Flyer Winding Machine Variable Geometry Wire Guide
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Solution Overview
Problem
Flyer machines for winding internal stators of brushless stepper motors face challenges in achieving precise wire guidance and control, leading to wire crossings and reduced filling factors, which affect the motor's performance due to their inherent inability to maintain correct stratification and efficient wire deposition.
Innovation Solution
A coil winding machine with a wire-guiding device featuring a non-rotating, frusto-pyramidal wire-guiding head with adjustable geometry, comprising two slidable front guiding elements that converge to form a variable geometry head, allowing precise control and adaptation to the winding support, preventing diagonal wire arrangements and ensuring continuous support for the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a flyer machine is used for high-speed winding, then productivity is improved, but manufacturing precision deteriorates due to difficulty in guiding the wire and maintaining correct stratification
Solution Approach 1:
A wire-guiding device is introduced as an intermediary between the flyer (wire dispensing member) and the winding support. This device includes guiding elements that define a wire-guiding head with a frusto-pyramidal side surface, acting as a mediator to control and guide the conducting wire during the winding process, thereby improving precision without sacrificing the high-speed capability of the flyer machine
Solution Approach 2:
The geometry of the wire-guiding head is made variable by allowing the front guiding elements to be slidable relative to the body of the wire-guiding device. This enables adjustment of the distance between guiding elements and the winding support, allowing optimization of wire guidance for different winding conditions and maintaining precision across varying operational parameters
2Manufacturing precision
If the distance between wire dispensing point and winding support is reduced, then manufacturing precision is improved, but device complexity increases due to additional wire-guiding mechanisms
Solution Approach 1:
The wire-guiding device performs multiple functions: it guides the wire, defines the stratification of turns, maintains proper wire arrangement, and allows geometric adjustment. By consolidating these functions into a single integrated device with a frusto-pyramidal guiding head, the patent achieves improved precision without proportionally increasing complexity
Solution Approach 2:
The wire-guiding head geometry is made dynamic through slidable front guiding elements that can adjust their position relative to the body. This dynamic capability allows the device to adapt to different winding requirements and maintain optimal wire guidance, achieving precision improvement without permanent complexity increase
3Manufacturing precision
If a needle machine is used for precise wire guidance, then manufacturing precision is improved, but productivity deteriorates due to slow operation speed and mechanical inertia
Solution Approach 1:
The patent merges the high-speed rotational capability of the flyer system with the precise wire guidance functionality traditionally provided by needle machines. The wire-guiding device with its frusto-pyramidal head and slidable elements provides needle-like precision guidance while the flyer continues to rotate at high speed, combining advantages of both systems
Data Source
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AI summary
Flyer coil winding machine (1) comprising a wire-guiding device (5) wherein: said wire-guiding device (5) comprises a first front guiding element (6) and a second front guiding element (7) which form a non-rotating wire-guiding head (8), with a variable geometry, facing said support (3); said wire-guiding head (8) has a frusto-pyramidal side surface (21) and a front frame (22) which defines a front opening (23); the front guiding elements (6, 7) are slidable in converging directions so as to modify the geometry of the wire-guiding head (8).