Winding device and winding method

Abstract

A wire winding device comprises: a winding core; a wire unwinding mechanism that supplies 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 controller that controls a power storage mechanism and the wire unwinding mechanism, the controller controls the wire unwinding mechanism in a manner that unwinds the wire at an average winding speed of the wire wound on the rotating winding core, and controls the power storage mechanism in 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

Technical Field

[0001] The invention relates to a wire winding device and a wire winding method. Background Art

[0002] At present, for example, Japanese Patent Application Laid-Open No. JP2000-128433A discloses a tensioning device which is provided in a winding machine for winding a wire material around a winding core to form a coil and applies a predetermined tension to the wire material. Fig.15 As shown, this tensioning device comprises: a capstan 3 for hanging the wire 2 unwound from a wire source; a tension arm 4 that can rotate around a rotation fulcrum 4a at the base end; a guide pulley 5 that is installed at the top end of the tension arm 4 and turns to guide the wire 2 wound from the capstan 3 to the winding machine after passing it; an elastic member 6 that imparts an elastic force corresponding to the rotation angle to the tension arm 4 at a predetermined position between the rotation fulcrum 4a of the tension arm 4 and the guide pulley 5; a potentiometer 7 that detects the rotation angle of the tension arm 4; and an unwinding motor 8 that controls the rotation of the capstan 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 capstan 3 via the guide pulley 5 toward the winding machine not shown in the figure.

[0003] Here, the wire 2 is guided to the winding machine via the guide pulley 5 and is wound on its winding core. Regarding the unwinding speed of the wire 2 unwound from the existing tensioning device, the rotation of the capstan 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 by the winding core. In addition, a predetermined tension is applied to the wire 2 by the tension arm 4 to which the elastic force is given by the elastic member 6.

[0004] 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 in the rotation angle of the tension arm 4 is fed back to the rotation of the capstan 3 via the potentiometer 7, the rotation speed of the capstan 3 is adjusted by the unwinding motor 8 in such a way that the rotation angle of the tension arm 4 immediately becomes a predetermined angle, and the tension applied to the wire 2 returns to a predetermined value.

[0005] As mentioned above, in Fig.15In the conventional tensioning device shown, the tension arm 4 changes its rotation angle to absorb the change in the winding speed of the wire 2. However, when the wire 2 is wound on a winding core with different diameters and different outer diameters of the cross section, for example, a winding core with a rectangular cross section and significantly different short and long sides, the speed of the wire 2 wound on the winding core varies significantly periodically during one rotation of the winding core. As a result, the rotation angle of the tension arm 4 to absorb the change in speed increases significantly.

[0006] That is, when the wire 2 unwound from the capstan 3 is at the guide pulley 5, Fig.15 When the wire 2 is turned in a manner bent at a substantially right angle to the tension arm and guided to the winding machine, the winding speed of the wire 2 in the winding machine is increased, and when the predetermined length L1 is wound up extra per unit time, the guide pulley 5 is also pulled toward the winding machine side by the predetermined length L1 that is wound up extra as shown by the solid arrow. In addition, the tension arm 4 provided with the guide pulley 5 at the top is rotated in a manner that overcomes the elastic force of the elastic member 6, thereby allowing the guide pulley 5 at the top to move the predetermined length L1.

[0007] However, when the speed of the wire 2 wound on the winding core in the winding machine changes significantly and its speed temporarily increases significantly, the guide pulley 5 is pulled hard by the wire 2, and the rotation of the tension arm 4, which is provided with the guide pulley 5 at the top end and absorbs the change, cannot keep up with the trend of the pulled guide pulley 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 pulley 5 provided at the top end of the tension arm 4 and the winding core.

[0008] On the contrary, when the winding speed of the wire 2 in the winding machine is reduced and the amount of the predetermined length L2 wound per unit time is reduced, the guide pulley 5 moves the reduced predetermined length L2 in the direction of separation from the winding machine due to the elastic force of the elastic member 6. In addition, the tension arm 4 provided with the guide pulley 5 at the top end rotates due to the elastic force of the elastic member 6, thereby allowing the guide pulley 5 at the top end to move the predetermined length L2 as shown by the dotted line.

[0009] 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 temporarily decreases significantly, the force of the wire 2 pulling the guide pulley 5 temporarily decreases significantly, and the rotation of the tension arm 4, which is provided with the guide pulley 5 at the top and absorbs the change, cannot be followed by the elastic force of the elastic member 6 due to its inertia. As a result, the wire 2 between the guide pulley 5 provided at the top of the tension arm 4 and the winding core temporarily relaxes. Therefore, in the existing tensioning device, when the speed of the wire 2 wound on the winding cores of different diameters in the winding machine changes significantly, there is a problem that it is difficult to keep the tension of the wire 2 supplied to the winding machine constant. Summary of the invention

[0010] An object of the present invention is to provide a wire winding device and a wire winding method capable of maintaining a constant tension of a wire wound around a core even when a winding speed of the wire around the core varies significantly.

[0011] According to one embodiment of the present invention, there is provided a winding device, the winding device comprising: a winding core; a wire unwinding mechanism that supplies wire to the winding core; a power storage mechanism that slows down 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 so that the wire supplied from the wire unwinding mechanism and given tension by the tensioning device is wound on the winding core; a controller that controls the power storage mechanism and the wire unwinding mechanism, the controller controlling the wire unwinding mechanism in a manner that the wire is unwound at an average winding speed of the wire wound on the rotating winding core, and the controller controlling the power storage mechanism in a manner that the speed of the wire unwound from the wire unwinding mechanism is equal to the winding speed of the wire wound by the rotating winding core.

[0012] In addition, according to another embodiment of the present invention, a winding method is provided, wherein the winding core is rotated to wind the wire supplied from a wire unwinding mechanism and given tension by a tensioning device around the winding core, the wire is unwound from the wire unwinding mechanism at an average winding speed of the wire wound on the rotating core, and the speed of the wire unwound from the wire unwinding mechanism is decelerated or accelerated to be equal to the winding speed of the wire wound on the rotating core.

[0013] (Effects of the Invention)

[0014] According to the aspect of the invention described above, even when the winding speed of the wire material on the winding core significantly fluctuates, the tension of the wire material wound on the winding core can be kept constant. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a front view which shows the winding device in embodiment of this invention.

