TWI847002B - Winding device and winding method - Google Patents

Abstract

A winding device comprises: a winding core; a wire unwinding mechanism that supplies wire to the winding core in a manner that the supply speed can be changed; a tension device that applies tension to the wire supplied from the wire unwinding mechanism to the winding core; a winding core rotating unit that rotates the winding core so that the wire supplied from the wire unwinding mechanism and tensioned by the tension device is wound around the winding core; and a controller that controls the wire unwinding mechanism in a manner that the wire is supplied at a speed equal to the winding speed of the wire wound around the rotating winding core.

Description

Winding device and winding method

The present invention relates to a wire winding device and a wire winding method.

At present, for example, Japanese Patent Publication No. JP2000-128433A discloses a tensioning device which is installed in a winding machine that winds a wire around a winding core to form a coil and applies a predetermined tension to the wire. As shown in FIG12 , this tensioning device includes: a reel 3 on which the wire 2 unwound from a wire source is hung; a tensioning arm 4 that can rotate around a rotation fulcrum 4a at the base end; a guide wheel 5 that is mounted on the front end of the tensioning arm 4 and turns after the wire 2 unwound from the reel 3 passes through to guide it to the winding machine; and an elastic member 6 that is connected between the rotation fulcrum 4a of the tensioning arm 4 and the guide wheel 5. The wire rod 2 is provided with a predetermined position between the guide wheel 5 and the tension arm 4, and an elastic force corresponding to the rotation angle is given to the tension arm 4; a potentiometer 7 is used to detect the rotation angle of the tension arm 4; and a reeling motor 8 is used to control the rotation of the reel 3 in such a way that the rotation angle detected by the potentiometer 7 becomes a predetermined angle, and controls the speed of the wire rod 2 from the reel 3 through the guide wheel 5 toward the winding machine not shown in the figure.

Here, the wire 2 is guided to the winding machine via the guide wheel 5 and wound around its winding core. Regarding the unwinding speed of the wire 2 unwound from the known tension device, the rotation of the reel 3 is controlled so that the rotation angle of the tension arm 4 becomes a predetermined angle, thereby ensuring the balance between the unwinding speed of the wire 2 and the winding speed of the wire wound on the winding core. In addition, a predetermined tension is applied to the wire 2 through the tension arm 4 given elastic force by the elastic member 6.

When the winding speed of the wire wound by the winding core changes, the tension of the wire 2 changes, but the change is absorbed by changing the rotation angle of the tension arm 4. In addition, since the change of the rotation angle of the tension arm 4 is fed back to the rotation of the reel 3 via the potentiometer 7, the rotation angle of the tension arm 4 immediately becomes a predetermined angle, and the rotation speed of the reel 3 is adjusted by the unwinding motor 8, and the tension applied to the wire 2 is restored to the predetermined value.

[Problem to be solved by the invention] As described above, in the known tension device shown in FIG. 12, the change in the winding speed of the wire 2 is absorbed by changing the rotation angle of the tension arm 4. However, when the wire 2 is wound around a winding core of different diameters with different cross-sectional outer diameters, for example, a winding core of a rectangular cross-sectional shape with significantly different short and long sides, the speed of the wire 2 wound around the winding core will periodically change significantly during one rotation of the winding core. As a result, the rotation angle of the tension arm 4 that absorbs the change in speed is significantly increased or decreased.

That is, the wire 2 unwound from the reel 3 is turned by the guide wheel 5 in a manner bent at a substantially right angle relative to the tension arm as shown in FIG. 12 and guided to the winding machine. When the winding speed of the wire 2 in the winding machine is increased and the predetermined length L1 is wound more per unit time, the guide wheel 5 is pulled toward the winding machine side and moved by the predetermined length L1 wound more as shown by the solid arrow. In addition, the tension arm 4 provided with the guide wheel 5 at the front end rotates to overcome the elastic force of the elastic member 6, thereby allowing the guide wheel 5 at the front end to move the predetermined length L1.

However, when the speed of the wire 2 wound on the winding core in the winding machine changes significantly and its speed increases significantly at once, the guide wheel 5 is pulled strongly by the wire 2, and the rotation of the tension arm 4, which is provided with the guide wheel 5 at the front end and absorbs the change, cannot follow the trend of the pulled guide wheel 5. As a result, a tension force exceeding the elastic force given by the elastic member 6 is temporarily given to the wire 2 between the guide wheel 5 provided at the front end of the tension arm 4 and the winding core.

On the contrary, when the winding speed of the wire rod 2 in the winding machine is reduced and the amount of winding per unit time is reduced by the predetermined length L2, the guide wheel 5 moves in the direction of separation from the winding machine by the reduced predetermined length L2 due to the elastic force of the elastic member 6. In addition, the tension arm 4 provided with the guide wheel 5 at the front end rotates due to the elastic force of the elastic member 6, thereby allowing the guide wheel 5 at the front end to move by the predetermined length L2 as shown by the dotted arrow.

However, when the speed of the wire 2 wound on the winding core in the winding machine changes significantly and the speed of the wire 2 wound on the winding core in the winding machine decreases significantly at once, the force of the wire 2 pulling the guide wheel 5 decreases significantly at once, and the tension arm 4, which is provided with the guide wheel 5 at the front end and absorbs the change, cannot follow the rotation due to its inertia force even with the elastic force of the elastic member 6. As a result, the wire 2 between the guide wheel 5 provided at the front end of the tension arm 4 and the winding core is temporarily loosened. Therefore, in the known tension device, when the speed of the wire 2 wound on the winding cores of different diameters in the winding machine varies significantly, there is a problem that it is difficult to keep the tension of the wire 2 supplied to the winding machine constant.

An object of the present invention is to provide a winding device and a winding method which can keep the tension of a wire wound around a winding core constant even when the winding speed of the wire in the winding core varies significantly.

