Coil Winding Feedback Control for Figure-Eight Payout Hole Alignment
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Solution Overview
Problem
Existing coil winding methods rely on predicted coil diameter calculations, which are inaccurate due to factors like filamentary material properties and line tension, leading to misalignment and uneven dimensions in the payout hole and coil density, resulting in suboptimal coil configurations.
Innovation Solution
A system that measures the actual coil diameter during winding using sensors and a controller to adjust parameters like hole shift, hole taper, and density independently, ensuring a consistent and accurate figure-eight coil configuration with a straight payout hole.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If predicted coil diameter calculations are used based on layer number and wire diameter, then the winding process is simple, but the payout hole becomes misaligned and dimensions become uneven
Solution Approach 1:
The patent implements feedback control by continuously measuring the actual coil diameter during winding and using this measurement to dynamically adjust winding parameters. The system measures coil diameter, compares it to the predicted diameter, and adjusts traverse speed and layer placement accordingly to maintain accurate payout hole alignment and dimensions throughout the winding process.
Solution Approach 2:
The patent changes winding parameters (traverse speed, layer placement) based on actual coil diameter measurements. By dynamically adjusting these parameters rather than using fixed predetermined values, the system compensates for variations in wire diameter, tension, and material properties to maintain manufacturing precision.
2Ease of manufacture
If fixed traverse speed offsets are used to create figure-eight patterns, then the winding process is straightforward, but coil density becomes uneven in outer layers
Solution Approach 1:
The patent transitions from static fixed traverse speed offsets to dynamic adjustable offsets. The system continuously measures coil diameter and adjusts the traverse speed offset for each layer based on actual measurements, allowing the winding parameters to adapt to changing coil conditions and maintain uniform density throughout all layers.
Solution Approach 2:
The patent adjusts traverse speed offsets dynamically based on measured coil diameter and layer number. By changing these parameters throughout the winding process rather than using fixed values, the system compensates for the increasing diameter effect that causes density variations in outer layers.
3Manufacturing precision
If actual coil diameter is measured and used to control winding parameters, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical measurement systems with simpler optical or electromagnetic sensors to measure coil diameter. This substitution reduces mechanical complexity while maintaining measurement accuracy, allowing precise control of winding parameters without overly complicating the physical measurement apparatus.
Solution Approach 2:
The system uses the coil's own growth characteristics (measured diameter) to automatically adjust its winding parameters. The measurement system and control system work together in a self-regulating manner where the coil's actual state directly informs the adjustments needed, reducing the need for external complex control mechanisms.
Data Source
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AI summary
An apparatus for winding filamentary material includes a mandrel rotatable about a spindle axis of rotation and a traverse reciprocating at a distance with respect to the spindle axis to wind the filamentary material in a figure-eight coil configuration with a payout hole extending radially from the inner to the outer wind of the coil. The apparatus includes a measurement device for measuring the diameter of the coil as it is being wound around the mandrel, and a controller for controlling the reciprocating movement of the traverse with respect to the rotation of the mandrel based on the measured diameter of the coil. The measurement device may include a first sensor configured to measure a length of filamentary material wound about the mandrel and a second sensor configured to measure an angular displacement of said mandrel during the winding of the length of filamentary material about said mandrel.