Multi-Axis Winding Apparatus for Belt-Like Wire
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Solution Overview
Problem
Existing winding apparatuses face challenges in efficiently winding belt-like wires around complexly shaped bobbins without forming kinks or bends, particularly due to the difficulty in accurately positioning and rotating the wire along multiple axes to match the intricate shape of the bobbin.
Innovation Solution
A winding apparatus with a bobbin, core, pressing section, moving unit, first and second rotating units, and control unit, which allows for precise movement and rotation of the pressing section along multiple axes to press and wind the wire around the bobbin, utilizing a control unit to create coordinate information and operation recipes for optimal wire placement and winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanism is provided to rotate the bobbin and move the head along one axis, then the head can follow the circumferential surface of the bobbin, but it becomes difficult to accurately position and rotate the wire along multiple axes to match intricate bobbin shapes
Solution Approach 1:
The winding apparatus divides the positioning system into two independent parts: the head moving mechanism that handles simple linear motion along one axis, and the wire rotating mechanism that handles complex multi-axis rotation. This segmentation allows each subsystem to specialize in its specific function, improving both operational simplicity and positioning precision for intricate bobbin shapes.
Solution Approach 2:
The invention adds a rotational dimension to the wire feeding system. While the head moves along one axis (1D), the wire can now be rotated along multiple axes (3D), enabling accurate matching of complex bobbin geometries that require multi-dimensional positioning capabilities.
2Device complexity
If the head moves along one axis while the bobbin rotates, then the structure remains simple, but it cannot efficiently wind wires around complexly shaped bobbins without kinks or bends
Solution Approach 1:
The system separates the simple linear positioning function (head moving along one axis) from the complex orientation function (wire rotating along multiple axes). This segmentation maintains structural simplicity for the positioning mechanism while adding rotational capabilities specifically for wire orientation, ensuring high-quality winding without kinks or bends on complex bobbins.
Solution Approach 2:
The wire feeding system transitions from a static, single-axis movement to a dynamic, multi-axis rotation system. The wire can dynamically adjust its orientation along multiple axes to match the changing geometry of complex bobbins, ensuring continuous surface contact and preventing kinks or bends during the winding process.
3Manufacturing precision
If multi-axis rotation and movement mechanisms are added to the head, then wire positioning precision improves, but the device complexity increases
Solution Approach 1:
Instead of making the entire head assembly complex with multi-axis rotation, the invention segments the functionality: the head maintains its simple single-axis movement structure, while the wire feeding mechanism independently provides multi-axis rotation. This segmentation achieves high positioning precision without complicating the head's mechanical structure.
Solution Approach 2:
The wire rotating mechanism acts as an intermediary between the simple head positioning system and the complex bobbin geometry. It translates the simple linear head movement into precise multi-dimensional wire positioning, achieving high manufacturing precision without directly complicating the head mechanism itself.
Data Source
AI summary
According to one embodiment, winding apparatus includes a bobbin, a core, a pressing section, a moving unit, a first rotating unit, a second rotating unit and a control unit. The moving unit is configured to move the pressing section relatively to the core along each of first to third axes perpendicular to each other. The first rotating unit is configured to rotate the pressing section relatively to the core around fourth and fifth axes perpendicular to each other, and set on the core. The second rotating unit is configured to rotate the pressing section relatively to the core around a sixth axis which becomes parallel to, when the core is in an initial position at which the fourth and fifth axes become parallel to any two of the first to third axes, a remaining one of the first to third axes.