Apparatus and Methods for Winding Coil

摘要

Systems and methods for winding wire are disclosed. A system includes a wire take-up unit and a wire tensioning unit. The take-up unit includes a rotating mandrel and a wire directing device, the wire directing device arranged to cause the wire to be wound in a figure-eight configuration on the rotating mandrel to form a coil having many layers of wire. The wire tensioning unit applies tension to said wire as it is wound, and applies a first amount of tension to a predetermined amount of wire constituting at least a first two layers of the coil, and a second amount of tension to the wire beyond the predetermined amount. In one embodiment, the wire tensioning unit includes digital self-relieving air regulator pneumatically coupled to and controlling a pressure in said pressurized chamber of a pre-lubricating cylinder that is coupled to the wire being wound.

主权项

1. A system for winding wire, comprising:
a) a wire take-up unit including a rotating mandrel and a wire directing device, said wire directing device arranged to cause said wire to be wound in a figure-eight configuration on said rotating mandrel to form a coil having many layers of the wire; b) a wire tensioning unit that applies tension to said wire as it is wound, said wire tensioning unit having a tension applier that applies a first amount of tension to a predetermined amount of the wire constituting at least a first two layers of the coil, and applies a second amount of tension to the wire beyond said predetermined amount, said second amount of tension being at least 50% higher than said first amount of tension.