Wire Winding Device With Elastic Tension Control
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Solution Overview
Problem
Existing wire winding devices struggle to efficiently produce wire windings with precise tension and adaptability for various electrical drive and generator applications, as they often require manual adjustments and lack flexibility in bending pin configurations and wire tension control.
Innovation Solution
A device comprising multiple rotatably mounted drums with adjustable bending pins and a movable wire guide that aligns and winds wire under elastic tension, allowing for customizable wire windings by varying the number and spacing of bending pins and the direction of rotation, enabling the production of wire windings with specific bending radii and curve shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple drums with bending pins are used to produce wire windings, then manufacturing precision and adaptability are improved, but device complexity increases
Solution Approach 1:
The device is divided into multiple independent drums (first drum, second drum, third drum) each with specific bending pins, allowing complex wire winding to be broken down into simpler sequential operations on each drum, thereby achieving high precision without excessive overall complexity
Solution Approach 2:
The drums are designed with interchangeable bending pins and adjustable positions, enabling the same basic drum structure to perform multiple different winding functions by simply changing the bending pin configuration, thus improving adaptability without proportionally increasing device complexity
2Manufacturing precision
If wire is wound under elastic tension between multiple drums, then manufacturing precision and wire quality are improved, but device complexity and operational complexity increase
Solution Approach 1:
The wire guide device automatically maintains elastic tension on the wire as it passes between the drums, with the tension being self-regulated through the elastic properties of the wire itself and the geometric arrangement of the drums, eliminating the need for complex external tension control mechanisms
Solution Approach 2:
The wire is pre-aligned and tensioned between the bending pins before the actual winding operation begins, ensuring that the wire is properly positioned and under correct tension prior to being wound onto the drums, which simplifies the main winding operation
3Adaptability or versatility
If drums are mounted at predetermined distances with specific bending pin configurations, then adaptability to different winding requirements is improved, but device complexity increases
Solution Approach 1:
The drums are mounted on a rotatable shaft that can be rotated to different angular positions, dynamically changing the relative positions and spacing of the bending pins between drums, thereby adapting the device to different winding requirements without physical reconfiguration
Solution Approach 2:
The effective spacing and configuration parameters between bending pins are changed by rotating the shaft to different angles, allowing the same physical drum arrangement to produce different winding patterns and dimensions through parameter variation rather than structural modification
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 enables rapid and precise production of wire windings with controlled tension, accommodating diverse winding requirements by allowing for adjustable drum positions, interchangeable drums, and variable wire guide movements, ensuring accurate tolerances and adaptability for different applications.
Implementation Method 1
the wire guide device aligns the wire between two bending pins under a predeterminable elastic tension
Data Source
Figure 1
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AI summary
The invention relates to a device (1) for producing wire coils, in particular for electrical drives and generators, having at least two drums (34, 36, 38) which are mounted in a rotatably movable manner and which are mounted at a predefined distance to one another, wherein the at least two drums (34, 36, 38) each have at least one bending peg (34.1, 36.1, 38.1) which are fastened protruding substantially vertically on a lateral surface (34.2, 36.2, 38.2) of the corresponding drum (34, 36, 38), wherein a movable wire guiding device (28) winds the wire (5) around the bending pegs (34.1, 36.1, 38.1) protruding from the at least two drums (34, 36, 38) in order to generate at least one wire coil. According to the invention, the wire guiding device (28) aligns the wire (5) between two bending pegs (34.1, 36.1, 38.1) under a predefinable elastic tension and coils the wire (5) under tension by a rotational movement around the respective bending peg (34.1, 36.1, 38.1).