One-Piece Inductive Winding Forming for Automated Coil Production
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Solution Overview
Problem
Existing methods for manufacturing windings for inductive components face challenges in achieving good electrical properties and automated production, particularly when connection sections need to be joined by soldering or welding, leading to inconsistent electrical performance.
Innovation Solution
A method involving a flat, one-piece electrically conductive blank with integral strip-shaped winding sections of constant width, allowing for simple formation into a winding by wrapping, with connection sections remaining accessible for easy connection to other components, and optionally using a magnetically conductive core as a bending shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a wire is bent into a coil shape manually or with conventional methods, then the coil can be formed, but the efficiency is low and production time is long
Solution Approach 1:
The patent replaces manual or conventional mechanical coil bending methods with a robotic system that uses a robotic arm equipped with a bending tool. The robotic arm executes pre-calculated motion paths to bend the wire into coil shapes, significantly improving production efficiency and reducing manual labor while maintaining precision.
Solution Approach 2:
The system performs preliminary actions by pre-calculating the robotic arm's motion path and the bending tool's positioning before actual coil formation. The control unit stores and retrieves bending parameters in advance, allowing the robotic system to execute coil bending operations quickly and efficiently without real-time computation delays.
2Manufacturing precision
If conventional coil bending methods are used, then coils can be produced, but manufacturing precision and consistency are poor
Solution Approach 1:
The patent replaces imprecise conventional bending methods with a robotic system that uses pre-calculated motion paths and controlled bending forces. The robotic arm precisely positions the bending tool at specific locations along the wire, ensuring consistent coil geometry and shape accuracy across all produced coils.
Solution Approach 2:
The system achieves precise coil formation by controlling and adjusting various parameters including bending force, bending speed, tool position, and motion path. The control unit manages these parameters systematically, ensuring that each coil is formed with consistent precision while maintaining ease of manufacture through automated parameter control.
3Ease of operation
If manual coil formation is used, then flexibility in handling different wire types is maintained, but labor costs and operational complexity are high
Solution Approach 1:
The robotic system is designed with universal capabilities to handle different wire types, coil shapes, and bending requirements through programmable control. The same robotic arm and bending tool can be reconfigured via software to produce various coil geometries, eliminating the need for multiple specialized devices while reducing operational complexity through automated control.
Solution Approach 2:
The system achieves ease of operation through self-service automation where the robotic arm autonomously performs wire feeding, positioning, bending, and coil formation without continuous human intervention. The control unit manages the entire process automatically, reducing operational complexity while maintaining flexibility for different production requirements.
Data Source
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AI summary
The invention relates to a method for producing a winding for an inductive component, comprising the steps of: producing a planar, single-piece and electrically conductive blank, the blank comprising at least a first connection portion, a second connection portion and a strip-shaped winding portion having a constant width, and shaping the planar blank to form a winding by wrapping the winding portion around a bending die.