TWI862769B - Winding device and winding method - Google Patents

Abstract

A winding device comprises: a winding core; a wire unwinding mechanism that supplies a wire to the winding core; 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 given tension by the tensioning device is wound around the winding core; and a control unit. The controller controls the accumulation mechanism and the wire unwinding mechanism, wherein the controller controls the wire unwinding mechanism in such a manner that the wire is unwound at the average winding speed of the wire wound on the rotating winding core, and controls the accumulation mechanism in such a manner that the speed of the wire unwound from the wire unwinding mechanism is equal to the winding speed of the wire wound on the rotating winding core.

Description

Winding device and winding method

The present invention relates to a winding device and a 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 FIG15 , this tensioning device comprises: 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 predetermined position between the wheels 5 gives the tension arm 4 an elastic force corresponding to the rotation angle; the potentiometer 7 detects the rotation angle of the tension arm 4; the unwinding motor 8 controls 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 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 on 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 in such a way 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 to which the elastic force is given 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 the change of 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 through the potentiometer 7, the rotation angle of the tension arm 4 immediately becomes the 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.

As described above, in the known tension device shown in FIG. 15, 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 with a rectangular cross-sectional shape and significantly different short and long sides, the speed of the wire 2 wound around the winding core will change significantly periodically 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.

That is, the wire 2 unwound from the reel 3 is turned at a substantially right angle to the tension arm at the guide wheel 5 as shown in FIG. 15 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 moves 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 hard by the wire 2, and the rotation of the tension arm 4, which is provided at the front end with the guide wheel 5 and absorbs the change, cannot follow the trend of the pulled guide wheel 5. As a result, a tension 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 2 in the winding machine is reduced and the amount of winding per unit time is reduced by a 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 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.

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

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 wire to the winding core; a storage mechanism that decelerates or accelerates the speed of the wire unwound from the wire unwinding mechanism; 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, thereby causing the wire supplied from the wire unwinding mechanism and stored by the tensioning device to be stored. The wire with tension applied thereto is wound around the aforementioned winding core; and a controller that controls the aforementioned storage mechanism and the aforementioned wire unwinding mechanism, wherein the aforementioned controller controls the aforementioned wire unwinding mechanism in such a manner that the aforementioned wire is unwound at the average winding speed of the aforementioned wire wound around the aforementioned rotating winding core, and controls the aforementioned storage mechanism in such a manner that the speed of the aforementioned wire unwound from the aforementioned wire unwinding mechanism is equal to the winding speed of the aforementioned wire wound by the aforementioned rotating winding core.

In addition, according to another aspect of the present invention, a winding method is provided, wherein the winding core is rotated so that the wire supplied from the wire unwinding mechanism and tensioned by the tension device is wound around the winding core, the wire is unwound from the wire unwinding mechanism at the average winding speed of the wire wound around the rotating winding core, and the speed of the wire unwound from the wire unwinding mechanism is decelerated or accelerated so as to be equal to the winding speed of the wire wound around the rotating winding core.

According to the above-mentioned 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.

2: Wires

3: Scroll

4: Tension arm

4a: Rotation fulcrum

5: Guide wheel

6: Elastic components

7: Potentiometer

8: Electric motor for unwinding

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

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

54a: Rotating axis

55: Ball screw

56: Female thread component

60: Accumulation mechanism

61a: Fixed roller

61b: Fixed roller

63: Movable roller

64:Servo motor

66: Ball screw

67: Movable table

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

71: Roller

73: Second encoder

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

81: Roller

82: Auxiliary board

83: First encoder

a, b, c: length

d: line diameter

L1: Predetermined length

L2: Predetermined length

T: offset

w: winding width

O: Rotation center

The front view of Figure 1 is a wiring device showing an implementation method of the present invention.

Figure 2 is a top view of the winding device.

The schematic diagram of Figure 3 shows the state where the wire is decelerated by the accumulation mechanism.

The schematic diagram of Figure 4 shows the state where the wire is accelerated by the accumulation mechanism.

The schematic diagram of Figure 5 shows the relationship between the calculated winding speed, the measured unwinding speed and the measured winding speed.

The schematic diagram of FIG6 shows the situation where there is a deviation in the time axis direction between the measured unwinding speed and the measured winding speed, and corresponds to FIG5.

The schematic diagram in Figure 7 shows the situation where the measured winding speed is faster than the calculated winding speed.

The schematic diagram of Figure 8 shows the situation where the measured winding speed is slower than the calculated winding speed.

Figure 9 is a schematic diagram showing the relationship between the rotation angle of the winding core and the speed of the wire wound thereon.

FIG10 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 FIG9 .

FIG11 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 FIG10 .

Figure 12 is an enlarged view of part A of Figure 2, showing the state of winding the wire around the winding core until the second layer.

The schematic diagram of Figure 13 shows the state where the wire is wound around the winding core until the third layer, and corresponds to Figure 12.

The front view of Figure 14 shows another winding device of the present invention and corresponds to Figure 1.

Figure 15 is a front view showing a known tensioning device.

Next, the method for implementing the present invention is described in detail based on the attached drawings.

