Wire Harness Tape Winding With Controlled Overlap and Higher Throughput
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Solution Overview
Problem
Conventional tape winding methods for electric wires are inefficient due to limitations in tape movement per winding, making it difficult to secure a desired lapping width.
Innovation Solution
A tape winding method that includes a winding start step, a lapped winding step where tapes partially overlap, and a winding end step, allowing for movement of the tape set by the sum of tape spacing and lapping width, ensuring efficient tape winding while maintaining a desired lapping width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If lapped winding is performed with limited tape movement per winding to secure the desired lapping width, then the lapping width requirement is met, but the tape winding efficiency deteriorates
Solution Approach 1:
The tape winding process is segmented into three distinct phases: winding start step, lapped winding step, and winding end step. Each phase has specific control parameters optimized for its function. The lapped winding step specifically controls tape movement amount to be the sum of tape spacing and lapping width, enabling efficient progression while maintaining required overlap.
Solution Approach 2:
The tape movement amount is dynamically adjusted according to the winding phase. During the lapped winding step, the tape movement amount is set to the sum of tape spacing and lapping width, which is larger than conventional methods. This dynamic adjustment allows the system to maintain required lapping width while improving overall winding efficiency.
2Productivity
If the tape set is moved by a larger amount per winding to improve efficiency, then the tape winding efficiency improves, but the lapping width may become insufficient
Solution Approach 1:
The winding start step performs preliminary tape winding before the lapped winding step begins. This preliminary action establishes the initial tape positioning and ensures that when the lapped winding step moves the tape set by the sum of tape spacing and lapping width, the required lapping width is maintained from the outset.
Solution Approach 2:
The control unit calculates and controls the tape movement amount based on the relationship between tape spacing and lapping width. This feedback mechanism ensures that even with increased movement per winding, the actual lapping width applied to the wire bundle meets the required specifications.
3Device complexity
If conventional tape winding methods are used, then the process is simple, but the winding efficiency remains low
Solution Approach 1:
The winding process uses dynamic control of tape movement amount based on the current winding phase. The control unit adjusts the tape movement amount to be the sum of tape spacing and lapping width during the lapped winding step, which simplifies the control logic while significantly improving efficiency compared to conventional fixed-movement methods.
Solution Approach 2:
The lapped winding step enables continuous tape winding with minimal stops or adjustments. By setting the tape movement amount to the sum of tape spacing and lapping width, the system maintains continuous productive action throughout the winding process, eliminating inefficiencies associated with frequent adjustments.
Data Source
AI summary
The efficiency of the tape winding task is improved while a desired lapping width (R11) is secured. A tape winding method includes a winding start step (step S11 to step S14), a lapped winding step (step S15 and step S16) of performing lapped winding in which adjacent tapes (21) partially overlap each other, while the tape set (2) is moved by an amount of movement per lapped winding that is a sum of a tape spacing (T11) and a lapping width (R11), and a winding end step.