Wire Winding Apparatus with Segmented Flyer Storage
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Solution Overview
Problem
The existing coil manufacturing apparatus is limited to producing small-size coils due to the length of the wire rod supplied, making it difficult to quickly manufacture large-size coils with a large number of turns.
Innovation Solution
A winding apparatus and method that includes a pair of flyers and wire storage tools allowing for the simultaneous winding of a long wire rod on the winding core, enabling the production of large-size coils with both ends of the coil located on the outermost peripheral layer by rotating the flyers and winding core in synchronized or separate directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a relatively long wire rod is stored in the wire storage unit to obtain a large coil, then the coil size can be increased, but more time is spent for the wire storing step and it becomes difficult to quickly manufacture a coil
Solution Approach 1:
The wire storage unit is divided into multiple wire storage units, each capable of storing a portion of the total wire rod length. This segmentation allows the system to handle long wire rods for large coils without requiring a single excessively long wire to be stored and prepared in advance, thereby reducing the wire storing time while still enabling large coil manufacturing.
2Productivity
If the wire rod supplied from the wire rod supply unit is stored in the wire storage unit as a preliminary stage, then the winding process can be initiated, but the size of the obtained coil is limited by the length of the wire rod suppliable from the wire storage unit
Solution Approach 1:
The system uses multiple wire storage units that can be individually supplied with wire rods of manageable lengths. During the winding process, these multiple units work in parallel or sequence to provide continuous wire supply, enabling the production of large coils that exceed the capacity of a single wire storage unit while maintaining efficient winding operation.
Solution Approach 2:
The wire storage unit is designed with multi-functionality to handle both short wire rods for quick manufacturing and can be expanded through multiple units to accommodate long wire rods for large coils. This universal design allows the same basic structure to serve different production needs without fundamental redesign.
Data Source
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AI summary
A winding apparatus (10), includes a winding core (12), a wire rod (10) being wound on the winding core (12); a pair of flyers (31) arranged across the winding core (12) in an axial direction; flyer rotation means (51) for rotating either one or both of the pair of flyers (31); wire storage tools (61) respectively detachably provided on the pair of flyers (31), the wire rod (10) to be wound on the winding core (12) being stored on the wire storage tools (61); and tension devices (71) respectively provided on the pair of flyers (31), the tension devices (71) applying a tension to the wire rod (10) fed from the wire storage tools (61) and introduced to the winding core (12).