Bobbin Wire Guide and Terminal Limiting for Automatic Winding
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Solution Overview
Problem
Existing latching relays face issues with automatic winding of enameled wires due to overlapping start and end wires, leading to voltage differences and short circuits, and the movable spring terminals are prone to shaking, affecting mechanical properties.
Innovation Solution
A bobbin design with a wire guide portion and wire hanging portion for automatic winding, and a movable spring terminal limiting structure with a limiting portion and pressure contact portion to prevent up and down movement, ensuring consistent mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If bridging terminals are provided on the middle flange part to space apart start and end wires, then short circuit risk is reduced, but automatic winding becomes impossible and manual winding is required
Solution Approach 1:
The patent introduces a wire guide portion as an intermediary structure on the flange part. This wire guide portion guides the enameled wire from the winding part to the terminal hole, enabling automatic winding while maintaining proper wire spacing. The wire guide portion acts as a mediator between the winding process and terminal connection, eliminating the need for bridging terminals that would prevent automation.
Solution Approach 2:
The patent utilizes the vertical dimension by providing a wire guide portion that extends from the flange part surface. This three-dimensional structure guides the wire in space, allowing automatic winding machines to properly position and space the enameled wire without requiring complex bridging terminal structures that would block automation.
2Object-affected harmful factors
If crimping mechanism is used to crimp the end wire between bridge terminal and end terminal, then wire height is reduced and interference with relay base is avoided, but processing complexity increases and manual assistance is required
Solution Approach 1:
The patent extracts the wire guiding and positioning function from the terminal structure itself. By integrating the wire guide portion directly into the flange part, the design eliminates the need for separate crimping mechanisms and manual intervention. The wire guide portion naturally positions and spaces the wire during the winding process, removing the harmful effect of wire interference without adding complex processing equipment.
3Ease of manufacture
If movable spring terminal is inserted into cavity with gap, then installation is simple, but terminal shakes up and down under external force affecting mechanical properties
Solution Approach 1:
The patent applies preliminary anti-action by providing a limiting portion on the movable spring terminal that prevents upward movement before external forces can cause instability. The limiting portion engages with the cavity structure to restrict the terminal's movement range, counteracting the tendency to shake up and down under external forces while maintaining simple installation through the insertion structure.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A bobbin that facilitates automatic winding includes a first flange part (1), a second flange part (2), a third flange part (3), a first winding part (4) and a second winding part (5), the first winding part (4) is provided between the first flange part (1) and the second flange part (2), the second winding part (5) is provided between the second flange part (2) and the third flange part (3); the first flange part (1) is provided with a plurality of terminal holes, the plurality of terminal holes includes a first terminal hole (11) for inserting a start terminal (8) and a second terminal hole (13) for inserting an end terminal (9); the first flange part (1) is provided with a wire hanging portion, and a bottom end of the wire hanging portion is lower than a top end of the first flange part (1), and the second flange part (2) is provided with a first wire guide portion for guiding a enameled wire (7) from the second winding part (5) to the wire hanging portion. In the present disclosure, a manual winding of enameled wire is avoided, and the wire hanging portion is used to hang the wire to reduce the height of the end wire part of the enameled wire (7) located between the first flange part (1) and the second flange part (2), at the same time, an effective isolation between the enameled wire layers of the second winding part (5) and the first winding part (4) can be ensured, and the risk of interlayer breakdown can be avoided, thereby avoiding the use of a wire crimping mechanism to crimp the wire and ensuring safety at the same time.