Coil Winding Gap and Support Winding for Precision
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Solution Overview
Problem
The challenge in winding coils for electrical components like servomotors and electric motors is to achieve high precision and small dimensional tolerances while maximizing power density, particularly with conical coils where irregularities and larger dimensional tolerances occur due to the cone-shaped geometry, leading to inefficient space utilization and reduced performance.
Innovation Solution
A method involving the formation of a gap between turns in the first winding layer, allowing for a support winding that prevents lateral slipping and precise positioning of subsequent layers, enabling precise wire placement and adaptation to available volume, thus enhancing space utilization and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conical coils are used to make better use of the volume available, then space utilization is improved, but dimensional tolerances worsen due to irregularities during winding
Solution Approach 1:
A gap is formed at a predeterminable point between turns during the winding process, and a support winding is introduced to provide a receptacle for subsequent windings. This preliminary structural feature enables precise positioning of the wire in later winding layers, compensating for the irregularities inherent in conical coil geometry and allowing tight dimensional tolerances to be achieved while maintaining high space utilization
Solution Approach 2:
The support winding acts as an intermediary element that mediates between the conical coil geometry and the subsequent winding layers. By providing a defined receptacle structure, the support winding enables precise wire placement without requiring the entire winding process to achieve perfect precision, thus resolving the contradiction between conical shape benefits and manufacturing tolerances
2Reliability
If coils are arranged at a distance from one another to account for tolerances, then reliability is improved, but space utilization worsens
Solution Approach 1:
The support winding creates a pneumatic-like constraint system where the gap and support structure form a defined channel that guides and constrains subsequent wire paths. This constraint system ensures reliable wire positioning without requiring additional clearance between coils, allowing coils to be placed closer together while maintaining arrangement reliability through the internal support structure rather than external spacing
3Manufacturing precision
If wire is supported against lateral slipping to achieve precise positioning, then manufacturing precision is improved, but device complexity worsens due to additional support structures
Solution Approach 1:
The support winding is merged with the functional windings of the coil, serving dual purposes: providing mechanical support to prevent lateral slipping and contributing to the electrical function of the coil. This integration means the support structure is not an additional complex element but rather a multifunctional component that achieves precise wire positioning without significantly increasing overall device complexity
Data Source
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AI summary
The invention relates to a method for the mechanical winding of a coil (1) comprising at least one wire (4), said coil (1) having an inner coil face (14) and at least two individual windings (2), one individual winding (2) being formed by convolutions (5) lying substantially parallel to the inner coil face (14). The aim of the invention is to increase the precision of the winding and to reduce the measurement tolerances of the winding. To achieve this, at least during the winding of a first individual winding (21) a gap (6) is formed at a predeterminable point between a first convolution (54) and a second convolution (55) that is adjacent to the first convolution (54), the second convolution (55) being wound immediately after the first convolution (54), the width of the gap (6), at least in some sections, at least equalling that of the diameter of the wire and the wire (4) is guided into the gap (6) after the winding of the second convolution (5) and optionally after the winding of additional convolutions (5), thus forming a supporting convolution (51).