Relay Coil Winding Device with Rotatable Yoke Carrier
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Solution Overview
Problem
Existing coil winding devices are inefficient when wrapping two coils arranged parallel to each other on a U-shaped coil yoke, requiring individual wrapping and subsequent placement on the yoke legs, which is not only cumbersome but also inefficient in terms of space and speed.
Innovation Solution
A device with a rotatable spool yoke and wrap nozzle system that allows for simultaneous wrapping of two coils by aligning their longitudinal axes with the rotation axis, enabling the coils to be wound without removing the yoke from the device, thus reducing installation space and increasing winding speed and precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If two coils are wrapped individually and then arranged on the yoke legs, then each coil can be wrapped separately, but the process is inefficient and requires more space
Solution Approach 1:
The patent combines the wrapping of two coils into a single integrated process by positioning both coils on a common rotating carrier. The wrapping device wraps both coils simultaneously or sequentially without removing the yoke from the device, merging what were previously separate operations into one unified process.
Solution Approach 2:
The rotating carrier serves multiple functions: it holds both coils in parallel arrangement, positions them for wrapping, and enables rotation during the wrapping process. This multi-functional component eliminates the need for separate handling and positioning mechanisms for each coil.
2Speed
If a rotatable wrapping device is used to wrap two coils simultaneously, then winding speed increases, but the device complexity increases
Solution Approach 1:
Instead of moving the wrapping device to each coil, the patent inverts the approach by rotating the coils (mounted on a carrier) into position under a stationary or simplified wrapping mechanism. The carrier rotates to bring each coil into the wrapping zone, reversing the traditional motion paradigm.
Solution Approach 2:
The patent introduces dynamic rotation of the carrier to enable high-speed wrapping. The carrier can rotate continuously or intermittently to present both coils to the wrapping device in sequence, enabling faster processing compared to static positioning methods.
3Area of stationary object
If the wrap nozzle is positioned parallel to the rotary axis, then installation space is reduced, but the wrapping precision must be maintained
Solution Approach 1:
The patent positions the wrap nozzle parallel to the rotary axis rather than perpendicular, utilizing a different spatial dimension for the wrapping operation. This orientation reduces the footprint of the device while the rotational motion of the carrier maintains wrapping precision through consistent radial engagement.
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
The solution enables efficient and precise wrapping of two coils in parallel, reducing the need for additional equipment, minimizing installation space, and achieving higher rotary speeds and wrap precision.
Implementation Method 1
a rotatable wrapping device (101) for holding the coil yoke (108) has a rotation axis (101-1), wherein the wrapping device (101) can be rotated around the rotation axis (101-1)
Implementation Method 2
to position the first coil body (105-1) in such a way that the first longitudinal axis (105-11) coincides with the rotation axis (101-1), and to position the second coil body (105-2) in such a way that the second longitudinal axis (105-22) coincides with the rotation axis (101-1)
Implementation Method 3
a wrap nozzle (102), which is formed to hand over the coil wire (107) in parallel to the rotation axis (101-1)
Data Source
Figure 1A~1D
Figure 2A~2D
Figure 3A~3E
AI summary
The present invention relates to a winding device (100) for winding coil wire onto coil formers of a coil yoke (108) of a relay. The coil yoke (108) comprises first and second yoke limbs (108-1, 108-2) each with first and second coil formers (105-1, 105-2), which extend in the direction of first and second longitudinal axes (105-11, 105-22) and are arranged parallel to one another. The winding device (100) comprises a rotatable coil receptacle (101), which can be rotated about an axis of rotation (101-1) which is oriented parallel to the first and second longitudinal axes (105-11, 105-22), to hold the coil yoke (108). The coil receptacle (101) is designed to support the coil yoke (108) displaceably transversely to the axis of rotation (101-1) to position the coil formers with the first and second longitudinal axes (105-11, 105-22) on the axis of rotation (101-1) for winding coil wire onto said first and second coil formers (105-1, 105-2). The winding device (100) further comprises a winding nozzle (102), which is designed to dispense the coil wire parallel to the axis of rotation (101-1).