FIG. 1 and FIG. 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 such a way that the X axis extends in the horizontal front-back direction, the Y axis extends in the horizontal lateral direction, the Z axis extends in the vertical direction, and the wire 13 is unwound in the Y axis direction.

On a base plate 15a erected on the upper surface of a main body 15 installed at a location, a winding motor 14 serving as a winding core rotating unit is installed in a manner such that its rotation axis 14a is oriented in the X-axis direction and extends in the horizontal direction. The winding machine 11 of this embodiment is configured in such a manner that the winding motor 14 rotates the winding 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 around 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. In addition, 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 provided at a location where a winding machine 11 is provided 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 foot member 17b fixed to the location so as not to be movable. In addition, the base 17 is provided 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 to manufacture the coil of the motor parts. The wire 13 is wound on a larger 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 the 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 for the wire 13 to pass through. 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 that passes through the through hole 22a and extends in the Z-axis direction 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 has: a reel 24, which is used to hang the wire 13 that overcomes the winding characteristics by a plurality of small rollers 23a and turns the wire 13; an unwinding motor 26 as an unwinding drive unit, which is installed on the table 23 in a manner that the rotating shaft 26a faces the X-axis direction, and the reel 24 is installed on the rotating shaft 26a.

When the wire 13 is wound on the reel 24 for at least one turn, the unwinding motor 26 is driven to rotate the reel 24, and the wire 13 released from the reel 18 is pulled up and rewound, and the already wound wire 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 is provided on the lead straightening plate 30 for applying tension to the wire 13 supplied from the wire unwinding mechanism 21 to the winding core 12.

The first turning pulley 32 and the 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 33 is used to hang the wire 13 directed toward the winding machine 11 through the first turning pulley 32. The first turning pulley 32 and the second turning pulley 33 of this embodiment use pulleys with larger diameters to facilitate the hanging of the wire 13.

The tensioning device 31 includes: a guide wheel 34, on which the wire 13 is hung, 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 track 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 track 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 for hanging the wire 13 turned by the second turning pulley 33.

In addition, an elastic member 35 for applying force to 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 platform 37, and the other end thereof is mounted on the movable body 41 in a manner separated in a direction away from the winding machine 11 (Figure 1).

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 applied 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 parallel with the coil springs 35, 35 and supports the movable body 41 to be movable in the Y-axis direction; a male thread 43, which is screwed with the movable body 41 mounted on the track 42 in a movable manner 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 coil springs 35, 35, one end of which is mounted on the support 37, are connected to the movable body 41 at the other end. Thus, 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 springs 35, 35 is adjusted.

Here, the position sensor 45 is a sensor for detecting 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 mechanism 40 performs the tension adjustment on the coil springs 35, 35 as the initial setting before starting the winding, so as to set the tension applied to the wire 13 to be constant without performing the aforementioned tension adjustment during the winding.

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 winding motor 14, which is the core rotating unit. The core 12 is configured to be rotationally driven by the winding motor 14, thereby rotating around its axis. In this embodiment, the cross-sectional shape of the reel portion 12a is shown as a rectangular shape (FIG. 9 to FIG. 11).

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 comprises: a support pin 52, which is provided on the base plate 15a in parallel with the axis of rotation 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 in such a manner that its rotating shaft 54a is adjacent to the support pin 52 and parallel to the support pin 52. A ball screw 55 is coaxially arranged on the rotating shaft 54a. In addition, a female threaded component 56 that is threadedly engaged 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 axially 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 12 and 13).

As shown in FIG1 , the winding device 10 also has an accumulation mechanism 60 for decelerating or accelerating the wire 13 unwound from the wire unwinding mechanism 21 at a predetermined speed. In this embodiment, the accumulation mechanism 60 is shown to be arranged between the wire unwinding mechanism 21 and the tensioning device 31, and in the figure, the accumulation mechanism 60 is shown to be arranged on the lead straight plate 30.

The storage mechanism 60 in the figure has: a pair of fixed rollers 61a and 61b, which are arranged along the conveying path of the wire 13 in a manner to guide the wire 13; a movable roller 63, on which the wire 13 is hung, and is arranged between the pair of fixed rollers 61a and 61b in a manner that can move in a direction intersecting the conveying path of the wire 13, in this embodiment, in a straight line direction (Z-axis direction); and a servo motor 64 as a movable roller moving device, which moves the movable roller 63.

In this embodiment, a pair of fixed rollers 61a and 61b are arranged on the lead straight plate 30 along the extension direction of the wire 13 unwound from the wire unwinding mechanism 21 and turned to be horizontal by the first turning pulley 32. On the lead straight plate 30, a ball screw 66 is arranged to extend along the lead straight direction in a manner of being located between the pair of fixed rollers 61a and 61b. The rotating shaft of the servo motor 64 is connected to the ball screw 66 in a manner that enables the ball screw 66 to rotate. The movable table 67 is screwed with the ball screw 66, and the movable roller 63 is pivoted on the movable table 67. In addition, the control output of the controller 46 is connected to the servo motor 64.

In the accumulation mechanism 60, when the servo motor 64 is driven according to the command from the controller 46 to rotate the ball screw 66, the movable table 67 screwed therewith in the vertical direction moves together with the movable roller 63. The wire 13 turned by the first turning pulley 32 and directed toward the horizontal direction passes through the lower side of a pair of fixed rollers 61a and 61b, and the wire 13 located between the pair of fixed rollers 61a and 61b is hung from above on the movable roller 63 located above it.

