Coil Winding Carriage for High-Speed Wire End Fixing
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Solution Overview
Problem
Existing machines for manufacturing coils around components in electronic cigarette cartridges operate at reduced speeds due to the need to fix wire ends to the component before moving the carriage, which slows down the production process.
Innovation Solution
The method and machine design involve fixing the wire ends to the carriage instead of the component, allowing the carriage to move at high speeds even after winding, while keeping the wire under tension and correctly positioned without immediate welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire ends are fixed to the component before moving the carriage, then the wire remains securely positioned, but the operating speed of the machine is reduced
Solution Approach 1:
The patent divides the fixing function into two separate stages: temporary fixing to the carriage during winding, and permanent welding to the component afterwards. This segmentation allows the carriage to move freely at high speed during winding while ensuring secure wire positioning through subsequent welding, thus resolving the contradiction between positioning stability and operating speed.
Solution Approach 2:
The wire ends are preliminarily fixed to the carriage before the winding process begins. This preliminary action ensures the wire is securely held during the high-speed winding operation, allowing the carriage to move at full speed without worrying about wire positioning, while the actual component attachment is deferred to a later welding stage.
2Productivity
If the carriage is moved immediately after winding, then high operating speed is achieved, but the wire may become loose or mispositioned
Solution Approach 1:
The patent separates the wire securing function into two distinct phases: initial securing to the carriage enabling high-speed movement, and final securing to the component through welding that ensures precise positioning. This segmentation allows the carriage to move at high speed immediately after winding without compromising wire positioning accuracy, as the welding process subsequently guarantees precise attachment.
Solution Approach 2:
The carriage acts as an intermediary holder for the wire ends during the winding process. It temporarily secures the wire in the correct position, allowing the carriage to be moved at high speed, while the component serves as the final anchor point through welding. This intermediary role of the carriage enables high-speed operation without sacrificing positioning accuracy.
3Reliability
If a welding station is arranged in the same area as the winding station, then wire fixing is achieved, but the machine complexity and space requirements increase
Solution Approach 1:
The patent segments the wire fixation process into two distinct operational phases performed at the same location: winding with temporary carriage fixation, and subsequent welding for permanent component attachment. This segmentation maintains reliability by ensuring proper wire fixation while avoiding the need for separate dedicated stations, thus reducing overall machine complexity and space requirements compared to having entirely separate winding and welding areas.
Data Source
AI summary
Method and machine (14) to manufacture a coil (11) around a component (1) of an article. It is provide to: move, by means of a main conveyor ((1155)) and along an assembling path (P), a carriage (16) provided with a seat (18) designed to house the component (1); place, in an input station (SI) arranged along the assembling path (P), the component (1) in the seat (18) of the carriage (16); wind, in a winding station (S5) arranged along the assembling path (P) downstream of the input station (SI), an externally insulated conductor wire (13) around the component (1) in order to obtain a series of turns making up the coil (11); lock an initial end of the wire (13) to the carriage (16) before starting to wind the wire (13); and lock a final end of the wire (13) to the carriage (16) at the end of the winding of the wire (13).