Precision Layer-Wound Coils for Dense 3D Wire Alignment
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Solution Overview
Problem
Current methods for creating electromagnetic coils, such as layer winding, are limited by their inability to produce complex 3D geometries and precise packing of wire, leading to potential electrical or mechanical failures and inefficiencies in coil geometry translation.
Innovation Solution
A 3D printing-based approach using a dispenser with multiple degrees of freedom to lay down copper wire or conducting materials on a build platform, with a bondable overcoat for adhesion and a processor-controlled system to create complex coil designs, allowing for precise positioning and alignment of wire sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If CNC coil winding machines are used to create layer wound coils, then packing density is improved, but the ability to create complex 3D geometries deteriorates
Solution Approach 1:
The patent transitions from traditional 2D planar coil winding to 3D spatial coil construction by adding vertical stacking capability and rotational freedom. The coil winding apparatus can now create coils with complex three-dimensional geometries by moving the wire feed and mandrel in multiple dimensions, not just planar paths.
Solution Approach 2:
The system introduces dynamic control of the mandrel rotation and wire feed positioning, allowing the coil geometry to be precisely controlled in real-time during the winding process. This enables adaptation to various complex 3D shapes while maintaining packing density.
2Adaptability or versatility
If wire is wound and then reshaped to create complex geometries, then adaptability is improved, but reliability deteriorates due to mechanical failures
Solution Approach 1:
The patent performs preliminary shaping of the coil during the winding process itself, rather than attempting to reshape the coil after winding. The mandrel and wire feed system are positioned and moved in advance to create the final complex geometry directly, avoiding subsequent reshaping operations that could damage the conductors.
3Adaptability or versatility
If heating is applied after winding to translate shape, then adaptability is improved, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces thermal shaping methods with a mechanically controlled winding system. Instead of heating the wire after winding to reshape it, the system uses precisely controlled mechanical movement of the wire feed and mandrel during winding to achieve the desired complex geometry directly, ensuring manufacturing precision is maintained.
4Ease of manufacture
If CNC machines with 3-axis control are used, then ease of manufacture is maintained, but the ability to create intricate coil designs deteriorates
Solution Approach 1:
The patent extends the traditional 3-axis CNC control to include additional degrees of freedom, such as mandrel rotation and vertical positioning, enabling the creation of intricate three-dimensional coil designs while maintaining the programmable precision of CNC machining.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of densely packed, precision-aligned electromagnetic coils with complex geometries, reducing mechanical stress and improving reliability, consistency, and efficiency in coil design, particularly for small or intricate motor designs and applications like galvanometers and voice coils.
Implementation Method 1
a coating applicator to apply a bondable overcoat to the wire, such that when a section of the wire is laid adjacent to another section of the wire, the bondable overcoats of the respective sections bond to each other
Data Source
AI summary
An apparatus for creating an electromagnetic coil, including: a platform for building the coil; a dispenser to dispense a wire via a nozzle; a wire feeder to feed the wire through the dispenser; a coating applicator to apply a bondable overcoat to the wire, such that when a section of the wire is laid adjacent to another section of the wire, the bondable overcoats of the respective sections bond to each other; one or more actuators to provide at least three degrees of freedom to the dispenser and/or the platform; and a processor to control the one or more actuators to move the dispenser and/or platform such that the wire is dispensed at a specified location relative to the platform; wherein the processor controls the one or more actuators based on a program stored in a memory, the program including instructions for laying the wire according to a predetermined pattern.