Linked Coil Formation Device Parallel Winding Lines
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing linked coil formation methods face challenges in achieving high arrangement precision, reliability, and efficiency due to variations in coil arrangement and electrical characteristics, particularly in the welding and folding processes, which lead to manufacturing complexities and potential displacement issues during the formation of linked coils.
Innovation Solution
A linked coil formation device comprising parallel coil winding processing lines and a material transfer unit that allows for continuous transfer and processing of flat wire to form linked coils without welding or folding, ensuring precise alignment and efficient production by forming first and second coil parts in rectangular cylinder shapes and linking them on the same face.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to connect end parts of wires via communication terminal, then electrical connection between coils is achieved, but manufacturing complexity increases and reliability becomes problematic
Solution Approach 1:
The patent extracts and eliminates the welding process and communication terminals from the coil connection system. Instead of welding wire ends to terminals, the invention uses a communication groove structure where coils are mechanically inserted and electrically connected through the groove geometry, removing the problematic welding step entirely
Solution Approach 2:
The communication groove acts as an intermediary structure that provides both mechanical support and electrical connection between coils. The groove geometry itself serves as the connection medium, replacing the need for separate terminals and welding operations
2Ease of manufacture
If folding of linking part is performed to form integrated coils, then coil integration is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the coil formation process into distinct winding operations rather than requiring a single continuous folding operation. Multiple coils are wound separately in parallel and then connected through the communication groove, avoiding the complexity of folding and repositioning a single continuous wire structure
Solution Approach 2:
Instead of folding a continuous wire to create integrated coils, the invention inverts the approach by winding separate coils and connecting them through a shared communication groove structure, achieving integration through connection rather than continuous formation
3Productivity
If parallel coil winding processing lines are used, then productivity increases, but alignment precision becomes difficult to maintain
Solution Approach 1:
The communication groove serves multiple functions simultaneously: it provides mechanical support for multiple coils, establishes electrical connections between them, and acts as a reference structure for alignment. This multi-functional design enables parallel processing while maintaining precision through the groove's geometric constraints
Solution Approach 2:
The patent replaces complex mechanical alignment systems with a geometric constraint system based on the communication groove. The groove's fixed geometry provides inherent alignment references, eliminating the need for sophisticated mechanical positioning mechanisms in parallel processing lines
4Reliability
If welding process is used for coil connection, then electrical characteristics can be controlled, but variation in electrical characteristics occurs due to workmanship
Solution Approach 1:
The patent extracts the welding process from the electrical connection system and replaces it with a mechanical insertion method. Coils are inserted into communication grooves where electrical contact is established through the groove geometry itself, eliminating workmanship variation associated with welding
Solution Approach 2:
The communication groove structure provides self-aligning and self-contacting features that ensure consistent electrical characteristics without requiring skilled manual operation. The groove geometry automatically guides coil placement and establishes reliable electrical contact through its fixed dimensional parameters
Data Source
AI summary
[Problem to be solved] A first coil and a second coil are efficiently formed in the shape of a rectangular cylinder and in parallel to each other, by bending and processing a flat wire, and a linking part of each of the coils, is linked with the same material without welding or folding.[Means for solving the problem] Provided are: a first coil winding processing line having a first winding head forming a first coil part in the shape of a rectangular cylinder at one end part of a flat wire W; a second coil winding processing line disposed in parallel to the first coil winding processing line and having a second winding head on which a second coil part in the shape of a rectangular cylinder is formed at the other end part of the flat wire W and both of the coil parts are arranged to be adjacent to each other on an identical face; and a coil placement unit for conveying the flat wire W having the first coil part from the first coil winding processing line to the second coil winding processing line along each coil winding processing line.