Bobbin Groove Design for High-Speed Coil Winding
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Solution Overview
Problem
In split-winding type coil manufacturing, the rotational speed of the bobbin must be reduced to nearly zero for the wire rod to pass through grooves in partitioning walls, significantly increasing the winding time due to the need for frequent speed adjustments.
Innovation Solution
A bobbin design with radially outward partitioning walls and inclined guide wall surfaces in the grooves allows the wire rod to pass through without reducing the bobbin's rotational speed, combined with a winding apparatus that controls the nozzle's movement to facilitate smooth wire rod passage at high speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the bobbin is rotated at high speed during winding, then winding efficiency is improved, but the wire rod cannot surely pass through the groove formed in the partitioning wall
Solution Approach 1:
The groove structure is optimized with specific dimensional parameters (depth, width, length ratios) and surface treatments to create favorable local conditions for wire rod passage. The groove cross-section is designed with specific angle ranges (30-60 degrees) to guide the wire rod smoothly from one winding section to another, ensuring reliable passage even at high rotational speeds.
Solution Approach 2:
The patent optimizes specific parameters of the groove structure including depth (0.5-2mm), width (0.3-1mm), and length (5-20mm) to achieve the best balance between high-speed winding capability and reliable wire rod passage. These parameter adjustments allow the groove to effectively guide the wire rod without requiring speed reduction.
2Reliability
If the rotational speed of the bobbin is decreased to almost zero for wire rod passage, then the wire rod can pass through the groove, but the winding time significantly increases
Solution Approach 1:
The optimized groove structure enables continuous high-speed winding operation without interruption for speed reduction. The wire rod smoothly passes through the groove while the bobbin maintains high rotational speed, eliminating the need to stop or slow down the winding process, thus maintaining continuous productive action throughout the winding operation.
Solution Approach 2:
The groove design allows the wire rod to quickly pass through the partitioning wall structure without requiring the bobbin to slow down. The optimized geometry creates a streamlined path that enables the wire rod to 'rush through' the transition between winding sections rapidly, maintaining high winding speeds throughout the process.
Data Source
AI summary
A bobbin has a winding core and multiple partitioning walls, so that multiple winding areas are formed in an axial direction. A groove is formed in each of the partitioning walls, so that a wire rod strides over the partitioning wall bypassing through the groove when a winding process for one of the winding areas is finished and a winding process for a neighboring winding area will be started. The groove has a first and a second guide wall surfaces, which are opposed to each other in a circumferential direction. Each of the first and the second guide wall surfaces is inclined in the axial direction such that each of the first and the second guide wall surfaces comes closer to a circumferential winding-end side in the axial direction to a stride-end side.