System and method for manufacturing an ignition coil

Abstract

A coil winding system includes a scale configured to determine a weight of new spool of wire destined for inclusion in the system. The scale is electrically coupled to a controller portion of the system to automatically provide the determined weight. The controller is configured to automatically receive the weight information and associate it with a particular spindle. The controller calculates the maximum number of complete winding cycles possible, based on the weight, and stops winding after such maximum number has been completed.

1 . A method of winding a bobbin to form a coil comprising the step of determining a weight of a spool containing wire and electrically providing said determined weight to a winding system configured to use said determined weight to control winding of said bobbin.  
     
     
         2 . The method of  claim 1  further including the step of determining a number of complete winding cycles that can be performed based on said determined weight.  
     
     
         3 . The method of  claim 2  further including the step of discontinuing a sequence of complete winding cycles when said spool of wire has been used to wind one or more bobbins over said determined number of complete winding cycles.  
     
     
         4 . The method of  claim 2  further including the step of generating an alarm a predetermined number of cycles prior to completing said determined number of complete winding cycles.  
     
     
         5 . The method of  claim 1  wherein said step of determining said weight is performed by the substeps of placing the spool on an electronic scale that is electrically coupled to said winding system.  
     
     
         6 . The method of  claim 5  wherein said winding system includes a plurality of spindles configured to receive a corresponding plurality of bobbins for winding, said method further including the step of identifying one of said spindles for an operator and soliciting an acceptance of said one identified spindle.  
     
     
         7 . The method of  claim 2  wherein said step of determining said number of complete winding cycles is performed in accordance with said determined weight and a unit weight corresponding to an amount of wire wound on a fully wound bobbin.  
     
     
         8 . The method of  claim 1  wherein said coil is selected from the group comprising an ignition coil, a stator winding, a motor winding, an insertion winding, a layered winding, a progressive winding, a segment winding, a yoke winding, a bobbin type winding, a paper sectioned winding, a toroidal winding, and a bondable wire type winding.  
     
     
         9 . The method of  claim 8  wherein said selected coil is an ignition coil comprising at least one of a primary ignition coil and a secondary ignition coil.  
     
     
         10 . A system for winding a bobbin to form a coil comprising: 
 a scale for generating a weight signal indicative of a weight of a wire spool;    a winding system having an input configured to receive said weight signal, said winding system responsive to said weight signal to control winding of said bobbin using wire from said wire spool.    
     
     
         11 . The system of  claim 10  wherein said winding system includes a plurality of spindles configured to receive a plurality of bobbins for winding, said winding system having a controller configured to determine a maximum number of complete winding cycles that can be performed using the wire on the wire spool based on said weight signal.  
     
     
         12 . The system of  claim 11  wherein said controller is further configured to discontinue a sequence of complete winding cycles when said wire spool of wire has been used to wind one or more coils over said maximum number of complete winding cycles.  
     
     
         13 . The system of  claim 12  wherein said controller is further configured to generate an alarm a predetermined number of cycles prior to said maximum number of complete winding cycles.  
     
     
         14 . The system of  claim 13  wherein said coil is selected from the group comprising an ignition coil, a stator winding, a motor winding, an insertion winding, a layered winding, a progressive winding, a segment winding, a yoke winding, a bobbin type winding, a paper sectioned winding, a toroidal winding, and a bondable wire type winding.  
     
     
         15 . A method of winding a bobbin to form a coil comprising the steps of: 
 automatically determining a weight of a wire spool containing wire and electronically providing said determined weight to a winding system configured to use said determined weight to control winding of a corresponding bobbin;    associating said determined weight with one of a plurality of spindles of said winding system on which said bobbin is received;    determining a maximum number of complete winding cycles that can be performed based on said determined weight, each cycle corresponding to a full winding of a bobbin with wire; and    discontinuing a sequence of complete winding cycles when the maximum number of complete winding cycles has been completed for associated spindle.