Direct Coil Winding Around Components With Thin-Wire Breakage Control

The patent applies beforehand cushioning by implementing a tension control system that anticipates and compensates for traction forces before wire breakage occurs. The system monitors wire tension in real-time and adjusts winding parameters proactively to maintain tension within safe limits, preventing breakage rather than reacting after it occurs. This allows high-speed operation while maintaining wire integrity.

The patent employs parameter changes by dynamically adjusting winding parameters such as winding speed, acceleration rates, and tension thresholds based on real-time wire condition monitoring. The system modifies these parameters adaptively to match the mechanical limits of the thin wire, enabling high productivity while preventing excessive traction that would cause breakage.

The patent implements self-service by providing an automated wire breakage detection and restoration system that operates without expert operator intervention. The system automatically detects wire breaks through tension monitoring and triggers restoration mechanisms such as wire feeders or splicing devices, maintaining continuous operation. This eliminates the need for manual intervention while preserving wire continuity, thereby maximizing productivity.

The patent replaces the mechanical system of manual wire restoration with an automated electromechanical system. Sensors, controllers, and automated wire feeding mechanisms substitute for expert operator actions, enabling continuous operation without human intervention. This substitution dramatically reduces stoppage time while maintaining wire continuity through automated detection and restoration processes.

The patent applies parameter changes by optimizing wire diameter within the 50-200 μm range based on specific application requirements, balancing electrical performance with mechanical strength. The system also changes operational parameters such as winding tension, speed, and environmental conditions to accommodate the use of thin, fragile wires while maintaining both transponder performance and wire integrity during manufacturing.

The patent implements beforehand cushioning by providing protective measures before wire breakage occurs, such as using wire with controlled tensile strength, implementing tension monitoring systems, and designing winding paths that minimize stress concentration. These preventive measures allow the use of thin wires for optimal transponder performance while compensating for their low mechanical resistance through engineered protection during the winding process.