Stator Winding Assembly With Integrated Wire Tension Control
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Solution Overview
Problem
Conventional needle winding machines struggle to maintain optimal wire tension during the winding cycle, especially with accelerations and decelerations of the spindle rotation, leading to irregular windings and inefficiencies.
Innovation Solution
A multi-spindle winding machine with integrated wire tensioning assemblies that include a wire guiding tube, motor-transmission system, and a wire tensioning mechanism with adjustable pulleys and load cells to maintain constant tension and rapid wire uptake, ensuring precise and even windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spindle winding machines are used, then the structure is simple and easy to operate, but the wire tension cannot be kept constant during accelerations and decelerations of spindle rotation
Solution Approach 1:
The wire tensioning assembly is integrated within the spindle assembly structure, with the tensioning mechanism nested inside the spindle housing. The wire guiding tube is positioned within the spindle, and the tensioning components are arranged concentrically around the wire path, creating a compact nested configuration that maintains constant tension without adding external complexity
Solution Approach 2:
A wire tensioning assembly acts as an intermediary mechanism between the wire source and the winding point. This assembly includes a wire guiding tube and tensioning components that mediate the wire tension, ensuring constant force is applied to the wire during spindle accelerations and decelerations, thereby resolving the tension consistency issue
2Productivity
If the spindle rotation speed is increased to improve productivity, then the winding rapidity increases, but the wire tension becomes difficult to control during acceleration and deceleration phases
Solution Approach 1:
The wire tensioning assembly is designed with dynamic components that can respond to changing spindle speeds. The wire guiding tube and tensioning mechanism are configured to dynamically adjust and maintain constant wire tension regardless of spindle acceleration or deceleration, enabling high productivity while preserving tension control precision
Solution Approach 2:
The wire tensioning assembly incorporates a feedback mechanism where the tension of the wire is continuously monitored and adjusted. This feedback system ensures that even during rapid spindle accelerations and decelerations, the wire tension remains constant, allowing increased productivity without sacrificing manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The machine achieves consistent wire tension management and increased rapidity of wire uptake throughout the winding cycle, enhancing the quality and precision of windings, even with multiple spindles.
Implementation Method 1
a wire tensioning mechanism with adjustable pulleys and load cells to maintain constant tension
Implementation Method 2
a wire tensioning mechanism with adjustable pulleys and load cells to maintain constant tension
Data Source
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AI summary
A winding machine (10) for winding a wire on one or more poles arranged inside a cylindrical surface, particularly magnetic poles of stators (S), which comprises one or more winding assemblies (4) which comprise a supporting structure (42) which supports a spindle (3) which extends longitudinally along a spindle axis (Yl), and which is provided with a head (44) which supports a wire guiding tube (45) which is movable with respect to the spindle (3), which is rotatable about, and translatable along, the spindle axis (Yl), the spindle (3) and the wire guiding tube (45) being functionally connected to at least one motor-transmission assembly (47). The peculiarity of the invention consists in that each one of the winding assemblies (4) is coupled to at least one wire tensioning assembly (20) for automatically adjusting the tension of the wire (f), the wire tensioning assembly (20) being arranged adjacent and laterally to the winding assembly (4) and comprising a series of elements that define a path for the wire (f) and which comprise: - a wire takeup arm (25), which protrudes laterally toward the spindle axis (Y1), and - a wire pushing and braking element (24), provided with an adjustment pulley (21) which can rotate about an adjustment axis (XI) which lies on an adjustment plane (α) which is substantially parallel to the spindle axis (Yl).