Non-Circular Coil Manufacturing Apparatus with Swinging Core
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Solution Overview
Problem
Conventional methods for manufacturing non-circular coils, such as those for small-sized speakers, face difficulties in removing the coil from a core without damaging the wire coating and in achieving a desired shape due to the lack of effective tension distribution and contact resistance on cores with oblong or oval cross-sections.
Innovation Solution
An apparatus and method utilizing a pair of swinging pieces with adjustable distance and an operation piece that enlarges the distance between the swinging pieces to facilitate wire winding and then reduces it for easy coil removal, ensuring the wire is wound without bulging and maintaining contact with the core surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a wire guide is used to forcibly remove the coil from the core by abutment, then the coil can be removed from the core, but the surface coating of the wire is damaged due to sliding friction against the core
Solution Approach 1:
The core is designed with a swingable distal end that can dynamically change its orientation. During coil winding, the distal end swings to maintain tangential contact with the wire, ensuring proper tension distribution. During coil removal, the distal end swings to create clearance between the core and the coil, allowing easy removal without friction-induced coating damage
Solution Approach 2:
The core's distal end is pre-configured with a swinging mechanism that automatically positions it in the appropriate state before each operation. Before coil winding, the distal end is positioned to provide tangential contact. Before coil removal, the distal end is positioned to create clearance, eliminating the need for forceful extraction that would damage the coating
2Productivity
If a predetermined tension is applied to the wire in the longitudinal direction, then the wire can be wound around the core, but the wire bulges away from straight-line portions of the core without adequate contact resistance
Solution Approach 1:
The core is designed with different surface characteristics at different locations. The distal end features straight-line portions with specific surface properties that enhance contact resistance when the wire is wound around them. This local quality enhancement ensures the wire maintains proper contact and does not bulge away, while still allowing efficient winding with predetermined tension
Solution Approach 2:
The swinging mechanism of the distal end dynamically adjusts the contact angle between the wire and the core surface during winding. This dynamic adjustment ensures optimal tangential contact at straight-line portions, maintaining adequate contact resistance and preventing wire bulging while preserving winding efficiency
Data Source
AI summary
An apparatus for manufacturing a non-circular coil, includes a pair of swinging pieces, an operation piece to be inserted and removed from between the distal ends of the pair of swinging pieces to increase or reduce the distance between the distal ends of the pair of swinging pieces, and a winding mechanism for winding a wire around an outer circumference of a distal end of the pair of swinging pieces so as to form a non-circular coil, wherein side surfaces of the operation piece, which avoid contact with the pair of swinging pieces, bulge outward to be curved and are formed so as to be continuous with outer circumferential surfaces of the pair of swinging pieces, around which the wire is wound, in a state in which the operation piece is inserted between the distal ends of the pair of swinging pieces.