Helical Wire Winding on Closed Cores Without Mechanical Stress
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Solution Overview
Problem
The challenge lies in automating the winding process of rectangular or flat wires onto closed cores for transformers, which is complex, time-consuming, and prone to mechanical stress due to the sensitivity of ferrite core materials, especially when high mechanical forces are required to expand helical air-core coils onto closed cores.
Innovation Solution
A device comprising a feed device, a reshaping device, and a gradient sensor device that allows for automatic winding of wires, including rectangular or flat wires, onto closed cores by bending them helically without generating mechanical stresses, using a guide device and pitch sensor to achieve a compressed winding with minimal mechanical forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If helical air-core coils are expanded onto closed cores to overcome core cross-section, then the coil can be installed on the core, but high mechanical forces act on the core and the process is complex and time-consuming
Solution Approach 1:
Instead of expanding a pre-formed helical coil onto the core (which requires high forces), the invention inverts the approach by directly winding the wire helically onto the core during manufacturing. This eliminates the need for post-forming expansion and the associated high mechanical forces on the core.
Solution Approach 2:
The helical shape is formed during the winding process itself rather than as a preliminary step. The wire is wound directly into its final helical configuration on the core, eliminating subsequent forming operations and their associated mechanical stresses.
2Productivity
If rectangular or flat wires are used for winding to achieve high inductance, then high amperage currents can be conducted, but automated winding becomes extremely difficult and time-consuming
Solution Approach 1:
The invention replaces complex mechanical winding mechanisms with a more straightforward winding approach. By using a winding device that guides the rectangular wire through forming elements rather than relying on complex mechanical manipulation, automation becomes feasible and simpler.
Solution Approach 2:
The invention introduces forming elements as intermediaries between the wire and the winding mechanism. These forming elements shape the rectangular wire into the desired configuration during winding, simplifying the overall device complexity while enabling automated processing of rectangular wires.
3Reliability
If ferrite core materials are used for transformers, then high inductance is achieved, but the core materials are very sensitive to mechanical stress effects
Solution Approach 1:
The invention applies preliminary anti-action by designing a winding process that prevents mechanical stress from acting on the ferrite core in the first place. The wire is wound directly onto the core in its final configuration without requiring subsequent expansion or forming operations that would subject the stress-sensitive ferrite material to harmful mechanical forces.
Data Source
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AI summary
The invention relates to a device (1) for winding a wire (2), comprising an advancing device (10) for advancing the wire (2), a shaping device (20), and a pitch-producing device (30) for bending the wire (2). The shaping device (20) and the pitch-producing device (30) are designed such that the wire (2) is bent in a spiral manner in the shaping device (20) and the pitch-producing device (30) when the wire is advanced. The invention further relates to an inductive component (4) which can be produced using the method.