[Means for Solving the Problem] According to one aspect of the present invention, a winding device is provided, the winding device comprising: a winding core; a wire unwinding mechanism that supplies a wire to the winding core in a manner that a supply speed can be changed; a tensioning device that applies tension to the wire supplied from the wire unwinding mechanism to the winding core; a winding core rotating unit that rotates the winding core so that the wire supplied from the wire unwinding mechanism and tensioned by the tensioning device is wound around the winding core; and a controller that controls the wire unwinding mechanism in a manner that supplies the wire at a speed equal to a winding speed of the wire wound around the rotating winding core.

In addition, according to another aspect of the present invention, a winding method is provided, wherein the winding core is rotated to allow the wire supplied from the wire unwinding mechanism and given tension by the tension device to be wound around the winding core, the winding speed of the wire wound around the winding core is calculated to obtain a calculated winding speed, and the wire is unwound from the wire unwinding mechanism at a speed equal to the calculated winding speed.

[Effect of the invention] According to the above-mentioned aspect of the invention, even when the winding speed of the wire in the winding core varies significantly, the tension of the wire wound on the winding core can be kept constant.

Next, the method for implementing the present invention is described in detail according to the accompanying drawings.

1 and 2 show a winding device 10 of the present invention. The winding device 10 includes: a winding machine 11 that rotates a winding core 12 to wind a wire 13 around the winding core 12; a wire unwinding mechanism 21 that supplies the wire 13 to the winding core 12; and a tensioning device 31 that applies tension to the wire 13 supplied from the wire unwinding mechanism 21 to the winding core 12.

Here, three axes X, Y, and Z are set to be orthogonal to each other, and the winding device 10 of the present invention is described in a manner in which the X axis extends in a horizontal front-to-back direction, the Y axis extends in a horizontal lateral direction, the Z axis extends in a vertical direction, and the wire 13 is unwound in the Y axis direction.

A winding motor 14 as a core rotating unit is mounted on a base plate 15a erected on the upper surface of a main body 15 installed at a location, with its rotation axis 14a facing the X-axis direction and extending in the horizontal direction. The winding machine 11 of this embodiment is configured so that the winding motor 14 rotates the core 12 at a constant speed.

The winding machine 11 is configured such that the winding core 12 is coaxially mounted on the rotating shaft 14a of the winding motor 14, and the winding core 12 is rotated about the shaft, so that the wire 13 supplied from the wire unwinding mechanism 21 and tensioned by the tension device 31 is wound around the winding core 12. The rotation angle sensor 16 is a sensor for detecting the rotation angle of the winding core 12.

As shown in FIG1 , a base 17 is installed at a location where a winding machine 11 is installed so as to be separated from the winding machine 11. The base 17 is provided with a roller 17a for making the base 17 easy to move and a leg member 17b fixed to the location so as not to be movable. The base 17 is installed at a position offset in the Y-axis direction relative to the winding machine 11.

The wire 13 of this embodiment is a coated copper wire with a circular or square cross section used for manufacturing coils of motor parts. The wire 13 is wound on a relatively large reel 18 and stored. The reel 18 is arranged in an offset manner at the end of the base 17 separated from the winding machine 11 as a wire source. On the base 17, a housing 19 for setting a controller 46 described later is mounted in a manner adjacent to the reel 18. The wire unwinding mechanism 21 is mounted on the base 17 via the housing 19.

Specifically, the wire unwinding mechanism 21 is provided on a flat plate 22, and the flat plate 22 is mounted on the housing 19 in a manner that covers the winding shaft 18 from the side in the Z-axis direction. A through hole 22a is formed on the flat plate 22, through which the wire 13 can pass. A table 23 is erected near the through hole 22a of the flat plate 22, and a plurality of small rollers 23a are provided on the table 23, which clamp the wire 13 extending in the Z-axis direction through the through hole 22a from both sides in the Y-axis direction and overcome its curling characteristics.

In addition, in this embodiment, the wire unwinding mechanism 21 for unwinding the wire 13 toward the winding machine 11 includes: a reel 24 with a larger diameter, on which the wire 13 that overcomes the winding characteristics by a plurality of small rollers 23a is hung and the wire 13 is turned; an auxiliary pulley 25, which is adjacent to the reel 24 and has a smaller diameter than the reel 24 pivoted on the table 23; and an unwinding motor 26 as an unwinding drive unit, which rotates the reel 24.

The wire rod 13 is wound at least once on the reel 24 and the auxiliary pulley 25 in a manner that the reel 24 and the auxiliary pulley 25 are connected. In addition, when the reel 24 is driven by the unwinding motor 26 to rotate, the wire rod 13 released from the reel 18 is pulled up and rewound, and the already wound wire rod 13 is released from the reel 24 and unwound toward the winding machine 11.

A lead straightening plate 30 is provided on the housing 19 between the wire unwinding mechanism 21 and the winding machine 11 so as to extend in the Y-axis direction. A tensioning device 31 for applying tension to the wire 13 supplied from the wire unwinding mechanism 21 to the winding core 12 is provided on the lead straightening plate 30.

A first turning pulley 32 and a second turning pulley 33 are provided on the lead straightening plate 30, wherein the first turning pulley 32 sets the wire 13 turned from the winding drum 24 to be horizontal and directed toward the winding machine 11, and the second turning pulley 32 is used to hang the wire 13 directed toward the winding machine 11 by the first turning pulley 32. The first turning pulley 32 and the second turning pulley 33 of this embodiment use pulleys with larger diameters in order to facilitate the hanging of the wire 13.

The tensioning device 31 includes: a guide wheel 34, on which is hung the wire 13 which is unwound from the wire unwinding mechanism 21 and is directed away from the winding machine 11 through the second turning pulley 33; an elastic member 35 as a force-applying unit, which applies force to the guide wheel 34 in the direction of applying tension to the wire 13, that is, in the direction away from the winding machine 11, and applies tension to the wire 13 corresponding to the position of the guide wheel 34.

That is, a rail 36 is provided on the lead straight plate 30 in a manner extending in the Y-axis direction, and a support platform 37 is provided on the rail 36 in a manner movable in the Y-axis direction, and the support platform 37 supports the guide wheel 34 so as to be rotatable. The guide wheel 34 is hung with the wire 13 unwound from the wire unwinding mechanism 21, and in this embodiment, it is used as a pulley around which the wire 13 turned by the second turning pulley 33 is hung.

