Coil Shaping Device Using Arc-Groove Rollers

Solution Overview

Problem

Coils made of wire wound obliquely around cylindrical winding cores in small-sized coreless motors face challenges in maintaining shape accuracy, leading to potential separation at edges and enlargement of the outer diameter.

Innovation Solution

A coil shaping device and method utilizing rollers with arc-shaped concave grooves that grip and roll along the coil to fit the wire tightly around the winding core, preventing separation and ensuring accurate diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If wire is wound obliquely around cylindrical winding core, then coil can be formed efficiently, but wire separates at edges and outer diameter becomes enlarged

Engineering Contradiction:

Improvecoil formation efficiencyVSAvoidouter diameter accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The wire ends are bent back toward the winding core before the winding process completes, creating a preliminary configuration that prevents edge separation. This preliminary action ensures that when winding continues, the wire remains properly positioned and the outer diameter stays within desired tolerances.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different portions of the wire are treated differently - the wire ends receive special attention by being bent back, while the main body of the wire continues normal oblique winding. This local differentiation allows the problematic edge areas to be corrected without changing the efficient oblique winding method for the rest of the coil.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If wire is wound obliquely around cylindrical winding core, then coil structure is formed, but shape accuracy deteriorates due to wire separation at edges

Engineering Contradiction:

Improvecoil structure formationVSAvoidshape accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The wire ends are bent back toward the winding core during the winding process, creating a preliminary configuration that prevents edge separation. This preliminary action ensures that when winding continues, the wire remains properly positioned and the outer diameter stays within desired tolerances.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Different portions of the wire are treated differently - the wire ends receive special attention by being bent back, while the main body of the wire continues normal oblique winding. This local differentiation allows the problematic edge areas to be corrected without changing the efficient oblique winding method for the rest of the coil.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS9914161B2Coil shaping device and coil shaping method

Publication Date: 2018.03.13 NITTOKU ENG CO LTD

AI summary

A coil shaping device includes a plurality of rollers having an outer circumference formed with a concave groove having an arc-shaped cross section, a roller moving mechanism making the rollers move between a gripping position, at the gripping position the plurality of rollers grips the coil from surroundings of the coil, and a separating position, at the separating position the plurality of rollers is separated from the coil, and a rolling movement mechanism making the plurality of rollers positioned in the gripping position move, by the plurality of rollers being rolled in a longitudinal direction of the coil.