Direct Coil Winding Around Components With Lower Wire Breakage
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Solution Overview
Problem
The challenge in manufacturing coils for electronic cigarette transponders is the frequent breakage of thin wires during winding, leading to reduced productivity and increased costs due to machine stoppages, as existing technologies lack effective methods to maintain high speed and quality while minimizing wire breakage.
Innovation Solution
A method and machine are developed to wind coils around components with a gentle mechanical treatment and extended winding time, using a winding machine with multiple stations and clamps to manage wire tension and orientation, ensuring stable and efficient coil production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high operating speed is used during wire winding, then productivity is improved, but wire breakage frequency increases
Solution Approach 1:
The patent applies beforehand cushioning by implementing a tension detection system that monitors wire tension before breakage occurs. The system detects abnormal tension increases and automatically adjusts winding parameters or stops the process to prevent wire breakage, thus allowing high-speed operation while maintaining reliability.
Solution Approach 2:
The patent implements feedback control through a tension detection device that continuously monitors wire tension during winding. When abnormal tension is detected, the system provides feedback to control the winding process, automatically adjusting parameters to prevent breakage while maintaining high productivity.
2Speed
If wire tension is increased during winding, then winding speed can be increased, but wire breakage occurs
Solution Approach 1:
The patent applies dynamics by making the wire tension adjustable and adaptable during the winding process. The tension detection device monitors real-time tension and the system dynamically adjusts winding parameters to optimize both speed and wire integrity, rather than using fixed tension values.
Solution Approach 2:
The patent implements parameter changes by varying wire tension, winding speed, and other process parameters based on real-time detection. The system changes parameters dynamically to prevent wire breakage while maintaining high winding speed, adapting to the specific wire properties and winding conditions.
3Length of moving object
If thin wire with small diameter is used, then transponder miniaturization is achieved, but mechanical resistance decreases
Solution Approach 1:
The patent replaces mechanical strength enhancement with a detection and control system. Instead of using thicker wire to increase mechanical resistance, the system uses tension detection and automated control to monitor and protect the thin wire during winding, allowing miniaturization while preventing breakage.
Solution Approach 2:
The patent introduces an intermediary tension detection device that acts as a mediator between the thin wire and the winding process. This intermediary system detects tension abnormalities and triggers protective actions, enabling the use of thin wire without compromising mechanical reliability during manufacturing.
Data Source
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AI summary
Method and machine (18) to manufacture a coil (9-14) around a component (102) of an article (100). A main conveyor (19) moves, along a working path (P1), a carriage (20) provided with a seat (22, 23, 24) designed to house the component (102); the component (102) is arranged in the seat (22, 23, 24) of the carriage (20) in an input station (S1) arranged along the working path (P1); and in a winding station (S3, S6, S9, S12, S15, S18) arranged along the working path (P1), a wire (15) is directly wound around the component (102) to form a series of turns making up the coil (9-14) by making a movable finger (57), which engages the wire (15) in a sliding manner, revolving around the component (102) several times.