Coil Winding Device Bristle Force Annealing
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Solution Overview
Problem
Existing methods for winding fully annealed copper tubes into coils introduce work hardening and result in loosely wound, randomly spaced coils that are susceptible to damage during transport, requiring excessive storage space and incomplete annealing of initial windings.
Innovation Solution
A device applying perpendicular forces using bristles to restrict movement and ensure tight winding of coils, minimizing work hardening and optimizing coil spacing, with an integrated annealing process to prevent initial winding issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If rollers are used to bend the tube into coils, then the tube can be wound into a coil shape, but the hardness of the tube increases due to work hardening
Solution Approach 1:
A support surface acts as an intermediary between the tube and the winding process. The tube is supported along its entire length on this surface during coiling, which prevents excessive bending stresses and work hardening while still allowing the tube to form the desired coil shape.
Solution Approach 2:
The support surface moves in coordination with the winding process, maintaining contact with the tube throughout coiling. This dynamic support system adjusts to the tube's position and movement, providing continuous support that minimizes work hardening while enabling coil formation.
2Ease of manufacture
If the tube is loosely wound into coils, then the winding process is simpler, but more cubic space is required for packaging and transportation
Solution Approach 1:
The tube is pre-annealed before the coiling process to ensure it is fully soft and pliable. This preliminary heat treatment allows the tube to be wound tightly into coils without excessive force or complexity, while achieving compact packaging dimensions.
3Ease of manufacture
If layers of coils are loosely wound with random spacing, then the coiling process is easier, but the coils are more susceptible to damage during transport
Solution Approach 1:
The tube undergoes pre-annealing to achieve optimal softness before coiling, allowing tight winding with uniform spacing. The support surface is also prepared in advance to provide appropriate guidance and spacing during the winding process, ensuring both ease of manufacture and damage resistance.
4Manufacturing precision
If nitrogen gas is blown through the tube during annealing, then oxygen is displaced from within the tube, but the first few windings are not correctly annealed due to incorrect tube speed
Solution Approach 1:
The tube is pre-annealed completely before the coiling process begins, ensuring that the entire tube length achieves proper annealing. The nitrogen gas flow is established and stabilized prior to winding, eliminating speed-related annealing defects and ensuring consistent quality throughout all windings.
Data Source
AI summary
A device for winding an elongate member into a coil includes at least one first body portion adapted to rotate about a first axis; at least one fixing device for fixing a portion of an elongate member to the at least one first body portion; and at least one force applicator for applying a force to the elongate member. The force includes first and second force components acting in perpendicular first and second directions respectively, in order to restrict movement of the elongate member in directions parallel with the first and said second directions. The first force component acts towards the first body portion to which the elongate member is fixed.