mold before powder pressing removes welding steps, improves coil alignment, and raises inductor manufacturing efficiency.

A slurry-coated wire is wound and cured in place to build coils that resist insulation failure in high-temperature electromagnets.

Segmented spiral stator coils create refrigerant flow paths and larger heat-dissipation areas, improving motor cooling without sacrificing space factor.

Hot air injected into the winding gap polymerizes the bonding coat during winding, cutting heating time and improving layer uniformity.

A needle ring with a deflection roller and external magazine elements guides wire accurately around small toroidal cores without an annular magazine.

Mechanical manipulation structures deform a reusable mould membrane for tight encapsulation, faster deployment, and easy removal.

Movable processing and transport positions let wire lines switch lengths by cycle, keeping continuous production with less downtime.

A winding mandrel accommodates pivotable coil body extensions using a dedicated clamp receptacle positioned outside the active winding space.

Loop slack segmentation in toroidal windings balances current distribution and reduces transformer size.

An operation piece expands and compresses swinging pieces to wind wire around a non-circular core, preventing coating damage during removal.

Twisting the tip end of a rectangular cross-section wire reduces the second moment of area, lowering force required to transform leads from the core.

An automated wire disposing assembly guides and corrects wire placement during coil winding to ensure precise layering.

Transport rollers and ejectors guide wire through small-diameter toroidal cores, eliminating magazine space constraints.

Automated deviation detection replaces manual monitoring in winding devices, preventing work surface damage while maintaining continuous operation efficiency.

Stacked wiring layers fill vertical space to boost inductance, overcoming the size limits of traditional winding coils.

Printed conductive tracks replace coaxial cables in the balun transformer, eliminating parasitic effects from welding imprecision.

Segmented ring elements enable bidirectional winding of toroidal components, eliminating intermediate wire cuts and maintaining electrical continuity.

A laminated coil device uses screen-printed conductive paste in laser-etched trenches to form precise internal electrodes.

Dual clamping gaps in a solenoid valve bobbin prevent winding wire slippage and ensure reliable electrical connections despite manufacturing tolerances.

An integrated sheet metal casing forms a conical magnetic pole, reducing magnetic resistance from flux transitions across multiple components.

Optimizing MRI electromagnet coil current density patterns to generate precise magnetic field shapes.

Transverse channels in an annular guide ensure precise turn spacing and winding symmetry, resolving manufacturing precision issues in toroidal coil production.

Etched substrate recesses deposit magnetic cores and conductive coils, boosting productivity while maintaining compact size for portable electronics.

A hybrid inductor combines magnetic metal layers in the core part with ferrite layers in the cover parts to achieve high inductance.

Gap fillers absorb roll-forming loads to maintain a smooth roller path, reducing tool chatter and extending component life.

An auxiliary winding core stores odd layers during multi-layer flat wire coil production, reducing assembly complexity and electrical discharge risks.

Tangential wire retainers eliminate tapered retainer surface roughness and manufacturing costs while ensuring uniform wire length during diagonal coil winding.

Stepped terminal bases with exposed shaft portions prevent burrs and enhance dimensional accuracy during slide mold formation.

A converting machine automates rewinding coil changes using a revolving disc and carriage-mounted cutting mechanism.

Plastic deformation increases wire diameter on supports to prevent slippage and short circuits during solenoid valve assembly.