Toroidal Winding Machine with Reversible Ring Element
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Solution Overview
Problem
Current methods for winding toroidal components of electrical machines are limited to single-direction winding, require disassembly and reassembly of winding elements, and necessitate intermediate wire cuts, which hinder precision, reliability, and productivity.
Innovation Solution
A machine that uses a ring-shaped winding element with adjustable rollers and motors to enable winding in two directions without disassembly or intermediate wire cuts, utilizing a spool and tensioning system to manage wire tension and direction reversal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a ring-shaped winding element is used to wind toroidal components, then the winding operation can be performed, but the winding direction is limited to only one direction
Solution Approach 1:
The winding element is divided into two separate half-rings that can be assembled around the toroidal component. This segmentation allows the winding element to be opened and closed, enabling wire feeding from both directions without requiring a completely different winding element configuration.
Solution Approach 2:
The winding element incorporates movable engagement elements that can be opened and closed dynamically. This dynamic capability allows the same winding element structure to accommodate winding operations in both clockwise and counter-clockwise directions by simply changing the engagement state of the half-rings.
2Adaptability or versatility
If the winding element is disassembled and reassembled to change winding direction, then different winding directions can be achieved, but productivity is reduced due to intermediate operations
Solution Approach 1:
The two half-rings of the winding element are pre-configured with engagement elements that can be quickly connected or disconnected. This preliminary preparation allows for rapid switching between winding directions without requiring complex disassembly and reassembly operations during the winding process.
Solution Approach 2:
The engagement elements are designed to be dynamically openable and closable, allowing the winding element to adapt to different winding directions on-the-fly. This dynamic capability eliminates the need for intermediate stopping, disassembly, and reassembly operations, thereby maintaining high productivity.
3Ease of operation
If manual wire arrangement is used around the winding element, then the winding operation can be performed, but precision and reliability are compromised
Solution Approach 1:
The patent replaces manual wire arrangement with an automated wire feeding system. The wire is automatically fed from a spool through a tensioning device and guided by rollers onto the toroidal component, eliminating manual intervention and ensuring consistent winding tension and precision.
Solution Approach 2:
The wire feeding system is designed to automatically manage wire tension and guiding without manual intervention. The tensioning device and rollers work together to self-regulate the wire feeding process, maintaining constant tension and precise wire placement throughout the winding operation.
4Adaptability or versatility
If intermediate wire cuts are made during winding, then the winding element can be reconfigured, but electrical continuity is interrupted and reliability is reduced
Solution Approach 1:
The patent enables continuous wire feeding throughout the entire winding process by using a spool-based feeding system. The wire is fed continuously from the spool through the tensioning device and onto the toroidal component without interruption, maintaining electrical continuity and eliminating the need for intermediate wire cuts.
Solution Approach 2:
The engagement elements of the winding element are designed to be dynamically openable and closable, allowing the same continuous wire to be used for winding in both clockwise and counter-clockwise directions. This dynamic reconfiguration capability eliminates the need to cut and reattach wires when changing winding directions.
Data Source
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AI summary
A machine (1) for winding toroidal components of electrical machines, which comprises first means (5) for supporting the toroidal component (6) to be wound and first means (7) for actuating the toroidal component (6) with a rotary motion about its own axis (6a) in relation to the first supporting means (5). The machine also comprises: a winding element (14), which is shaped like a ring that can be closed in a position which is concatenated with the toroidal component (6), second means (17) for supporting the winding element (14) so that its axis (14a) is arranged substantially at right angles to the axis (6a) of the toroidal component (6), and second means (22) for the actuation of the winding element (14) with a rotary motion about its own axis (14a) with respect to the second supporting means (17). The winding element (14) is provided with a magazine (26) for gathering the winding wire (27) arranged on the winding element (14). The winding element (14) is rotatable about its own axis (14a) in relation to the second supporting means (17) by the action of the second actuation means (22) in one direction of rotation to accumulate the wire (27) that arrives from a spool (34) in the magazine (26) and to wind the wire (27) around the toroidal component (6) in a winding direction and in the opposite direction to wind the wire (27) around the toroidal component (6) in an opposite winding direction, by using at least part of the wire (27) accumulated in the magazine (26).