Therefore, as shown in FIG3 , when the servo motor 64 is driven to make the movable roller 63 rise as shown by the dotted arrow, the lead straight distance between the pair of fixed rollers 61a, 61b and the movable roller 63 is expanded. Then, the wire 13 of twice the length of the lead straight distance between the pair of fixed rollers 61a, 61b and the movable roller 63 is accumulated between the pair of fixed rollers 61a, 61b. Therefore, when the movable roller 63 is in the middle of rising, even if the wire 13 is unwound at a constant speed from the wire unwinding mechanism 21, since part of the wire 13 is accumulated between the pair of fixed rollers 61a, 61b, the wire 13 is also decelerated and the speed is reduced.

On the contrary, as shown in FIG. 4 , when the servo motor 64 is driven in such a manner that the movable roller 63 descends, the lead straight distance between the pair of fixed rollers 61a, 61b and the movable roller 63 is shortened, thereby discharging the accumulated wire 13. Therefore, when the movable roller 63 is in the middle of descending as shown by the dotted arrow, even if the wire 13 is unwound at a constant speed from the wire unwinding mechanism 21, the wire 13 is accelerated and its speed is increased because the wire 13 is added to the discharged wire 13.

In addition, the winding device 10 also has: an unwinding speed detection sensor 70 as an unwinding speed detection unit, which detects the speed of the wire 13 moving toward the tension device 31 through the accumulation mechanism 60; and a winding speed detection sensor 80 as a winding speed detection unit, which detects the speed of the wire 13 moving toward the winding core 12 through the tension device 31.

The winding speed detection sensor 80 of this embodiment is provided on an auxiliary plate 82 erected on the end of the outer casing 19 on the winding machine 11 side. On the auxiliary plate 82, there are provided a pair of rollers 81, 81 pivoted in a manner of clamping the wire 13, and a first encoder 83 for detecting the rotation angle of either roller 81.

On the other hand, the unwinding speed detection sensor 70 of this embodiment is provided on the lead straight plate 30 on the downstream side of the accumulation mechanism 60. On the lead straight plate 30, there are provided 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.

In addition, the outer casing 19 contains a controller 46 for controlling the winding motor 14 constituting the winding core rotation 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, respectively. The controller 46 is configured to perform the so-called neat winding, which is to drive the winding motor 14 to rotate the core 12 at a constant speed, and control the guide motor 54 so that the guide member 53 moves in the rotation direction of the core 12 by an amount equivalent 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 (Figures 12 and 13).

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 identify 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 to be able to change the rotation speed of its rotating shaft 26a. The reel 24 driven by the unwinding motor 26 is configured to be able to 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 in such a way that the wire 13 is supplied at a speed equal to the average winding speed of the wire 13 wound on the rotating winding core 12.

In addition, the controller 46 decelerates or accelerates the wire 13 unwound from the wire unwinding mechanism 21 at an average winding speed, and controls the servo motor 64 in the storage mechanism 60 so that the speed is equal to the winding speed of the wire 13 wound by 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 calculated winding speed or the calculated average winding speed of the wire 13 wound on 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 in a manner to supply the wire 13 according to the calculated average winding speed calculated by the calculation circuit 46c, and controls the accumulation mechanism 60 in a manner to reduce or increase the speed of the wire 13 unwound from the wire unwinding mechanism 21 to 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 80 is provided, the detection outputs of the first encoder 83 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 way that the speed of the wire 13 unwound from the wire unwinding mechanism 21 and decelerated or accelerated by the accumulation mechanism 60 is equal to the winding speed of the wire 13 wound on the winding core 12.

Next, the winding method of the present invention using the above-mentioned winding device is described.

The winding method of the present invention is a method of rotating the winding core 12 around an axis 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.

Since the above-mentioned winding device 10 is used, as shown in FIG1 , the wire 13 is wound around the reel 18 and stored, and the wire 13 unwound from the reel 18 as the wire source passes through the through hole 22a of the flat plate 22, passes through a plurality of small rollers 23a to overcome the winding characteristics, and is wound around the reel 24 constituting the wire unwinding mechanism 21.

In addition, the wire 13 extending from the winch 24 is turned by the first turning pulley 32 to face the horizontal direction and passes through the lower side of a pair of fixed rollers 61a and 61b in the storage mechanism 60. Then, the wire 13 between the pair of fixed rollers 61a and 61b is hung from above on the movable roller 63 located above them.

The wire 13 after passing through the storage mechanism 60 is routed in such a way that its direction is changed by the second turning pulley 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 at 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 (Figure 12), and data related to the wire diameter d of the wire 13 wound on 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 its rotation angle and feeds back to the controller 46.

In addition, as shown in Figures 12 and 13, the guide member 53 moves in the axial direction of the winding core 12 by an amount equivalent to the outer diameter of the wire 13 every time the winding core 12 rotates one circle. 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.