In addition, an elastic member 35 for urging the guide wheel 34 in a direction away from the winding machine 11 is provided on the straight lead plate 30. The elastic member 35 of this embodiment is composed of a pair of coil springs 35, 35. One end of the pair of coil springs 35, 35 is mounted on the support stand 37, and the other end thereof is mounted on the movable body 41 (FIG. 1) in a manner separated in a direction away from the winding machine 11.

Since the pair of coil springs 35, 35 apply force to the support platform 37 in a direction away from the winding machine 11, a tension corresponding to the position of the guide wheel 34 pivoted on the support platform 37 in the Y-axis direction is imparted to the wire 13 hung on the guide wheel 34 and directed toward the winding machine 11.

The force applied by the coil springs 35, 35 to the guide wheel 34 is adjusted by the tension adjustment mechanism 40. The tension adjustment mechanism 40 includes: a track 42, which is arranged on the lead straight plate 30 in a manner parallel to the coil springs 35, 35 and supports the movable body 41 so as to be movable in the Y-axis direction; a male thread 43, which is screwed with the movable body 41 movably mounted on the track 42 and is pivoted on the lead straight plate 30; and an adjustment knob 44, which is used to rotate the male thread 43.

In addition, the other end of the coil spring 35, 35 mounted on the support 37 is connected to the movable body 41. By rotating the adjustment knob 44 to rotate the male thread 43, the movable body 41 is separated from or in contact with the winding machine 11, and the tension of the coil spring 35, 35 is adjusted.

Here, the position sensor 45 is a sensor that detects the position of the guide wheel 34 in the Y-axis direction, and its detection output is connected to the input of the controller 46.

In addition, the tension adjustment of the coil springs 35, 35 by the tension adjustment mechanism 40 is implemented as an initial setting before starting the winding, and is not implemented during the winding in order to set the tension applied to the wire 13 to be constant.

In addition, the winding machine 11 in the winding device 10 of the present invention rotates the core 12 around the axis, thereby winding the wire 13 around the core 12. The core 12 of this embodiment has: a barrel portion 12a, on which the wire 13 is wound; and a flange portion 12b, which is provided on both end surfaces of the barrel portion 12a and limits the winding width of the wire 13. The core 12 is coaxially mounted on the rotating shaft 14a of the core rotating unit, that is, the winding motor 14. The core 12 is configured to be rotationally driven by the winding motor 14, thereby rotating around its axis. In this embodiment, the case where the cross-sectional shape of the reel portion 12a is a rectangle is shown.

In addition, the winding machine 11 is provided with a guide mechanism 51 for guiding the wire 13 wound on the winding core 12 in the axial direction. The guide mechanism 51 includes: a support pin 52, which is provided on the base plate 15a in parallel with the rotation axis of the winding core 12 and is provided to be movable in the axial direction; a guide member 53, which is mounted on the front end of the support pin 52 and restricts the axial movement of the wire 13 on the winding core 12; and a guide motor 54 (FIG. 2) which moves the support pin 52 in the axial direction.

As shown in Fig. 2, the guide motor 54 is installed so that its rotation shaft 54a is adjacent to the support pin 52 and parallel to the support pin 52. A ball screw 55 is coaxially provided on the rotation shaft 54a. In addition, a female thread member 56 screwed with the ball screw 55 is installed at the base end of the support pin 52.

Therefore, when the guide motor 54 is driven to rotate the ball screw 55, the support pin 52 moves in the axial direction together with the female threaded member 56 that moves by being threaded with the ball screw 55, so that the guide member 53 provided at the front end of the support pin 52 moves in the axial direction of the winding core 12. In addition, the guide member 53 is configured to clamp the wire 13 from both sides of the axial direction of the winding core 12 and limit the passing position of the wire 13 in the axial direction (Figures 10 and 11).

In addition, the winding device 10 also has: a reeling speed detection sensor 70 as a reeling speed detection unit, which detects the speed of the wire 13 unwound from the wire reeling mechanism 21 toward the tensioning device 31; and a reeling speed detection sensor 60 as a reeling speed detection unit, which detects the speed of the wire 13 passing through the tensioning device 31 toward the winding core 12.

The winding speed detection sensor 60 of this embodiment is provided on an auxiliary plate 62 erected on the end of the winding machine 11 side of the outer casing 19. On the auxiliary plate 62, a pair of rollers 61, 61 pivoted in a manner of clamping the wire 13 and a first encoder 63 for detecting the rotation angle of either roller 61 are provided.

On the other hand, the unwinding speed detection sensor 70 of this embodiment is arranged on the lead straight plate 30 between the first turning pulley 32 and the second turning pulley 33. On the lead straight plate 30, a pair of rollers 71, 71 pivoted in a manner of clamping the wire 13 and a second encoder 73 for detecting the rotation angle of either roller 71 are arranged.

In addition, the housing 19 contains a controller 46 for controlling the winding motor 14 constituting the winding core rotating unit and the guide motor 54 in the guide mechanism 51. The controller 46 contains a CPU for controlling the winding operation performed by the winding device 10 and a memory 46a as a storage unit storing information or data required for the processing operation of the CPU. The memory 46a stores, for example, a predetermined angular velocity ω described later. In addition, an input device 46b for inputting the information is connected to the controller 46.

Therefore, the control output from the controller 46 is connected to the winding motor 14 and the guide motor 54. The controller 46 is configured to perform so-called aligned winding, which is to drive the winding motor 14 to rotate the core 12 at a constant speed, and control the guide motor 54 to move the guide member 53 in the rotation direction of the core 12 by an amount corresponding to the outer diameter of the wire 13 every time the core 12 rotates one circle, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tension device 31 while being in close contact with the core 12.

In addition, the detection output of the rotation angle sensor 16 is connected to the control input of the controller 46, and the controller 46 is configured to always be able to recognize the rotation angle of the winding core 12 rotating at a constant speed.

