Wire Coil Deflection Hook for Winding Stability
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Solution Overview
Problem
Existing methods for producing wire coils lack flexibility in design, particularly in the winding window, and fail to ensure reliable electrical connections between wire coils, leading to potential shifts and instability of windings.
Innovation Solution
The method involves using an electrically insulating deflection hook fixed to the coil core to securely hold the last winding, preventing shifts and allowing for a high degree of design flexibility by deflecting the wire, which is made from insulated material to prevent electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional winding methods are used without a deflection hook, then the manufacturing process is simpler, but the wire coil lacks design flexibility and winding stability
Solution Approach 1:
An electrically insulating deflection hook is introduced as an intermediary component between the wire and the winding process. The deflection hook guides and secures the wire during winding, enabling precise control over wire placement and coil geometry without requiring complex winding machinery or procedures
Solution Approach 2:
The deflection hook is pre-positioned and secured to the coil core before the winding process begins. This preliminary arrangement establishes the geometric constraints and guidance paths needed to achieve the desired winding pattern and coil shape, allowing for greater design flexibility without increasing manufacturing complexity
2Productivity
If the wire is allowed to shift during winding, then the manufacturing process is faster, but the electrical connection reliability between wire coils deteriorates
Solution Approach 1:
The deflection hook serves as a mediating element that actively prevents wire shift during the winding process. By providing a fixed reference point and guidance structure, it ensures consistent wire positioning and reliable electrical connections between wire coils while maintaining efficient manufacturing speeds
Solution Approach 2:
The deflection hook is designed to counteract the tendency of the wire to shift during winding. By pre-positioning the hook to engage with the wire at critical points, it applies preliminary restraining forces that prevent unwanted movement and ensure stable electrical connections throughout the winding process
3Adaptability or versatility
If a larger deflection angle is required for design freedom, then the design flexibility improves, but the mechanical stress on the wire increases
Solution Approach 1:
The deflection hook acts as a mechanical intermediary that distributes and manages the stresses generated by large deflection angles. By providing a structured pivot point and support during wire deflection, it enables larger deflection angles for design freedom while preventing concentration of mechanical stress that could damage the wire
Solution Approach 2:
The deflection hook allows dynamic adjustment of the deflection angle parameter during the winding process. By enabling controlled variation of this geometric parameter, the system achieves design freedom for different coil configurations while managing the mechanical stress implications through controlled deflection paths
Data Source
AI summary
A method for producing a wire coil. Multiple windings of a ply of the wire coil including an insulated wire are wound onto a coil core of the wire core starting from a first winding up to a last winding. The last winding is hooked in an electrically insulating deflection hook of the wire coil which is fixed with respect to the coil core and the wire is deflected by the deflection hook.