Winding device and winding method

Abstract

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

Description

Technical Field

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

[0002] At present, for example, Japanese Patent Application Laid-Open No. JP2000-128433A discloses a tensioning device that is provided in a winding machine that winds a wire around a winding core to form a coil and applies a predetermined tension to the wire. Figure 12 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 a base end; a guide pulley 5 that is mounted on the top end of the tension arm 4 and deflects the wire 2 unwound from the capstan 3 after passing through and guides it to a winding machine; 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 so 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 a winding machine not shown.

[0003] Here, the wire 2 is guided to the winding machine via a guide pulley 5 and wound onto its core. The unwinding speed of the wire 2 unwound from the conventional tensioning device is controlled by rotating the capstan 3 so that the rotation angle of the tension arm 4 is a predetermined angle, thereby ensuring a balance between the unwinding speed of the wire 2 and the winding speed of the wire wound onto the core. Furthermore, a predetermined tension is applied to the wire 2 by the tension arm 4, which is given an elastic force by an elastic member 6.

[0004] When the winding speed of the wire wound on the winding core changes, the tension of the wire 2 changes, but this change is absorbed by the change in 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 so that the rotation angle of the tension arm 4 immediately reaches the predetermined angle, and the tension applied to the wire 2 returns to the predetermined value.

[0005] As mentioned above, in Figure 12In the conventional tensioning device shown, fluctuations in the winding speed of the wire 2 are absorbed by changing the rotation angle of the tension arm 4. However, when the wire 2 is wound around a winding core having different outer diameters, such as a core having a rectangular cross-section with significantly different short and long sides, the speed of the wire 2 wound around the core fluctuates significantly and periodically during one rotation of the core. As a result, the rotation angle of the tension arm 4, which absorbs these speed fluctuations, increases or decreases significantly.

[0006] That is, when the wire 2 unwound from the capstan 3 is Figure 12 In the case where the wire 2 is bent at a substantially right angle to the tension arm and directed to the winding machine, the winding speed of the wire 2 in the winding machine is increased, and in this case, the guide pulley 5 is pulled toward the winding machine by the predetermined length L1 that is excessively wound per unit time, as shown by the solid arrow. In addition, the tension arm 4, on which the guide pulley 5 is provided at the top, rotates 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 being wound on the winding core in the winding machine fluctuates 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 to absorb the fluctuation, cannot keep up with the trend of the pulled guide pulley 5. As a result, a tension exceeding the elastic force applied by the elastic member 6 is temporarily applied to the wire 2 between the guide pulley 5 provided at the top 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 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 pulley 5 at the top end is rotated 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 being wound onto the core of the winding machine fluctuates significantly, and the speed of the wire 2 being wound onto the core of the winding machine temporarily decreases significantly, the force exerted by the wire 2 on the guide pulley 5 is temporarily and significantly reduced. The tension arm 4, which has the guide pulley 5 at its top end and absorbs this fluctuation, cannot follow the rotation due to its inertia using the elastic force of the elastic member 6. As a result, the wire 2 between the guide pulley 5 at the top end of the tension arm 4 and the core temporarily slackens. Therefore, in conventional tensioning devices, when the speed of the wire 2 being wound onto cores of different diameters in the winding machine fluctuates significantly, it is difficult to maintain a constant tension in the wire 2 supplied to the winding machine. Summary of the Invention

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

[0011] According to one embodiment of the present invention, there is provided a winding device comprising: a winding core; a wire unwinding mechanism that supplies wire to the winding core at a variable supply speed; a tensioning device that applies tension to the wire supplied from the wire unwinding mechanism to the winding core; a winding core rotation 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 the wire unwinding mechanism in such a manner that the wire is supplied at a speed equal to the winding speed of the wire wound around the rotating winding core.

[0012] In addition, according to another embodiment of the present invention, a winding method is provided, wherein the wire supplied from a wire unwinding mechanism and given tension by a tensioning device is wound around the winding core by rotating the winding core. In the winding method, the winding speed of the wire wound around the winding core is calculated to obtain a calculated winding speed, and the wire is unwound from the wire unwinding mechanism at a speed equal to the calculated winding speed.

[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 fluctuates significantly, the tension of the wire material wound around the winding core can be kept constant. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Figure 1 It is a front view showing the winding device in the embodiment of the present invention.

[0016] Figure 2 It is a top view of the winding device in the embodiment of the present invention.