[0016] Figure 2 A top view of the winding device.

[0017] Figure 3 This is a diagram showing a state where the wire is decelerated by the force storage mechanism.

[0018] Figure 4 This is a diagram showing a state where the wire is accelerated by the force storage mechanism.

[0019] Figure 5 It is a graph showing the relationship between the calculated winding speed, the measured unwinding speed and the measured winding speed.

[0020] Figure 6 This is a diagram showing that there is a time axis deviation between the measured unwinding speed and the measured winding speed. Figure 5 The corresponding figure.

[0021] Figure 7 This is a diagram showing a case where the measured winding speed is faster than the calculated winding speed.

[0022] Figure 8 This is a diagram showing a case where the measured winding speed is slower than the calculated winding speed.

[0023] Fig. 9 This is a diagram showing the relationship between the rotation angle of the winding core and the speed of the wire material wound around the winding core.

[0024] Fig.10 The relationship between the angle of the winding core and the speed of the wire wound thereon is shown in Figure 1. Fig. 9 The corresponding figure.

[0025] Fig.11 The relationship between the angle of the winding core and the speed of the wire wound thereon is shown in Figure 1. Fig.10 The corresponding figure.

[0026] Fig.12 This indicates the state where the wire is wound around the core until the second layer. Figure 2 Enlarged view of part A.

[0027] Fig.13This is a diagram showing the state of winding the wire material around the winding core until the third layer. Fig.12 The corresponding figure.

[0028] Fig.14 Another winding device of the present invention is shown in FIG. Figure 1 The corresponding main view.

[0029] Fig.15 The figure is a front view showing an existing tensioning device. DETAILED DESCRIPTION

[0030] Next, a mode for carrying out the present invention will be described in detail with reference to the drawings.

[0031] exist Figure 1 as well as Figure 2 , a winding device 10 of the present invention is shown. The winding device 10 comprises: a winding machine 11, which rotates a winding core 12 to wind a wire 13 around the winding core 12; a wire unwinding mechanism 21, which supplies the wire 13 to the winding core 12; and a tensioning device 31, which applies tension to the wire 12 supplied from the wire unwinding mechanism 21 to the winding core 12.

[0032] 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 the horizontal front-to-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.

[0033] A winding motor 14 as a core rotating unit is installed on a base plate 15a erected on the upper surface of a main body 15 installed at a location, and the winding motor 14 is installed in such a manner that its rotation shaft 14a is oriented in the X-axis direction and extends in the horizontal direction. The winding machine 11 in this embodiment is configured in such a manner that the winding motor 14 rotates the core 12 at a constant speed.

[0034] In the winding machine 11, 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 given tension by the tensioning 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.

[0035] like Figure 1As shown, 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. A roller 17a for making the base 17 easy to move and a foot member 17b fixed to the location in a manner that cannot be moved are provided on the base 17. In addition, the base 17 is provided at a position offset in the Y-axis direction relative to the winding machine 11.

[0036] The wire 13 in 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 stored in a manner of being wound on a relatively large reel 18. 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 through the housing 19.

[0037] 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 reel 18 from the upper 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. The plurality of small rollers 23a 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.

[0038] In addition, in this embodiment, the wire unwinding mechanism 21 for unwinding the wire 13 toward the winding machine 11 includes: a capstan 24, which is used to hang and turn the wire 13 that overcomes the curling characteristics due to a plurality of small rollers 23a; an unwinding motor 26 as an unwinding drive unit, which is installed on the table 23 in such a way that the rotating shaft 26a is oriented toward the X-axis direction, and the capstan 24 is installed on the rotating shaft 26a.

[0039] When the wire 13 is wound around the capstan 24 for at least one circle, the unwinding motor 26 drives the capstan 24 to rotate, pulls up the wire 13 unwound from the reel 18 and rewound, and unwinds the already wound wire 13 from the capstan 24 and unwinds it toward the winding machine 11.

[0040] A vertical 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 vertical plate 30 to apply tension to the wire 13 supplied from the wire unwinding mechanism 21 to the winding core 12.

[0041] The vertical plate 30 is provided with a first deflection pulley 32 and a second deflection pulley 33, wherein the first deflection pulley 32 sets the wire 13 deflected by the capstan 24 to be horizontal and directed toward the winding machine 11, and the second deflection pulley 32 is used to wind the wire 13 directed toward the winding machine 11 by the first deflection pulley 32. The first deflection pulley 32 and the second deflection pulley 33 of this embodiment use pulleys with relatively large diameters in order to facilitate winding of the wire 13.

[0042] The tensioning device 31 comprises: a guide pulley 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 due to the second turning pulley 33; an elastic component 35 as a force-applying unit, which applies force to the guide pulley 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 corresponding to the position of the guide pulley 34 to the wire 13.

[0043] That is, a track 36 is provided on the vertical plate 30 in a manner extending in the Y-axis direction, and a support 37 is provided on the track 36 in a manner movable in the Y-axis direction, and the support 37 supports the guide pulley 34 so as to be rotatable. The guide pulley 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 after being turned by the second turning pulley 33.

[0044] In addition, an elastic member 35 for applying force to the guide pulley 34 in a direction away from the winding machine 11 is provided on the vertical plate 30. The elastic member 35 in 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 37, and the other end thereof is mounted on the movable body 41 ( Figure 1 ).

[0045] 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 in the Y-axis direction of the guide pulley 34 pivotally supported on the support platform 37 is applied to the wire 13 hung on the guide pulley 34 and directed toward the winding machine 11.

[0046] The force exerted on the guide pulley 34 by the coil springs 35, 35 is adjusted by the tension adjustment mechanism 40. The tension adjustment mechanism 40 includes: a rail 42 which is provided on the vertical plate 30 in parallel with the coil springs 35, 35 and supports the movable body 41 so as to be movable in the Y-axis direction; a male screw 43 which is screwed with the movable body 41 movably mounted on the rail 42 and is pivotally supported on the vertical plate 30; and an adjustment knob 44 for rotating the male screw 43.

