Coil Forming Machine Configuration via 3D Model Comparison

Solution Overview

Problem

The existing methods for manufacturing custom coils are time-consuming and labor-intensive, often resulting in wasted coils due to a trial and error approach, which increases the cost of fabrication.

Innovation Solution

A method and system that utilize a 3D model comparison between a production coil and a coil forming machine to adjust the machine settings, incorporating a computer-assisted design system with a scanner to ensure precise alignment and minimize waste by iteratively adjusting the machine until the desired coil shape is achieved within predetermined tolerances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a trial and error approach is used to manufacture custom coils, then the coil forming machine can be adjusted to produce different coil shapes, but the process becomes time-consuming and labor-intensive

Engineering Contradiction:

Improvecoil shape customizationVSAvoidsetup time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system performs preliminary actions by receiving a 3D model of the desired coil and generating a corresponding 3D model of the coil forming machine configuration before actual manufacturing begins. This pre-planning allows the system to calculate and determine the optimal machine setup in advance, eliminating the need for time-consuming trial and error adjustments during production setup.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates a digital 3D copy of the desired coil model and uses this copy to generate the corresponding machine configuration model. By working with digital copies and simulations rather than physical trial coils, the system can determine the correct setup virtually before manufacturing, significantly reducing setup time and material waste.

Inventive Principle:

Principle #26Copying

2Adaptability or versatility

If a trial and error approach is used to manufacture custom coils, then different coil shapes can be produced, but many coils are wasted that cannot be used

Engineering Contradiction:

Improvecoil shape customizationVSAvoidcoil waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The system performs preliminary actions by receiving a 3D model of the desired coil and generating a corresponding 3D model of the coil forming machine configuration before actual manufacturing begins. This pre-planning allows the system to calculate and determine the optimal machine setup in advance, eliminating the need for time-consuming trial and error adjustments during production setup.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system creates a digital 3D copy of the desired coil model and uses this copy to generate the corresponding machine configuration model. By working with digital copies and simulations rather than physical trial coils, the system can determine the correct setup virtually before manufacturing, significantly reducing setup time and material waste.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If manual adjustment and trial coils are used, then the coil forming machine can be configured, but the fabrication cost increases

Engineering Contradiction:

Improvemachine configurationVSAvoidfabrication cost

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The system replaces manual mechanical adjustment and physical trial coil fabrication with an automated computer-based system that receives 3D models, generates machine configuration models, and calculates the optimal setup. This substitution of mechanical trial-and-error methods with computational modeling significantly reduces material waste and labor costs, making the fabrication process more cost-effective.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a digital 3D copy of the desired coil model and uses this copy to generate the corresponding machine configuration model. By working with digital copies and simulations rather than physical trial coils, the system can determine the correct setup virtually before manufacturing, significantly reducing setup time and material waste.

Inventive Principle:

Principle #26Copying

Data Source

PatentUS9391498B2Methods and systems for use in configuring a coil forming machine

Publication Date: 2016.07.12 GE ENERGY POWER CONVERSION TECHNOLOGY LTD(GB)

AI summary

A method for configuring a coil forming machine is provided. The method comprises receiving a 3D model of a production coil, generating a 3D model of the coil forming machine, and comparing the received 3D production coil model to the 3D model of the coil forming machine to obtain a comparison. The method also includes outputting a display of the comparison and adjusting the coil forming machine in response to the comparison.