Wire Winding Machine Counteracting Tool Pitch Control
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Solution Overview
Problem
Existing wire winding machines face challenges in efficiently adjusting the pitch of coils during the winding process, leading to increased operator workload, reduced productivity, and complex spindle structures, especially when switching between random and coil-to-coil modes, and require specialized operators and additional reel types for different wire diameters.
Innovation Solution
A wire winding machine with a rotating spindle and a counteracting tool driven by electrical motion means to maintain coils juxtaposed and compact, allowing for quick and easy adjustment of the pitch without manual intervention, using a spindle with fixed flanges and an electrically driven counteracting tool to ensure proper spacing and prevent coil deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or semi-automatic adjustment of the movable flange is used to maintain coil-to-coil winding, then coil alignment is maintained, but operator workload increases and productivity decreases
Solution Approach 1:
The system uses sensors to automatically detect coil position and controls to automatically adjust the movable flange, enabling the winding machine to self-regulate coil alignment without operator intervention. This eliminates manual adjustments while maintaining precise coil-to-coil alignment throughout the winding process.
Solution Approach 2:
The system incorporates sensors that continuously monitor coil position and provide feedback to the control system, which then automatically adjusts the movable flange position to maintain proper coil alignment. This closed-loop feedback mechanism ensures precise coil alignment while eliminating the need for manual intervention.
2Manufacturing precision
If complex spindle structure with adjustable flange and locking system is used, then coil-to-coil winding can be maintained, but device complexity increases and reliability decreases
Solution Approach 1:
The system replaces manual mechanical adjustment and locking operations with an automated control system that uses sensors to detect coil position and electronically controls the movable flange position. This substitution of mechanical manual operations with automated control reduces structural complexity while maintaining precision.
Solution Approach 2:
The control system serves multiple functions: it detects coil position, calculates required flange adjustment, actuates the movable flange, and maintains optimal winding parameters throughout the process. This multi-functional approach consolidates what would otherwise require separate mechanical systems into a single integrated control mechanism.
3Adaptability or versatility
If compression of coil is used to adapt reel distance for different wire diameters, then reel adaptability is improved, but coil deformation and breakage risk increase
Solution Approach 1:
The system dynamically adjusts the distance between flanges based on real-time detection of wire diameter and coil characteristics. Rather than using fixed compression, the movable flange is positioned at optimal distances for different wire types, allowing the system to adapt to various wire diameters without applying excessive compressive forces that could deform or break the coil.
Solution Approach 2:
The system changes the positional parameter of the movable flange based on detected wire diameter and coil characteristics. By adjusting the flange position parameter rather than applying mechanical compression, the system adapts to different wire types while maintaining coil integrity and preventing deformation or breakage.
4Adaptability or versatility
If multiple types of reels with different widths are used for different wire diameters, then wire diameter compatibility is improved, but handling complexity and storage requirements increase
Solution Approach 1:
The system uses a single universal reel design that can accommodate different wire diameters through automated adjustment of the movable flange position. The control system detects wire diameter and automatically configures the winding parameters, eliminating the need for operators to handle and switch between multiple specialized reel types for different wire specifications.
Solution Approach 2:
The system automatically detects wire diameter and self-adjusts the flange positioning and winding parameters, eliminating the need for manual reel selection and configuration. This self-adjusting capability allows a single reel type to serve multiple wire diameter requirements, greatly simplifying handling and storage operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances productivity by eliminating machine stops and reducing operator workload, making the machine safer and less complex, with simpler construction and reduced costs, while maintaining high-quality coil alignment without manual adjustments.
Implementation Method 1
The counteracting tool is driven by electrical motion means adapted to move it linearly in an axial direction in the winding direction of the coils
Data Source
AI summary
A wire-winding machine comprises a station for winding the wire into a reel comprising a spindle rotatable around an axis of rotation to draw the wire and a spool removably anchored on said spindle and enclosed between a starting stroke flange and an end stroke flange for winding the wire into a reel, and a counteracting tool adapted to operate against the last wound coil to keep the coils mutually juxtaposed. The counteracting tool is controlled by electrical moving means adapted to move it linearly and axially in the winding direction of the coils with a predetermined pitch for each revolution of the spindle.