[0047] The other ends of the coil springs 35, 35 are connected to the movable body 41. The tension of the coil springs 35, 35 is adjusted so that the male screw 43 rotates by rotating the adjustment knob 44 and the movable body 41 moves away from or in contact with the winding machine 11.

[0048] Here, the position sensor 45 is a sensor that detects the position of the guide pulley 34 in the Y-axis direction, and the detection output thereof is connected to the input of the controller 46 .

[0049] The adjustment of the tension of the coil springs 35 , 35 by the tension adjustment mechanism 40 is performed as an initial setting before starting the winding, and is not performed during the winding in order to make the tension applied to the wire 13 constant.

[0050] In addition, the winding machine 11 in the winding device 10 of the present invention rotates the core 12 around the axis, so that the wire 13 is wound around the core 12. The core 12 of this embodiment has: a winding body 12a, which is for winding the wire 13; and a flange 12b, which is provided on both end surfaces of the winding body 12a and limits the winding width of the wire 13. The core 12 is coaxially mounted on the rotating shaft 14a of the winding core rotation unit, that is, the winding motor 14. The core 12 is configured to rotate around its axis by being driven to rotate by the winding motor 14. In the present embodiment, a case where the cross-sectional shape of the winding body 12a is a rectangle is shown ( Figures 9 to 11 ).

[0051] 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 direction of the rotation axis. The guide mechanism 51 comprises: a support pin 52, which is provided on the base plate 15a in a manner parallel to 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 top of the support pin 52 and restricts the movement of the wire 13 in the axial direction of the winding core 12; a guide motor 54 ( Figure 2 ), which causes the support pin 52 to move in the axial direction.

[0052] like Figure 2 As shown, 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 screw member 56 screwed with the ball screw 55 is installed at the base end of the support pin 52.

[0053] Therefore, when the guide motor 54 is driven to rotate the ball screw 55, the support pin 52 and the female threaded member 56 that moves by screwing with the ball screw 55 move in the axial direction, so that the guide member 53 provided at the top end of the support pin 52 moves in the rotation axis direction of the winding core 12. In addition, the guide member 53 is configured to clamp the wire 13 from both sides of the rotation axis direction of the winding core 12 and limit the passing position of the wire 13 in the rotation axis direction ( Fig.12 , Fig.13 ).

[0054] like Figure 1 As shown, the winding device 10 also includes a power storage mechanism 60 for decelerating or accelerating the wire 13 unwound at a predetermined speed from the wire unwinding mechanism 21. In this embodiment, the power storage mechanism 60 is provided between the wire unwinding mechanism 21 and the tensioning device 31, and in the figure, the power storage mechanism 60 is provided on the vertical plate 30.

[0055] The power storage mechanism 60 in the figure includes: 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, which is a vertical direction (Z-axis direction) in this embodiment; and a servo motor 64, which moves the movable roller 63.

[0056] In this embodiment, a pair of fixed rollers 61a, 61b are arranged on the vertical plate 30 along the extending 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 vertical plate 30, a ball screw 66 extending in the vertical direction in a manner located between the pair of fixed rollers 61a, 61b is provided. The rotating shaft of the servo motor 64 is connected to the ball screw 66 in a manner that can rotate the ball screw 66. The movable table 67 is screwed with the ball screw 66, and the movable roller 63 is pivotally supported on the movable table 67. In addition, the control output of the controller 46 is connected to the servo motor 64.

[0057] In the power storage mechanism 60, when the servo motor 64 is driven to rotate the ball screw 66 according to the command from the controller 46, the movable table 67 and the movable roller 63 screwed therewith move in the vertical direction together. The wire 13 turned by the first turning pulley 32 and directed to the horizontal direction passes through the lower side of the 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 the pair of fixed rollers 61a and 61b.

[0058] Therefore, if Figure 3As shown in the figure, when the servo motor 64 is driven to make the movable roller 63 rise as shown by the dotted line, the vertical distance between the pair of fixed rollers 61a, 61b and the movable roller 63 is expanded. In this way, the wire material of twice the length of the vertical distance between the pair of fixed rollers 61a, 61b and the movable roller 63 is accumulated between the pair of fixed rollers 61a, 61b. Thus, when the movable roller 63 is in the middle of rising, even if the wire material 13 is unwound at a constant speed from the wire material unwinding mechanism 21, since a part of the wire material 13 is accumulated between the pair of fixed rollers 61a, 61b, the wire material 13 is also decelerated and the speed is reduced.

[0059] On the contrary, Figure 4 As shown, when the servo motor 64 is driven in a manner that the movable roller 63 descends, the vertical 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, since the wire 13 is added to the discharged wire 13, the wire 13 is also accelerated to increase its speed.

[0060] 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 moving toward the tensioning device 31 through the power storage mechanism 60; and a reeling speed detection sensor 80 as a reeling speed detection unit, which detects the speed of the wire 13 moving toward the winding core 12 through the tensioning device 31.

[0061] The winding speed detection sensor 80 of this embodiment is provided on an auxiliary plate 82 erected on the end of the winding machine 11 side of the housing 19. On the auxiliary plate 82, a pair of rollers 81, 81 pivotally supported in a manner of clamping the wire 13 and a first encoder 83 for detecting the rotation angle of either roller 81 are provided.

[0062] On the other hand, the unwinding speed detection sensor 70 in this embodiment is provided on the vertical plate 30 on the downstream side of the power storage mechanism 60. The vertical plate 30 is provided with a pair of rollers 71, 71 pivotally supported in a manner to clamp the wire 13, and a second encoder 73 for detecting the rotation angle of either roller 71.

[0063] In addition, the housing 19 contains a controller 46 for controlling the winding motor 14 or the guide motor 54 in the guide mechanism 51 constituting the winding core rotation unit. 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.

[0064] Therefore, the control output from the controller 46 is connected to the winding motor 14 or the guide motor 54. The controller 46 is configured to perform the so-called array winding, which is to drive the winding motor 14 to rotate the winding core 12 at a constant speed, and control the guide motor 54 to move the guide member 53 in the rotation direction of the winding core 12 by an amount equivalent to the outer diameter of the wire 13 each time the winding core 12 rotates one circle, so that the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 is wound while being in close contact with the winding core 12 ( Fig.12 as well as Fig.13 ).