[0017] Figure 3 Graph showing the relationship between the calculated take-up speed, the measured unwinding speed, and the measured take-up speed.

[0018] Figure 4 This is the deviation between the measured unwinding speed and the measured winding speed. Figure 3 The corresponding figure.

[0019] Figure 5 This is a graph showing a case where the measured winding speed is faster than the calculated winding speed.

[0020] Figure 6 This is a diagram showing a case where the measured winding speed is slower than the calculated winding speed.

[0021] Figure 7 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.

[0022] Figure 8 The relationship between the angle of the winding core and the speed of the wire wound thereon is shown in Figure 1. Figure 7 The corresponding figure.

[0023] Figure 9 The relationship between the angle of the winding core and the speed of the wire wound thereon is shown in Figure 1. Figure 8 The corresponding figure.

[0024] Figure 10 Indicates the state of winding the wire material on the core until the second layer Figure 2 Magnified view of part A.

[0025] Figure 11 This is the state in which the wire is wound on the core until the third layer. Figure 10 The corresponding figure.

[0026] Figure 12 It is a front view showing an existing tensioning device. DETAILED DESCRIPTION

[0027] Next, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0028] exist Figure 1 as well as Figure 2, a winding device 10 of the present invention is shown. The winding device 10 includes: a winding machine 11 that rotates a winding core 12 to wind a wire around the winding core 12; a wire unwinding mechanism 21 that supplies a wire 13 to the winding core 12; and a tensioning device 31 that applies tension to the wire 12 supplied from the wire unwinding mechanism 21 to the winding core 12.

[0029] 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.

[0030] A winding motor 14, serving as a core rotation unit, is mounted on a base plate 15a erected on the upper surface of a main body 15 located at a location. The winding motor 14 is mounted with its rotation shaft 14a extending horizontally in the X-axis direction. The winding machine 11 in this embodiment is configured so that the winding motor 14 rotates the core 12 at a constant speed.

[0031] 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 about 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 that detects the rotation angle of the winding core 12.

[0032] like Figure 1 As shown in the figure, a base 17 is installed in a location where the winding machine 11 is installed so as to be separated from the winding machine 11. The base 17 is provided with rollers 17a for facilitating the movement of the base 17 and foot members 17b fixed to the location in a manner that cannot be moved. In addition, the base 17 is installed at a position offset in the Y-axis direction relative to the winding machine 11.

[0033] The wire 13 in this embodiment is a copper wire with a circular or square cross-section used to manufacture coils for motor components. The wire 13 is stored by being wound around a relatively large reel 18. The reel 18, serving as the wire source, is offset and positioned at the end of the base 17 separated from the winding machine 11. A housing 19 for the controller 46, described later, is mounted on the base 17 adjacent to the reel 18. The wire unwinding mechanism 21 is mounted on the base 17 via this housing 19.

[0034] Specifically, the wire unwinding mechanism 21 is provided on a flat plate 22, which is mounted on the housing 19 so as to cover the reel 18 from above in the Z-axis direction. The flat plate 22 is formed with a through-hole 22a through which the wire 13 can pass. A platen 23 is erected near the through-hole 22a of the flat plate 22, and a plurality of small rollers 23a are provided on the platen 23. These 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, thereby suppressing its curling characteristics.

[0035] In addition, in this embodiment, the wire unwinding mechanism 21 for unwinding the wire 13 toward the winding machine 11 includes: a relatively large diameter capstan 24, which is used to hang the wire 13 whose curling characteristics are overcome by multiple small rollers 23a and to turn the wire 13; an auxiliary pulley 25, which is adjacent to the capstan 24 and has a smaller diameter than the capstan 24 pivotally supported on the table 23; and an unwinding motor 26 as an unwinding drive unit, which rotates the capstan 24.

[0036] The wire 13 is wound around the capstan 24 and the auxiliary pulley 25 in a manner that connects the capstan 24 and the auxiliary pulley 25. When the unwinding motor 26 is driven to rotate the capstan 24, the wire 13 unwound from the reel 18 is pulled up and rewound, and the already wound wire 13 is unwound from the capstan 24 and unwound toward the winding machine 11.

[0037] 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.

[0038] A first deflection pulley 32 and a second deflection pulley 33 are provided on the vertical plate 30. The first deflection pulley 32 sets the wire 13, which has been deflected by the capstan 24, horizontally and directs it toward the winding machine 11. The second deflection pulley 32 is used to wind the wire 13 directed toward the winding machine 11 by the first deflection pulley 32. In this embodiment, relatively large diameter pulleys are used for the first deflection pulley 32 and the second deflection pulley 33 to facilitate winding of the wire 13.

