Automated Wire Disposing Assembly for Precision Magnetic Coil Winding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of high-intensity, uniform magnetic coils for MRI requires precise control over winding geometry to avoid defects like gaps and anomalies, which is challenging due to human error in manual correction and the difficulty in achieving uniform epoxy distribution, especially in epoxy-supported coils.
Innovation Solution
An automated wire disposing assembly with a support, axial traverser sub-assembly, and radial positioning device is used to guide and correct wire placement in real-time, ensuring precise layering and uniform resin distribution, reducing human intervention and defects in the coil winding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual correction is used during coil winding, then operators can make small-scale steering adjustments and error detection, but human errors occur and the process slows down
Solution Approach 1:
The system uses automatic control mechanisms where the wire disposing assembly self-regulates wire placement through feedback from detection devices, eliminating the need for manual intervention while maintaining precision and increasing productivity
Solution Approach 2:
Detection devices monitor wire placement in real-time and provide feedback to the control system, which automatically adjusts the wire disposing assembly to correct any deviations, ensuring precision without manual intervention
2Stability of the object's composition
If wet winding method is used to maximize epoxy coverage, then uniform resin distribution is improved, but wire placement precision becomes more difficult to maintain due to slipping
Solution Approach 1:
The system applies epoxy to the wire before winding begins, allowing the wire to be precisely positioned on the support surface before the epoxy sets, preventing slipping while ensuring uniform distribution
Solution Approach 2:
The system replaces manual mechanical placement with an automated wire disposing assembly that uses detection devices and feedback control to maintain precise wire placement even when epoxy is present
3Productivity
If automated control is implemented for wire placement, then productivity increases and human errors are reduced, but device complexity increases
Solution Approach 1:
The wire disposing assembly is designed to perform multiple functions including wire guidance, positioning, and epoxy application through a single integrated mechanism, reducing overall system complexity while maintaining high productivity
Solution Approach 2:
The system uses an intermediary wire disposing assembly that acts as a mediator between the wire supply and the coil form, simplifying the control architecture by consolidating multiple control functions into a single device
Data Source
AI summary
A wire disposing assembly having a support, an axial traverser sub-assembly, a support arm, and a linear stage is provided. The support is configured to receive a plurality of turns of a wire, where the support is configured to rotate. The axial traverser sub-assembly is operatively coupled to the support. Further, a rate of motion of the axial traverser sub-assembly is coupled to a speed of rotation of the support. The support arm includes a resin unit configured to dispose resin on at least a portion of the wire, and a wire disposing device configured to guide a portion of the wire being disposed on a surface of the support. The linear stage is operatively coupled to the support arm.