[0065] 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 be able to always recognize the rotation angle of the winding core 12 rotating at a constant speed.

[0066] On the other hand, the unwinding motor 26 in the wire unwinding mechanism 21 is configured to make the rotation speed of its rotating shaft 26a variable. The capstan 24 driven by the unwinding motor 26 is configured to change the unwinding speed of the wire 13 by changing its rotation speed. In addition, the control output of the controller 46 is connected to the unwinding motor 26 in the wire unwinding mechanism 21. The controller 46 controls the winding motor 14 and the wire unwinding mechanism 21 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.

[0067] The controller 46 decelerates or accelerates the wire 13 unwound from the wire unwinding mechanism 21 at the average winding speed, and controls the servo motor 64 in the power storage mechanism 60 so that the speed is equal to the winding speed of the wire 13 wound on the rotating winding core 12 .

[0068] 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 by the information or data stored in the memory 46a. In addition, the controller 46 controls the wire unwinding mechanism 21 in a manner that the wire 13 is supplied according to the calculated average winding speed calculated by the calculation circuit 46c, and controls the power storage mechanism 60 in a manner that the wire 13 unwound from the wire unwinding mechanism 21 is decelerated or increased to the calculated winding speed calculated by the calculation circuit 46c.

[0069] 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 a manner that the speed of the wire 13 unwound from the wire unwinding mechanism 21 and decelerated or accelerated by the power storage mechanism 60 is equal to the winding speed of the wire 13 wound on the winding core 12.

[0070] Next, the winding method of the present invention using the above-mentioned winding device will be described.

[0071] The wire winding method of the present invention is a method of rotating the winding core 12 about an axis to wind the wire 13 supplied from the wire unwinding mechanism 21 and to which tension is applied by the tensioning device 31 around the winding core 12 .

[0072] Since the winding device 10 is used, Figure 1 As shown, the wire 13 is stored in the form of being wound on a reel 18. The wire 13 unwound from the reel 18 as the wire source passes through the through hole 22a of the flat plate 22, overcomes the curling characteristics through multiple small rollers 23a, and is wound on the capstan 24 that constitutes the wire unwinding mechanism 21.

[0073] The wire 13 extending from the capstan 24 is deflected by the first deflection pulley 32 to face the horizontal direction and passes under the pair of fixed rollers 61a and 61b in the power 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 the fixed rollers 61a and 61b.

[0074] The wire 13 having passed through the power storage mechanism 60 is routed so that its direction is changed by the second deflection pulley 33 and is wound around the guide pulley 34 of the tensioner 31 before reaching the winding machine 11. In the winding machine 11, the wire 13 having passed through the guide member 53 is locked to the winding core 12.

[0075] In this embodiment, information related to the winding core 12 used (specifically, information on the shape and size of the winding core), that is, the cross-sectional shape of the winding body portion 12a of the winding core 12 on which the wire 13 is directly wound and its winding width w ( Fig.12 ) and data related to the wire diameter d of the wire material 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.

[0076] 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 is detected by the rotation angle sensor 16 and fed back to the controller 46 .

[0077] In addition, in the guide mechanism 51, as Fig.12 as well as Fig.13 As shown, each time the winding core 12 rotates one circle, the guide member 53 is moved in the direction of the rotation axis of the winding core 12 by an amount equivalent to the outer diameter of the wire 13. In this way, the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 is arranged and wound on the winding core 12.

[0078] In addition, the characteristic point of the winding method of the present invention is that the wire 13 is unwound from the wire unwinding mechanism 21 at the average winding speed of the wire 13 wound on the rotating core 12, and the speed of the wire 13 unwound from the wire unwinding mechanism 21 is slowed down or accelerated so as to be equal to the winding speed of the wire 13 wound on the rotating core 12.

[0079] That is, in actual winding, the winding core 12 is rotated at a predetermined angular velocity ω stored in the memory 46a. However, in this embodiment, Fig. 9 As shown in (a), the cross section of the winding body 12a of the winding core 12 for winding the wire 13 is rectangular, in which the length from the rotation center O to the long side is a, the length from the rotation center O to the short side is b, and the distance from the rotation center O to the corner is c. In addition, when the rotation angular velocity ω of the winding core 12 is kept constant, as shown in FIG. Fig. 9 As shown in (b), the speed (vertical axis) of the wire 13 wound around the core 12 changes so as to generate inflection points of aω, cω, bω, cω, aω, . . . with respect to the rotation angle (horizontal axis) of the core 12.

[0080] 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 to each part from the rotation center O 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.

[0081] In this embodiment, since the information related to the cross-sectional shape of the winding body portion 12a of the winding core 12 used for directly winding the wire 13 (that is, the information related to the winding core 12) is stored in the memory 46a, the calculation circuit 46c in the controller 46 obtains the information related to the winding core 12 by multiplying the lengths a, b, and c from the rotation center O of the winding core 12 to each portion for winding the wire 13 by the angular velocity ω of the rotation of the winding core 12. Fig. 9 The calculated winding speed is shown by the solid line curve in (b).

[0082] In addition, the calculation circuit 46c in the controller 46 obtains the following Fig. 9 After calculating the winding speed shown by the solid line curve in (b), the average of the calculated winding speed is calculated. Fig. 9 (b) The average winding speed is shown by the dotted line. That is, the average winding speed is calculated by winding the core 12 with Fig. 9 The solid line curve in (b) is a value obtained by dividing the length of the wire 13 wound when the winding speed is calculated and the wire 13 rotates once by the time required for the wire 13 to rotate once.

[0083] 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 average winding speed obtained by the operation circuit 46c.

[0084] In addition, the controller 46 rotates the ball screw 66 and the movable table 67 screwed with the ball screw 66 to move the movable roller 63 as shown in FIG. Fig. 9 The long dashed curve in (b) moves up and down in the vertical direction, and controls the servo motor 64 in the power storage mechanism 60 so as to decelerate or accelerate the wire 13 unwound from the wire unwinding mechanism 21 at the average winding speed to the calculated winding speed.

