High-Density Coil Manufacturing via Sequential Press Working
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Solution Overview
Problem
Existing methods for manufacturing high-density coils are limited to producing coils with rectangular cross sections and cannot accommodate coils with various cross-sectional shapes, such as tapered cross sections, due to uniform pressing conditions in two directions.
Innovation Solution
A method involving sequential press working of coils in multiple directions (X, Y, Z) with a time lag, allowing for different pressing forces and durations in each direction to accommodate various cross-sectional shapes, such as a tapered shape, by using a press working machine with independent pressing portions for each axis direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If uniform pressing conditions are applied in two directions, then a high-density coil with rectangular cross section can be manufactured, but coils with various cross-sectional shapes (e.g., tapered) cannot be produced
Solution Approach 1:
The press working process is segmented into multiple sequential pressing operations in different directions (first pressing in vertical direction, then pressing in horizontal direction with time lag). This segmentation allows each pressing operation to be independently controlled, enabling the formation of various cross-sectional shapes including tapered shapes while maintaining process manageability
Solution Approach 2:
The pressing conditions are made dynamic by introducing time lags between pressing operations in different directions and allowing different pressing forces to be applied sequentially. This dynamic approach enables adaptation to various cross-sectional shape requirements while using a relatively simple press working machine structure
2Manufacturing precision
If pressing force is increased to achieve high density, then space factor is enhanced, but copper wire may be damaged
Solution Approach 1:
The coil is pre-formed with round copper wire having specific elongation properties (30-40% elongation) before pressing. This preliminary preparation allows the wire to be more resistant to damage during subsequent pressing operations while still achieving high density when pressed under controlled conditions
Solution Approach 2:
Pressing is applied periodically in sequential steps with time lags between different directions rather than as a single continuous force. This periodic application allows the copper wire to adjust and distribute stress, achieving high space factor while preventing wire damage through controlled, intermittent pressing
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
Enables the manufacture of high-density coils with diverse cross-sectional shapes by optimizing pressing conditions for each axis direction, preventing damage to the copper wire and achieving the desired shape effectively.
Implementation Method 1
a step of sequential press working the coil, which is set at the predetermined press working position, in a plurality of directions sequentially with a time lag
Data Source
AI summary
A method of manufacturing a high-density coil formed by press working a coil to cope with the manufacture of high-density coils having various cross-sectional shapes. The method includes: a step of setting the coil at a predetermined press working position in a press working machine; and a step of sequential press working the coil, which is set at the predetermined press working position, in a plurality of directions sequentially with a time lag.