In addition, the winding method of the present invention is characterized in that the wire 13 is unwound from the wire unwinding mechanism 21 at the average winding speed of the wire 13 wound around the rotating winding core 12, and the speed of the wire 13 unwound from the wire unwinding mechanism 21 is reduced or accelerated so as to be equal to the winding speed of the wire 13 wound around the rotating winding core 12.

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 9(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. In addition, when the rotational angular velocity ω of the winding core 12 is maintained at a constant value, as shown in FIG9(b), the speed (longitudinal axis) of the wire 13 wound around the winding core 12 changes in a manner that generates inflection points (inflection points) of aω, cω, bω, cω, aω, ... relative 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 winding 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 by the solid line curve in FIG. 9(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 portion on which the wire 13 is wound, by the angular velocity ω of the rotating winding core 12.

In addition, after obtaining the calculated winding speed as shown by the solid line curve in FIG9(b), the operation circuit 46c in the controller 46 calculates the average winding speed as shown by the dotted straight line in FIG9(b) obtained by averaging the calculated winding speed. That is, the calculated average winding speed is the value obtained by dividing the length of the wire 13 wound when the winding core 12 rotates one circle at the calculated winding speed as shown by the solid line curve in FIG9(b) by the time required for the winding core 12 to rotate one circle.

In addition, the controller 46 controls the winding motor 14 so 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 so that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated average winding speed obtained by the operation circuit 46c.

In addition, the controller 46 rotates the ball screw 66, so that the movable roller 63 and the movable table 67 screwed with the ball screw 66 move up and down in the vertical direction as shown by the long dashed curve in Figure 9 (b), and controls the servo motor 64 in the accumulation mechanism 60 in such a way that the wire 13 unwound from the wire unwinding mechanism 21 at the calculated average winding speed is decelerated or accelerated to set the calculated winding speed.

Here, in the above-mentioned winding device 10, there are provided an unwinding speed detection sensor 70 for detecting the speed of the wire 13 unwound from the accumulation mechanism 60 toward the tension device 31, and a winding speed detection sensor 80 for detecting the speed of the wire 13 passing through the tension device 31. Thus, when the speed is reduced or accelerated in the accumulation mechanism 60 in a manner equal to the calculated winding speed shown in FIG. 5(a), the measured unwinding speed shown in FIG. 5(b) is detected as the speed of the wire 13 passing through the accumulation mechanism 60, and the measured winding speed shown in FIG. 5(c) is detected as the speed of the wire 13 passing through the tension device 31.

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 around the winding core 12 changes. Therefore, when the wire 13 is unwound from the wire unwinding mechanism 21 at a constant speed without providing an accumulation mechanism 60 for decelerating or accelerating the wire 13 as in the prior art, the guide wheel 34 swings periodically as shown by the dotted arrow in FIG. 1, and the tension applied to the wire 13 changes due to the swing.

In contrast, in the present invention, the wire 13 is unwound from the wire unwinding mechanism 21 at a calculated average winding speed as a constant value. In addition, by providing an accumulation mechanism 60, as shown in FIG. 3 or FIG. 4, the wire 13 is periodically decelerated or accelerated, thereby setting the speed equal to the calculated winding speed shown in FIG. 5(a).

Therefore, as shown in FIG5(c), when the winding speed of the wire 13 wound on the winding core 12 increases, as shown in FIG5(b), the accumulation mechanism 60 accelerates the wire 13 unwound from the wire unwinding mechanism 21 along with the increase, thereby increasing the speed of the wire 13. Similarly, when the winding speed of the winding core 12 decreases, the accumulation mechanism 60 decelerates the wire 13 unwound from the wire unwinding mechanism 21 along with the decrease, thereby reducing the speed of the wire 13.

In this way, when the speed of the wire 13 unwound from the wire unwinding mechanism 21 is slowed down or accelerated to match the actual winding speed of the wire 13 of the winding core 12, the periodic swing of the guide wheel 34 as shown by the dotted line in Figure 1 disappears, and the tension of the wire 13 supplied to the winding core 12 can be kept constant. As a result, a higher quality coil can be manufactured.

In addition, the controller 46 rotates the winding core 12 at a constant speed (i.e., at a predetermined angular velocity ω), and moves the guide member 53 in the axial direction of the winding core 12, so that the wires 13 are neatly arranged and wound around the winding core 12. When the wires 13 are wound around the winding core 12 in a manner that covers multiple layers, as shown in FIG. 12, 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, the third layer of winding is performed on the outer periphery of the second layer of the wire 13 as shown in FIG. 13.

In this way, when the wire 13 is wound around the winding drum 12a in multiple layers, as shown in Figures 10 and 11, the length from the rotation center O of the winding core 12 to each part where the wire 13 is wound increases toward the outer layer, and when the winding core 12 rotates at a predetermined angular velocity ω, the winding speed of the wire wound around the winding core 12 accelerates toward the outer layer.

Specifically, as shown in FIG9, in the case of the first layer, the length from the rotation center O of the core 12 to each part where the wire 13 is wound is the outer peripheral shape of the cross section of the core 12 itself. As shown in FIG10, the length from the rotation center O of the core 12 to each part where 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 FIG11, the length from the rotation center O of the core 12 to each part where 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 added sequentially to the cross-sectional shape of the winding core 12 are pre-stored in the memory 46a. Therefore, the calculation circuit 46c in the controller 46 of Figure 1 can derive the rotation speed required for neatly arranged winding of each layer by dividing the winding width w by the wire diameter d.

