Solenoid Bobbin Opening Geometry for Stable Wire Winding
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Solution Overview
Problem
Bobbins with larger openings can cause a radial offset between adjacent wire windings, negatively affecting the winding and magnetic field of a solenoid.
Innovation Solution
A bobbin design with a wall thickness that decreases towards an opening, featuring tapered regions and guide elements to minimize the radial offset between wire windings, and optionally larger openings for coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If larger openings are provided in the bobbin wall, then coolant flow and oil exchange are improved, but radial offset between adjacent wire windings increases
Solution Approach 1:
The wall thickness is varied locally around the opening: thicker in regions away from the opening to maintain structural integrity and guide wire windings, and thinner in regions adjacent to the opening to minimize radial offset. This local variation in wall thickness allows the opening to be larger while maintaining winding precision.
Solution Approach 2:
The wall around the opening is divided into different functional regions: guide regions with greater wall thickness that provide structural support and winding guidance, and transition regions with reduced wall thickness that minimize radial offset. This segmentation allows different parts of the wall to serve different purposes.
2Manufacturing precision
If wall thickness is reduced toward the opening, then radial offset between wire windings is minimized, but structural strength of the bobbin wall decreases
Solution Approach 1:
The wall thickness is not uniformly reduced but is selectively varied: thinner only in specific regions adjacent to the opening where radial offset occurs, while maintaining sufficient thickness in other regions to preserve overall structural strength and integrity of the bobbin.
Solution Approach 2:
The wall thickness distribution around the opening is asymmetric, with thinner walls positioned to minimize radial offset in critical areas while thicker sections are strategically placed to maintain structural support, creating an optimized asymmetric thickness profile.
Data Source
AI summary
A bobbin for a solenoid. The bobbin includes a main body for receiving wire windings of a wire, wherein the main body extends hollow-cylindrically along an axial direction and has a wall having a wall thickness, wherein at least one opening is formed in the wall, wherein the wall thickness becomes smaller along the axial direction toward the opening, and/or wherein the geometric shape of the opening is designed to vary along the axial direction, at least in sections. A solenoid having such a bobbin and at least one wire winding, is also described.