Winding-Type Electronic Component Twisting Without Wire Disconnection
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Solution Overview
Problem
In the conventional method of manufacturing winding-type electronic components using stranded wires, there is a risk of disconnection during the twisting process due to inadequate transmission of tension force and entanglement of wires between the tensioner and nozzle.
Innovation Solution
A method involving a rotatable chuck that holds a core with flange portions, where windings are fixed to the flange portions and twisted by rotating the chuck, eliminating the need for nozzle rotation and thus preventing disconnection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the nozzle is rotated to strand the conductive wires during winding, then the wires are properly twisted, but the tension force from the tensioner is not properly transmitted and the wires may disconnect
Solution Approach 1:
Instead of rotating the nozzle to strand the wires, the patent inverts the approach by rotating the core itself. The core is rotated by a rotating device while the nozzle remains stationary, allowing the wires to be wound and stranded simultaneously without disconnection issues. This inversion of the rotating element from nozzle to core resolves the contradiction between wire twisting stability and connection reliability.
Solution Approach 2:
The patent introduces a rotating device as an intermediary between the tensioner and the core. This rotating device receives the tensioned wires from the tensioner and transfers them to the core while rotating, ensuring both proper tension transmission and wire stranding. The intermediary device eliminates the direct conflict between tension transmission and wire twisting.
2Shape
If the conductive wires are stranded between the tensioner and nozzle, then the wires are twisted, but the tension force transmission is compromised
Solution Approach 1:
The patent inverts the stranding location from between the tensioner and nozzle to between the rotating device and the core. By rotating the core instead of the nozzle, the wires maintain continuous tension from the tensioner through the rotating device to the core, while stranding occurs at the core interface. This inversion preserves both wire shape formation and force transmission.
Solution Approach 2:
The rotating core serves dual functions: it acts as the winding surface for the wires and simultaneously performs the stranding operation through its rotation. The core's rotation automatically strands the wires as they are wound, eliminating the need for separate stranding mechanisms that would compromise tension force transmission.
3Ease of manufacture
If the nozzle is rotated to feed and strand wires, then wire twisting is achieved, but wire disconnection occurs
Solution Approach 1:
The patent inverts the rotation function from the nozzle to the core. The stationary nozzle feeds wires continuously while the rotating core winds and strands them. This inversion eliminates wire disconnection issues while maintaining the ease of manufacture benefit, as the stranding process is still achieved through rotation but at a location that preserves wire integrity.
Solution Approach 2:
The rotating device acts as an intermediary that receives tensioned wires from the stationary nozzle and transfers them to the rotating core. This intermediary ensures continuous wire feeding without disconnection while achieving the desired stranding effect, maintaining both manufacturing ease and connection reliability.
Data Source
AI summary
A method of manufacturing a winding-type electronic component using stranded wires which can suppress a disconnection of a winding when a plurality of windings is twisted. The method of manufacturing a winding-type electronic component includes: a preparation step of allowing a chuck to hold a core having a winding core portion (14) and flange portions; a first step of fixing a portion of each of windings supplied from nozzles (N1, N2) to the flange portion; and a second step of twisting the windings by rotating the chuck.