In addition, if it is the winding of the second layer, as shown in Figure 10, 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 winding of the third layer, as shown in Figure 11, 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 with the above-mentioned lengths (a+d), (b+d), (c+d), (a+2d), (b+2d), (c+2d), the calculated winding speed of each layer can be obtained (Figure 10(b), Figure 11(b)).

In addition, after obtaining the calculated rolling speed of each layer (Figure 10(b), Figure 11(b)), the operation circuit 46c in the controller 46 calculates the calculated average rolling speed of each layer from the calculated rolling speed, and obtains the calculated average rolling speed as shown by the dotted line in Figure 10(b) or Figure 11(b).

Furthermore, even after the second layer, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 so that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated average winding speed for each layer obtained by such operation. At the same time, the controller 46 moves the movable roller 63 up and down in the lead vertical direction as shown by the long dashed curve in FIG. 10(b) or FIG. 11(b) to decelerate or accelerate the wire 13 supplied from the wire unwinding mechanism 21, and controls the servo motor 64 in the accumulation mechanism 60 at a speed equal to the calculated winding speed for each layer obtained by such operation even after the second layer.

Therefore, even after the second layer, the unwinding amount is controlled in such a way that the speed (unwinding amount) of the wire 13 passing through the accumulation mechanism 60 is balanced with the winding speed (winding amount) of the wire 13 on the winding core 12 (i.e., maintained in balance).

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

Here, in actual winding, the controller 46 detects the speed of the wire 13 unwound toward the tension device 31 through the accumulation mechanism 60 and the speed of the wire 13 toward the winding core 12 through the tension device 31. In addition, the servo motor 64 in the accumulation mechanism 60 is controlled in a manner 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.

That is, in the present invention, the speed of the wire 13 wound by the winding core 12 and its average winding speed are calculated in advance, the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated average winding speed, and the wire 13 is decelerated or accelerated in the accumulation mechanism 60, thereby setting the calculated winding speed. As shown in FIG5, the speed of the wire 13 does not shift in the time axis direction before and after the tension device 31.

When the rotation speed of the winding core 12 is increased, the deceleration or acceleration of the wire 13 in the storage mechanism 60 changes at a faster speed. Therefore, even if the controller 46 controls the servo motor 64 according to the calculated winding speed, the movement of the movable roller 63 may not follow and the deceleration or acceleration of the wire 13 may be delayed. As a result, there is a deviation between the speed of the wire 13 unwound from the storage mechanism 60 toward the tension device 31 and the speed of the wire 13 wound around the winding core 12 through the tension device 31.

Here, the actual speed of the wire 13 unwound from the accumulation mechanism 60 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 80. 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 80 with the speed change state of the measured unwinding speed determined by the detection output of the unwinding speed detection sensor 70. In addition, the deceleration or acceleration of the wire 13 is implemented in the accumulation mechanism 60 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.

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 FIG6(c) and the measured unwinding speed shown by the dotted line in FIG6(b), the controller 46 obtains the time offset T. In addition, the offset T is subtracted from the calculated winding speed shown by the solid line in FIG6(a), thereby obtaining a corrected winding speed as shown by the double-dotted line.

In this regard, the controller 46 of this embodiment has a speed correction unit that calculates the offset 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 offset T from the calculated reeling speed to obtain a corrected reeling speed.

In addition, the controller 46 controls the servo motor 64 in the accumulation mechanism 60 along the corrected winding speed shown by the double-dotted line in FIG. 6(a) obtained. Therefore, the controller 46 controls the accumulation mechanism 60 in a state where the calculated winding speed shown by the solid line in FIG. 6(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. 6(c) and the speed of the wire 13 decelerated or accelerated by the accumulation mechanism 60 and directed toward the tension device 31 can be made consistent as shown by the solid line in FIG. 6(b).

Thus, even if the rotation speed of the winding core 12 is increased and the winding speed to the winding core 12 changes at a faster speed, the storage mechanism 60 can decelerate or accelerate to 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 decelerated or accelerated by the storage mechanism 60 and supplied to the tension device 31 is eliminated, thereby preventing the periodic swing of the guide wheel 34 in the tension device 31. Thus, even if the rotation speed of the winding core 12 is increased, the elastic member 35 can provide an unchanging constant tension corresponding to the position of the guide wheel 34.

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 to the winding core 12 are different, the wire supply amount and the wire winding amount will be inconsistent.

Therefore, in the tension device 31, the guide wheel 34 with the wire 13 hanging thereon moves along the track 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 in such a way that the position of the guide wheel 34 returns to a predetermined position of the track 36, such as approximately the center, and obtains the calculated average winding speed based on the corrected winding speed after the increase or decrease. In addition, the controller 46 controls the rotation speed of the unwinding motor 26 based on the calculated average winding speed, and increases or decreases the unwinding speed of the wire 13 in the wire unwinding mechanism 21, thereby balancing the unwinding speed of the wire 13 and the winding speed of the winding core 12.

