Concentric Bushing Twisting Assembly for Precise Winding Wire Alignment
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Solution Overview
Problem
Existing methods for preparing inductive windings require manual intervention, leading to high costs, inaccuracies, and human errors due to the need for precise spatial orientation and shaping of wires, which are time-consuming and prone to mechanical stress.
Innovation Solution
A twisting assembly for inductive windings comprising a fixed frame with a carousel and concentric bushings that allow for automatic and precise alignment and insertion of wires, minimizing mechanical stress through controlled rotational and translational movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual positioning and shaping of wires is used, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated twisting assembly that uses controlled rotational movement of a carousel to orient wires. The system employs mechanical guides and positioning features within the carousel seats to automatically achieve precise spatial orientation, eliminating manual intervention while maintaining accuracy through engineered mechanical constraints rather than human skill.
Solution Approach 2:
The patent changes the operational parameters from manual control to automated controlled rotation. The carousel rotates to specific angular positions to orient wires correctly, transforming the positioning process from dependent on operator skill to dependent on controlled rotational parameters. This allows rapid repositioning and reorientation by simply changing rotation angles, thereby improving both speed and precision.
2Manufacturing precision
If manual shaping and orienting of wires is performed, then complex positioning can be achieved, but costs increase and human errors occur
Solution Approach 1:
The patent divides the wire preparation process into discrete segments: wire insertion into carousel seats, carousel rotation to orientation positions, and twisting operations. Each seat on the carousel is designed to hold wires in specific orientations, and the carousel rotates to bring different seats into position. This segmentation allows complex positioning to be achieved through simple, repeatable operations rather than a single complex manual maneuvering step.
Solution Approach 2:
The carousel acts as an intermediary device between wire storage and the twisting mechanism. It provides a standardized interface for holding and orienting multiple wires, mediating the transition from random wire storage to precisely oriented wire presentation. This intermediary structure simplifies the overall system by providing a reusable, programmable positioning platform rather than requiring direct complex positioning mechanisms at each operation point.
3Productivity
If rapid wire preparation is implemented, then productivity increases, but mechanical stress on wires increases
Solution Approach 1:
The patent employs dynamic, controlled movement of the carousel rather than static positioning. The carousel rotates smoothly to predetermined angular positions, allowing wires to be oriented rapidly through rotational motion rather than manual manipulation. This dynamic approach maintains wire integrity by using controlled, uniform motion forces rather than abrupt manual handling, achieving high speed while protecting wire strength.
Solution Approach 2:
The patent performs preliminary positioning of wires in the carousel seats before the twisting operation. Wires are inserted and pre-oriented in the rotating carousel at controlled speeds, allowing them to be prepared in advance without subjecting them to excessive stress during the main twisting operation. This preliminary action separates the high-speed positioning from the stress-inducing twisting, maintaining wire integrity while achieving rapid preparation.
Data Source
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AI summary
A twisting assembly (1) for wires (A, B) of inductive windings that comprises a fixed frame (2) on which a carousel (3) provided with at least one pair of seats for respective wires (A, B) of different lengths can rotate. The assembly (1) comprises: at least two bushings (4a, 4b, 4c, 4d, 4e, 4f, 4g), having a circular cross-section, which are mutually concentric and provided with respective channels (5a, 5b, 5c, 5d, 5e, 5f, 5g) which are substantially parallel to the axis of symmetry (a) and each of which defines at least one seat for at least one respective wire (A, B) which is open on a side directed toward the at least one contiguous bushing (4a, 4b, 4c, 4d, 4e, 4f, 4g); at least one upper shaped portion (6b, 6d, 6f) which is provided, on at least one upper surface of at least one bushing (4a, 4b, 4c, 4d, 4e, 4f, 4g), with a conveyance chute for the terminal front of at least one wire (A, B) inside a seat of the at least one other bushing (4a, 4b, 4c, 4d, 4e, 4f, 4g); at least one element (3a) for moving the at least two bushings (4a, 4b, 4c, 4d, 4e, 4f, 4g) for the rotation of at least one first bushing (4b, 4d, 4f) with respect to at least one second bushing (4a, 4c, 4e, 4g), the rotation being adapted for the temporary alignment of at least one upper shaped portion (6b, 6d, 6f) of at least one first bushing (4b, 4d, 4f) with at least one channel (5a, 5c, 5e, 5g) of at least one second bushing (4a, 4c, 4e, 4g) which is open toward the first bushing (4b, 4d, 4f).