Coil Component Twisted Wire Direction Alternation
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Solution Overview
Problem
Conventional coil component manufacturing methods often result in kinks in wires due to continuous rotation of the winding nozzle in a constant direction, leading to torsion and superposition of twisting, which affects the reliability and capacity of the twisted wire portions.
Innovation Solution
A taping reel and manufacturing method that includes coil components with twisted wire portions having opposite twisting directions, allowing the winding nozzle to be revolved in opposite directions, reducing torsion and the need for continuous constant rotation, and storing these components irregularly in pockets to minimize kinks and manufacturing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the winding nozzle is continuously revolved in a constant direction to maintain unified twisting directions, then the twisting direction uniformity is improved, but wire kinks occur due to torsion superposition
Solution Approach 1:
The winding nozzle alternates its revolution direction periodically during the winding process. Instead of continuously rotating in one direction, the nozzle switches between clockwise and counter-clockwise rotation at regular intervals, which prevents torsion from accumulating in the same direction and thereby eliminates wire kinks while still producing twisted wire portions with consistent twisting directions in the final product.
Solution Approach 2:
The invention inverts the conventional approach by allowing the winding nozzle to rotate in opposite directions rather than maintaining a constant rotation direction. This inversion of the rotation direction strategy resolves the torsion accumulation problem that occurs with unidirectional rotation, while achieving the desired uniform twisting direction in the completed coil components.
2Reliability
If the winding nozzle changes direction frequently to prevent torsion, then wire kinks are reduced, but manufacturing time increases
Solution Approach 1:
The periodic alternation of winding nozzle rotation direction is implemented in a regular, rhythmic manner that optimizes the balance between preventing torsion accumulation and maintaining manufacturing efficiency. The periodic switching prevents wire kinks while avoiding excessive direction changes that would slow production.
Solution Approach 2:
The winding process maintains continuous useful action by ensuring that the alternation of rotation directions occurs seamlessly during the winding operation. The nozzle switches directions without stopping or significant delays, keeping the winding process continuously productive while still preventing torsion-related wire kinks through directional alternation.
3Adaptability or versatility
If coil components with opposite twisting directions are mixed in the taping reel, then winding direction flexibility is improved, but component sorting complexity increases
Solution Approach 1:
The taping reel is segmented into distinct regions or zones, with each zone containing coil components that have the same twisting direction. This segmentation allows for efficient organization and retrieval of components by twisting direction, reducing the complexity of handling mixed components while maintaining the flexibility to produce both clockwise and counter-clockwise twisted coils.
Solution Approach 2:
Different regions of the taping reel are assigned different local qualities in terms of component twisting directions. By organizing components with uniform twisting directions in specific local areas of the reel, the system achieves both flexibility in producing different twisting directions and simplicity in component management within each localized zone.
Data Source
AI summary
A taping reel with a plurality of coil components packed in the tape reel, comprising a tape including a plurality of pockets arranged along a longitudinal direction and each having one of the coil components stored therein, and a reel around which the tape is wound. The coil components each include a core including a winding core part, and a coil wound around the winding core part and including a plurality of wires. The coil includes a twisted wire portion in which the plurality of wires is twisted together. The plurality of coil components includes first coil components having the twisting direction of the twisted wire portion opposite to the twisting direction of the twisted wire portion of other coil components.