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 FIG7(a), and the guide wheel 34 gradually approaches the winding machine 11, then as shown in FIG7(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. In addition, the corrected average winding speed is calculated based on the corrected winding speed. The corrected average winding speed is also increased at a constant rate, and the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 to unwind the wire 13 at the corrected average winding speed increased in this way, and the accumulation mechanism 60 decelerates or accelerates the wire 13, so that the measured unwinding speed of the wire 13 toward the tensioning device 31 is consistent with the measured winding speed as shown in FIG. 7(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 FIG8(a), and the guide wheel 34 gradually moves away from the winding machine 11, then as shown in FIG8(b), the calculated winding speed is reduced at a constant ratio in such a way that the unwinding amount of the wire 13 implemented by the wire unwinding mechanism 21 is reduced, and a corrected winding speed that is substantially consistent with the measured winding speed is obtained. In addition, a corrected average winding speed is calculated based on the corrected winding speed. The corrected average winding speed is also reduced at a constant rate, and the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 to unwind the wire 13 at the corrected average winding speed reduced in this way, and the accumulation mechanism 60 decelerates or accelerates the wire 13, so that the measured unwinding speed of the wire 13 toward the tensioning device 31 is consistent with the measured winding speed as shown in FIG8(c).

Thereby, the guide wheel 34 returns to a predetermined position of the track 36, such as approximately 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 includes: a winding core 12; a wire unwinding mechanism 21, which supplies a wire 13 to the winding core 12; an accumulation mechanism 60, which decelerates or accelerates the speed of the wire 13 unwound from the wire unwinding mechanism 21; a tensioning 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 causing the wire 13 supplied from the wire unwinding mechanism 21 and supplied by the tensioning device 31 to be tensioned. The wire 13 with tension is wound around the winding core 12; the controller 46 controls the accumulation mechanism 60 and the wire unwinding mechanism 21, and the controller 46 controls the wire unwinding mechanism 21 in a manner that the wire 13 is unwound at the average winding speed of the wire 13 wound around the rotating winding core 12, and controls the accumulation mechanism 60 in a manner that the speed of the wire 13 unwound from the wire unwinding mechanism 21 is equal to the winding speed of the wire 13 wound by 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, unwinding the wire 13 from the wire unwinding mechanism 21 at the average winding speed of the wire 13 wound around the rotating winding core 12, and decelerating or accelerating the speed of the wire 13 unwound from the wire unwinding mechanism 21 to be equal to the winding speed of the wire 13 wound around the rotating winding core 12.

According to the above structure, although the wire 13 is unwound from the wire unwinding mechanism 21 at a constant speed, since the unwinding speed is set to the average winding speed and is set to a speed equal to the winding speed of the wire 13 wound around the winding core 12 after deceleration or acceleration, even if the tensioning device 31 has a member such as a guide wheel 34 that hangs 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 with the speed change of the wire 13.

As a result, since the tension change of the wire 13 caused by the movement of the member such as the guide wheel 34 is avoided, the tension of the wire 13 wound on the winding core 12 can be kept constant even when the speed of the wire 13 wound on the winding core 12 of different diameters changes significantly.

In addition, in the winding device 10 of the present embodiment, the accumulation mechanism 60 has: a pair of fixed rollers 61a and 61b, which are arranged along the moving path of the wire 13 in a manner to guide the wire 13; a movable roller 63, which is provided for the wire 13 to be hung and is arranged between the pair of fixed rollers 61a and 61b in a manner that can move in a direction intersecting the moving path of the wire 13; and a servo motor 64, which moves the movable roller 63.

In addition, in the winding method of the present embodiment, the wire 13 between a pair of fixed rollers 61a and 61b provided along the moving path of the wire 13 is hung on the movable roller 63, and the movable roller 63 is moved in a direction intersecting the moving path of the wire 13.

According to the above structure, the wire 13 between a pair of fixed rollers 61a and 61b arranged along the moving path of the wire 13 is hung on the movable roller 63, and the movable roller 63 is moved in a direction intersecting the moving path of the wire 13, so that the speed of the wire 13 unwound from the wire unwinding mechanism 21 can be slowed down or accelerated.

In addition, the winding device 10 of the present embodiment is also provided with: a memory 46a for storing information related to the winding core 12; an operation circuit 46c for calculating the calculated winding speed and the calculated average winding speed of the wire 13 wound on the winding core based on the information related to the winding core; and a tensioning device 31 having: a guide wheel 34 for hanging the wire 13; an elastic member 3 5, which applies force to the guide wheel 34, and the controller 46 controls the wire unwinding mechanism 21 in a manner to supply the wire 13 according to the calculated average winding speed calculated by the operation circuit 46c, and controls the accumulation mechanism 60 in a manner to reduce or increase the speed of the wire 13 unwound from the wire unwinding mechanism 21 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 calculates the calculated winding speed and the calculated average winding speed of the wire 13 wound on the winding core 12 according to the information related to the winding core 12, and the wire 13 is supplied by the wire unwinding mechanism 21 according to the calculated average winding speed calculated by the calculation circuit 46c, and the speed of the wire 13 unwound from the wire unwinding mechanism 21 is decelerated or accelerated in a manner that becomes the calculated winding speed calculated by the calculation circuit 46c, and the tension device 31 has: a guide wheel 34, which is provided with the wire 13 hanging; an elastic member 35, which applies force to the guide wheel 34.

