Manual Coil Winding Tension Maintainer for Stable Wire Feeding
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Solution Overview
Problem
Manual winding of enameled wires onto coil formers, such as in transformers, inductors, or motors, is challenging due to difficulties in adjusting wire arrangement, maintaining stable wire tension, and preventing the wire from coming loose, leading to reduced production efficiency and quality.
Innovation Solution
A manual winding device comprising a wire bracket, clamp, winder, and tension maintainer with a sliding block and connecting rods to maintain wire tension, allowing one-handed operation for efficient and rapid winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual winding is performed using only the operator's hands, then the operation is simple, but the wire arrangement adjustment is difficult and winding quality is poor
Solution Approach 1:
The patent introduces a tension maintainer mechanism as an intermediary device between the operator and the wire. This mechanism includes a tensioning roller and adjustment mechanism that mediates the wire feeding process, providing consistent tension and proper wire arrangement automatically, thus improving winding quality while keeping the operation simple.
Solution Approach 2:
The tension maintainer is designed to automatically regulate wire tension through its adjustment mechanism without requiring continuous manual intervention. Once set, the system self-regulates the wire arrangement and tension throughout the winding process, maintaining high winding quality while minimizing operational complexity.
2Device complexity
If manual winding is performed without assistance, then the device structure is simple, but stable wire tension cannot be maintained
Solution Approach 1:
A tension maintainer mechanism is introduced as an intermediary device that automatically regulates wire tension. This mechanism includes a tensioning roller with adjustable pressure, providing stable tension control without requiring complex active control systems, thus maintaining relatively simple device structure while achieving tension stability.
Solution Approach 2:
The tension maintainer allows for parameter adjustment (pressure on the tensioning roller) to optimize wire tension stability. By adjusting this physical parameter, the system can adapt to different wire types and winding requirements, maintaining stable tension with a relatively simple adjustable mechanism.
3Device complexity
If manual winding is performed without a tension maintenance mechanism, then the device is simple, but the wire may come loose requiring process restart
Solution Approach 1:
The tension maintainer is configured to preliminarily establish proper wire tension before winding begins and maintains it throughout the process. This preliminary tensioning action prevents wire loosening during winding, ensuring process continuity without requiring complex real-time monitoring or adjustment systems.
Solution Approach 2:
The tension maintainer acts as an intermediary safeguard between the wire source and the winding process. It continuously maintains appropriate tension, preventing wire loosening and potential process interruptions, thereby improving reliability while adding only a relatively simple mechanical mechanism.
4Manufacturing precision
If two-handed operation is required for wire feeding and position adjustment, then wire control is better, but production efficiency is reduced
Solution Approach 1:
The tension maintainer is designed to self-regulate wire tension and arrangement without requiring continuous manual adjustment. Once the adjustment mechanism is initially set, the system automatically maintains proper wire control throughout the winding process, freeing one hand for position adjustment while maintaining wire control precision, thus improving productivity.
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 device ensures stable wire tension and improved winding quality by allowing operators to feed wire with one hand while adjusting the winding position with the other, enhancing efficiency and reducing the need for restarting the process.
Implementation Method 1
The tension maintainer comprises a sliding base, a sliding block, and four connecting rods... The tension maintainer is configured to maintain the tension of the wire
Implementation Method 2
the other two connection points each being provided with a pulley, and the wire is wound around each pulley
Implementation Method 3
the wire is wound around each pulley
Data Source
AI summary
A manual winding device comprises a wire bracket, a clamp, a winder, and a tension maintainer. The wire bracket supplies wire, while the clamp holds it in place. The winder, adjacent to the clamp, includes a driving mechanism and a coil former holding unit. The coil former holding unit is configured to mount a coil former. The driving mechanism is configured to drive the coil former holding unit to rotate, winding the wire onto the coil former. The tension maintainer, located between the clamp and the winder, includes a sliding base, a sliding block, and four connecting rods forming a quadrilateral. The sliding block is movably disposed on the sliding base. Two opposite connection points are pivotally mounted on the base and sliding block, while the other two points each hold a pulley around which the wire passes. The tension maintainer ensures the wire's tension is maintained during winding.