Bead Wire Winding Guide Mechanism for Variable Cross-Section Cores
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Solution Overview
Problem
Existing bead wire winding and forming devices are limited in versatility, as they can only produce bead cores with a rectangular cross-section and face difficulties in accurately winding bead wires around a former due to the construction of the device.
Innovation Solution
A bead wire winding and forming device with a rotatable former, guide means that includes a movable body with a swingable guide body and a restriction member, allowing for accurate guidance and restriction of the bead wire's motion, enabling the production of bead cores with various cross-sectional shapes by allowing the guide body to swing freely during winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a belt-shaped tape bead is wound around the outer circumferential surface of a drum, then the device can manufacture bead cores with a rectangular cross-section, but the device lacks versatility to produce other cross-sectional shapes
Solution Approach 1:
The guide body is made swingable in the horizontal direction, allowing it to dynamically adjust its position according to different winding requirements. This dynamic capability enables the device to produce various cross-sectional shapes (rectangular, hexagonal, round) without fundamental structural changes, thereby improving versatility while maintaining reasonable device complexity
Solution Approach 2:
The guide body serves multiple functions: it guides the bead wire during winding, swings to accommodate different winding positions, and works with the restriction member to control wire movement. This multi-functional design allows a single device structure to handle various bead core shapes, enhancing adaptability without proportionally increasing complexity
2Adaptability or versatility
If a single line of continued bead wire is wound around the outer circumference of a former in plural rows, then bead cores with various cross-sectional shapes can be manufactured, but it becomes difficult to accurately wind the bead wire around the former
Solution Approach 1:
The guide body acts as an intermediary between the bead wire and the former during winding. It provides a stable reference point and guidance surface that ensures accurate wire placement even as the wire is wound in multiple rows around the rotating former, thereby maintaining manufacturing precision while enabling versatility
Solution Approach 2:
The swingable guide body mechanism replaces complex mechanical positioning systems that would otherwise be needed to maintain winding accuracy across multiple rows and different cross-sectional shapes. The simple swing motion provides sufficient control to achieve accurate winding without elaborate mechanical guidance systems
3Manufacturing precision
If the guide body is allowed to swing freely during winding, then the bead wire can be accurately guided to different positions on the former, but the guide body may swing excessively causing positioning errors
Solution Approach 1:
The restriction member changes the operational parameters of the guide body by allowing swing motion only within specific angular ranges. When the movable body is at the retracted position, the guide body can swing freely for positioning; when at the advanced position, the swing is restricted to prevent excessive motion. This parameter-based control maintains both accuracy and stability
Data Source
AI summary
In a bead wire winding and forming device, a guide mechanism guiding a bead wire to a former is supported to be movable in a tangential direction of the former and includes a movable body capable of clamping and unclamping the bead wire, a guide body supported on the movable body to be swingable in a plane parallel to a rotational axis of the former and having a guide portion for guiding the bead wire in the tangential direction of the former, and a restriction member for allowing the swing motion of the guide body when the movable body is at a retracted position but for restricting the swing motion of the guide body when the movable body is at an advanced position.