According to the above structure, by using the calculated winding speed and the calculated average winding speed pre-stored in the storage device 46a, the accumulation mechanism 60 and the wire unwinding mechanism 21 are controlled respectively, so that the speed of the wire 13 unwound from the wire unwinding mechanism 21 is reduced or accelerated to be consistent with the actual winding speed of the wire 13 wound by the winding core 12, so that the periodic swing of the guide wheel of the tensioning device disappears, so that the tension of the wire 13 supplied to the winding core 12 can be kept constant. As a result, a higher quality coil can be manufactured.

In addition, in the winding device 10 of the present embodiment, the accumulation mechanism 60 is provided between the wire unwinding mechanism 21 and the tensioning device 31, and the accumulation mechanism 60 is provided with: an unwinding speed detection sensor 70, which detects the unwinding speed of the wire 13 unwound from the accumulation mechanism 60 toward the tensioning device 31; a winding speed detection sensor 80, which detects the winding speed of the wire 13 passing through the tensioning device 31; The winding speed of the wire 13 toward the winding core 12 is detected, and the controller 46 controls the accumulation mechanism 60 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 80 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 wire 13 unwound from the wire unwinding mechanism 21 toward the tension device 31 is accelerated or decelerated, and the unwinding speed of the wire 13 accelerated or decelerated toward the tension device 31 and the winding speed of the wire 13 wound on the winding core 12 through the tension device 31 are detected, and the wire 13 is accelerated or decelerated in a manner that eliminates the deviation of the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed in the time axis direction.

According to the above structure, even if the rotation speed of the winding core 12 is increased and the winding speed to the winding core 12 changes at a faster speed, the accumulation mechanism 60 can decelerate or accelerate to follow the speed change. Therefore, 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 decelerated or accelerated by the accumulation mechanism 60 and supplied to the tension device 31 is eliminated, thereby preventing the periodic swing of the guide wheel 34 in the tension device 31. Therefore, even if the rotation speed of the winding core 12 is increased, the elastic member 35 can provide an unchanging constant tension corresponding to the position of the guide wheel 34.

Although the above embodiment describes a case where the tension device 31 has a guide wheel 34 that is movable along the track 36, the tension device may also rotate the tension arm 4 using an elastic member 6 as shown in FIG. 15, and apply tension to the wire 2 unwound from the guide wheel 5 mounted on the front end of the tension arm 4.

Even in the case of a tensioning device having a tensioning arm 4 as shown in FIG15, if the wire unwinding from the wire unwinding mechanism 21 at an average winding speed is decelerated or accelerated by using an accumulation mechanism and the speed of the wire is set to a speed equal to the winding speed of the wire wound on the winding core, the movement of the guide wheel 5 of the tensioning device 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 on the winding core 12 can be kept constant.

In addition, in the above-mentioned embodiment, the elastic member 35 that applies force to the guide wheel 34 in the tension device 31 is exemplified as a coil spring. However, a fluid pressure cylinder that applies 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 its elastic force, the elastic force can be changed more easily by changing the fluid pressure such as compressed air in the cylinder.

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

In this case, the controller 46 controls the wire unwinding mechanism 21 so as to supply the wire 13 according to the calculated average winding speed stored in the storage 46a, and controls the accumulation mechanism 60 so as to reduce or accelerate the speed of the wire 13 unwound from the wire unwinding mechanism 21 to the calculated winding speed stored in the storage 46a. In this way, since the 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.

In addition, in the above-mentioned embodiment, the case where the storage mechanism 60 is provided between the wire unwinding mechanism 21 and the tensioning device 31 is described. However, as shown in FIG. 14 , the storage mechanism 60 may also be provided on the downstream side of the tensioning device 31.

In the case of the winding device 10 shown in FIG. 14 , the wire 13 unwound from the wire unwinding mechanism 21 at an average winding speed passes through the tension device 31 at the average winding speed to be given a predetermined tension, and then the speed of the wire 13 after passing through the tension device 31 is decelerated or accelerated to be equal to the winding speed of the wire 13 wound around the rotating winding core 12.

Even in this winding device 10, the speed of the wire 13 passing through the tension device 31 is made equal to the winding speed of the wire 13 wound on the rotating winding core 12. Therefore, even if the tension device 31 has a guide wheel 34 that is hung around the wire 13 and moves due to the elastic member 35, the guide wheel 34 can be prevented from moving with the speed change of the wire 13. As a result, the tension of the wire 13 wound on the winding core 12 can be kept constant.

Although the implementation method of the present invention is described above, the above implementation method only shows a part of the application examples of the present invention and does not mean that the technical scope of the present invention is limited to the specific structure of the above implementation method.