On the other hand, the unwinding motor 26 in the wire unwinding mechanism 21 is configured so that the rotation speed of the rotating shaft 26a can be changed. The reel 24 driven by the unwinding motor 26 can change the unwinding speed of the wire 13 by changing its rotation speed. In addition, the control output of the controller 46 is also connected to the unwinding motor 26 in the wire unwinding mechanism 21. The controller 46 controls the wire unwinding mechanism 21 together with the winding motor 14 so that the wire 13 is supplied at a speed equal to the winding speed of the wire 13 wound around the rotating winding core 12.

Specifically, the controller 46 is provided with a calculation circuit 46c as a calculation unit. The calculation circuit 46c is configured to calculate the winding speed of the wire 13 wound around the rotating winding core 12 through the information or data stored in the memory 46a. In addition, the controller 46 controls the wire unwinding mechanism 21 together with the winding motor 14 so that the wire 13 is supplied to the winding core 12 at a speed equal to the winding speed of the wire 13 wound around the rotating winding core 12 based on the calculated winding speed calculated by the calculation circuit 46c.

In this embodiment, since the unwinding speed detection sensor 70 or the winding speed detection sensor 60 is provided, the detection outputs of the first encoder 63 and the second encoder 73 are connected to the control input of the controller 46. In addition, the controller 46 detects the measured unwinding speed or the measured winding speed, and performs feedback control in such a manner that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the winding speed.

Next, the wire winding method of the present invention using the above-mentioned wire winding device will be described.

The winding method of the present invention is a method of causing the winding core 12 to rotate around an axis, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tension device 31 around the winding core 12.

Since the above-mentioned winding device 10 is used, as shown in Figure 1, the wire 13 is wound around the reel 18 and stored. After the wire 13 is unwound from the reel 18 as the wire source, it passes through the through hole 22a of the flat plate 22, overcomes the winding characteristics through a plurality of small rollers 23a, and is wound around the reel 24 and the auxiliary pulley 25 constituting the wire unwinding mechanism 21.

The wire 13 extending from the reel 24 is routed in such a manner that the direction thereof is changed in sequence by the first and second turning pulleys 32 and 33, and after being hung on the guide wheel 34 in the tensioning device 31, it reaches the winding machine 11. In the winding machine 11, the wire 13 passing through the guide member 53 is stopped by the winding core 12.

In this embodiment, information related to the winding core 12 used (specifically, information on the shape and size of the winding core), that is, data on the cross-sectional shape of the winding barrel portion 12a of the winding core 12 on which the wire 13 is directly wound and its winding width w ( FIG. 10 ), and data related to the wire diameter d of the wire 13 wound around the winding core 12 are stored in the memory 46a as the storage unit of the controller 46 via the input device 46b. Winding starts from this state.

During actual winding, the controller 46 drives the winding motor 14 to rotate the winding core 12 at a constant speed, and the rotation angle sensor 16 detects the rotation angle and feeds back to the controller 46.

In addition, as shown in FIG10 and FIG11, the guide member 53 is moved in the rotation axis direction of the winding core 12 by an amount corresponding to the outer diameter of the wire 13 every time the winding core 12 rotates once. In this way, the wire 13 supplied from the wire unwinding mechanism 21 and tensioned by the tension device 31 is neatly arranged and wound around the winding core 12.

The winding method of the present invention is characterized in that the winding speed of the wire 13 wound around the winding core 12 is calculated in advance to obtain a calculated winding speed, and the wire 13 is unwound from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed.

That is, although in actual winding, the winding core 12 is rotated at a predetermined angular velocity ω stored in the storage device 46a, in this embodiment, as shown in Figure 7 (a), the cross-section of the winding drum portion 12a of the winding core 12 for winding the wire 13 is rectangular, and in this cross-section, the length from the rotation center O to the long side is set to a, the length from the rotation center O to the short side is set to b, and the distance from the rotation center O to the corner is set to c. Furthermore, when the rotational angular velocity ω of the winding core 12 is maintained at a constant value, as shown in FIG. 7( b ), the speed (longitudinal axis) of the wire 13 wound around the winding core 12 changes in such a manner as to generate inflection points aω, cω, bω, cω, aω, … with respect to the rotational angle (horizontal axis) of the winding core 12 .

In this way, although the winding speed of the wire 13 wound on the core 12 changes, the cross-sectional shape of the core 12 is clear. If the distance from the rotation center O to each part is clear, the speed of the wire 13 wound on the core 12 can be calculated by multiplying it by the rotation angular velocity ω of the core 12.

In this embodiment, since information related to the cross-sectional shape of the winding drum portion 12a of the winding core 12 used, on which the wire 13 is directly wound (i.e., information related to the winding core 12) is stored in the memory 46a, the operation circuit 46c in the controller 46 obtains the calculated winding speed as shown in Figure 7 (b) by multiplying the information related to the winding core 12, specifically, the lengths a, b, and c from the rotation center O of the winding core 12 to each part on which the wire 13 is wound, by the angular velocity ω that rotates the winding core 12.

In addition, the controller 46 controls the winding motor 14 in such a manner that the winding motor 14 is driven and the winding core 12 is rotated at a predetermined angular velocity ω, and controls the unwinding motor 26 in the wire unwinding mechanism 21 in such a manner that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed obtained by the operation circuit 46c.

Here, in the above-mentioned winding device 10, an unwinding speed detection sensor 70 for detecting the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tension device 31, and a winding speed detection sensor 60 for detecting the speed of the wire 13 passing through the tension device 31 are provided. Thereby, when the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed as shown in FIG. 3 (a), the measured unwinding speed of the wire 13 starting from the wire unwinding mechanism 21 as shown in FIG. 3 (b) and the measured winding speed of the wire 13 toward the winding core 12 as shown in FIG. 3 (c) are detected.

Here, when the wire 13 is wound around the winding core 12 having a non-circular cross-section such as a rectangle, the winding speed of the wire 13 wound on the winding core 12 changes. Therefore, when the unwinding speed of the wire 13 starting from the wire unwinding mechanism 21 is set to be constant as in the prior art, as shown by the dotted arrow in Figure 1, the guide wheel 34 swings periodically, and the tension applied to the wire 13 changes due to the swing.

