Toroidal Coil Winding Guide with Transverse Channels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing devices for forming toroidal coils lack precision in arranging turns, leading to inconsistent inductive coupling performance, particularly in applications like wireless charging, where precise symmetry is crucial for efficient charging processes.
Innovation Solution
A device with an annular guide component featuring transversely arranged channels allows for precise positioning of turns around a toroidal magnetic core, ensuring consistent spacing and symmetry, enabling the formation of coils with one or more windings that can be used in wireless charging systems with improved inductive coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a curved guide component with longitudinally arranged channels is used, then the wire can be helically wound around the core, but a specific spacing between turns cannot be assured
Solution Approach 1:
The guide component is segmented into multiple transverse channels arranged across the annular structure. Each channel acts as an independent guide path for the wire, ensuring that turns are formed at precise, predetermined intervals as the core rotates. This segmentation allows control over turn spacing while maintaining the helical winding process.
Solution Approach 2:
The transverse channels serve as intermediary elements between the wire feed and the core. These channels constrain the wire's path and position, acting as a mediator that translates rotational motion into precisely spaced turns. The channels mediate the relationship between winding speed and turn spacing, eliminating the direct dependency that caused precision issues in the curved guide design.
2Device complexity
If a single channel is used in the guide component, then the structure is simpler, but winding becomes more difficult and cannot accommodate multiple windings or rectangular cores
Solution Approach 1:
The annular guide component with multiple transverse channels is designed to perform multiple functions: it can wind toroidal cores with rectangular or circular sections, accommodate one or multiple windings, and maintain precise turn spacing. The universal design allows the same guide structure to adapt to different core types and winding configurations without requiring separate specialized tools.
Solution Approach 2:
The guide component transitions from a single-channel linear arrangement to a multi-channel annular structure distributed in multiple dimensions around the core. This dimensional expansion allows simultaneous engagement with multiple turns and adaptation to different core geometries, transforming the guide from a simple linear path to a comprehensive three-dimensional winding system.
3Productivity
If continuous wire feeding with rotational speed control is used, then the winding process is continuous, but turn order precision depends on multiple factors making verification necessary
Solution Approach 1:
The channels are pre-positioned at specific intervals and angles on the annular guide component before the winding process begins. This preliminary arrangement of the guide structure ensures that as the core rotates, turns are automatically placed in the correct positions without requiring real-time speed synchronization. The precision is built into the guide's geometry rather than relying on dynamic control during winding.
Data Source
Figure 1a
Figure 1b
Figure 2
AI summary
The device comprises a guide component (1) including channels (2) for receiving portions of a wire that form turns (3) of said toroidal coil when being arranged around a toroidal magnetic core (4), said channels (2) being defined on a face of said guide component (1) to be arranged opposite an outer face of said toroidal magnetic core (4), and said guide component (1) having an annular shape with an annular inner wall (1i) demarcating a central space (5) for accommodating the toroidal magnetic core (4); and a plurality of said channels (2) arranged transversely, from base to base of the annular guide component (1), distributed throughout said annular inner wall (1i) separated from one another in accordance with a predetermined order.