Coil Winding Device Continuous Lead Wire Formation
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Solution Overview
Problem
The existing coil winding devices require excessive time to form lead wires due to repeated stopping and starting of the nozzle's rotational movement, which increases the overall time required for the process, especially when multiple lead wires are involved.
Innovation Solution
A coil winding device with a nozzle that moves rotationally around a winding core on a slanted track, featuring hook rods and a moving mechanism that allows for continuous wire drawing and twisting without stopping the nozzle's rotation, utilizing a hook hand that can move in three axes to hook and twist the wire efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the nozzle's rotational movement is stopped repeatedly to draw out and twist lead wires, then the wire can be properly engaged on hook rods and twisted into shape, but the time required to form lead wires increases significantly
Solution Approach 1:
The hook rods are pre-positioned around the winding core before the winding process begins. The wire is drawn out and engaged on the hook rods while the nozzle continues its rotational movement, rather than stopping to perform these actions. This preliminary positioning of components enables continuous operation while maintaining lead wire formation accuracy.
Solution Approach 2:
The nozzle maintains continuous rotational movement throughout the wire feeding, drawing out, and twisting processes. The hook rods rotate together with the winding core, allowing the wire to be continuously engaged and twisted without interrupting the nozzle's rotation. This continuous action eliminates idle time while ensuring proper lead wire formation through the coordinated rotation of all components.
2Productivity
If the nozzle rotates continuously without stopping, then productivity increases and time is reduced, but it becomes difficult to engage wire on hook rods and perform twisting operations
Solution Approach 1:
The hook rods are merged with the winding core rotation system, causing them to rotate together at the same speed. This combination allows the wire engagement and twisting operations to be performed during continuous nozzle rotation, as the hook rods are already in the correct rotational position to receive and twist the wire without requiring separate stopping phases.
Solution Approach 2:
The hook rods act as intermediaries between the continuously rotating nozzle and the wire. They receive the wire from the moving nozzle and perform the twisting function through their own rotation, mediating the continuous motion of the nozzle with the wire formation requirements without requiring the nozzle to stop.
Data Source
AI summary
The coil winding device includes a nozzle configured to feed a wire to wind the wire around the winding core to form a coil, a plurality of hook rods disposed in predetermined intervals around an end part of the winding core, the wire drawn out from an edge of the coil being configured to be hooked to each of the plurality of hook rods during a forming process of the coil, a winding core rotating mechanism configured to rotate the winding core together with the plurality of hook rods, a hook rod rotating mechanism configured to rotate the plurality of the hook rods, and a wire drawing-out mechanism configured to draw out the wire from the edge of the coil and hook the wire on the hook rods during the forming process of the coil.