Toroidal Core Winding Without Magazine
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Solution Overview
Problem
Conventional devices for winding toroidal cores with annular magazines cannot accommodate cores with small internal diameters or tubular cores due to space constraints, limiting their ability to be wound effectively.
Innovation Solution
A device and method for winding toroidal cores without a magazine, utilizing transport rollers and a wire ejector to guide and tension the wire directly, allowing for perpendicular orientation and eliminating the need for a conventional magazine, enabling the winding of cores with small diameters or unique geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If an annular magazine is used for guiding and feeding the winding wire, then the wire can be magazined and wound effectively, but the device cannot accommodate toroidal cores with small internal diameters or tubular cores due to space constraints
Solution Approach 1:
The patent removes the annular magazine component entirely from the winding device. Instead of using a magazine to guide and feed the wire, the invention uses a simplified wire guide system with transport rollers that directly guide the wire through the toroidal core opening, eliminating the space requirements of a magazine while maintaining wire feeding functionality
Solution Approach 2:
Instead of guiding the wire through a magazine structure that passes through the core, the invention inverts the approach by having the wire guide elements positioned outside the core path, with the wire being fed through the core opening in a reversed sequence: first through the core, then guided by transport rollers, allowing accommodation of small-diameter cores
2Ease of operation
If a magazine is used for wire guidance, then wire feeding is enabled, but the device becomes more complex and expensive to produce
Solution Approach 1:
The patent extracts and removes the magazine component from the winding device, replacing it with a simpler wire guide system using transport rollers and guide elements that achieve the same wire feeding function with fewer parts, reducing manufacturing complexity and cost
Solution Approach 2:
The invention replaces the expensive, complex magazine structure with simpler, more economical wire guide elements and transport rollers that perform the essential wire feeding function at lower cost, accepting that these simpler components may require more frequent replacement or adjustment
Data Source
AI summary
The invention relates to a device and to a method for winding toroidal cores without using a magazine, comprising a toroidal-core retainer and comprising elements that are substantially arranged in a wire-guiding plane and that serve to guide and to magazine wire. The device comprises: a first transport roller and a second transport roller, which are arranged in relation to the toroidal-core retainer in such a way that a wire to be magazined on the transport rollers in the wire-guiding plane and to be wound can be guided between the first and the second transport roller through the toroidal core; a wire ejector arranged adjacently to the second transport roller; and a wire tensioner.