In contrast, in the present invention, as shown in FIG3 (a), the wire 13 is supplied from the wire unwinding mechanism 21 to the winding core 12 at a speed equal to the winding speed of the wire 13 wound on the winding core 12. Therefore, as shown in FIG3 (c), when the winding speed of the wire 13 wound on the winding core 12 increases, as shown in FIG3 (b), the supply speed of the wire 13 from the wire unwinding mechanism 21 also increases with the increase. Similarly, when the winding speed of the winding core 12 decreases, the supply speed of the wire 13 from the wire unwinding mechanism 21 also decreases.

In this way, when the supply speed of the wire 13 from the wire unwinding mechanism 21 and the winding speed of the wire 13 on the winding core 12 are consistent, the periodic swing of the guide pulley 34 as shown by the dotted arrow in FIG. 1 disappears, and the tension of the wire 13 supplied to the winding core 12 can be kept constant. As a result, a high-quality coil can be manufactured.

In addition, the controller 46 rotates the core 12 at a constant speed (i.e., rotates at a predetermined angular velocity ω) and moves the guide member 53 in the axial direction of the core 12, thereby winding the wires 13 in an orderly manner around the core 12. When the wires 13 are wound around the core 12 in a manner that covers multiple layers, as shown in FIG. 10, when the first layer of winding to the drum portion 12a is completed, the second layer of winding is performed on the outer periphery of the first layer of the wire 13, and when the second layer of winding is completed, as shown in FIG. 11, the third layer of winding is performed on the outer periphery of the second layer of the wire 13.

In this way, when the wire 13 is wound around multiple layers of the drum portion 12a, as shown in Figures 8 and 9, the length from the rotation center O of the core 12 to each portion where the wire 13 is wound increases toward the outer layer, and when the core 12 rotates at a predetermined angular velocity ω, the winding speed wound around the core 12 accelerates toward the outer layer.

Specifically, as shown in FIG7 , in the case of the first layer, the length from the rotation center O of the core 12 to each portion around which the wire 13 is wound is the outer peripheral shape itself in the cross section of the core 12. As shown in FIG8 , in the second layer, the length from the rotation center O of the core 12 to each portion around which the wire 13 is wound is the length obtained by adding the wire diameter d of the wire 13 to the outer peripheral shape of the cross-sectional shape of the core 12. As shown in FIG9 , in the third layer, the length from the rotation center O of the core 12 to each portion around which the wire 13 is wound is the length obtained by further adding the wire diameter d of the wire 13 to the second layer.

The data of the wire diameter d of the wire 13 and the winding width w of the drum portion 12a are stored in advance in the memory 46a. Therefore, the operation circuit 46c in the controller 46 of FIG. 1 can derive the rotation speed required for the neat arrangement winding of each layer by dividing the winding width w by the wire diameter d.

In addition, if it is the second layer of winding, as shown in Figure 8, the lengths (a+d), (b+d), and (c+d) from the rotation center O of the winding core 12 to each portion around which the wire 13 is wound are obtained. If it is the third layer of winding, as shown in Figure 9, the lengths (a+2d), (b+2d), and (c+2d) from the rotation center O of the winding core 12 to each portion around which the wire 13 is wound are obtained. Then, by multiplying the angular velocity ω of the rotating winding core 12 by the above-mentioned lengths (a+d), (b+d), (c+d), (a+2d), (b+2d), and (c+2d), the calculated winding speed of each layer can be obtained (Figure 8(b), Figure 9(b)).

Furthermore, even after the second layer, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 so as to supply the wire 13 from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed for each layer obtained by such calculation.

Therefore, even after the second layer, the unwinding amount is controlled in such a manner that the unwinding speed (unwinding amount) of the wire 13 of the wire unwinding mechanism 21 and the winding speed (winding amount) of the wire 13 of the winding core 12 are balanced.

Therefore, even after the second layer, the periodic swing of the guide wheel 34 in the tension device 31 can be suppressed. Thereby, the elastic member 35 gives the wire 13 hung on the guide wheel 34 an invariable constant tension corresponding to the position of the guide wheel 34.

Here, in actual winding, the controller 46 detects the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tension device 31 and the speed of the wire 13 passing through the tension device 31 toward the winding core 12. In addition, the unwinding motor 26 is controlled so as to eliminate the deviation in the time axis direction between the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed, and the wire 13 is unwound from the wire unwinding mechanism 21.

That is, in the present invention, the unwinding motor 26 is controlled in such a manner that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed obtained by pre-calculating the speed of the wire 13 wound around the winding core 12, and as shown in FIG. 3, there is no offset in the time axis direction between the winding speed and the unwinding speed of the wire 13.

When the rotation speed of the winding core 12 is increased, the supply speed of the wire 13 from the wire unwinding mechanism 21 changes at a faster speed. Therefore, even if the controller 46 controls the unwinding motor 26 based on the calculated winding speed, there may be a deviation between the actual winding speed of the wire 13 wound by the winding core 12 and the supply amount of the wire 13 driven and supplied by the unwinding motor 26.

Here, the actual speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tension device 31 is detected by the unwinding speed detection sensor 70, and the actual winding speed of the wire 13 wound by the winding core 12 is detected by the winding speed detection sensor 60. Thus, the controller 46 always compares the speed change state of the measured winding speed determined by the detection output of the winding speed detection sensor 60 with the speed change state of the measured unwinding speed determined by the detection output of the unwinding speed detection sensor 70. Furthermore, the unwinding motor 26 is controlled so as to eliminate the deviation in the time axis direction between the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed, and the wire 13 is unwound from the wire unwinding mechanism 21.

Specifically, when an offset T in the time axis direction occurs between the speed changes of the measured winding speed shown by the solid line in FIG. 4(c) and the measured unwinding speed shown by the dotted line in FIG. 4(b), the controller 46 obtains the time offset T. Furthermore, the offset T is subtracted from the calculated winding speed shown by the solid line in FIG. 4(a), thereby obtaining a corrected winding speed as shown by the double-dotted line.