[0085] Here, in the above-mentioned winding device 10, a winding speed detection sensor 70 is provided to detect the speed of the wire 13 unwound from the power storage mechanism 60 toward the tensioning device 31, and a winding speed detection sensor 80 is provided to detect the speed of the wire 13 after passing through the tensioning device 31. Figure 5 (a) shows the method of calculating the winding speed. When the speed of the wire 13 after passing through the power storage mechanism 60 is decelerated or accelerated, the speed of the wire 13 is detected. Figure 5 The measured unwinding speed shown in (b) is the speed of the wire 13 after passing through the tensioning device 31. Figure 5 (c) The measured winding speed is shown.

[0086] Here, when the wire 13 is wound around the winding core 12 having a non-circular cross-section such as a rectangular shape, 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 a power storage mechanism 60 for decelerating or accelerating the wire 13 as in the prior art, Figure 1 As shown by the dotted arrow, the guide pulley 34 periodically vibrates, and the tension applied to the wire 13 varies due to the vibration.

[0087] In contrast, in the present invention, the wire 13 is unwound from the wire unwinding mechanism 21 at a calculated average winding speed that is a constant value. Figure 3 or Figure 4 As shown, the wire 13 is periodically decelerated or accelerated to be set to Figure 5 The calculated winding speed is equal to the speed shown in (a).

[0088] Therefore, if Figure 5 As shown in (c), when the winding speed of the wire 13 wound on the winding core 12 increases, as shown in Figure 5 As shown in (b), along with the increase, the power storage mechanism 60 accelerates the wire 13 unwound from the wire unwinding mechanism 21, thereby increasing the speed of the wire 13. Similarly, when the winding speed of the winding core 12 decreases, along with the decrease, the power storage mechanism 60 decelerates the wire 13 unwound from the wire unwinding mechanism 21, thereby reducing the speed of the wire 13.

[0089] In this way, when the speed at which the wire 13 is unwound from the wire unwinding mechanism 21 is decelerated or accelerated, and the speed at which the wire 13 is actually wound up by the winding core 12 is made consistent, Figure 1 The periodic vibration of the guide pulley 34 shown by the dotted line 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.

[0090] 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 rotation axis direction of the winding core 12, so that the wires 13 are arranged and wound around the winding core 12. When the wires 13 are wound around the winding core 12 in a manner covering multiple layers, as shown in FIG. Fig.12 As shown in FIG. 1 , when the first layer of winding of the winding body portion 12 a is completed, the second layer of winding is performed on the periphery of the first layer of wire 13, as shown in FIG. Fig.13 As shown, when the winding of the second layer is completed, the winding of the third layer is performed on the outer periphery of the wire 13 of the second layer.

[0091] In this way, when the wire material 13 is wound in multiple layers on the winding body portion 12a, as shown in FIG. Fig.10 as well as Fig.11 As shown, the length from the rotation center O of the core 12 to each part where the wire 13 is wound increases toward the outer layer. When the core 12 rotates at a predetermined angular velocity ω, the winding speed wound on the core 12 accelerates toward the outer layer.

[0092] Specifically, if Fig. 9 As shown, in the case of the first layer, the length from the rotation center O of the winding core 12 to each location where the wire 13 is wound is the outer peripheral shape itself in the cross section of the winding core 12. Fig.10 As shown in FIG. 1 , the length of the second layer from the rotation center of the winding core 12 to each portion 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 in the cross-sectional shape of the winding core 12. Fig.11 As shown, the length of the third layer from the rotation center of the winding core 12 to each location around which the wire 13 is wound is the length obtained by adding the wire diameter d of the wire 13 to the length of the second layer.

[0093] Data on the wire diameter d of the wire material 13 and the winding width w of the winding body 12a added to the cross-sectional shape of the winding core 12 are stored in the memory 46a in advance. Figure 1 The calculation circuit 46c in the controller 46 can derive the rotation speed required for the arrangement and winding of each layer by dividing the winding width w by the wire diameter d.

[0094] In addition, if it is the second layer of winding, then Fig.10 As shown in FIG. 1 , the lengths (a+d), (b+d), and (c+d) from the rotation center O of the winding core 12 to each location where the wire 13 is wound are calculated. If it is the third layer of winding, then Fig.11As shown in FIG. 1 , the lengths (a+2d), (b+2d), and (c+2d) of the third layer from the rotation center O of the winding core 12 to each portion where the wire 13 is wound are obtained. Then, by multiplying the angular velocity ω of the rotating winding core 12 by the above lengths (a+d), (b+d), (c+d), (a+2d), (b+2d), and (c+2d), the calculated winding speed ( Fig.10 (b) Fig.11 (b)).

[0095] In addition, the calculation circuit 46c in the controller 46 obtains the calculated winding speed (10 (b), Fig.11 (b)) After that, the calculated average winding speed of each layer is calculated from the calculated winding speed, and the calculated average winding speed of each layer is obtained. Fig.10 (b) or Fig.11 The calculated average winding speed is shown by the dashed line in (b).

[0096] 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 the above calculation. Fig.10 (b) or Fig.11 As shown in the long dashed curve in (b), the movable roller 63 is moved up and down in the vertical direction, so that the wire 13 supplied from the wire unwinding mechanism 21 is decelerated or accelerated. Even after the second layer, the servo motor 64 in the power storage mechanism 60 is controlled in a manner to set the speed equal to the calculated winding speed for each layer obtained by such calculation.

[0097] Thus, even after the second layer, the unwinding amount is controlled so as to balance (i.e., maintain equilibrium) the speed (unwinding amount) of the wire 13 after passing through the power storage mechanism 60 and the winding speed (winding amount) of the wire 13 on the winding core 12 .

[0098] Thus, even after the second layer, the periodic vibration of the guide pulley 34 in the tensioner 31 is suppressed. Thus, the wire 13 wound around the guide pulley 34 is given a constant tension according to the position of the guide pulley 34 by the elastic member 35 .

[0099] Here, in actual winding, the controller 46 detects the speed of the wire 13 unwound toward the tensioning device 31 through the power storage mechanism 60, and the speed of the wire 13 toward the winding core 12 through the tensioning device 31. In addition, the servo motor 64 in the power storage 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.

