System and method for winding an ignition coil

Abstract

A coil winding system is provided for making a secondary winding for an automotive ignition coil. The system includes a roller configured to apply a holding force to wire being dispensed from a wire nozzle onto a bobbin. The nozzle and roller are moved by a drive mechanism under control of a controller from one axial end to the other axial end of the bobbin for winding the bobbin in a progressive winding fashion. The roller allows an increase in the winding angle of the layers, which reduces the voltage difference between adjacent layers, thereby reducing incidence of dielectric break down in that region.

1 . A method of winding a bobbin having a main axis to form a coil comprising the step of holding wire being wound on the bobbin in place using a roller.  
     
     
         2 . The method of  claim 1  wherein said bobbin extends along the main axis and has first and second opposing axial ends, said bobbin having a winding flange at said first axial end tapered at a predetermined angle relative to said main axis, said method further including the step of orienting said roller such that a rotation axis associated therewith is parallel to said tapered winding flange.  
     
     
         3 . The method of  claim 2  wherein said wire is dispensed from a movable nozzle associated with a winding system, said method further comprising the step of: 
 moving said nozzle and said roller relative to said bobbin from said first axial end to said second axial end.  
 
     
     
         4 . The method of  claim 3  further comprising the step of: 
 providing said roller having an outer surface with a predetermined hardness.  
 
     
     
         5 . The method of  claim 4  wherein said providing step comprises the substep of: 
 selecting a material for said outer surface having a pliability within a preselected range.  
 
     
     
         6 . The method of  claim 4  wherein said providing step comprises the substep of: 
 selecting a rubber material for said outer surface.  
 
     
     
         7 . The method of  claim 3  wherein said providing step comprises the substep of: 
 forming said outer surface so as to have a predetermined texture configured to facilitate holding said wire in place.  
 
     
     
         8 . The method of  claim 1  wherein said wire is progressively wound according to a winding angle relative to said main axis, said method further comprising the step of: 
 orienting said roller so that a rotation axis associated therewith is parallel to said winding angle.  
 
     
     
         9 . The method of  claim 1  wherein said holding step comprises the substep of: 
 holding said wire using a plurality of rollers.  
 
     
     
         10 . A method of winding a bobbin to form a secondary ignition coil comprising the steps of: 
 (A) providing a roller with an outer surface comprising rubber material having a hardness in a predetermined range;    (B) providing a nozzle configured to dispense wire onto said bobbin according to a progressive winding strategy with a winding angle relative to a main axis associated with said bobbin; and    (C) dispensing wire from said nozzle onto said bobbin and holding said wire in place using said roller.    
     
     
         11 . The method of  claim 10  further comprising the step of: 
 orienting said roller such that an axis of rotation associated therewith is parallel to said winding angle.  
 
     
     
         12 . The method of  claim 10  wherein said bobbin has first and second axial ends, and wherein said dispensing and holding step comprises the substep of: 
 moving said nozzle and roller relative to said bobbin from said first axial end to said second axial end.  
 
     
     
         13 . A winding system for winding a bobbin to form a coil comprising: 
 a base including at least one spindle configured to receive said bobbin;    a nozzle proximate said spindle configured to dispense wire onto said bobbin;    a roller proximate said spindle configured to hold dispensed wire in place on said bobbin; and    a controller configured to rotate said spindle and move said nozzle and roller axially relative to said spindle.    
     
     
         14 . The system of  claim 13  wherein said roller is configured to allow rotation about a rotation axis associated therewith.  
     
     
         15 . The system of  claim 14  wherein said roller includes an outer surface comprising material with a hardness in a predetermined range.  
     
     
         16 . The system of  claim 15  wherein said material comprises rubber.  
     
     
         17 . The system of  claim 14  wherein said roller is oriented such that said rotation axis is parallel to a winding angle of the wire being dispensed by said nozzle.  
     
     
         18 . The system of  claim 14  wherein said system comprises a plurality of rollers associated with said at least one spindle.