In this regard, the controller 46 of this embodiment includes a speed correction unit that calculates the deviation T of the speed change of each of the measured reeling speed and the measured unreeling speed in the time axis direction and subtracts the deviation T from the calculated reeling speed to obtain a corrected reeling speed.

In addition, the controller 46 controls the unwinding motor 26 along the corrected winding speed shown by the double-dotted line in FIG. 4 (a) obtained. Therefore, the controller 46 controls the unwinding motor 26 in a state where the calculated winding speed shown by the solid line in FIG. 4 (a) is advanced by the amount of offset T. In addition, the actual winding speed of the wire 13 wound by the winding core 12 shown by the solid line in FIG. 4 (c) and the speed of the wire 13 actually supplied from the wire unwinding mechanism 21 can be made consistent as shown by the solid line in FIG. 4 (b).

Thereby, even when the rotation speed of the winding core 12 is increased and the winding speed onto the winding core 12 is changed at a faster speed, the supply speed of the wire 13 from the wire unwinding mechanism 21 can follow the speed change.

In this way, the deviation between the actual winding speed of the wire 13 wound by the winding core 12 and the supply amount of the wire 13 driven and supplied by the unwinding motor 26 is eliminated, thereby preventing the periodic swing of the guide wheel 34 in the tension device 31. In this way, even if the rotation speed of the winding core 12 is increased, it is possible to apply a constant tension corresponding to the position of the guide wheel 34 by the elastic member 35.

On the other hand, although there is no offset in the time axis direction between the speed changes of the measured winding speed and the calculated winding speed, if the winding speed itself is offset, that is, if the calculated winding speed and the actual winding speed of the wire 13 onto the winding core 12 are different, the wire supply amount and the wire winding amount are inconsistent.

Therefore, in the tension device 31, the guide wheel 34 around which the wire 13 is hung moves along the rail 36, thereby changing the interval between the guide wheel 34 and the winding core 12, and the position change in the Y-axis direction is the amount of the inconsistent wire 13. In this way, the difference between the supply amount and the winding amount is absorbed by the change in the position of the guide wheel 34 in the tension device 31. In addition, the movement of the guide wheel 34 is detected by the position sensor 45 and fed back to the controller 46.

Here, when the guide wheel 34 moves, the tension applied to the wire 13 gradually changes. Thus, when the change in the position of the guide wheel 34 is detected by the detection output of the position sensor 45, the controller 46 increases or decreases the calculated winding speed as the supply amount of the wire 13 at a constant ratio so that the position of the guide wheel 34 returns to a predetermined position of the track 36, for example, the approximate center, and controls the rotation speed of the unwinding motor 26 according to the corrected winding speed after the increase or decrease. Therefore, the unwinding speed of the wire 13 of the wire unwinding mechanism 21 and the winding speed of the winding core 12 are balanced.

That is, if the measured winding speed of the wire 13 to the winding core 12 is faster than the calculated winding speed as shown in FIG5(a), and the guide wheel 34 gradually approaches the winding machine 11, then as shown in FIG5(b), the calculated winding speed is increased at a constant ratio in such a manner that the unwinding amount of the wire 13 implemented by the wire unwinding mechanism 21 increases, and a corrected winding speed substantially consistent with the measured winding speed is obtained. Based on the corrected winding speed thus increased, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21, thereby making the measured unwinding speed consistent with the measured winding speed as shown in FIG5(c).

On the other hand, if the measured winding speed of the wire 13 to the winding core 12 is slower than the calculated winding speed as shown in FIG6(a), and the guide wheel 34 gradually moves away from the winding machine 11, then as shown in FIG6(b), the calculated winding speed is reduced at a constant ratio in such a manner that the unwinding amount of the wire 13 implemented by the wire unwinding mechanism 21 is reduced, and a corrected winding speed substantially consistent with the measured winding speed is obtained. Based on the corrected winding speed thus reduced, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21, thereby making the measured unwinding speed consistent with the measured winding speed as shown in FIG6(c).

Thereby, the guide wheel 34 returns to a predetermined position of the rail 36, for example, substantially the center, and the tension applied to the wire 13 returns to a predetermined value.

According to this implementation method, the following effects are achieved.

The winding device 10 of the present embodiment comprises: a winding core 12; a wire unwinding mechanism 21, which supplies the wire 13 to the winding core 12 in a manner in which the supply speed can be changed; a tension device 31, which applies tension to the wire 13 supplied from the wire unwinding mechanism 21 to the winding core 12; a winding motor 14, which rotates the winding core 12, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tension device 31 around the winding core 12; and a controller 46, which controls the wire unwinding mechanism 21 in a manner in which the wire 13 is supplied at a speed equal to the winding speed of the wire 13 wound around the rotating winding core 12.

In addition, the winding method of the present embodiment rotates the winding core 12, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tension device 31 around the winding core 12, calculating the winding speed of the wire 13 wound around the winding core 12 to obtain the calculated winding speed, and unwinding the wire 13 from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed.

According to the above structure, since the wire 13 is unwound from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13 wound around the winding core 12, even if the tensioning device 31 has a member such as a guide wheel 34 that is hung around the wire 13 and moves due to the elastic member 35, it is possible to prevent the member such as the guide wheel 34 from moving due to the speed change of the wire 13.

Therefore, since the change of the tension of the wire rod accompanying the movement of the member such as the guide wheel 34 is avoided, the tension of the wire rod 13 wound on the winding core 12 can be kept constant even when the speed of the wire rod 13 wound on the winding cores of different diameters varies significantly.

In addition, in the winding device 10 of the present embodiment, the wire unwinding mechanism 21 includes: a reel 24, on which the wire 13 supplied from the reel 18 is hung; an unwinding motor 26, which rotates the reel 24 to supply the hung wire 13 to the winding core 12, and the controller 46 controls the unwinding motor 26 in a manner that supplies the wire 13 at a speed equal to the winding speed of the wire 13.

In addition, in the winding method of the present embodiment, the reel 24 around which the wire 13 supplied from the reel 18 is hung is rotated by the unwinding motor 26, so that the wire 13 is supplied to the winding core 12, and the unwinding motor 26 is controlled in such a manner that the speed of the wire 13 supplied to the winding core 12 due to the rotation of the reel 24 is consistent with the calculated winding speed.

