Toroidal Core Winding Without a Magazine for Small-Diameter Coils
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Solution Overview
Problem
Existing toroidal core winding devices with magazines face challenges in winding cores with small diameters and thicker wires, as the magazine cannot be guided through the core, and the winding quality is compromised due to lack of wire monitoring and control.
Innovation Solution
A device and method for winding toroidal cores without a magazine, utilizing a toroidal core retaining element and a needle roller with a deflecting roller and baffle plate, which aligns perpendicular to the wire and allows for automated winding by guiding wire sections through a guide groove and onto storing elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a magazine is used for storing and winding wire, then wire storage and winding can be achieved, but the magazine cannot be guided through toroidal cores with small diameters and the device complexity increases
Solution Approach 1:
The invention extracts and eliminates the magazine component from the winding device. Instead of using a traditional magazine to store and feed wire, the patent employs a wire feeder that directly supplies wire to the winding point, simplifying the overall device structure while maintaining wire storage functionality through alternative means.
Solution Approach 2:
The wire feeder serves multiple functions: it stores wire, feeds wire continuously, and controls wire tension. This multi-functional component replaces the traditional magazine system, reducing device complexity while maintaining or improving wire management capabilities.
2Productivity
If a magazine is used for winding, then wire feeding is possible, but winding quality is reduced due to lack of wire monitoring and control
Solution Approach 1:
The invention incorporates feedback mechanisms through wire tension sensors and control systems that continuously monitor wire feeding during winding. This feedback enables real-time adjustment of wire feed rate and tension, ensuring consistent winding quality while maintaining high productivity. The system detects wire tension variations and automatically compensates to prevent winding defects.
3Adaptability or versatility
If the magazine is guided through the toroidal core, then winding can be performed, but toroidal cores with small diameters cannot be wound due to spatial requirements
Solution Approach 1:
By removing the magazine from the system, the invention eliminates the spatial constraints that prevented winding of small-diameter toroidal cores. The wire feeder can be positioned externally and guide wire through the core opening without requiring the core to accommodate a large magazine structure.
Solution Approach 2:
The invention introduces a wire guide as an intermediary component that facilitates wire passage through the toroidal core. This guide can be positioned and adjusted to accommodate cores of various sizes, including small-diameter cores, without requiring the core itself to contain the wire storage mechanism.
4Device complexity
If no magazine is used, then device complexity is reduced and small diameter cores can be wound, but wire monitoring and control during operation is lost
Solution Approach 1:
The patent incorporates feedback control systems with sensors that monitor wire tension, feed rate, and winding quality in real-time. This feedback mechanism ensures reliable winding operation even without a magazine, as the system continuously detects and corrects deviations from optimal winding parameters.
Solution Approach 2:
The invention replaces the mechanical magazine system with a controlled wire feeding mechanism that uses electronic sensors and actuators for wire management. This substitution maintains winding reliability through electronic control and monitoring while achieving the desired device simplicity and eliminating magazine-related spatial constraints.
Data Source
AI summary
The invention relates to a device and a method for winding toroidal cores One aspect includes a substantially circular needle roller which is arranged on a winding plane substantially parallel to the wire, is rotatably mounted, and can be positioned relative to the toroidal core retaining element such that the needle roller winds a wire section located on the winding plane through and about a toroidal core which is guided in the toroidal core retaining element during operation. A deflecting roller may be rotatably mounted on the needle roller in a first recess on the winding plane and may be designed to wind the wire section through and about the toroidal core during operation. A baffle plate arranged on the needle roller may be designed to guide the wire to be wound between the winding plane and a storing plane arranged substantially parallel to the winding plane.