Flat-Wire Coil Winding With Dynamic Clamping for Gap-Free Iron Cores

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Solution Overview

Problem

Conventional coil winding methods, particularly horizontal winding, face challenges with heat dissipation and production difficulties due to discrepancies in wire expansion and contraction, leading to potential plastic deformation and gaps between the coil and iron core.

Innovation Solution

A coil winding machine and method that incorporates a tension mechanism, rotary mechanism, and clamping mechanism to tightly abut and wind a flat wire onto an iron core, ensuring consistent tension, pressure, and rotational speed for efficient winding without deformation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If vertical winding is used to improve heat dissipation, then heat dissipation performance is improved, but gaps appear between the coil and iron core

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidgap between coil and iron core

Core Design Contradiction:

TemperatureVSManufacturing precision

Solution Approach 1:

The clamping mechanism is designed to be movable and adjustable, allowing it to apply dynamic pressure to the flat wire during winding. This ensures the wire remains tightly pressed against the iron core throughout the winding process, eliminating gaps while maintaining vertical orientation for heat dissipation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system changes the pressure parameter applied to the flat wire by the clamping mechanism during the winding process. By dynamically adjusting and maintaining optimal pressure, the wire is kept tightly bound to the iron core, preventing gap formation while preserving the vertical winding configuration for improved heat dissipation

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If horizontal winding is used to simplify the winding process, then manufacturing complexity is reduced, but heat dissipation performance deteriorates

Engineering Contradiction:

Improvewinding process simplicityVSAvoidheat dissipation performance

Core Design Contradiction:

Ease of manufactureVSTemperature

Solution Approach 1:

The clamping mechanism enables vertical winding by dynamically pressing the flat wire against the iron core during rotation, making the previously complex vertical winding process feasible and efficient, thereby improving heat dissipation while maintaining manufacturing simplicity

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If the flat wire is wound with tight clamping to eliminate gaps, then manufacturing precision is improved, but plastic deformation occurs due to wire expansion and contraction

Engineering Contradiction:

Improvetightness of windingVSAvoidwire deformation

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The clamping mechanism is designed to be co-rotatable with the core base, providing dynamic and uniform pressure distribution throughout the winding process. This prevents localized excessive pressure that causes plastic deformation, while still achieving tight winding without gaps

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system maintains correspondence between tension, clamping pressure, and rotational speed, creating a balanced winding process that prevents wire deformation while ensuring tight winding. The coordinated control of these parameters prevents plastic deformation

Inventive Principle:

Principle #23Feedback

4Device complexity

If the clamping mechanism is fixed during winding, then device complexity is reduced, but the flat wire cannot be tightly pressed against the rotating iron core

Engineering Contradiction:

Improveclamping mechanism structureVSAvoidtightness of wire to core

Core Design Contradiction:

Device complexityVSManufacturing precision

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

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 solution effectively addresses heat dissipation and production challenges by ensuring tight winding without plastic deformation, improving the slot filling rate and efficiency of the coil winding process.

Implementation Method 1

a tension provided by the tension mechanism, a pressure provided by the clamping mechanism, and a rotational speed of the core base correspond to one another

Methodology Applied

Scientific EffectTension: Tension

Implementation Method 2

a tension provided by the tension mechanism, a pressure provided by the clamping mechanism, and a rotational speed of the core base correspond to one another

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS20240321515A1Coil winding machine and coil winding method thereof

Publication Date: 2024.09.26 METAL INDS RES & DEV CENT

AI summary

A coil winding machine is adapted for winding a conductive flat wire onto an iron core. The coil winding machine includes a base, a tension mechanism mounted on the base and adapted for delivering the flat wire and providing tension to the flat wire, a rotary mechanism mounted on the base and including a core base that is rotatable and that is adapted to be mounted with the iron core, and at least one clamping mechanism mounted on the base, being co-rotatable with the core base, and operable for abutting the flat wire tightly against the iron core. A tension provided by the tension mechanism, a pressure provided by the clamping mechanism, and a rotational speed of the core base correspond to one another such that rotation of the core base and the at least one clamping mechanism winds the flat wire onto the iron core.