According to the above structure, by controlling the unwinding motor 26 that rotates the reel 24, the speed of the wire 13 supplied to the winding core 12 due to the rotation of the reel 24 can be consistent with the calculated winding speed. As a result, the wire 13 can be supplied from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13.

In addition, the winding device 10 of the present embodiment is also provided with: a memory 46a, which stores information related to the winding core 12; an operation circuit 46c, which calculates the winding speed of the wire 13 wound on the winding core 12 according to the information related to the winding core 12, and the tensioning device 31 has: a guide wheel 34, on which the wire 13 is hung; an elastic member 35, which applies force to the guide wheel 34, and the controller 46 controls the unwinding motor 26 in a manner of supplying the wire 13 according to the calculated winding speed calculated by the operation circuit 46c.

In addition, in the winding method of the present embodiment, the storage device 46a stores information related to the winding core 12, and the calculation circuit 46c is used to calculate the winding speed of the wire 13 wound on the winding core 12 according to the information related to the winding core 12, and the unwinding motor 26 is controlled in a manner to supply the wire 13 according to the calculated winding speed calculated by the calculation circuit 46c. The tensioning device 31 has: a guide wheel 34, on which the wire 13 is hung; and an elastic member 35, which applies force to the guide wheel 34.

According to the above structure, since the supply speed of the wire 13 from the wire unwinding mechanism 21 and the winding speed of the wire 13 wound by the winding core 12 are made consistent, the periodic swing of the guide wheel 34 disappears, and the tension of the wire 13 supplied to the winding core 12 can be kept constant. As a result, a high-quality coil can be manufactured.

In addition, the winding device 10 of the present embodiment is further provided with: an unwinding speed detection sensor 70, which detects the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tension device 31; a winding speed detection sensor 60, which detects the speed of the wire 13 passing through the tension device 31 toward the winding core 12, and the controller 46 controls the unwinding motor 26 in a manner to eliminate the deviation in the time axis direction between the speed change state of the measured winding speed determined by the detection output of the winding speed detection sensor 60 and the speed change state of the measured unwinding speed determined by the detection output of the unwinding speed detection sensor 70.

In addition, in the winding method of the present embodiment, the unwinding speed of the wire 13 from the wire unwinding mechanism 21 toward the tension device 31 and the winding speed of the wire 13 wound by the winding core 12 through the tension device 31 are detected, and the wire 13 is unwound from the wire unwinding mechanism 21 in a manner that eliminates the deviation in the time axis direction between the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed.

According to the above structure, even when the rotation speed of the core 12 is increased and the winding speed to the core 12 changes at a faster speed, the supply speed of the wire 13 from the wire unwinding mechanism 21 can follow the speed change. Therefore, the deviation between the actual winding speed of the wire 13 wound by the core 12 and the supply amount of the wire 13 driven by the unwinding motor 26 is eliminated, thereby preventing the guide wheel 34 in the tension device 31 from cyclically swinging. Therefore, even if the rotation speed of the core 12 is increased, it is possible to apply a constant tension that does not change according to the position of the guide wheel 34 by the elastic member 35.

Although in the above-mentioned embodiment, the tension device 31 is described as having a guide wheel 34 that is arranged in a manner that can move along the rail 36, the tension device can also use an elastic member 6 to rotate the tension arm 4 as shown in Figure 12, and apply tension to the wire 2 unwound from the guide wheel 5 installed at the front end of the tension arm 4.

Even in the tensioning device having the tension arm 4 as shown in FIG. 12 , if the wire is unwound from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13 wound around the winding core 12, and the speed of the wire is set to a speed equal to the winding speed of the wire wound around the winding core, the movement of the guide wheel 5 caused by the change in the speed of the wire can be prevented. As a result, since the change in the tension of the wire caused by the movement of the guide wheel 5 is avoided, the tension of the wire wound around the winding core 12 can be kept constant.

In the above-mentioned embodiment, the elastic member 35 for applying force to the guide wheel 34 in the tension device 31 is exemplified as a coil spring. However, a fluid pressure cylinder for applying force in a direction to make the rod sink or protrude by fluid pressure such as air pressure may be used as the elastic member. When such a fluid pressure cylinder is used as the elastic member, when it is desired to change the elastic force, the elastic force can be changed relatively easily by changing the fluid pressure such as compressed air in the cylinder.

In the above embodiment, the operation circuit 46c is provided on the controller 46, and the operation circuit 46c calculates the calculated scroll speed from the information or data stored in the memory 46a. However, the operation circuit 46c may not be provided, but the scroll speed may be calculated separately from the controller 46 in advance, and the memory 46a may store the calculated scroll speed provided separately.

In this case, the controller 46 controls the unwinding motor 26 so as to supply the wire 13 according to the calculated winding speed stored in the memory 46a. Thereby, since frequent movement of the guide wheel 34 is avoided, the tension of the wire 13 wound on the winding core 12 can be kept constant.

Although the embodiments of the present invention have been described above, the embodiments described above merely illustrate a part of the application examples of the present invention and do not mean that the technical scope of the present invention is limited to the specific structure of the embodiments described above.

This application claims priority based on Tokugan Application No. 2020-004193 filed with the Japan Patent Office on January 15, 2020, and all the contents of that application are incorporated into this specification by reference.

