Spherical coil winding machine

An apparatus for winding spherical coils, comprising:

• a frame;
• a feeder spool rotationally mounted on the frame and configured to rotate about a first rotational axis, the feeder spool having a first wire wound thereon and a second wire wound thereon;
• a first hemispherical bobbin rotationally mounted on the frame, the first hemispherical bobbin having a first inner surface and configured to rotate about a second rotational axis that is parallel to the first rotational axis;
• a second hemispherical bobbin rotationally mounted on the frame, the second hemispherical bobbin having a second inner surface and configured to rotate about the second rotational axis, the second hemispherical bobbin spaced apart from the first hemispherical bobbin to define a wire-feeder gap through which the first and second wires may be fed;
• a first slit formed in, and extending through, the first hemispherical bobbin;
• a second slit formed in, and extending through, the second hemispherical bobbin;
• a first spring-loaded pin mounted on the first inner surface;
• a second spring-loaded pin mounted on the second inner surface;
• a spool motor coupled to the feeder spool, the spool motor operable to regulate a rate at which the first and second wires are being supplied;
• a motor arrangement coupled to the first and second hemispherical bobbins, the motor arrangement configured to cause the first hemispherical bobbin to rotate in a first rotational direction about the second rotational axis, and cause the second hemispherical bobbin to rotate in a second rotational direction about the second rotational axis, the second rotational direction opposite to the first rotational direction;
• an image sensor mounted on the frame and spaced apart from the first and second hemispherical bobbins, the image sensor disposed to capture images through the first and second slits and supply feedback signals;
• and
• a control in operable communication with the image sensor, the spool motor, and the motor arrangement, the control coupled to receive the feedback signals from the image sensor and configured, in response thereto, to control the spool motor and motor arrangement.

An apparatus for winding spherical coils, comprising:

• a frame;
• a feeder spool rotationally mounted on the frame and configured to rotate about a first rotational axis, the feeder spool having a first wire wound thereon and a second wire wound thereon;
• a first hemispherical bobbin rotationally mounted on the frame, the first hemispherical bobbin having a first inner surface and configured to rotate about a second rotational axis that is parallel to the first rotational axis, the first inner surface defining a first hemispherical cavity;
• a second hemispherical bobbin rotationally mounted on the frame, the second hemispherical bobbin having a second inner surface and configured to rotate about the second rotational axis, the second hemispherical bobbin spaced apart from the first hemispherical bobbin to define a wire-feeder gap through which the first and second wires may be fed, the second inner surface defining a second hemispherical cavity;
• a first hemispherical body disposed within the first hemispherical cavity and adapted to have the first wire wound thereon;
• a second hemispherical body disposed within the second hemispherical cavity and adapted to have the second wire wound thereon;
• a first slit formed in, and extending through, the first hemispherical bobbin;
• a second slit formed in, and extending through, the second hemispherical bobbin;
• a first spring-loaded pin mounted on the first inner surface;
• a second spring-loaded pin mounted on the second inner surface;
• a spool motor coupled to the feeder spool, the spool motor operable to regulate a rate at which the first and second wires are being supplied;
• a motor arrangement coupled to the first and second hemispherical bobbins, the motor arrangement configured to cause the first hemispherical bobbin to rotate in a first rotational direction about the second rotational axis, and cause the second hemispherical bobbin to rotate in a second rotational direction about the second rotational axis, the second rotational direction opposite to the first rotational direction;
• an image sensor mounted on the frame and spaced apart from the first and second hemispherical bobbins, the image sensor disposed to capture images through the first and second slits and supply feedback signals;
• and
• a control in operable communication with the image sensor, the spool motor, and the motor arrangement, the control coupled to receive the feedback signals from the image sensor and configured, in response thereto, to control the spool motor and motor arrangement.