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.