Saddle Coil Bending Layout to Prevent Wire Stretching
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing saddle coils cause wire deformation and insulation damage due to lateral sliding and stretching during the bending process, particularly with rectangular wires, and require electrical leads to be positioned inside the coil.
Innovation Solution
A saddle coil winding apparatus and method that uses a flexible coil bending plate with removable components to form a saddle coil with electrical leads on the outside, employing a length-preserving geometric transformation to avoid lateral wire motion and stretching, allowing for the assembly of multilayer coils without additional deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional bending methods are used to form saddle coils, then the coil can be shaped, but wire stretching and lateral sliding occur causing deformation and insulation damage
Solution Approach 1:
The wire is pre-formed into a flat coil configuration with the correct dimensions before bending. The flat coil is wound with precise control over wire length and layer spacing, so that when bent into the saddle shape, no additional stretching or deformation is required. This preliminary formation eliminates the harmful lateral sliding and stretching that occur in traditional methods.
Solution Approach 2:
The invention changes the geometric parameters of the coil formation process by using a flat coil configuration with specific dimensional relationships. The flat coil is designed with wire length L, coil width W, and layer spacing S that satisfy specific mathematical relationships, ensuring that when bent into a saddle shape, the wire maintains its original length without stretching or compression.
2Quantity of substance
If rectangular wire is used in traditional bending, then larger wire sizes can be accommodated, but wire corners interfere with each other preventing lateral motion and causing deformation
Solution Approach 1:
Rectangular wire is pre-formed into a flat coil configuration where the wire runs parallel to itself throughout the coil structure. The wire is wound such that corners are positioned at the ends of the coil layers rather than at the corners of the coil cross-section, eliminating corner-to-corner interference that would prevent lateral motion during bending.
3Ease of manufacture
If traditional winding methods are used, then coils can be manufactured, but electrical leads must be positioned inside the coil requiring wire to pass over windings
Solution Approach 1:
The coil structure is segmented into distinct regions: the flat coil winding section and the lead extension section. The electrical leads are formed as separate extensions from the main coil windings, allowing them to be positioned on the outer surface of the coil rather than requiring wires to pass through or over the windings. This segmentation simplifies lead positioning and reduces manufacturing complexity.
Data Source
AI summary
The invention relates to saddle coil winding apparatus, methods of manufacturing saddle coils, and saddle coils produced using the winding apparatus and/or manufacturing methods. The saddle coil winding apparatus and methods of manufacturing beneficially reduce or eliminate the stretching of electrical wires, and do not cause the electrical wires to slide past each other. The saddle coils produced using the winding apparatus and/or manufacturing methods may have electrical leads provided on the outside of the coil.