[0039] The tensioning device 31 includes: a guide pulley 34, on which is hung the wire 13 that 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 to the wire 13 corresponding to the position of the guide pulley 34.

[0040] That is, a rail 36 is provided on the vertical plate 30 so as to extend in the Y-axis direction, and a support 37 is provided on the rail 36 so as to be movable in the Y-axis direction. The support 37 rotatably supports the guide pulley 34. 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 deflected by the second deflection pulley 33.

[0041] Furthermore, an elastic member 35 is provided on the vertical plate 30 to bias the guide pulley 34 in a direction away from the winding machine 11. 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 attached to the support 37, and the other end thereof is attached to the movable body 41 ( Figure 1 ).

[0042] 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.

[0043] The force exerted on the guide pulley 34 by the coil springs 35, 35 is adjusted by a tension adjustment mechanism 40. The tension adjustment mechanism 40 includes a rail 42 provided on the vertical plate 30 in parallel with the coil springs 35, 35 and supporting a movable body 41 so as to be movable in the Y-axis direction; a male screw 43 threadably engaged with the movable body 41 movably mounted on the rail 42 and pivotally supported on the vertical plate 30; and an adjustment knob 44 for rotating the male screw 43.

[0044] The other ends of the coil springs 35, 35, each of which has one end attached to the support 37, are connected to the movable body 41. The tension of the coil springs 35, 35 is adjusted by rotating the adjustment knob 44 to rotate the male screw 43, thereby moving the movable body 41 away from or in contact with the winding machine 11.

[0045] 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 .

[0046] The tension adjustment mechanism 40 adjusts the tension of the coil springs 35 , 35 as an initial setting before starting winding, and is not performed during winding to make the tension applied to the wire 13 constant.

[0047] 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 portion 12b, which is provided on both end faces of the winding body 12a and limits the winding width of the wire 13. The core 12 is coaxially mounted on the core rotation unit, that is, the rotating shaft 14a of the winding motor 14. The core 12 is configured to be rotated by the winding motor 14 so as to rotate around its axis. In this embodiment, the cross-sectional shape of the winding body 12a is shown to be rectangular.

[0048] In addition, the winding machine 11 is provided with a guide mechanism 51 for guiding the wire 13 wound on the 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 core 12 and is provided to be movable in the axial direction; a guide member 53, which is mounted on the top end of the support pin 52 and limits the movement of the wire 13 in the axial direction of the core 12; a guide motor 54 ( Figure 2 ), which moves the support pin 52 in the axial direction.

[0049] like Figure 2 As shown, the guide motor 54 is mounted so that its rotation shaft 54a is adjacent to 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 that is threadedly engaged with the ball screw 55 is mounted on the base end of the support pin 52.

[0050] Therefore, when the guide motor 54 is driven to rotate the ball screw 55, the support pin 52 and the female screw member 56 that moves by screwing with the ball screw 55 move in the axial direction, thereby moving the guide member 53 provided at the top end of the support pin 52 in the direction of the rotation axis of the winding core 12. In addition, the guide member 53 is configured to clamp the wire 13 from both sides in the direction of the rotation axis of the winding core 12 and limit the passing position of the wire 13 in the direction of the rotation axis ( Figure 10 、 Figure 11 ).

[0051] In addition, the winding device 10 also includes: a unwinding speed detection sensor 70 as a unwinding speed detection unit, which detects the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tensioning device 31; and a winding speed detection sensor 60 as a winding speed detection unit, which detects the speed of the wire 13 passing through the tensioning device 31 toward the winding core 12.

[0052] The winding speed detection sensor 60 of this embodiment is provided on an auxiliary plate 62 erected on the end portion of the housing 19 on the winding machine 11 side. The auxiliary plate 62 is provided with a pair of rollers 61, 61 pivotally supported so as to clamp the wire 13, and a first encoder 63 for detecting the rotation angle of either roller 61.

[0053] On the other hand, the unwinding speed detection sensor 70 in this embodiment is provided on the vertical plate 30 between the first deflection pulley 32 and the second deflection pulley 33. The vertical plate 30 is provided with a pair of rollers 71, 71 pivotally supported so as to sandwich the wire 13, and a second encoder 73 for detecting the rotation angle of one of the rollers 71.

