Coil Winding Tension Control for Signal Integrity
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Solution Overview
Problem
Existing coil winding technologies face challenges in applying figure-eight winding patterns to different types of wires, particularly in maintaining optimal tension to prevent physical deformity and ensuring consistent cable signal performance while managing coil size.
Innovation Solution
A system with a spindle shaft, mandrel, traverse, and tensioner that initially winds the first two to four layers of wire at a lower tension, followed by a gradual or immediate increase to a higher tension, using a pneumatic cylinder controlled by a digital self-relieving air regulator to maintain optimal wire tension and prevent deformity, ensuring consistent signal performance and coil size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high tension is applied during the winding of the first two to four layers, then the coil maintains structural integrity, but physical deformity occurs at wire crossovers and cable signal performance deteriorates
Solution Approach 1:
The patent applies preliminary low tension during the critical first two to four layers of winding to prevent deformity at wire crossovers before the coil structure is established. This preliminary action with reduced tension ensures that the initial layers, which form the foundation of the coil, do not cause physical deformity or signal performance issues, while subsequent layers can then apply higher tension for structural integrity.
2Reliability
If low tension is applied during the winding of the first two to four layers, then physical deformity is avoided at wire crossovers, but the coil may lack structural stability
Solution Approach 1:
The patent implements dynamic tension adjustment during the winding process, transitioning from low tension during the first two to four layers to higher tension in subsequent layers. This dynamic approach allows the system to adapt tension levels based on the winding stage: low tension initially protects against deformity and maintains signal performance, while higher tension in later layers ensures structural stability and integrity of the finished coil.
3Manufacturing precision
If consistent high tension is applied throughout the winding process, then the coil maintains uniform density, but wire deformity occurs at crossovers in the initial layers
Solution Approach 1:
The patent applies local quality by differentiating tension levels based on the specific stage of winding. The first two to four layers receive low tension locally to protect wire crossovers from deformity, while subsequent layers receive higher tension to achieve uniform density. This localized differentiation of tension quality ensures that each portion of the coil receives the appropriate tension for its specific requirements.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively avoids physical deformity at wire crossovers, enhances cable signal performance, and maintains a consistent coil size by adjusting tension levels during the winding process, optimizing the winding of various wire types.
Implementation Method 1
using a pneumatic cylinder controlled by a digital self-relieving air regulator to maintain optimal wire tension
Data Source
AI summary
Systems and methods for winding wire are disclosed. A system includes a wire take-up unit and a wire tensioning unit. The take-up unit includes a rotating mandrel and a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire tensioning unit applies tension to said wire as it is wound, and applies a first amount of tension to a predetermined amount of wire constituting at least a first two layers of the coil, and a second amount of tension to the wire beyond the predetermined amount. In one embodiment, the wire tensioning unit includes digital self-relieving air regulator pneumatically coupled to and controlling a pressure in said pressurized chamber of a pre-lubricating cylinder that is coupled to the wire being wound.