[0100] 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 power storage mechanism 60 to set the calculated winding speed. Figure 5 As shown, originally, the speed of the wire 13 does not deviate in the time axis direction before and after the tensioning device 31 .

[0101] When the rotation speed of the winding core 12 is increased, the deceleration or acceleration of the wire 13 in the power storage mechanism 60 changes at a relatively fast 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 cannot keep up, and the deceleration or acceleration of the wire 13 is delayed. As a result, there is a deviation between the speed of the wire 13 unwound from the power storage mechanism 60 toward the tensioning device 31 and the speed of the wire 13 wound on the winding core 12 through the tensioning device 31.

[0102] Here, the actual speed of the wire 13 unwound from the power storage mechanism 60 toward the tensioning 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. In this way, 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 power storage mechanism 60 in a manner that eliminates the deviation of the speed change state of the measured unwinding speed and the speed change state of the measured winding speed in the time axis direction.

[0103] Specifically, when Figure 6 The measured winding speed shown by the solid line in (c) and Figure 6 When there is an offset T in the time axis direction between the speed changes of the measured unwinding speeds shown by the dotted lines in (b), the controller 46 obtains the temporal offset T. Figure 6 The deviation T is subtracted from the calculated winding speed shown by the solid line in (a) to obtain the corrected winding speed shown by the two-dot chain line.

[0104] In this regard, the controller 46 in this embodiment includes a speed correction unit that calculates the time axis deviation T of the speed changes of the measured winding speed and the measured unwinding speed and obtains a corrected winding speed by subtracting the deviation T from the calculated winding speed.

[0105] In addition, the controller 46 follows the obtained Figure 6 The controller 46 controls the servo motor 64 in the power storage mechanism 60 by correcting the winding speed shown by the double-dashed line in (a). Figure 6 The power storage mechanism 60 is controlled in a state where the calculated winding speed is advanced by the amount of deviation T as shown by the solid line in (a). Figure 6 The actual winding speed of the wire 13 wound by the winding core 12 shown by the solid line in (c) and the speed of the wire 13 decelerated or accelerated by the power storage mechanism 60 and directed toward the tensioning device 31 are shown in FIG. Figure 6 The solid line in (b) is consistent.

[0106] Thus, even when the rotation speed of the winding core 12 is increased and the winding speed to the winding core 12 changes at a relatively high speed, the power storage mechanism 60 can be used to 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 power storage mechanism 60 and supplied to the tensioning device 31 is eliminated, thereby preventing the periodic vibration of the guide pulley 34 in the tensioning device 31. Thus, even when the rotation speed of the winding core 12 is increased, the elastic member 35 can be used to provide a constant tension that does not change according to the position of the guide pulley 34.

[0107] 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 core 12 are different, the wire supply amount and the wire winding amount are inconsistent.

[0108] Thus, in the tensioning device 31, the guide pulley 34 on which the wire 13 is wound moves along the rail 36, thereby changing the interval between the guide pulley 34 and the winding core 12, and the position in the Y-axis direction changes by 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 pulley 34 in the tensioning device 31. In addition, the movement of the guide pulley 34 is detected by the position sensor 45 and fed back to the controller 46.

[0109] Here, when the guide pulley 34 moves, the tension applied to the wire 13 gradually changes. Thus, when the change in the position of the guide pulley 34 is detected by the detection output of the position sensor 45, the controller 46 returns the position of the guide pulley 34 to a predetermined position of the track 36, such as the approximate center, and increases or decreases the calculated winding speed as the supply amount of the wire 13 at a constant ratio, and obtains the calculated average winding speed based on the increased or decreased corrected winding speed. 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.

[0110] That is, if Figure 7 As shown in (a), compared with the calculated winding speed, the measured winding speed of the wire 13 toward the winding core 12 is faster, and the guide pulley 34 gradually approaches the winding machine 11. Figure 7 As shown in (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 is increased, 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 increased at a constant ratio, and the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 in such a manner that the wire 13 is unwound at the corrected average winding speed after the increase, and uses the power storage mechanism 60 to decelerate or accelerate the wire 13, so that the measured unwinding speed of the wire 13 toward the tensioning device 31 is as shown in FIG. Figure 7 (c) shows the same result as the measured winding speed.

[0111] On the other hand, if Figure 8 As shown in (a), compared with the calculated winding speed, the measured winding speed of the wire 13 toward the winding core 12 is slower, and the guide pulley 34 gradually moves away from the winding machine 11. Figure 8 As shown in (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 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 ratio, and the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21 in such a manner that the wire 13 is unwound at the corrected average winding speed after such reduction, and uses the power storage mechanism 60 to decelerate or accelerate the wire 13, so that the measured unwinding speed of the wire 13 toward the tensioning device 31 is as shown in FIG. Figure 8 (c) shows the same result as the measured winding speed.

[0112] Thereby, the guide pulley 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.

[0113] According to this embodiment, the following effects are achieved.

[0114] The winding device 10 involved in this embodiment includes: a winding core 12; a wire unwinding mechanism 21, which supplies a wire 13 to the winding core 12; a power storage 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 supplying the wire 13 supplied from the wire unwinding mechanism 21 and supplied by the tensioning device The wire 13 to which tension is imparted is wound on the winding core 12; a controller 46 controls the force storage mechanism 60 and the wire unwinding mechanism 21, the controller 46 controls the wire unwinding mechanism 21 in a manner that the wire 13 is unwound at an average winding speed of the wire 13 wound on the rotating winding core 12, and controls the force storage 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 on the rotating winding core 12.

[0115] In addition, the winding method involved in 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 tensioning device 31 around the winding core 12, unwinds the wire 13 from the wire unwinding mechanism 21 at the average winding speed of the wire 13 wound on the rotating core 12, and decelerates or accelerates the speed of the wire 13 unwound from the wire unwinding mechanism 21 so as to be equal to the winding speed of the wire 13 wound around the rotating core 12.

[0116] 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 that is subsequently decelerated or accelerated and wound on the core 12, even if it is assumed that the tensioning device 31 has a component such as a guide pulley 34 that hangs the wire 13 and moves due to the elastic component 35, it is possible to prevent the movement of the guide pulley 34 that is caused by the speed change of the wire 13.

