Synchronized Winding Device for Twisted Wire
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Solution Overview
Problem
Conventional winding methods for twisted wires around a core are limited by the number of twists possible between spools and nozzles, and require reverse rotation of nozzles to eliminate twist, disrupting continuous winding processes.
Innovation Solution
A winding device with a nozzle holding mechanism, spool supporting mechanism, and control unit that synchronizes the rotation of nozzles and spools, allowing continuous winding without twist limitations by ensuring equal tension across wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If wires are unwound from separate spools and inserted through nozzles separately, then each wire can be delivered individually, but the wires between spools and nozzles become twisted when nozzles are rotated, limiting the number of twists possible
Solution Approach 1:
The system segments the wire delivery by providing separate spools for each wire, allowing independent control and delivery of each wire through its own nozzle, preventing unwanted twisting between wires during the delivery process
Solution Approach 2:
The spools are pre-positioned and configured before the winding process begins, with each spool assigned to a specific nozzle position, ensuring that wires are delivered in the correct sequence and orientation from the start of the operation
2Manufacturing precision
If nozzles are rotated to twist wires for winding around core, then twisted wires can be wound around the core, but reverse rotation is required to eliminate twist between spools and nozzles, interrupting continuous winding
Solution Approach 1:
The desired twist is applied to the wires in advance during the nozzle rotation phase, before the winding process begins. This preliminary twisting eliminates the need for reverse rotation to remove excess twist, allowing continuous winding operations without interruption
Solution Approach 2:
The system maintains continuous useful action by eliminating the reverse rotation step that previously interrupted the winding process. The nozzle rotation for twisting is performed once at the beginning, and the winding then proceeds continuously without needing to reverse or pause
3Device complexity
If the same nozzle rotation mechanism is used for both twisting wires and winding, then device complexity is reduced, but the twist amount is limited by the physical space between spools and nozzles
Solution Approach 1:
The system extends the twisting capability into the temporal dimension by allowing multiple rotation cycles before winding begins. Instead of being limited by physical space constraints in one dimension, the twist can accumulate over time through repeated rotations, effectively increasing the available twist length
Data Source
AI summary
A winding device includes a nozzle holding mechanism for holding a plurality of nozzles in substantially parallel with each other, a nozzle rotation driving mechanism for rotating the nozzle holding mechanism about a rotation axis being substantially parallel with the plurality of nozzles, a spool supporting mechanism for supporting a plurality of spools in substantially parallel with each other, a spool rotation driving mechanism for rotating the spool supporting mechanism about a rotation axis being substantially parallel with the plurality of spools and being coaxially with or substantially parallel with the rotation axis of the nozzle holding mechanism, and a control unit for controlling the spool rotation driving mechanism in such a manner as to rotate the spool supporting mechanism in synchronism with rotation of the nozzle holding mechanism.