Air Core Coil Winding Machine with Reciprocating Shafts
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Solution Overview
Problem
Conventional automatic winding machines for manufacturing air core coils face inefficiencies due to the need for frequent machine stops and the generation of gaps between unit wound portions, leading to reduced space factors and incomplete wire attachment when the coils are wound around cores.
Innovation Solution
An automatic winding machine with a rotation drive mechanism and reciprocating winding core shafts that form trapezoidal and rectangular shapes, allowing continuous production of unit wound portions with varying inner circumferential lengths while maintaining the same outer circumferential lengths, and a pressing roller mechanism for close wire attachment, enabling efficient coil formation and reduced gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automatic winding machines wind coils around rotating cores, then coil manufacturing is automated, but the machines require frequent stops and generate gaps between unit wound portions reducing space factors
Solution Approach 1:
Instead of rotating the core and winding wire around it (conventional method), the invention inverts the approach by rotating the winding core shafts themselves and winding wire along their rotation paths. This inversion eliminates the need for frequent machine stops and gap generation between unit wound portions, achieving continuous production while maintaining automation.
2Ease of manufacture
If conventional winding machines use fixed winding paths, then manufacturing is simplified, but gaps occur between unit wound portions leading to reduced space factors
Solution Approach 1:
The invention employs dynamic winding core shafts that can reciprocate and change their rotation paths during the winding process. This dynamic adjustment allows the wire to be wound tightly along the core surface without gaps, improving manufacturing precision while maintaining ease of manufacture through automated control of the dynamic motion.
Solution Approach 2:
The invention changes the parameters of the winding core shafts by varying their rotation radii and reciprocation positions during the winding process. This parameter variation enables continuous, gap-free winding that achieves tight wire attachment while preserving the simplicity of the manufacturing process through automated parameter control.
3Manufacturing precision
If unit wound portions are wound with different inner circumferential lengths, then the coil fits the core better, but frequent machine stops are required to change winding parameters
Solution Approach 1:
The invention achieves continuous winding action by rotating multiple winding core shafts simultaneously along different circular paths with different radii. This allows unit wound portions with different inner circumferential lengths to be produced continuously without machine stops, maintaining both manufacturing precision and production efficiency.
Solution Approach 2:
The invention segments the winding function into multiple independent winding core shafts, each capable of rotating at different radii. This segmentation allows simultaneous production of unit wound portions with different dimensions in a single continuous operation, eliminating the need to stop and reconfigure for different sizes.
Data Source
AI summary
An automatic winding machine has a rotation drive mechanism, four winding core shafts protruding from the drive mechanism and being rotated integrally with a rotation center of the drive mechanism, the winding core shafts whose axial centers are parallel to the rotation center, a reciprocating mechanism for reciprocating the winding core shafts, at least one pressing roller biased in the direction of bringing close to a rotation passage of the winding core shafts from the outer circumferential side, and a conductive wire supply mechanism for continuously supplying a conductive wire between the winding core shafts and the pressing roller.