[0117] As a result, since the change in the tension of the wire caused by the movement of components such as the guide pulley 34 is avoided, the tension of the wire 13 wound on the core 12 can be kept constant even if the speed of the wire 13 wound on the core 12 of different diameters changes significantly.

[0118] In addition, in the winding device 10 involved in the present embodiment, the power storage mechanism 60 includes: a pair of fixed rollers 61a, 61b, which are arranged along the moving 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, 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.

[0119] In the winding method according to the present embodiment, the wire 13 between a pair of fixed rollers 61a and 61b arranged along the moving path of the wire 13 is wound around the movable roller 63 and the movable roller 63 is moved in a direction intersecting the moving path of the wire 13 .

[0120] According to the above structure, since the wire 13 located 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, the speed of the wire 13 unwound from the wire unwinding mechanism 21 can be slowed down or accelerated.

[0121] In addition, the winding device 10 involved in 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 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 the tensioning device 31 has: a guide pulley 34, on which the wire 13 is hung; an elastic component 35, which applies force to the guide pulley 34, and the controller 46 controls the wire unwinding mechanism 21 in a manner that supplies the wire 13 according to the calculated winding speed calculated by the operation circuit 46c, and controls the power storage mechanism 60 in a manner that slows down or increases the speed of the wire 13 unwound from the wire unwinding mechanism 21 to become the calculated winding speed calculated by the operation circuit 46c.

[0122] In addition, in the winding method involved in the present embodiment, the memory 46a stores information related to the core 12, and the calculated winding speed and the calculated average winding speed of the wire 13 wound on the core 12 are calculated by the operation circuit 46c based on the information related to the core 12. The wire 13 is supplied by the wire unwinding mechanism 21 according to the calculated average winding speed calculated by the operation circuit 46c, and the speed of the wire 13 unwound from the wire unwinding mechanism 21 is accelerated or decelerated in a manner to become the calculated winding speed calculated by the operation circuit 46c. The tensioning device 31 has: a guide pulley 34, on which the wire 13 is hung; and an elastic component 35, which applies force to the guide pulley 34.

[0123] According to the above configuration, by using the calculated winding speed and the calculated average winding speed pre-stored in the memory 46a, the power storage 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 decelerated or accelerated to match the actual winding speed of the wire 13 wound by the winding core 12, so that the periodic vibration of the guide pulley of the tensioning device 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.

[0124] In addition, in the winding device 10 involved in the present embodiment, the force storage mechanism 60 is arranged between the wire unwinding mechanism 21 and the tensioning device 31, and the force storage mechanism 60 includes: an unwinding speed detection sensor 70, which detects the unwinding speed of the wire 13 unwound from the force storage 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 toward the winding core 12, and the controller 46 controls the force storage mechanism 60 in a manner to eliminate the offset 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.

[0125] In addition, the winding method involved in the present embodiment accelerates or decelerates the wire 13 unwound from the wire unwinding mechanism 21 toward the tensioning device 31, and detects both the unwinding speed of the wire 13 accelerated or decelerated toward the tensioning device 31 and the winding speed of the wire 13 wound onto the winding core 12 through the tensioning device 31, and accelerates or decelerates the wire 13 in a manner that eliminates the offset 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.

[0126] According to the above configuration, even when the rotation speed of the winding core 12 is increased and the winding speed to the winding core 12 is changed at a relatively high speed, the power storage mechanism 60 can be used to 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 power storage mechanism 60 and supplied to the tensioning device 31 is eliminated, thereby preventing the periodic vibration of the guide pulley 34 in the tensioning device 31. Therefore, even if the rotation speed of the winding core 12 is increased, a constant tension that does not change according to the position of the guide pulley 34 can be applied by the elastic member 35.

[0127] In the above embodiment, the tensioning device 31 is described as including the guide pulley 34 provided so as to be movable along the rail 36. However, the tensioning device may also be Fig.15 As shown, the tension arm 4 is rotated by the elastic member 6 , and tension is applied to the wire 2 unwound from the guide pulley 5 attached to the front end of the tension arm 4 .

[0128] Even if Fig.15 In the tensioning device having the tension arm 4 shown, if the wire unwinding from the wire unwinding mechanism 21 at the average winding speed is decelerated or accelerated by the power storage 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 pulley 5 of the tensioning device caused by the speed change of the wire can also be prevented. As a result, since the tension change of the wire caused by the movement of the guide pulley 5 is avoided, the tension of the wire wound on the winding core 12 can be kept constant.

[0129] In addition, in the above-mentioned embodiment, the case where the elastic member 35 for applying force to the guide pulley 34 in the tensioner 31 is a coil spring is exemplified. However, a fluid pressure cylinder that applies force in a direction to make the rod sink or protrude by using 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 relatively easily by changing the fluid pressure such as compressed air in the cylinder.

[0130] In the above embodiment, the controller 46 is provided with the calculation circuit 46c, and the calculation circuit 46c calculates the calculated winding speed or the calculated average winding speed from the information or data stored in the memory 46a. However, the calculation circuit 46c is not provided, and the winding speed or the average winding speed may be calculated in advance separately from the controller 46, and the memory 46a may store the calculated winding speed or the average winding speed separately provided in this way.

[0131] In this case, the controller 46 controls the wire unwinding mechanism 21 in such a manner that the wire 13 is supplied according to the calculated average winding speed stored in the memory 46a, and the controller 46 controls the power storage mechanism 60 in such a manner that the speed of the wire 13 unwound from the wire unwinding mechanism 21 is decelerated or accelerated to the calculated winding speed stored in the memory 46a. Thereby, since frequent movement of the guide pulley 34 is avoided, the tension of the wire 13 wound on the winding core 12 can be kept constant.

[0132] In addition, in the above-mentioned embodiment, the case where the power storage mechanism 60 is provided between the wire unwinding mechanism 21 and the tensioning device 31 is described. Fig.14 As shown, the force storage mechanism 60 may also be disposed on the downstream side of the tensioning device 31 .

[0133] If the Fig.14 The winding device 10 shown in the figure has the wire 13 unwound from the wire unwinding mechanism 21 at an average winding speed, and is given a predetermined tension through the tensioning device 31 at the average winding speed. The speed of the wire 13 after passing through the tensioning device 31 is then decelerated or accelerated so as to be equal to the winding speed of the wire 13 wound on the rotating winding core 12.

