Electric Coil Continuous Winding Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical coils are complex to manufacture and prone to defects due to soldering or welding points, especially with thin wires, leading to potential current interruptions and increased susceptibility to mechanical vibrations, making them difficult to contact and produce efficiently, especially in large series.
Innovation Solution
A single winding wire is used for the main, start, and end windings without connection points, simplifying the manufacturing process and reducing errors, with an optional insulation layer and precise positioning of windings to enhance reliability and compactness, and a method for contacting using laser welding or soldering with channel-shaped contacts to ensure precise electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate windings are wound and soldered or welded together, then the coil can be manufactured with distinct functional sections, but the manufacturing process becomes complex and susceptible to defects at connection points
Solution Approach 1:
The patent merges the main winding, start winding, and end winding into a single continuous winding wire without separate connection points. This eliminates soldering or welding joints, thereby reducing manufacturing complexity and eliminating potential defect sources at connection points while maintaining the distinct functional sections through the continuous wire structure.
2Reliability
If conventional soldering or welding methods are used to connect windings, then electrical connections can be established, but contact resistances and interruptions can occur over service life due to mechanical vibrations
Solution Approach 1:
By combining all windings into a single continuous wire, the patent eliminates soldering or welding joints that are susceptible to mechanical vibrations and contact resistance issues. The continuous wire structure ensures reliable electrical connections throughout the service life without the degradation problems associated with conventional connection methods.
3Manufacturing precision
If thin wires with diameter of 50 μm or less are used, then the coil can achieve desired electrical properties, but the wires are difficult to contact using conventional methods due to lack of rigidity
Solution Approach 1:
The patent combines all windings into a single continuous thin wire, which maintains the desired electrical properties while eliminating the need for separate connection operations. The continuous structure provides inherent positioning stability, making the thin wire easier to manufacture and contact compared to separate windings that would require individual handling and connection of multiple rigid components.
4Productivity
If multiple soldering or welding points are used to connect windings, then the coil can be assembled from separate sections, but the production time increases and errors are more likely to occur
Solution Approach 1:
By merging all windings into a single continuous wire, the patent eliminates multiple soldering or welding operations, thereby significantly reducing production time and eliminating the potential for errors at each connection point. The single-continuous-wire structure can be manufactured in one process, improving both productivity and production quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design simplifies and speeds up the manufacturing process, reduces defects, and ensures reliable electrical connections, particularly for thin wires, by eliminating connection points and using precise laser-based joining techniques, thereby increasing the coil's service life and production quality.
Implementation Method 1
The coil core is machined (trowalized) using a vibratory grinding process, so that its surface is free of burrs and bumps.
Implementation Method 2
it is preferably a polymer layer that is applied to the coil core with the aid of a suitable coating process
Implementation Method 3
A Parylene coating, for example, which has been produced by chemical vapor deposition, is particularly suitable.
Implementation Method 4
The connection between the contacts of the electrical supply line and the start or end winding is produced according to the invention by welding or soldering
Implementation Method 5
The connection between the contacts of the electrical supply line and the start or end winding is produced according to the invention by welding or soldering
Data Source
AI summary
An electric coil comprising a coil core (10), a main winding (16) surrounding the coil core (10) and having an electrically conductive coil wire, a start winding (14) surrounding the coil core (10) and having an electrically conductive coil wire, and an end winding (18) surrounding the coil core (10) and having an electrically conductive coil wire, is characterized in that the coil wire of the main winding (16), the coil wire of the start winding (14), and the coil wire of the end winding (18) are formed by a continuous wound wire, and at least the main winding (16), preferably also the start winding (14), is wound directly onto the coil core (10).