Precision Magnetic Coil Winding System with Real-Time Feedback Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of high-intensity, uniform magnetic coils for MRI requires precise control over winding geometry to avoid defects like gaps and anomalies, which is challenging due to human error in manual correction and the difficulty in achieving consistent epoxy distribution, especially in epoxy-supported coils.
Innovation Solution
An automated system for precision magnetic coil winding that includes a wire disposing assembly with a support, axial traverser, and radial positioning device, coupled with a controller unit for real-time feedback and correction, ensuring precise wire placement and resin application to minimize defects and enhance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual correction is used for wire placement adjustments, then operators can detect and correct errors, but human errors occur and the process slows down
Solution Approach 1:
The system uses automatic control systems with sensors and feedback mechanisms to monitor wire placement in real-time and make corrections without human intervention. The controller receives feedback from position sensors and automatically adjusts the wire feeding and placement mechanisms, enabling the system to self-correct placement errors while maintaining high speed winding operations.
Solution Approach 2:
The patent implements closed-loop feedback control where sensors continuously monitor wire position and placement accuracy, and the controller uses this feedback information to make real-time adjustments to the winding process. This feedback mechanism ensures precise wire placement while maintaining automated high-speed operation without requiring manual intervention.
2Quantity of substance
If wet winding method is used to maximize epoxy coverage, then coverage is improved, but wire placement becomes difficult due to slipping
Solution Approach 1:
The system applies epoxy coating to the wire in a controlled manner before the winding process begins, or applies it in precise amounts during winding. The controller regulates the epoxy dispensing to ensure adequate coverage while preventing excessive epoxy that would cause wire slippage. This preliminary or controlled application ensures both coverage and placement accuracy.
Solution Approach 2:
The patent controls the viscosity, application amount, and timing of epoxy application as adjustable parameters. By optimizing these parameters, the system achieves sufficient epoxy coverage for thermal and mechanical stability while preventing excessive epoxy that would cause wire placement errors. The controller dynamically adjusts epoxy application parameters based on winding conditions.
3Manufacturing precision
If precise control over winding geometry is implemented, then defects are reduced, but manufacturing complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single automated winding system that combines wire feeding, epoxy application, position monitoring, and error correction capabilities. This multi-functional system achieves precise winding geometry control without requiring separate manual operations for each function, thereby reducing overall manufacturing complexity while maintaining high precision.
Solution Approach 2:
The system replaces manual mechanical wire placement and error correction operations with automated control systems that use sensors, feedback loops, and computer-controlled mechanisms. This substitution reduces the complexity of manual operations while achieving superior and more consistent winding geometry precision through automated control.
4Manufacturing precision
If automated control is implemented for wire placement, then precision is improved and speed is increased, but system complexity increases
Solution Approach 1:
The automated control system uses feedback from position sensors and monitoring devices to continuously track wire placement accuracy. The controller processes this feedback information and makes real-time adjustments to maintain precise placement. This feedback mechanism enables high precision and speed while managing system complexity through intelligent control algorithms.
Solution Approach 2:
The control system is designed to autonomously monitor, detect, and correct wire placement errors without external intervention. The system self-regulates the winding process by comparing actual placement with target positions and automatically making corrections, thereby achieving high precision and speed while minimizing the need for complex external control mechanisms.
Data Source
AI summary
A system for producing precision magnetic coil windings is provided. The system includes a wire disposing assembly having a support, an axial traverser sub-assembly, and a support arm. The support is configured to receive a plurality of turns of a wire. The axial traverser sub-assembly is operatively coupled to the support. The support arm includes a wire disposing device. The system further includes a linear stage, a monitoring unit, a feedback unit, and a controller unit. The linear stage is operatively coupled to the support arm. Moreover, the controller unit is configured to axially position an incoming portion of the wire and provide reference trajectories for tracking.