This application claims priority based on Japanese Patent Application No. 2020-004192 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

11: Winding machine

12: Roll core

12a: reel part

12b: flange

13: Wire

14: Winding motor (winding core rotation unit)

14a: Rotating axis

15: Main body

15a: Substrate

16: Rotation angle sensor

17: Abutment

17a: Roller

17b: Foot component

18: Scroll

19: Shell

21: Wire unwinding mechanism

22: Tablet

22a: Through hole

23: Table

23a: Small Roller

24: Reel

26: Electric motor for unwinding

26a: Rotating axis

30: Lead Straight Plate

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: Accumulation mechanism

61a, 61b: Fixed roller

63: Movable roller

64:Servo motor

66:Ball screw

67: Movable table

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

71: Roll

73: Second encoder

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

81: Roll

82: Auxiliary board

83: First encoder

Claims (8)

A winding device comprises: a winding core; a wire unwinding mechanism that supplies a wire to the winding core; a storage mechanism that decelerates or accelerates the speed of the wire unwound from the wire unwinding mechanism; a tensioning device that applies tension to the wire supplied from the wire unwinding mechanism to the winding core; and a winding core rotating unit that rotates the winding core to thereby supply the wire from the wire unwinding mechanism to the winding core. , and the wire to which the tension is applied by the tension device is wound around the winding core; and a controller that controls the accumulation mechanism and the wire unwinding mechanism, wherein the controller controls the wire unwinding mechanism in such a manner that the wire is unwound at the average winding speed of the wire wound around the rotating winding core, and controls the wire unwinding mechanism so that the speed of the wire unwound from the wire unwinding mechanism is equal to the speed of the rotating winding core. The storage mechanism is controlled in such a manner that the winding speed of the wire rod wound by the rotating winding core is equal to that of the wire rod; the storage mechanism is arranged between the wire rod unwinding mechanism and the tensioning device, and the winding device comprises: an unwinding speed detection unit, which detects the unwinding speed of the wire rod unwound from the storage mechanism toward the tensioning device; and a winding speed detection unit, which detects the winding speed of the wire rod unwound from the storage mechanism toward the tensioning device; The tension device detects the winding speed of the wire toward the winding core, and the controller controls the accumulation mechanism 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. The wire winding device as recited in claim 1, wherein the storage mechanism comprises: a pair of fixed rollers, which are arranged along the moving path of the wire in a manner to guide the wire; a movable roller, which is provided for the wire to be hung and is arranged between the pair of fixed rollers in a manner to be movable in a direction intersecting the moving path of the wire; and a movable roller moving device, which moves the movable roller. The winding device as recited in claim 1, 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 and the calculated average 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 wire unwinding mechanism in a manner of supplying the wire according to the calculated average winding speed stored in the storage unit, and controls the storage mechanism in a manner of reducing or increasing the speed of the wire unwound from the wire unwinding mechanism to the calculated winding speed stored in the storage unit. The winding device as recited in claim 1, further comprising: a storage unit for storing information related to the winding core; and a calculation unit for calculating the calculated winding speed and the calculated average winding speed of the wire wound on the winding core based on the information related to the winding core, the tension device having: a guide wheel for hanging the wire; and a force applying unit for applying force to the guide wheel, the controller controlling the wire unwinding mechanism in a manner to supply the wire according to the calculated average winding speed calculated by the calculation unit, and controlling the storage mechanism in a manner to reduce or increase the speed of the wire unwound from the wire unwinding mechanism to the calculated winding speed calculated by the calculation unit. A wire winding method is to rotate a winding core so that a wire supplied from a wire unwinding mechanism and given tension by a tension device is wound around the winding core, wherein the wire is unwound from the wire unwinding mechanism at an average winding speed of the wire wound around the rotating winding core, and the speed of the wire unwound from the wire unwinding mechanism is reduced or accelerated so as to be equal to the winding speed of the wire wound around the rotating winding core; The wire unwinding mechanism accelerates or decelerates the wire unwinding toward the tension device, and detects the unwinding speed of the wire accelerated or decelerated toward the tension device and the winding speed of the wire wound on the winding core through the tension device, so as to accelerate or decelerate the wire in a manner that eliminates the deviation of the detected speed change state of the measured unwinding speed and the speed change state of the measured winding speed in the time axis direction. A wire winding method as described in claim 5, wherein the wire located between a pair of fixed rollers arranged along the moving path of the wire is hung on a movable roller, and the movable roller is moved in a direction intersecting the moving path of the wire. The winding method as recited in claim 5, wherein the storage unit stores the winding speed of the wire wound around the rotating winding core, i.e., the calculated winding speed and the calculated average winding speed calculated in advance, and the wire is supplied by the wire unwinding mechanism according to the calculated average winding speed stored in the storage unit, so that the speed of the wire unwound from the wire unwinding mechanism is reduced or accelerated in a manner that becomes the calculated winding speed stored in the storage unit, and the tensioning device has: a guide wheel on which the wire is hung; and a force applying unit, which applies force to the guide wheel. A winding method as recited in claim 5, wherein a storage unit stores information related to the winding core, a calculation unit calculates a calculated winding speed and a calculated average winding speed of the wire wound on the winding core based on the information related to the winding core, and the wire unwinding mechanism supplies the wire according to the calculated average winding speed calculated by the calculation unit, so that the speed of the wire unwinded from the wire unwinding mechanism is reduced or accelerated in a manner that becomes the calculated winding speed calculated by the calculation unit, and the tensioning device has: a guide wheel for hanging the wire; and a force applying unit for applying force to the guide wheel.