Self-Centering Spool Endform Assembly for Mandrel Misalignment
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Solution Overview
Problem
Existing wire winding machines face issues with axial misalignment of endforms and mandrels due to wear or damage, leading to excessive bearing wear and machine downtime for repair and adjustment.
Innovation Solution
A spool endform assembly with a central collar and mount sub-assembly that allows for misalignment compensation, enabling easier connection and disconnection to a rotatable mandrel, using annular members, circular plates, and biasing members to maintain alignment and support rotation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the endform axis is fixed relative to the movable arm, then the structure is simple and stable, but misalignment occurs due to wear or damage causing bearing wear and machine downtime
Solution Approach 1:
The mounting structure transitions from a fixed rigid connection to a dynamic adjustable system. The movable arm incorporates adjustment mechanisms that allow the endform axis to be repositioned relative to the arm, enabling compensation for wear and misalignment while maintaining operational reliability
Solution Approach 2:
The system allows changing the positional parameters of the endform relative to the movable arm. By adjusting the axis position through the mounting structure, the system adapts to wear conditions and maintains proper alignment without requiring complete component replacement or complex realignment procedures
2Reliability
If manual adjustments are made to realign the endform axis, then alignment can be restored, but machine downtime increases due to repair and adjustment operations
Solution Approach 1:
The mounting structure incorporates self-adjusting features that allow the operator to realign the endform axis during routine maintenance without requiring complex manual adjustments or specialized repair operations. The design enables straightforward repositioning that reduces the time and skill required for alignment corrections
Solution Approach 2:
The system includes pre-configured adjustment mechanisms and alignment features that are prepared in advance, allowing quick realignment when misalignment occurs. The mounting structure is designed with built-in alignment references and adjustment capabilities that eliminate the need for time-consuming manual realignment procedures
3Adaptability or versatility
If the endform and mandrel are frequently connected and disconnected, then coil production is flexible, but misalignment accelerates bearing wear and increases maintenance requirements
Solution Approach 1:
The mounting structure provides dynamic adjustment capabilities that allow the endform axis to be realigned between connection and disconnection cycles. This prevents the accumulation of misalignment that would otherwise accelerate bearing wear during frequent assembly and disassembly operations
Solution Approach 2:
The system incorporates protective features in the mounting structure that compensate for potential misalignment before it causes bearing damage. The adjustable mounting mechanism acts as a cushion against misalignment stresses, protecting the bearings during repeated connection and disconnection operations
Data Source
Figure 1~2
Figure 3A~3B
Figure 3C
AI summary
A spool endform assembly includes an endform with a central collar that are configured to rotate about a rotational axis. The spool endform assembly further includes a mount subassembly configured to be mounted in a fixed orientation on a mounting structure. The spool endform assembly is further configured to permit misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar. In embodiments, controlled movement of the mounting structure can be used to connect or disconnect the spool endform assembly to a rotatable mandrel of a wire winding spool. By permitting misalignment of the fixed orientation of the mount sub-assembly relative to the rotational axis of the endform and central collar, the spool endform assembly makes it easier to connect the spool endform assembly to the rotatable mandrel and to disconnect the spool endform assembly from the rotatable mandrel. Other features and aspects are described and/or claimed.