Rotatable Nozzle Suspension for Coil Winding Radial Bulge Reduction
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Solution Overview
Problem
Existing winding technologies face challenges in producing coil-like winding bodies with reduced radial bulging, particularly on carrier bodies with non-circular, convex cross-sectional shapes, as existing solutions primarily address axial bulging while leaving radial bulging unresolved.
Innovation Solution
A nozzle suspension system that rotatably mounts the winding nozzle to allow for adjustable rotational positioning, using a contact surface to preform the winding material elastically and plastically, thereby reducing radial bulging by applying a counter-bending force that counteracts the convex shape of the carrier body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a contact surface is arranged at a distance from the longitudinal axis to preform the winding material, then radial bulging is reduced, but the complexity of the nozzle suspension increases
Solution Approach 1:
The rotatable nozzle holder serves multiple functions: it maintains the axial preforming action, enables radial bulge reduction through angular adjustment, and provides adaptability for different carrier body geometries. This multi-functionality consolidates what could be separate complex mechanisms into a single versatile component.
Solution Approach 2:
The contact surface is positioned at an optimized angle in advance to preform the winding material before it reaches the carrier body. This preliminary angular positioning allows the material to be shaped in a way that counteracts radial bulging, reducing the need for complex post-winding adjustments or additional correction mechanisms.
2Manufacturing precision
If the rotational position of the nozzle holder is cyclically controlled, then winding precision is improved, but the control system complexity increases
Solution Approach 1:
The cyclic control of the nozzle holder's rotational position incorporates feedback mechanisms that monitor the winding process and adjust the nozzle angle accordingly. This feedback loop ensures high winding precision by continuously optimizing the contact surface angle relative to the carrier body position, while the control system manages complexity through automated closed-loop regulation.
Solution Approach 2:
The nozzle holder's rotational position is adjusted periodically in sync with the winding cycle, creating a rhythmic pattern of angle adjustment that corresponds to the carrier body's rotation or progression. This periodic action simplifies control by establishing a predictable, repeating sequence rather than requiring continuous complex calculations.
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 system effectively minimizes or eliminates radial bulging by precisely controlling the rotational position of the nozzle holder, ensuring the winding material is securely and evenly applied to the carrier body, reducing material waste and improving winding precision.
Implementation Method 1
the material to be wound before being released from the mouth surface of the winding nozzle in the storage direction is elastically to plastically arranged by a contact surface arranged firmly on the mouth surface of the winding nozzle and at a distance from the longitudinal axis by counter-bending
Implementation Method 2
the material to be wound before being released from the mouth surface of the winding nozzle in the storage direction is elastically to plastically arranged by a contact surface arranged firmly on the mouth surface of the winding nozzle and at a distance from the longitudinal axis by counter-bending
Data Source
AI summary
The invention relates to a nozzle suspension (50) for at least one winding nozzle (1), particularly for producing an electric coil on a carrier body, said nozzle suspension (55) comprising at least one nozzle receiving portion (55) for the winding nozzle (1) for the purpose of receiving and securing the winding nozzle (1) in the correct position and such that it does not rotate in said nozzle receiving portion (55). The nozzle receiving portion (55) is rotatably mounted in the nozzle suspension (50) such that the winding nozzle (1) received in said nozzle receiving portion (55) is mounted to rotate about a winding nozzle (1) longitudinal axis (L) that runs transversely to a deposit direction of winding material (4) leaving said winding nozzle (1). A rotational position of the nozzle receiving portion (55) can be actively controlled by the nozzle suspension (50). The invention also relates to a winding device that comprises such a winding nozzle (1), as well as to a winding method.