Gear-Driven Winding Die for Universal Foil Core Winding
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Solution Overview
Problem
The existing technologies for manufacturing stereoscopic wound iron core transformers require specialized tooling devices and have low generalization degrees, making the winding process complex and costly, and requiring high operator skill.
Innovation Solution
A winding die with a gear baffle and cylinder that allows for the rotation of a foil or insulating material around an iron core post, driven by a gear mechanism, simplifying the winding process and reducing manufacturing costs by eliminating the need for traditional foil winding machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional foil winding machines are used, then winding precision and reliability are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent divides the winding system into modular components: a simple die body, a separate cylinder for foil storage, and a gear mechanism for rotation. This segmentation allows each component to perform its function independently, reducing overall system complexity while maintaining winding reliability through proper functional distribution.
Solution Approach 2:
The winding die is designed to be self-contained with the cylinder holding the foil and automatically feeding it during the rotation process. The gear mechanism automatically controls the rotation speed and foil feeding rate, eliminating the need for complex external control systems and operators, thus reducing device complexity while ensuring reliable winding.
2Manufacturing precision
If specialized winding dies and clamps are used for different foil coils, then winding precision is improved, but adaptability and manufacturing cost deteriorate
Solution Approach 1:
The patent designs a universal die body with standardized features that can accommodate different foil coils by simply changing the cylinder component. The gear mechanism and basic die structure remain the same, while the cylinder can be adjusted or replaced to match different winding requirements, thus maintaining precision across various applications while improving adaptability and reducing the need for multiple specialized dies.
Solution Approach 2:
The winding die incorporates adjustable elements, particularly in the cylinder positioning and height adjustment capabilities. This dynamic design allows the same die structure to adapt to different foil dimensions and winding specifications, enabling one die to serve multiple purposes while maintaining manufacturing precision through proper adjustment.
3Productivity
If high mechanization degree is achieved, then productivity is improved, but operator skill requirements and device complexity increase
Solution Approach 1:
The patent replaces complex automated winding machines with a simpler gear-based mechanical system. The gear mechanism provides inherent speed control and synchronization through its mechanical design, eliminating the need for electronic controls and highly skilled operators. This mechanical substitution maintains productivity through automated rotation while significantly reducing operator skill requirements and overall device complexity.
Data Source
AI summary
A winding die is disclosed, including: a gear baffle, where a middle portion of the gear baffle is provided with a first opening for placing an iron core post, and the gear baffle is provided with a first surface; and a cylinder, where the cylinder is arranged on the first surface of the gear baffle and connected with the gear baffle. The middle portion of the gear baffle is provided with the first opening for placing the iron core post, the gear baffle is fixedly connected with the cylinder, an external device is connected with a gear, and the cylinder on the gear baffle is driven to rotate around the iron core post by pulling the gear, so that a foil or an insulating material on the cylinder can be wound on the iron core post, finally realizing a foil winding.