10: Winding device 12: Core 13: Wire 14: Winding motor (core rotation unit) 18: Reel (wire source) 21: Wire unwinding mechanism 24: Reel 26: Unwinding motor 31: Tensioning device 46: Controller 46a: Storage (storage unit) 46c: Calculation circuit (calculation unit) 60: Winding speed detection sensor (winding speed detection unit) 70: Unwinding speed detection sensor (unwinding speed detection unit)

FIG1 is a front view of a winding device according to an embodiment of the present invention. FIG2 is a top view of the winding device. FIG3 is a schematic diagram showing the relationship between the calculated winding speed, the measured unwinding speed, and the measured winding speed. FIG4 is a schematic diagram showing a case where the measured unwinding speed and the measured winding speed are offset, and corresponds to FIG3. FIG5 is a schematic diagram showing a case where the measured winding speed is faster than the calculated winding speed. FIG6 is a schematic diagram showing a case where the measured winding speed is slower than the calculated winding speed. FIG7 is a schematic diagram showing the relationship between the rotation angle of the winding core and the speed of the wire wound thereon. FIG8 is a schematic diagram showing the relationship between the angle of the winding core and the speed of the wire wound thereon when the winding core is wound around the second layer of wire, and corresponds to FIG7. FIG9 is a schematic diagram showing the relationship between the angle of the winding core and the speed of the wire wound thereon when the winding core is wound around the third layer of wire, and corresponds to FIG8. FIG10 is an enlarged view of the A part of FIG2, showing the state in which the winding core is wound around the wire until the second layer. FIG11 is a schematic diagram showing the state in which the winding core is wound around the wire until the third layer, and corresponds to FIG10. FIG12 is a front view showing a known tensioning device.

10: Winding device

11: Winding machine

12: Roll core

12a: Reel section

12b: flange

13: Wires

14: Winding motor (winding core rotation unit)

14a: Rotation axis

15: Main body

15a: Substrate

16: Rotation angle sensor

17: Base

17a: Roller

17b: Foot component

18: Scroll

19: Shell

21: Wire unwinding mechanism

22: Tablet

22a: Through hole

23: Tabletop

23a: Small Roller

24: Scroll

25: Auxiliary pulley

26: Electric motor for unwinding

26a: Rotation axis

30: Lead straight board

31: Tension device

32: First steering pulley

33: Second steering pulley

34: Guide wheel

35: Elastic component (helical spring)

36: Track

37: Support platform

40: Tension adjustment mechanism

41: Movable body

42: Track

43: Male thread

44: Adjustment knob

45: Position sensor

46: Controller

46a: Memory (storage unit)

46b: Input device

46c: Operational circuit (operation unit)

51: Guidance Agency

52: Support pin

53: Guidance component

54: Guidance motor

60: Winding speed detection sensor (winding speed detection unit)

61: Roller

62: Auxiliary board

63: First encoder

70: Unwinding speed detection sensor (unwinding speed detection unit)

71: Roller

73: Second encoder

Claims (10)

A winding device comprises: a winding core; a wire unwinding mechanism that supplies wire to the winding core in a manner that the supply speed can be changed; a tensioning device that applies tension to the wire supplied from the wire unwinding mechanism to the winding core; a winding core rotating unit that rotates the winding core so that the wire supplied from the wire unwinding mechanism and tensioned by the tensioning device is wound around the winding core; and a controller that controls the wire unwinding mechanism in a manner that supplies the wire at a speed equal to the winding speed of the wire wound around the rotating winding core. The winding device as recited in claim 1, wherein the wire unwinding mechanism comprises: a reel on which the wire supplied from a wire source is wound; and an unwinding drive unit which rotates the reel to supply the wound wire to the winding core, and the controller controls the unwinding drive unit in such a manner that the wire is supplied at a speed equal to the winding speed of the wire. The winding device as described in claim 2, further comprising: a storage unit for storing the winding speed of the wire wound on the rotating winding core, i.e., the calculated winding speed calculated in advance, the tensioning device having: a guide wheel for hanging the wire; and a force applying unit for applying force to the guide wheel, the controller controls the unwinding drive unit in a manner that supplies the wire according to the calculated winding speed stored in the storage unit. The winding device as described in claim 2, further comprising: a storage unit for storing information related to the winding core; and an operation unit for calculating the winding speed of the wire wound on the winding core based on the information related to the winding core, the tensioning device having: a guide wheel for hanging the wire; and a force applying unit for applying force to the guide wheel, the controller controls the unwinding drive unit in a manner of supplying the wire according to the calculated winding speed calculated by the operation unit. A winding device as recited in any one of claims 2 to 4, further comprising: an unwinding speed detection unit, which detects the speed of the wire unwound from the wire unwinding mechanism toward the tensioning device; and a winding speed detection unit, which detects the speed of the wire passing through the tensioning device toward the winding core, the controller controls the unwinding drive unit in a manner that eliminates the deviation in the time axis direction between the speed change state of the measured winding speed determined by the detection output of the winding speed detection unit and the speed change state of the measured unwinding speed determined by the detection output of the unwinding speed detection unit. A wire winding method is to rotate a winding core so that a wire supplied from a wire unwinding mechanism and tensioned by a tension device is wound around the winding core, the winding speed of the wire wound around the winding core is calculated to obtain a calculated winding speed, and the wire is unwound from the wire unwinding mechanism at a speed equal to the calculated winding speed. A winding method as described in claim 6, wherein: the reel around which the wire supplied from a wire source is wound is rotated by an unwinding drive unit, thereby supplying the wire to the winding core; the unwinding drive unit is controlled in such a manner that the speed of the wire supplied to the winding core due to the rotation of the reel is consistent with the calculated winding speed. A winding method as described in claim 7, wherein: a storage unit stores the calculated winding speed calculated in advance, the unwinding drive unit is controlled in such a way as to supply the wire rod according to the calculated winding speed stored in the storage unit, and the tensioning device has: a guide wheel on which the wire rod is hung; and a force applying unit that applies force to the guide wheel. A winding method as described in claim 7, wherein: a storage unit stores information related to the winding core, a calculation unit calculates the winding speed of the wire wound on the winding core based on the information related to the winding core, a drive unit for unwinding is controlled in such a way as to supply the wire according to the calculated winding speed calculated by the calculation unit, the tension device comprises: a guide wheel on which the wire is hung; and a force applying unit that applies force to the guide wheel. A winding method as recited in any one of claims 6 to 9, wherein: the unwinding speed of the wire from the wire unwinding mechanism toward the tensioning device and the winding speed of the wire wound by the winding core through the tensioning device are detected, and the wire is unwound from the wire unwinding mechanism in a manner that eliminates the deviation in the time axis direction between the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed.