Back to EveryPatent.com
|United States Patent
February 25, 1992
Apparatus for forming electrical coil assemblies
Apparatus, for winding coils of various geometric configuration, includes a
rotary spindle provided with a mounting face on which a segmented core
spool assembly is mounted. This assembly is thus fixed by a clamping
flange extending a tongue into the spindle. A cam and a swash plate on the
spindle then articulate a pivoted arm on which a wire guide is fixed. The
cam is then useful in minimizing the dynamic components of the wire wound
onto an irregular shape while the swash plate controls the winding lace.
Lace; Donald A. (5041 Galway Circle, Huntington Beach, CA 92649)
March 23, 1990|
|Field of Search:
U.S. Patent Documents
|2595332||May., 1952||Chapman et al.||242/7.
|Foreign Patent Documents|
Primary Examiner: Stodola; Daniel P.
Assistant Examiner: Riggs, Jr.; Charles T.
Attorney, Agent or Firm: Bak-Boychuk; I. Michael
What is claimed is:
1. Apparatus for winding coils onto an irregularly shaped spool assembly
a rotary spindle mounted for rotation and including a face plate formed in
one end thereof, said face plate being provided with a rectangular recess
extending into said spindle;
a clamping fixture characterized by a flange and a tongue extending from
one face of said flange, said tongue being conformed for receipt in said
securing means formed on said spindle for securing said tongue within said
a cam formed on said spindle;
a pivoted arm deployed adjacent said spindle and urged to contact said cam
proximate a free end thereof;
wire spool means mounted for rotation adjacent said arm for storing wire
thereon, said arm including guide means conformed to receive said wire
extending from said spool means; and
a core assembly comprising a plurality of channel segments spaced from each
other by insulative spacers received in clamped engagement between said
flange and said face plate.
2. Apparatus according to claim 1 further comprising:
a swash plate affixed to said spindle; and
engagement means extending from said arm for sliding contact along said
swash plate for flexing said arm along the axis of said spindle.
3. Apparatus according to claim 2 further comprising:
tensioning means interposed between said spool and said guide means for
maintaining tension in said wire.
4. Apparatus according to claim 3 wherein:
each said segment includes separated projections conformed for wrapping
said wire thereon.
5. Apparatus according to claim 4 wherein:
said segments each include insulative coating.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to the method and apparatus for winding coils
and more particularly to a method and structure for forming geometrically
varied coil assemblies.
2. Description of the Prior Art
In my prior U.S. Pat. No. 4,809,578 I have described an acoustic pickup
assembly which, amongst its other features, includes an elongate
electrical winding. This winding, and other windings of complex geometric
form, present some difficulty in assembly.
In a typical prior art setting, coils are often wound in automated
processes, particularly when dimensional limits and miniaturization are
contemplated. Simply, coil windings often entail very thin wire sizes,
small winding dimensions and the consequent limits on winding tension and
wrapping that these present. These precise limits and physical constraints
are often beyond the limits of manual facility and thus are, of necessity,
automated. Accordingly, various automatic winding assemblies have been
devised in the past which accommodate these limitations without the
necessity of manual control.
These automated winding schemes, however, contain plate regular bobbins or
shapes for the coil assembly. Irregular shapes, in distinction, present
various wire force transients in the course of rotary winding. Thus, the
convenience of automatic coil assembly available for regular shapes is not
effective for novel geometries.
I have found that various novel results are obtainable from irregular coil
geometries. For example, the core pieces of the coil may be set in
isolation and thus become useful as the electrical terminals. Thus, by
segmenting and isolating core pieces plural windings may be achieved which
separately or in combination produce the desired results. These and other
results are obtainable in a geometry which is concurrently useful in
winding and it is one example thereof that I now set out.
SUMMARY OF THE INVENTION
Accordingly, it is the general object and purpose of the present invention
to provide a novel winding arrangement for geometrically irregular
Other objects of the invention are to provide a coil assembly useful in
defining a plurality of overlaid windings.
Yet further objects of the invention are to provide a coil winding method
of universal application.
Briefly, these and other objects are accomplished within the present
invention by conforming a core piece for an elongate coil by way of a
plurality of channel segments of integer segment dimension, such that one
channel segment is coterminous with one or more other channel segments
laid along side thereof. Preferrably, the channel members each include
perforations in the respective spines thereof, such perforations being
spaced in equal intervals along the channel length. A plurality of
insulative spacers is then provided with conforming posts engaged in the
perforations. Thus the insulators interlock the segments into a single
integral assembly. In this form the core assembly may be mounted onto the
winding post of a rotary fixture by way of a retainer extending a tongue
through the gap between adjacent spacers. This tongue is then secured in
the fixture compressing the core assembly therebetween.
