Rotating Traverse Wire Winding Figure-Eight Pattern
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Solution Overview
Problem
Existing coil winding technologies face challenges in efficiently winding wires in a figure-eight pattern without twisting, tangling, or kinking, particularly when dealing with diverse wire types and characteristics, such as twisted-pair cables and fiber-optic cables.
Innovation Solution
A system comprising a spindle shaft with a mandrel and a traverse that reciprocates and rotates to guide the wire in a figure-eight pattern, utilizing a reciprocating element driven by a crank or cam-arm, with a rotating gear and flexible belt mechanism to ensure precise wire placement and tension control, allowing for faster winding and efficient payout.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional winding mechanism is used to wind wire in a figure-eight pattern, then the wire can be wound around the mandrel, but the wire may twist, tangle, or kink during the winding process
Solution Approach 1:
The patent applies dynamics by making the wire guide both reciprocate (move back and forth) and rotate simultaneously during the winding process. This dynamic motion allows the wire to be laid down in a figure-eight pattern while maintaining proper orientation and tension, preventing twisting and tangling. The wire guide's rotation angle is specifically controlled to ensure the wire exits tangentially to the mandrel surface at all times.
Solution Approach 2:
The patent introduces an additional rotational dimension to the wire guide mechanism. Instead of simply moving linearly back and forth, the wire guide rotates about its own axis while reciprocating. This adds a rotational degree of freedom that enables the wire to be deposited in a controlled figure-eight pattern without twisting, as the rotation compensates for the changing orientation during reciprocation.
2Productivity
If the traverse moves faster to increase winding speed, then productivity improves, but the precision of wire placement and tension control may deteriorate
Solution Approach 1:
The patent ensures continuous useful action by making the wire guide rotate continuously throughout its reciprocating motion, rather than rotating only at turning points. This continuous rotation, combined with continuous reciprocation, maintains constant wire tension and steady deposition speed, allowing high winding speeds without sacrificing placement precision. The synchronized motion ensures the wire is always laid down at the correct angle and position.
Solution Approach 2:
The patent employs feedback control through sensors that detect the position and motion of the wire guide, and a controller that adjusts the reciprocation and rotation speeds based on detected conditions. This closed-loop control system maintains precise wire placement even at high winding speeds by continuously monitoring and correcting any deviations in the wire guide's motion or wire tension.
3Adaptability or versatility
If the wire guide remains stationary relative to the mandrel surface, then the mechanism is simpler, but the wire cannot accommodate increasing coil diameter as winding progresses
Solution Approach 1:
The patent applies dynamics by making the wire guide rotate about its own axis while reciprocating, creating a dynamic adaptation mechanism. As the coil diameter increases, the continuous rotation of the wire guide compensates for the changing geometry, maintaining proper wire orientation and tension throughout the winding process. This dynamic motion allows the system to adapt to growing coil dimensions without requiring mechanical adjustments.
Solution Approach 2:
The patent changes the motion parameters of the wire guide, specifically introducing rotational motion in addition to reciprocation. By controlling the rotation speed and angle of the wire guide, the system adapts to the changing coil diameter as winding progresses. The rotation parameter is adjusted to maintain the correct wire exit angle relative to the mandrel surface, enabling accommodation of coil growth without increasing mechanical complexity.
Data Source
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AI summary
Systems and methods for winding wire are disclosed. A system includes a wire take-up unit having a rotating mandrel and a traverse having a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire directing device reciprocates along an axis parallel to the axis of rotation of the mandrel. The wire directing device also rotates along an axis perpendicular to the axis of rotation of the mandrel so that the lay-down point of the wire directing device sweeps over an arc for each throw of the traverse.