Wire Inserting Device for Coil Winding Automation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing automatic wire inserting devices for binding wires in coil formation are costly due to complex structures, making them unsuitable for simple apparatuses and resulting in poor working efficiency when manually inserting wires at intermediate winding points.
Innovation Solution
A wire inserting device with a detector and a swingable wire holder that synchronizes with the detector's movement to insert a binding wire at the intermediate winding point, allowing for easy and efficient wire insertion with a simple structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a complicated automatic inserting device is used to insert binding wire automatically, then the automation level and productivity are improved, but the device complexity and cost increase significantly
Solution Approach 1:
The automatic inserting device is divided into independent functional modules: a wire holder that can be simply swung into position, a detector that triggers the insertion, and a swing mechanism. Each module performs a specific function, allowing the system to achieve automation without requiring a highly complex integrated structure.
Solution Approach 2:
The wire holder is designed to be swingable between a holding position and an inserting position, allowing it to dynamically adapt to the winding process. This dynamic positioning enables automatic insertion at the appropriate timing while maintaining structural simplicity through a single degree of freedom motion.
2Productivity
If a complicated automatic inserting device is used, then the productivity is improved, but the cost of the device increases
Solution Approach 1:
The detector automatically detects the intermediate winding point and triggers the wire holder to swing into the inserting position without requiring external control systems or complex sensors. The system uses the winding process itself to activate the insertion, eliminating the need for expensive control mechanisms while maintaining high productivity.
Solution Approach 2:
The invention uses simple, inexpensive components such as a basic swing mechanism and a straightforward detector instead of expensive automated positioning systems. These simple components are sufficient to achieve the required productivity without incurring high manufacturing costs.
3Device complexity
If manual wire insertion is performed, then the device complexity is reduced, but the productivity and working efficiency deteriorate
Solution Approach 1:
The wire holder swings automatically at the detected intermediate winding point, ensuring that wire insertion occurs continuously during the winding process without stopping or interrupting production. This maintains high productivity while keeping the device structure simple, as the insertion action is seamlessly integrated into the ongoing winding operation.
4Ease of manufacture
If manual wire insertion is performed, then the manufacturing cost is reduced, but the working efficiency is poor
Solution Approach 1:
The wire is pre-loaded into the wire holder in advance, and the holder is positioned ready for insertion before the winding process begins. When the detector identifies the intermediate winding point, the pre-positioned wire holder can immediately swing into place and perform insertion, achieving automatic operation with minimal complexity and high efficiency.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A wire inserting device, an elongated workpiece winding apparatus having the wire inserting device, and a wire inserting method are provided to insert a wire in a bundle of an elongated workpiece at an intermediate point in the bundle. The wire inserting device includes a detector arranged at a position corresponding to the intermediate point, and a wire holder configured to releasably hold the wire. The detector is configured to move when pushed by the elongated workpiece placed at the intermediate point during a formation of the bundle of the elongated workpiece. The wire holder is configured to move in synchronization with the detector to insert the wire in the bundle at the intermediate point.