Needle-Ring Toroidal Core Winding for Small-Diameter Cores
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Solution Overview
Problem
Conventional toroidal core winding devices face challenges with winding small diameter cores and thicker wires due to spatial constraints and reduced winding quality without a magazine, and existing magazine-free devices suffer from uncontrolled wire guidance and accuracy issues.
Innovation Solution
A device with a toroidal core holder and a needle ring with a deflection roller and baffle for perpendicular wire alignment, combined with magazine elements for wire storage and guidance, allowing for automated, magazine-free winding of toroidal cores with small diameters or non-circular geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an annular magazine is guided through the toroidal core for winding, then wire storage and automated winding are enabled, but toroidal cores with small diameters or tubular cores cannot be wound due to spatial constraints
Solution Approach 1:
The patent extracts the magazine structure from the traditional configuration where it must pass through the core opening. Instead, the magazine is positioned externally and delivers wire through a guide that enters the core from the side, allowing winding of small diameter and tubular cores without spatial interference
Solution Approach 2:
The wire delivery system transitions from a planar annular magazine configuration to a three-dimensional arrangement where the magazine operates in one plane while the wire is guided through another dimension (through the core opening from the side), enabling access to cores with restricted openings
2Extent of automation
If an annular magazine is used for wire storage, then automated winding is enabled, but the device structure becomes complex and manufacturing cost increases
Solution Approach 1:
The magazine is divided into multiple independent magazine elements arranged in a circular pattern, each capable of storing and delivering wire sections independently. This segmentation allows for simpler individual components that can be manufactured separately and assembled, reducing overall device complexity while maintaining automated winding capability
Solution Approach 2:
The magazine elements serve multiple functions: they store wire sections, guide the wire through the core, and can be adjusted for different wire diameters and core sizes. This multi-functionality reduces the need for additional specialized components, simplifying the overall device structure
3Device complexity
If magazine-free winding is implemented, then device structure is simplified, but wire control and winding quality are reduced
Solution Approach 1:
A wire guide acts as an intermediary element between the magazine and the core, providing precise control over wire positioning and tension. This intermediary component ensures accurate wire layer placement and proper crossing control while maintaining the simplified magazine-free structure
Solution Approach 2:
The system incorporates feedback mechanisms through tension sensors and position detectors that monitor wire placement in real-time. This feedback allows for automatic adjustment of wire feed rate and tension, ensuring consistent winding quality without complex mechanical control systems
Data Source
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AI summary
The invention relates to a device and a method for winding ring cores guided in a ring core holder with a wire comprising several wire sections without a magazine. The device further comprises: a substantially circular needle ring arranged in a winding plane that is substantially parallel to the wire, which is rotatably mounted and can be positioned relative to the ring core holder such that the needle ring winds a wire section located in the winding plane through and around a ring core guided in the ring core holder during operation.The needle ring further comprises a deflection roller, which is rotatably mounted in a first recess in the winding plane on the needle ring and is configured to wind the wire section located in the winding plane through and around the ring core during operation. It also comprises a baffle, which is arranged in a second recess in the winding plane adjacent to the first recess on the needle ring and is configured to guide the wire to be wound over a guide groove between the winding plane and a magazine plane arranged substantially parallel to the winding plane during operation. The device further comprises several magazine elements arranged in the magazine plane, which are mounted in a fixed position and rotatably and are configured to store wire sections located in the magazine plane.