| Abstract [eng] |
The project explores the new idea of automatically producing induction coils, and designs the equipment, that would be required to achieve it. The project is comprised of five parts: research, conceptual design, experiment, detailed design, economical part. During the research part, the existing technologies are analysed, including their working principle, main components, and production capabilities. Also, the shape of the induction coil inductor is analysed, and order of operations is determined. The conceptual design involves functional design of components based on the wire forming steps: wire feeding, 2D bending, parting-off and coiling. During conceptual design, the fully automatic process is created that starts from a wire workpiece and ends with a finished part. The purpose of experiment is to find the flexure stress-strain relationship of inductor material – annealed copper wire, which is used for calculating wire bending loads. The three-point bending experiment is performed and the stress-strain graph is converted from the results. The detailed design starts with analysing the purpose of the part and creating its shape with CAD software. Next, the maximum loads are calculated, and a simulation is run to find the maximum stresses, which are used in factor of safety calculations. The design and material of the part are selected such that the safety factor is larger than required. The main sub-assemblies of the machine are the spindle mechanism and the guide roller mechanism. The spindle mechanism consists of a rotating mandrel, on which wire is coiled into helical shape. The mandrel is mounted on the spindle head, that is powered by motor and gearbox, via chain and sprocket drive. The guide roller consists of a wheel that participates in wire coiling process. The wheel is moved by two actuators: vertical pneumatic actuator and horizontal screw drive. The other main components of the machine include 2D bending mechanism, wire feeding and straightening mechanism and machine frame. The economical part includes cost calculations of purchased standard parts and unique custom machined parts. It was determined that automatic machine without operator has 81 percent faster pay-back period than operator assisted machine. |
