Edgewise Coil Winding Guide with Rotational Support
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Solution Overview
Problem
Conventional methods for winding coils with rectangular conductors require complex operations and costly tool changes due to the need for different guide movements to form short and long sides, leading to increased costs and reduced efficiency.
Innovation Solution
A method and device that use a guide with a rotation mechanism to support the outer side surface of the coil during edgewise bending, allowing for continuous winding without the need for tool changes and reducing the complexity of the drive mechanism, by employing a guide that rotates in accordance with the bending operation and includes multiple guides to support the coil at different stages of formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a guide configuration is used that holds the inner circumferential side of the coil during edgewise bending, then the coil can be supported during winding, but the guide shape must be changed for each coil and tooling change is required
Solution Approach 1:
Instead of holding the inner circumferential side of the coil as in conventional methods, this invention holds the outer side surface of the coil. This inversion allows a single guide configuration to support coils of different sizes and shapes without requiring tooling changes, while still providing stable support during the winding process
Solution Approach 2:
The guide configured to hold the outer side surface of the coil can universally support different coil types and dimensions. This single guide structure serves multiple functions across different coil production scenarios, eliminating the need for multiple specialized guides and reducing device complexity
2Manufacturing precision
If the guide is made to rotate and move to depict an involute curve to follow the feeding of rectangular conductor, then the coil can be wound into rectangular shape, but two vertical axes and one rotation axis need independent control increasing device cost
Solution Approach 1:
Instead of having the guide perform complex rotational and translational movements to create an involute curve, this invention inverts the approach by having the guide hold the outer side surface while the coil naturally forms its rectangular shape. This eliminates the need for multiple independently controlled axes
Solution Approach 2:
The complex drive mechanism requiring two vertical axes and one rotation axis with independent control is extracted and removed from the system. The simplified guide configuration achieves coil shaping through a single rotational axis, reducing device complexity and cost
3Productivity
If tandem drive is used to increase winding speed, then productivity increases, but device cost increases
Solution Approach 1:
The guide is configured with rotational capability that allows it to dynamically adapt to the coil winding process. This dynamic configuration enables high winding speed through a single drive mechanism rather than requiring multiple tandem drives, maintaining productivity while reducing device cost
Data Source
AI summary
Provided is a method for winding an edgewise coil and a winding device capable of saving time and labor when changing a guide. A guide bar is disposed in contact with the side face of the rectangular conductor bent by the bending jig and the rotation center of the guide bar deviates from the rotation center of a bending jig for bending a rectangular conductor. The guide bar rotates in accordance with the action whereby the bending jig bends the rectangular conductor and supports the outside surface of a coil on the side of rotational direction of the bending jig.