Multi-Layer Coil Winding via Nested Unit Portions
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Solution Overview
Problem
Existing methods for manufacturing coils with multiple layers using a stepped winding jig are inefficient due to manual tasks, and automatic winding machines require complex configurations to change the winding core form for each wire winding step.
Innovation Solution
A winding method and apparatus that continuously form unit coil portions with different inner circumferential lengths by winding a conductive wire along a loop shape route with arc-shaped corner parts, using a shaft body with varying diameters and a bending mechanism to form arc-shaped corner parts at the same phase angle, allowing for multi-layering by compressing smaller units inside larger ones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stepped winding jig is used to manufacture coils with multiple layers, then the coil structure can be formed, but production efficiency is low due to manual tasks
Solution Approach 1:
The winding process is segmented into distinct phases: forming unit wound portions with different inner circumferential lengths, assembling them into unit coil portions, and compressing into multi-layer coil portions. This segmentation enables automated continuous winding while maintaining structural integrity
Solution Approach 2:
Unit wound portions are pre-formed with specific inner circumferential lengths before assembly. This preliminary formation allows automated winding machines to efficiently create the final multi-layer structure without complex real-time adjustments
2Adaptability or versatility
If an automatic winding machine changes the form of the winding core member for each wire winding step, then unit wound portions with different inner circumferential lengths can be formed, but the configuration becomes complicated
Solution Approach 1:
A shaft body with stepped portions serves as an intermediary tool during winding. Each stepped portion corresponds to a specific inner circumferential length, allowing the winding machine to maintain a simple configuration while achieving variable dimensions through the intermediary shaft structure
Solution Approach 2:
Multiple unit wound portions are wound by copying the same winding process around different stepped portions of the shaft body. This copying approach enables formation of various inner circumferential lengths without requiring the winding machine itself to be complex
3Volume of moving object
If unit wound portions are compressed to form multi-layer coil portions, then space factor increases, but the manufacturing process becomes more complex
Solution Approach 1:
Unit wound portions are nested within each other to form multi-layer coil portions. Smaller inner circumferential length portions are positioned inside larger ones, creating a compact nested structure that maximizes space factor while using a straightforward compression process
Data Source
AI summary
The present invention is to provide a plurality of unit coil portions formed by winding one conductive wire about a winding axis is placed side by side in the winding axis direction, each of the unit coil portions is formed by unit wound portions having different inner circumferential lengths from each other, the unit coil portion is multi-layered in at least a part thereof by pushing at least a part of the unit wound portion having a small inner circumferential length inside the unit wound portion having a large inner circumferential length, and the unit wound portion is wound along a loop shape winding route having a plurality of arc shape corner parts. In unit wound portions forming the unit coil portion, corner parts formed at the same phase angle with respect to the winding axis are formed in an arc shape having curvature center at the same position.