Winding Mandrel for Pivotable Coil Extensions
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Solution Overview
Problem
Conventional winding machines are unable to accommodate coils with a pivotable coil body extension, such as those described in DE 10 2012 006 434 A=WO 2013/144235 A1, due to their narrow design and special terminal block, which prevents them from being wound using standard equipment.
Innovation Solution
A device featuring a winding mandrel with a rotary drive and a wire guide device, including controllable winding nozzles and adjustable wire deflection pins, allows for the winding of coils with pivotable extensions by providing a clamp receptacle outside the winding space and enabling the use of a commercially available winding machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a pivotable coil body extension with terminal block is used, then the coil design is optimized for narrow applications, but the coil cannot be wound on conventional winding machines
Solution Approach 1:
A winding mandrel is introduced as an intermediary device between the conventional winding machine and the coil with pivotable extension. The mandrel includes a plug-in receptacle for the coil tube and a clamp receptacle for the extension, enabling the specialized coil to be wound on standard equipment through this mediating component.
Solution Approach 2:
The winding system is segmented into separate functional components: the conventional winding machine, the interchangeable winding mandrel, and the coil with pivotable extension. This segmentation allows the mandrel to be designed specifically to accommodate the pivotable extension while the main winding machine remains unchanged.
2Area of stationary object
If the clamp receptacle is positioned radially off-axis, then sufficient winding space is available, but the structure becomes more complex
Solution Approach 1:
The clamp receptacle is positioned in a different spatial arrangement (radially off-axis and set back axially) rather than directly on the rotation axis. This dimensional repositioning creates sufficient winding space while maintaining structural integrity through the support plate configuration.
3Length of moving object
If wire deflection pins are positioned close to winding pins, then wire loop length is optimized, but the pins may interfere with the pivotable extension
Solution Approach 1:
The wire deflection pins are designed to be movable relative to the clamp receptacle, allowing them to be lowered into position receptacles when not in use. This dynamic positioning enables the pins to be close to the winding pins during winding operations while being retracted during extension pivoting, eliminating interference.
4Adaptability or versatility
If the winding mandrel includes a plug-in receptacle and clamp receptacle, then coils with pivotable extensions can be wound, but the device complexity increases
Solution Approach 1:
The winding mandrel is designed with universal features that can accommodate different coil configurations. The plug-in receptacle accepts various coil tubes, while the clamp receptacle secures different pivotable extensions, making the mandrel adaptable to multiple coil types without requiring complete redesign.
Data Source
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AI summary
A device for winding onto a bobbin body (10) having a bobbin connection flange (13) and a pivotable bobbin body extension (12) that holds winding and unwinding pins (16, 17). A novel winding mandrel (2) makes it possible to wind onto the bobbin body (10) in that the bobbin body extension (12) is stopped outside of the winding area of the bobbin body (10).