Coil Winding Around a Soft Core Rod for Uniform Heater Resistance
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Solution Overview
Problem
The manual and labor-intensive process of winding a relatively rigid wire rod around a soft, string-shaped core rod in a spiral manner for electronic cigarette heater elements poses challenges in maintaining consistent electrical resistance and contact, leading to potential burning and variations in smoke quality.
Innovation Solution
A coil winding apparatus and method that utilize a core rod feeding unit, core rod drawing unit, wire rod feeding unit, rotator, and guide member to apply tension and rotate the wire rod around the core rod in a spiral manner, ensuring consistent contact and uniform diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operations are used to wind the wire rod around the core rod, then flexibility in handling the soft core rod is maintained, but manufacturing efficiency is low and consistency is poor
Solution Approach 1:
The core rod feeding unit dynamically adjusts the feeding speed and tension of the core rod to match the winding speed, while the rotator rotates at a controlled speed to wind the wire rod. This dynamic coordination enables automated winding while maintaining consistency and efficiency without excessive complexity
Solution Approach 2:
The guide member acts as an intermediary between the wire rod feeding unit and the rotating core rod. It guides the wire rod onto the core rod at the correct angle and position, facilitating automated winding while simplifying the overall mechanism by separating the feeding and winding functions
2Adaptability or versatility
If the core rod is made soft by binding fibers for smoking liquid impregnation, then smoking liquid absorption is improved, but consistent winding of the rigid wire rod becomes difficult
Solution Approach 1:
The core rod is pre-formed by binding heat-resistive fibers to create a soft, porous structure capable of smoking liquid impregnation. This preliminary preparation allows the core rod to maintain its softness for liquid absorption while the automated winding process subsequently applies the wire rod with consistent precision
Solution Approach 2:
The system controls the physical parameters of the core rod (softness, diameter, tensile strength) through the fiber binding process, and simultaneously controls the winding parameters (wire rod tension, rotation speed, feeding rate) to achieve consistent winding despite the soft core rod's deformability
3Ease of operation
If the wire rod is wound loosely around the core rod, then ease of assembly is improved, but electrical contact consistency deteriorates leading to burning and smoke quality variations
Solution Approach 1:
The wire rod feeding unit and rotator work with coordinated control to maintain appropriate tension and contact pressure between the wire rod and core rod during winding. This feedback-controlled process ensures consistent electrical contact and prevents burning, while the automated nature maintains ease of operation
Data Source
AI summary
A coil winding apparatus includes: a core rod feeding unit configured to feed a string-shaped core rod from a core rod nozzle; a core rod drawing unit configured to draw out the core rod; a wire rod feeding unit configured to feed a wire rod towards the core rod; a rotator capable of rotating about the core rod nozzle; the guide member provided on the rotator, the guide member being configured to clamp, with the core rod, the wire rod that has been fed from the wire rod feeding unit; and a rotating unit configured to rotate the rotator to rotate the guide member together with the rotator so as to revolve the wire rod around the core rod in a vicinity of the core rod nozzle.