Coil Winding Insulation Weak Point Automation
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Solution Overview
Problem
Existing coil winding machines require manual intervention and frequent stops to optimize layer insulation, which hampers efficiency and increases the risk of voltage flashovers in high-voltage coils.
Innovation Solution
An automated apparatus and method that uses a device to create a weak point in isolation material remotely, allowing continuous winding by determining the optimal time for layer changes and cutting the material at the weak point, ensuring controlled separation and secure bonding without interrupting the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual intervention is used to cut and bond layer insulation during winding, then the insulation can be precisely applied, but the winding process must be stopped twice per layer change, reducing productivity
Solution Approach 1:
A weak point (perforation or notch) is created in the insulation material in advance, before the winding process begins. This preliminary action enables automatic cutting at the weak point during layer changes without requiring manual intervention or stopping the winding machine, thus maintaining both precision and productivity
Solution Approach 2:
The insulation material is equipped with a built-in weak point that enables it to be automatically cut and repositioned during the winding process. The material essentially serves itself by containing the information (weak point) needed for its own proper application, eliminating the need for external manual control
2Manufacturing precision
If the winding machine is stopped for manual layer insulation adjustment, then precise insulation placement can be achieved, but the overall winding time increases
Solution Approach 1:
The weak point is created in the insulation material before winding begins. During layer changes, the weak point allows the material to be automatically cut and repositioned without stopping the machine, eliminating time loss while maintaining precise placement through the predetermined weak point location
Solution Approach 2:
The winding process continues uninterrupted because the insulation material with its built-in weak point can be automatically cut and repositioned during layer changes. The useful action of winding is maintained continuously without stops, while precision is ensured through the controlled weak point mechanism
3Productivity
If automated weak point production is used, then continuous winding is enabled, but additional devices and control systems are required
Solution Approach 1:
The weak point is created in advance on the insulation material itself, before the winding process begins. This preliminary preparation enables continuous winding without requiring complex real-time control systems or additional automated cutting devices during the winding process, thus maintaining productivity while limiting the increase in device complexity
Data Source
AI summary
A winding machine for electrical coils to be wound into layers has a device which supplies a material to the coil to be wound in order to separate adjacent layers of the coil from one another. The device has a device for producing a predetermined breaking point in the material, and a measuring unit. The measuring unit determines when the device for producing a predetermined breaking point is to be activated in order to produce a predetermined breaking point in the material. The device also has a guide device which fixes the material on the coil to be wound in the vicinity of the predetermined breaking point at a predetermined time, in order to sever the material at the predetermined breaking point. The winding machine therefore anticipates when a layer change is required, in order to then produce a predetermined breaking point in the material at a distance from the coil. The predetermined breaking point is pulled through as far as the coil, and this enables the material to be guided in a controlled and reliable manner. The material is torn off at the predetermined breaking point only after the material is secured on the coil.