Rounded Corner Winding Core for Coil Devices
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Solution Overview
Problem
Existing coil winding devices cause damage to wires due to springback and result in increased coil length, as the wire is pressed against steps on the winding core, leading to distortion and lengthening of the coil.
Innovation Solution
A winding core with a columnar shape divided into four core bars with rounded corners, forming a helical continuous smooth surface, allowing the core to be expanded for winding and contracted for easy removal, reducing the risk of wire damage and coil lengthening by minimizing contact with steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the winding tracks are widened to prevent wire damage from steps, then wire damage is reduced, but the clearance between adjacent turns increases and the total coil length increases
Solution Approach 1:
The winding core uses rounded corners instead of sharp steps to guide the wire. The rounded corner radius R is specifically designed to be larger than half the wire thickness, creating a smooth curved surface that guides the wire without creating damaging steps while maintaining precise winding track width control.
Solution Approach 2:
The winding core has different surface characteristics in different regions: the corner portions have rounded surfaces with specific radius R for wire guidance, while the track width W is precisely controlled in the radial direction. This localized differentiation allows wire protection without increasing overall track width.
2Ease of manufacture
If the winding core is formed with steps to create winding tracks, then wire winding is enabled, but the wire is damaged by the steps
Solution Approach 1:
The winding core replaces sharp angular steps with rounded corner surfaces. The rounded corners with radius R > wire thickness/2 provide smooth wire guidance while maintaining the stepped winding track structure for proper wire positioning and coil formation.
Solution Approach 2:
The winding core geometry is modified by changing the corner radius parameter from zero (sharp steps) to a specific value R that is larger than half the wire thickness. This parameter change transforms the harmful sharp edges into protective rounded surfaces while preserving the winding track functionality.
Data Source
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AI summary
A winding core for a coil winding device having a column shape with corners each having a rounded cross-section is used for forming a coil by winding a wire around the winding core into the coil of a polygonal shape. The winding core includes a helical continuous surface extending spirally around an axis of the winding core.