Coil Winding Length Correction for Accurate Round Terminal Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing winding devices face issues with forming start and end terminals of coil wire in a round shape to facilitate connection, and are susceptible to manufacturing variations in winding targets, leading to defects and higher defect rates.
Innovation Solution
A winding device with a length correction section, wire supply section, forming section, and winding section that corrects the reference length based on winding target variations, forms start and end terminals in a round shape, and adjusts the forming process to ensure accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the start and end terminal parts are formed at the design length position, then the positioning is simple and straightforward, but the start and end terminals cannot be formed at appropriate positions due to manufacturing variation in the winding target
Solution Approach 1:
The patent measures the actual outer shape dimensions of the winding target before winding, and pre-calculates the corrected reference length based on the measured variation. This preliminary measurement and correction action ensures that when the winding process starts, the accurate reference length is already prepared, allowing terminals to be positioned correctly despite manufacturing variations in the winding target.
Solution Approach 2:
The patent implements a feedback mechanism where the actual outer shape of the winding target is measured, the variation from design specifications is calculated, and this information is fed back to correct the reference length for terminal positioning. The control device uses this feedback to dynamically adjust the positioning, ensuring accurate terminal formation regardless of winding target variations.
2Reliability
If the wire is wound longer than the design winding length due to larger winding target outer shape, then the winding covers the entire target, but the start and end terminal parts end up being wound on the winding target instead of remaining as connection terminals
Solution Approach 1:
The patent performs preliminary measurement of the winding target's actual outer shape and pre-calculates the corrected reference length before winding begins. This allows the system to anticipate the required wire length and position terminals correctly from the start, preventing terminals from being inadvertently wound onto the target.
Solution Approach 2:
The patent applies preliminary anti-action by measuring the winding target variation in advance and calculating a corrected reference length that compensates for expected deviations. This pre-compensation prevents the harmful effect of terminal mispositioning before it occurs, ensuring terminals remain in round shape for connection purposes.
3Productivity
If the rectangular-shaped part is positioned at the wrong location due to length variation, then the winding continues without interruption, but the positioning of the round-shaped wire causes the winding to collapse and increases defect rate
Solution Approach 1:
The patent uses feedback by continuously monitoring the wire supply length and comparing it against the corrected reference length. When the supply length reaches the corrected value, the system automatically switches from forming rectangular shape to maintaining round shape for terminals. This feedback control ensures correct terminal positioning while maintaining continuous winding operation.
Solution Approach 2:
The patent implements dynamics by making the wire shape transformation dynamic and adaptive. The forming device switches between rectangular shaping (for winding portions) and round shape preservation (for terminals) based on the real-time wire supply length relative to the corrected reference length. This dynamic adjustment ensures both winding continuity and terminal positioning accuracy.
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A winding device (10) includes: a length correction section which corrects a predetermined reference length; a wire supply section (11) which supplies a round-shaped wire; a forming section (12) which forms the wire into a rectangular shape; a winding section (14) which winds the wire onto a winding target. The forming section (12) performs start and end terminal processing in which forming on a part of the wire corresponding to start and end terminals of the winding target is not performed, and a forming process in which the wire corresponding to a part to be wound on the winding target is formed. The length correction section performs a correction process to determine a correction reference length, and the start and end terminal processing is performed when a supply length of the wire supplied from the start of winding reaches the correction reference length.