Simulation of deflection coil winding theory and verification of swing

The winding process of the deflection coils is an important process in themanufacture of TVs. During this process, a wire is wound by a rotating mech-anism onto a winding jig, resulting in a deflection coil. Because there is a needto simulate this winding process, a simulation tool (the SWING program) hasbeen developed. The purpose of simulating the winding process is both to speedup the development of winding jigs and to make the design skills transferable.The main focus on the development of this tool was on the fast and accuratesimulation of the three main factors affecting the winding process:The dynamics of the wireThe contact description between the wire and the winding jigThe friction description of the wire-to-jig contactThe theory needed to descri be the dynamics of the wire is partly based on knownmultibody dynamics and further extended to be able to describe the contact andfriction boundary conditions in an efficient manner. This is achieved by usinglocal absolute coordinates, which results in an absence of Lagrange multipliers.It is shown that the proper choice of the local coordinate directions even results inan order n method. At the moment, this approach seems limited to mechanismswith the same characteristic as the wire: the ”single chain” character.An algorithm has been developed for the surface contact description that en-ables the development of a fast and accurate algorithm to detect contact betweenwire and winding jig, including narrow segment wings. For this purpose, fourEfferent types of nodes have been used. Two of these types are non-materiallodes, which have no fixed position with respect to the wire. The surface de-cription can be generated from within a CAD package such as, in our case,JNIGRAPHICS.