Multi-Station Coil Winding With Reorientation for High-Speed Precision
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Solution Overview
Problem
Current methods for manufacturing coils around components, such as those in electronic cigarette cartridges, face challenges in achieving high operating speed and quality, often resulting in a significant number of faulty pieces.
Innovation Solution
A machine and method are developed to efficiently manufacture multiple coils around a component, utilizing a conveyor system with multiple stations for winding and welding, allowing for precise orientation and handling of the component to ensure consistent coil production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional single-coil manufacturing methods are used, then device complexity is low, but productivity is insufficient and manufacturing precision deteriorates due to high faulty piece rates
Solution Approach 1:
The manufacturing system is divided into multiple independent winding stations (first winding station, second winding station, etc.), each capable of producing coils independently. This segmentation allows parallel processing of multiple components simultaneously, increasing overall productivity while maintaining quality control at each station
Solution Approach 2:
The conveyor system is designed to dynamically adjust the positioning and orientation of components as they move through different winding stations. The system can adaptively orient components based on their specific requirements, ensuring high manufacturing precision while maintaining continuous high-speed production
2Productivity
If high operating speed is pursued, then productivity improves, but manufacturing precision deteriorates due to increased faulty pieces
Solution Approach 1:
By dividing the production system into multiple specialized winding stations, each station can operate at optimized speeds for its specific task. This allows the overall system to achieve high productivity without sacrificing precision, as each segment maintains control over its own manufacturing quality
Solution Approach 2:
The conveyor system acts as an intermediary that precisely positions and transports components between winding stations. This intermediary mechanism ensures that even at high operating speeds, components are correctly oriented and positioned, preventing faulty pieces while maintaining high productivity
Data Source
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AI summary
Method and machine (18) to manufacture at least two different coils (9-14) around a component (1) of an article. The method comprises: moving, by means of a main conveyor (19) and along a winding path (P), a carriage (20) carrying at least one seat (22, 23, 24) designed to house the component (1); placing, in an input station (SI) arranged along the winding path (P), the component (1) in the seat (22, 23, 24) of the carriage (20); winding, in a first winding station (S3) arranged along the winding path (P) downstream of the input station (SI), a first externally insulated conductor wire (15) around the component (1) in order to obtain a series of turns making up a first coil (9-14); and winding, in a second winding station (S6) arranged along the winding path (P) downstream of the first winding station (S3), a second externally insulated conductor wire (15) around the component (1) in order to obtain a series of turns making up a second coil (9-14); and changing, in a first handling station (S5) arranged along the winding path (P) between the first winding station (S3) and the second winding station (S6), the orientation of the component (1) relative to the carriage (20).