[0134] Even in this winding device 10, the speed of the wire 13 after passing through the tensioning device 31 is equal to the winding speed of the wire 13 wound on the rotating winding core 12. Therefore, even if the tensioning device 31 has a guide pulley 34 that is hung and moved by the elastic member 35, the movement of the guide pulley 34 caused by the speed change of the wire 13 can be prevented. As a result, the tension of the wire 13 wound on the winding core 12 can be kept constant.

[0135] Although the embodiments of the present invention have been described above, the above embodiments merely illustrate a part of application examples of the present invention and do not intend to limit the technical scope of the present invention to the specific configurations of the above embodiments.

[0136] 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.

[0137] (Explanation of Reference Numerals)

[0138] 10: Winding device

[0139] 12: Core

[0140] 13: Wire

[0141] 14: Winding motor (core rotation unit)

[0142] 21: Wire unwinding mechanism

[0143] 31: Tensioning device

[0144] 46: Controller

[0145] 46a: Memory (storage unit)

[0146] 46c: Arithmetic circuit (arithmetic unit)

[0147] 60: Accumulation mechanism

[0148] 61a, 61b: Fixed rollers

[0149] 63: Movable roller

[0150] 64: Servo motor

[0151] 70: Unwinding speed detection sensor (unwinding speed detection unit)

[0152] 80: Winding speed detection sensor (winding speed detection unit)

Claims

1. A winding device, comprising: Roll core; a wire unwinding mechanism, which supplies the wire to the winding core; A power storage mechanism, which slows down or speeds up 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 so that the wire supplied from the wire unwinding mechanism and given tension by the tensioning device is wound around the winding core; A controller controls the power storage mechanism and the wire unwinding mechanism, The controller controls the wire unwinding mechanism so as to unwind the wire at an average winding speed of the wire wound on the rotating winding core. and controlling the power storage mechanism so that the speed of the wire unwound from the wire unwinding mechanism is equal to the winding speed of the wire wound by the rotating winding core. The power storage mechanism comprises: a pair of fixed rollers arranged along a moving path of the wire material in a manner to guide the wire material; a movable roller on which the wire is hung and is disposed between the pair of fixed rollers in a manner movable in a direction intersecting a moving path of the wire; A roller moving unit moves the movable roller.

2. The wire winding device according to claim 1, wherein: The storage unit further includes a storage unit for storing the winding speed of the wire wound around the rotating winding core, that is, the calculated winding speed and the calculated average winding speed calculated in advance. The tensioning device comprises: A guide pulley for hanging and winding the wire; a force applying unit, which applies force to the guide pulley, The controller controls the wire unwinding mechanism in such a manner that the wire is supplied according to the calculated average winding speed stored in the storage unit, Furthermore, the power storage mechanism is controlled so that the speed of the wire unwound from the wire unwinding mechanism is decelerated or increased to reach the calculated winding speed stored in the storage unit.

3. The wire winding device according to claim 1, wherein: Also available: A storage unit for storing information related to the winding core; a calculation unit that calculates a calculated winding speed and a calculated average winding speed of the wire wound on the core based on information related to the core, The tensioning device comprises: A guide pulley for hanging and winding the wire; a force applying unit, which applies force to the guide pulley, The controller controls the wire unwinding mechanism in such a manner that the wire is supplied according to the calculated average winding speed calculated by the calculation unit, Furthermore, the power storage mechanism is controlled so that the speed of the wire unwound from the wire unwinding mechanism is decelerated or increased to reach the calculated winding speed calculated by the calculation unit.

4. The wire winding device according to claim 2 or 3, wherein: The power storage mechanism is arranged between the wire unwinding mechanism and the tensioning device. The winding device comprises: an unwinding speed detection unit for detecting an unwinding speed of the wire unwound from the force storage mechanism toward the tensioning device; a winding speed detection unit for detecting a winding speed of the wire material passing through the tensioning device toward the winding core, The controller controls the power storage mechanism so as 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 unit and the speed change state of the measured unwinding speed determined by the detection output of the unwinding speed detection unit.

5. A wire winding method, which is performed by the wire winding device according to claim 1, wherein the wire supplied from the wire unwinding mechanism and given tension by the tensioning device is wound around the winding core by rotating the winding core, unwinding the wire from the wire unwinding mechanism at an average winding speed of the wire wound on the rotating winding core, 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, The wire rod between the pair of fixed rollers provided along the moving path of the wire rod is hung around the movable roller, and the movable roller is moved in a direction intersecting the moving path of the wire rod.

6. The winding method according to claim 5, wherein: causing a storage unit to store the winding speed of the wire wound around the rotating winding core, that is, the calculated winding speed and the calculated average winding speed calculated in advance, supplying the wire by the wire unwinding mechanism according to the calculated average winding speed stored in the storage unit, decelerating or accelerating the speed of the wire unwound from the wire unwinding mechanism so as to obtain the calculated winding speed stored in the storage unit, The tensioning device comprises: A guide pulley for hanging and winding the wire; A force applying unit applies force to the guide pulley.

7. The winding method according to claim 5, wherein: causing a storage unit to store information related to the winding core, The calculation unit calculates the calculated winding speed and the calculated average winding speed of the wire wound on the core based on the information related to the core. The wire is supplied by the wire unwinding mechanism according to the calculated average winding speed calculated by the computing unit, decelerating or accelerating the speed of the wire unwound from the wire unwinding mechanism so as to achieve the calculated winding speed calculated by the calculation unit, The tensioning device comprises: A guide pulley for hanging and winding the wire; A force applying unit applies force to the guide pulley.

8. The winding method according to claim 6 or 7, wherein: accelerating or decelerating the wire unwound from the wire unwinding mechanism toward the tensioning device, detecting both a speed of unwinding the wire material which is accelerated or decelerated toward the tensioning device and a speed of winding the wire material which is wound around the winding core after passing through the tensioning device, The wire rod is accelerated or decelerated so as to eliminate the deviation in the time axis direction between the detected speed change state of the actually measured unwinding speed and the detected speed change state of the actually measured winding speed.

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