Flanged Winding Core Guide for Regular Multi-Layer Wire Winding
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Solution Overview
Problem
Conventional winding devices struggle to achieve regular winding patterns around winding cores with flanges, leading to irregularities and difficulties in guiding wire rods to desired positions, especially when the number of layers exceeds ten, due to the risk of nozzle contact with flanges and increased gaps between the nozzle and the winding body.
Innovation Solution
A winding device equipped with a rotating guide member and an axial-direction moving mechanism that allows precise positioning of the guide member relative to the winding core, enabling the wire rod to be accurately guided to the desired location on the winding body, even with flanges present, by adjusting the distance and position of the guide members to maintain close contact and prevent irregularities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the nozzle is positioned close to the winding body to guide the wire rod, then regular winding can be achieved, but the nozzle comes into direct contact with the flanges causing interference
Solution Approach 1:
A guide member is introduced as an intermediary component between the nozzle and the winding body. The guide member receives the wire rod from the nozzle and guides it to the winding body, allowing the nozzle to be positioned away from the flanges while still achieving precise wire rod placement for regular winding patterns.
Solution Approach 2:
The winding device is segmented into distinct functional components: the nozzle for wire rod delivery, the guide member for wire rod guidance, and the winding body for coil formation. This segmentation allows each component to be optimized independently, with the guide member specifically designed to bridge the gap between nozzle and winding body without flange interference.
2Object-affected harmful factors
If the nozzle is positioned away from the winding body to avoid flange contact, then nozzle-flange interference is prevented, but the wire rod cannot be guided to the desired location accurately
Solution Approach 1:
The guide member serves as a mediator that extends the functional reach of the nozzle system. It allows the nozzle to be positioned safely away from flanges while the guide member reaches closer to the winding body to ensure accurate wire rod placement at the desired location.
Solution Approach 2:
The guide member is configured to rotate together with the winding core, adding rotational motion as a dimension to the wire rod guidance system. This rotational capability allows the guide member to maintain accurate positioning relative to the winding body throughout the winding process, compensating for the increased distance from the nozzle.
3Productivity
If the number of winding layers is increased to enhance output, then the dynamo-electric machine output increases, but irregularities build up making regular winding difficult
Solution Approach 1:
The guide member is designed to rotate dynamically together with the winding core, maintaining real-time synchronization with the winding process. This dynamic adjustment capability allows the system to maintain precise wire rod placement accuracy across multiple layers, preventing irregularity buildup even as the number of layers increases to enhance output.
Solution Approach 2:
The rotating guide member provides continuous feedback on the wire rod position relative to the winding body throughout the multi-layer winding process. This feedback mechanism enables real-time correction of any positioning deviations, ensuring winding regularity is maintained across all layers regardless of the total number of layers.
Data Source
AI summary
A winding device includes: a winding core having a winding body and flanges provided on both sides of the winding body in a rotation-axis direction, the winding core being configured such that a wire rod supplied from a supply source is wound around the winding body being rotated; a guide member configured to be rotated together with the winding core, the guide member being configured to guide the wire rod to the winding body; and an axial-direction moving mechanism configured to move the guide member in the rotation-axis direction of the winding core.