Rotatable Gripper Coil Winding for Accurate Alignment

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Solution Overview

Problem

Existing methods for manufacturing coils require complex structures due to the need to move wire rod guide holding portions in synchronization with winding, leading to intricate machinery designs.

Innovation Solution

A winding machine with a winding core, first and second winding jigs, and rotatable grippers that grip the winding using rollers, allowing for simplified winding processes by rotating the grippers around the core without requiring synchronized movement of guide holding portions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If wire rod guide holding portion is moved in synchronization with winding timing, then winding accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvewinding accuracyVSAvoidstructure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

Instead of moving the wire rod guide holding portion in synchronization with winding timing, the patent inverts the approach by making the gripper rotatable about the central axis while keeping the wire rod guide holding portion stationary. This inversion resolves the technical contradiction by achieving winding accuracy through rotational movement rather than synchronized linear movement, thereby reducing device complexity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent applies dynamics by making the gripper rotatable about the central axis of the winding core. This dynamic capability allows the gripper to follow the winding process and maintain proper positioning without requiring complex synchronized movement mechanisms, thus achieving winding accuracy with simpler structure.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If wire rod guide holding portion is moved in synchronization with winding, then winding alignment is improved, but ease of manufacture deteriorates

Engineering Contradiction:

Improvewinding alignmentVSAvoidmanufacturing simplicity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent inverts the conventional approach by keeping the wire rod guide holding portion stationary and instead making the gripper rotatable. This inversion achieves winding alignment through the rotational movement of the gripper about the central axis, thereby simplifying the manufacturing process as stationary components are easier to manufacture than synchronized moving components.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent segments the functions by separating the wire rod guide holding portion (stationary) from the gripper (rotatable). This segmentation allows each component to be manufactured independently with simpler requirements, improving ease of manufacture while maintaining winding alignment through the rotational capability of the gripper.

Inventive Principle:

Principle #1Segmentation

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 efficient and accurate winding of coils with a simpler machine structure, reducing complexity and enhancing the ability to align and fill windings effectively, thereby improving manufacturing efficiency and space utilization.

Implementation Method 1

At least one of the first gripper or the second gripper is rotatable about the central axis

Methodology Applied

Scientific EffectRotation:

Implementation Method 2

Each of the first gripper and the second gripper includes a pair of rollers to interpose and grip the winding

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS12354790B2Winding machine and method of manufacturing coil

Publication Date: 2025.07.08 NIDEC CORP(JP)

AI summary

A winding machine includes a winding core around which a winding is wound, a first winding jig and a second winding jig positioned with the winding core interposed therebetween in an axial direction of a central axis of the winding core, and a first gripper and a second gripper that are located on an outer side of the winding core in a radial direction around the central axis. An outer edge portion of the first winding jig in the radial direction and an outer edge portion of the second winding jig in the radial direction are located on an outer side, in the radial direction, from the winding core. Each of the first gripper and the second gripper includes a pair of rollers to interpose and grip the winding. At least one of the first gripper or the second gripper is rotatable about the central axis.