It will be noted that the resulting core assembly is generally elongate in
shape. When rotated along with the fixture the ends of the core assembly
describe a varying linear rate relative any wire guide. This varying
velocity, in turn, results in a varying kinematic effect (acceleration)
which varies the winding tension on the core assembly. To reduce this
kinematic variable a wrapping guide is positioned just outside the arc of
the core assembly and geared to move transversely across the core at a
selected multiple of the core rotation. Thus, only a short length of the
wire strand is in free response, limiting the mass contribution on the
Each core segment comprising the core assembly may be coated with an
insulative coating on its interior and may be plated, coated, or otherwise
prepared at the ends for electrical contact. Thus, the ends of each
segment may be formed as a tooth-like projection around which the wound
wire is terminated or wrapped.
In this manner convenient termination of each winding may be easily
achieved in an assembly which is conformed for automated winding.
Of course, various tensioning mechanisms may be employed in the course of
winding including spring-tensioned pulleys and friction devices along the
wire path. These then may be adjusted in tension and may be geared with
the tongue direction of the retainer for a modulated tension profile.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective illustration, separated by parts, of an inventive
FIG. 2 is an end view, in section, of a winding core mounted in accordance
with the present invention; and
FIG. 3 is a side view, in section, of a core mounted for winding in
accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIGS. 1-3 the inventive winding assembly, generally designated
by the numeral 10, comprises a rotary mount 11 provided with a circular
mounting boss 12 fixed adjacent a bilobed cam 14 on a spindle 15. A
rectangular pocket 16 extends from the exposed face of the boss 12 through
the cam 14 and into the interior spindle 15. This rectangular pocket 16 is
conformed to receive an elongate, rectangularly, sectioned tongue 18
extending from the flange 19 at one end thereof. The other face of the
flange 19 may be shaped to include a conical tie down 20 to which one end
of a wire W may be affixed.
Spindle 15 is then driven in rotation, across a gear train 25, by an
electrical motor 26. As thus rotated, spindle 15 also advances in rotation
cam 14 against a roller 31 at the free end of a spring loaded arm 32. A
jeweled guide 33 at the end of this arm then translates the turning angle
of the wire W to move with the motion of the roller.
In this form the winding assembly 10 is useful in receiving an elongate
core assembly generally shown at 50, and comprising a first elongate
channel segment 51 adjacent to a second and third segment 52 and 53.
Preferrably each of the segments is generally of a C-shaped section with
the spines perforated at even increments with paired holes 55. A plurality
of rectangular insulative separators 56 is then placed between the spines
of segment 51 and segments 52 and 53, each separator being provided with
posts 57 conformed for indexed receipt in holes 55.
Segments 52 and 53 may be of a length of integer division of the length of
segment 51. Thus, the combination of segments 51, 52 and 53 and the
separators 56 cooperate to form an integral core or spool assembly around
which the wire W is to be wound. This is effected by insertion of the
tongue 18 into the common interspace between the segments to compress the
assembly by the opposition of the flange 19 and the face of the boss 12.
Once thus compressed a set screw 39 extending into spindle 15 fixes the
tongue 18 in position.
One should note that in this arrangement the lobes 14L of the cam 14 may be
shaped and aligned to lead the advancement of the ends of the core
assembly 50. The cam shaping and lead may be selected to minimize the
dynamic loading of the wire W as it is laid up into the combined interior
of segments 51, 52 and 53. This dynamic loading may be further minimized
by way of spring loaded take up rollers 61 and 62 in the wire path from a
spool 63. Moreover, by selecting an arm length for the arm 32 for minimal
geometric effects a virtually even and consistent wire force can be
applied insuring an even wrapping onto the core assembly.
The wrapping lace or pattern may be further controlled by a swash plate 37
formed around the boss 12 against which a finger 36 from the arm 32 is
pressed. Thus, arm 32 may be transversely flexed, in the manner of a
derailleur, along with its pivotal motion on the cam, both to minimize
wire loading transients and to effect the necessary lacing.
Each of the segments 51, 52 and 53, moreover, may be insulatively coated on
their interior, preferrably to a thickness of 0.003 to 0.005 inches, each
segment including corresponding end fingers 51a, 52a, and 53a around which
the wire W may be electrically terminated by wrapping or soldering. Thus,
each segment 51, 52, and 53 also forms an electrical terminal with the
size convenience for miniaturized implementation.
In this form one or more windings may be overlaid onto a core spool of a
varying geometric arrangement where the segments of the core spool also
provide the electrical terminals for the thin wire (40-53 gauge) wound
thereon. In each instance the tapered end of the retainer is useful for
the beginning wire tie down which then can be variously reconnected on
Segments 51, 52 and 53, moreover, each comprise ferromagnetic material
structure which is characterized by substantial thermal mass and
conductivity. Thus, upon completion of a winding the wire filament W
wrapped onto the termination fingers 51a, 52a and 53a is geometrically
fixed to a localized path, allowing for soldered termination at which
sufficient heat is applied to melt and vaporize the thin insulative
coating normally on the filament. In this manner the core segment
arrangement and geometry render convenient the winding coils thereabout
while also providing a convenient soldering terminal for electrical
Obviously many modifications and changes may be made to the foregoing
description without departing from the spirit of the invention. It is
therefore intended that the scope of the invention be determined solely on
the claims appended hereto.