Torque Sensor Coil Winding Using Inclined Grooves and Axial Nozzle Movement
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Solution Overview
Problem
The existing method for manufacturing coils for magnetostrictive torque sensors is inefficient due to the large amount of bobbin rotation required, leading to entanglement of insulated wires when attempting to wind multiple wires simultaneously.
Innovation Solution
A method involving a cylindrical bobbin with inclined grooves on its surface, allowing insulated wires to be wound continuously in one direction without reversing the bobbin, using nozzles that move orthogonally to the rotation direction, preventing wire entanglement and enabling simultaneous winding of multiple wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the bobbin is rotated in reverse direction to wind insulated wires, then the winding process can be completed, but the large amount of movement causes insulated wires to entangle with each other
Solution Approach 1:
Instead of rotating the bobbin in reverse direction to change winding direction, the patent inverts the approach by maintaining continuous bobbin rotation in one direction and moving the nozzles back and forth in the axial direction. This inversion eliminates wire entanglement while achieving complete winding coverage.
Solution Approach 2:
The patent transitions the winding mechanism from bobbin rotation in the circumferential direction to nozzle movement in the axial direction. By adding axial movement of nozzles while maintaining continuous bobbin rotation, the system achieves winding without reverse rotation, preventing wire entanglement.
2Productivity
If multiple insulated wires are wound simultaneously around the bobbin, then productivity increases, but the nozzles may collide with each other due to limited space
Solution Approach 1:
The patent arranges multiple nozzles in the axial direction rather than only in the circumferential direction. This axial arrangement in a new dimension allows multiple wires to be wound simultaneously without nozzle collision, while maintaining continuous bobbin rotation and enabling higher productivity.
3Ease of manufacture
If the bobbin is held fixed and nozzles move in rotation direction, then winding can be achieved, but the nozzles must be driven in both rotation and axial directions increasing complexity
Solution Approach 1:
The patent combines the winding function with continuous bobbin rotation. By maintaining constant bobbin rotation and only moving nozzles in the axial direction, the system merges the rotational winding motion with the feeding motion, simplifying the drive mechanism to require only axial nozzle movement.
Data Source
AI summary
A method of manufacturing a coil for a torque sensor includes: holding a bobbin with a jig, the bobbin being formed in a cylindrical shape and provided with first inclined grooves and second inclined grooves on a cylindrical outer peripheral surface of the bobbin, the first inclined grooves being inclined at a preset specified angle with respect to an axial direction of the cylindrical shape, and the second inclined grooves being inclined at the specified angle with respect to the axial direction in a direction opposite to the first inclined grooves; and rotating the bobbin while simultaneously supplying insulated wires from nozzles arranged to surround the bobbin, and driving the nozzles in a direction orthogonal to a rotation direction of the bobbin so as to wind the insulated wires around the bobbin along the first inclined grooves or the second inclined grooves.