Wire Winding Nozzle Positioning to Prevent Film Damage
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Solution Overview
Problem
Conventional wire winding methods can cause twisting tendency and damage to wires due to rubbing between the guide and nozzle, leading to potential short circuits or breakage.
Innovation Solution
A wire winding method and apparatus that involves passing wires through a tensioner and nozzle with constant positional relationship between wire insertion holes, allowing only the wires between the nozzle and core to be twisted, preventing twisting between the tensioner and nozzle and reducing the risk of wire damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the nozzle rotates in a normal direction predetermined number of times to form a twisted portion of the wires between the guide and the nozzle, then the wires can be wound on the core, but twisting tendency is imparted to the wires between the guide and the nozzle and films of the wires are rubbed against each other causing damage
Solution Approach 1:
The patent divides the wire path into distinct segments: the segment between the guide and tensioner remains straight without twisting, while only the segment between the tensioner and core undergoes twisting during winding. This segmentation prevents twisting tendency and film damage in the guide-to-tensioner segment while achieving the required twisted winding structure on the core.
Solution Approach 2:
The tensioner acts as an intermediary device between the guide and the core. It receives wires from the guide and serves as the starting point for twisting operations. By positioning the tensioner as this intermediate element, the patent ensures that twisting occurs only after the wire exits the tensioner, preventing damage to the wire films between the guide and tensioner.
2Productivity
If the nozzle rotates to twist the wires between the guide and the nozzle, then the wires can be wound on the core, but the twisting operation causes rubbing between wire films leading to potential short circuits or breakage
Solution Approach 1:
The patent applies twisting operation locally only to the wire segment between the tensioner and the core, rather than to the entire wire length. The wire segment between the guide and tensioner maintains its original straight configuration without twisting, thus avoiding film rubbing and damage in that region while still achieving the desired twisted winding structure on the core.
3Manufacturing precision
If the mutual positional relationship between wire insertion holes and tensioner is not constant, then the nozzle can be more flexible, but twisting cannot be controlled properly and wire damage may occur
Solution Approach 1:
The tensioner serves multiple functions: it acts as a guide for the wire from the nozzle, serves as the fixed reference point for establishing the constant positional relationship with wire insertion holes, and acts as the starting point for the twisted portion. This multi-functionality simplifies the overall system while ensuring precise twisting control.
Data Source
AI summary
A wire winding method which can prevent twisting tendency of a wire and the occurrence of damage on the wire. The wire winding method includes: a first step of making a plurality of wires pass through a tensioner and a nozzle sequentially and fixing distal ends of the plurality of wires to a core side; and a second step of winding the plurality of wires on the core while twisting the plurality of wires by making the nozzle revolve around the core such that a mutual positional relationship between a plurality of wire insertion holes formed in the nozzle through which the plurality of wires are made to pass respectively with respect to the tensioner is set to a fixed value.