Twisted Wire Coil Winding With Guide Member Positioning
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Solution Overview
Problem
Conventional coil component manufacturing methods face challenges in winding twisted wire portions around a core with high positional accuracy, especially when the distance between the nozzle and the core is long, leading to difficulties in accurately positioning the twisted wires during the winding process.
Innovation Solution
A coil component manufacturing apparatus and method that incorporates a guide member positioned closer to the core than the nozzle, which guides the twisted wire portion to a predetermined position on the core, along with a wire winding mechanism that rotates the core to wind the twisted portion around it, improving positional accuracy. The guide member can be V-shaped and rotatably held, with a driving mechanism to adjust its position and a nozzle height adjustment mechanism to optimize the winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the nozzle and core are separated to form twisted portion with longer wires, then more wires can be wound around the core at one time, but it becomes difficult to wind the twisted portion at a desired position of the core with high positional accuracy
Solution Approach 1:
A guide member is introduced as an intermediary component between the nozzle and core. This guide member includes a guide groove that guides the twisted portion of wires to a predetermined position on the core during the winding process, enabling accurate positioning even when the nozzle and core are separated by a long distance.
Solution Approach 2:
The guide member adds a new spatial dimension to the winding system by positioning itself between the nozzle and core along the axial direction. The guide groove provides a directional path that constrains the twisted wires to follow a specific trajectory, solving the positioning problem in three-dimensional space.
2Adaptability or versatility
If the distance from the nozzle to the core is long, then more wires can be processed, but it becomes difficult to wind the twisted portion around the core with high positional accuracy
Solution Approach 1:
The guide member serves as a mediator that bridges the gap between the nozzle and core. It provides a physical reference (guide groove) that maintains positional accuracy regardless of the distance between nozzle and core, enabling the system to handle longer wire lengths and more wires simultaneously.
Solution Approach 2:
The guide groove is pre-formed on the guide member at a predetermined position. This preliminary preparation of the guidance path ensures that the twisted portion will be accurately positioned during winding, eliminating the need for real-time adjustment even over long distances.
Data Source
AI summary
A coil component manufacturing apparatus for winding a twisted portion of wires at a desired position of a core. A coil component manufacturing apparatus including a nozzle through which a plurality of wires can be inserted, a wire twisting mechanism that holds a core, rotates the core relative to the nozzle in a direction of twisting the wires, and forms a twisted portion in which the wires are twisted between the nozzle and the core, a wire winding mechanism that holds the core, rotates the core relative to the nozzle in a direction of winding the twisted portion is wound around the core, and winds the twisted portion around the core, and a guide member positioned closer to the core than the nozzle. The guide member guides the twisted portion to a predetermined position of the core when the twisted portion is wound around the core.