[0054] Furthermore, the housing 19 houses a controller 46 that controls the winding motor 14, which constitutes the core rotation unit, or the guide motor 54 in the guide mechanism 51. This controller 46 houses a CPU that controls the winding operation performed by the winding device 10, and a memory 46a, which serves as a storage unit and stores information and data required for the CPU's processing operations. The memory 46a stores, for example, a predetermined angular velocity ω, which will be described later. Furthermore, an input device 46b is connected to the controller 46 for inputting this information.

[0055] 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 so-called aligned winding, which is to drive the winding motor 14 to rotate the core 12 at a constant speed, and control the guide motor 54 so that each time the core 12 rotates one circle, 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, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 while being in close contact with the core 12.

[0056] Furthermore, 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.

[0057] On the other hand, the unwinding motor 26 in the wire unwinding mechanism 21 is configured so that the rotation speed of its rotating shaft 26a can be changed. The capstan 24 driven by the unwinding motor 26 is configured so that the unwinding speed of the wire 13 is changed 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 winding speed of the wire 13 wound on the rotating winding core 12.

[0058] Specifically, the controller 46 is provided with a calculation circuit 46c as a calculation unit. The calculation circuit 46c is configured to calculate the winding speed of the wire 13 wound around the rotating core 12 based on the information or data stored in the memory 46a. In addition, based on the calculated winding speed calculated by the calculation circuit 46c, the controller 46 controls the winding motor 14 and the wire unwinding mechanism 21 so that the wire 13 is supplied to the core 12 at a speed equal to the winding speed of the wire 13 wound around the rotating core 12.

[0059] In this embodiment, since the unwinding speed detection sensor 70 or the winding speed detection sensor 60 is provided, the detection outputs of the first encoder 63 and the second encoder 73 are connected to the control input of the controller 46. In addition, the controller 46 detects the measured unwinding speed or the measured winding speed and performs feedback control so that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the winding speed.

[0060] Next, the winding method of the present invention using the above-mentioned winding device will be described.

[0061] The 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 given tension by the tensioning device 31 around the winding core 12 .

[0062] Since the above-mentioned winding device 10 is used, Figure 1 As shown, the wire 13 is stored in the form of being wound around 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 around the capstan 24 and the auxiliary pulley 25 that constitute the wire unwinding mechanism 21.

[0063] The wire 13 extending from the capstan 24 is routed so that its direction is sequentially changed by the first deflection pulley 32 and the second deflection pulley 33, and is wound around the guide pulley 34 in the tensioning device 31 before reaching the winding machine 11. In the winding machine 11, the wire 13 passing through the guide member 53 is secured to the winding core 12.

[0064] 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 ( Figure 10 ) and the 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 is started from this state.

[0065] During actual winding, the controller 46 drives the winding motor 14 to rotate the winding core 12 at a constant speed. The rotation angle is detected by the rotation angle sensor 16 and fed back to the controller 46 .

[0066] In addition, in the guide mechanism 51, as shown in FIG. Figure 10 as well as Figure 11 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 corresponding to the outer diameter of the wire 13. In this way, the wire supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 is arranged and wound on the winding core 12.

[0067] The characteristic point of the winding method of the present invention is that the winding speed of the wire 13 wound on the winding core 12 is calculated in advance to obtain a calculated winding speed, and the wire 13 is unwound from the wire winding mechanism 21 at a speed equal to the calculated winding speed.

[0068] 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, Figure 7 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 this cross section, 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. Figure 7 As shown in (b), the speed (vertical axis) of the wire 13 wound around the core 12 varies so as to generate inflection points aω, bω, cω, bω, aω, . . . with respect to the rotation angle (horizontal axis) of the core 12.

[0069] 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 speed of the wire 13 wound on the core 12 can be calculated by multiplying it by the rotational angular velocity ω of the core 12.

[0070] 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 the wire 13 to be directly wound (i.e., the information related to the winding core 12) is stored in the memory 46a, the calculation circuit 46c in the controller 46 obtains the angular velocity of the winding core 12 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 for the wire 13 to be wound by the angular velocity of the winding core 12. Figure 7 (b) Calculated take-up speed shown.

[0071] In addition, the controller 46 controls the winding motor 14 in such a manner that the winding motor 14 is driven and the winding core 12 is rotated at a predetermined angular velocity ω, and controls the unwinding motor 26 in the wire unwinding mechanism 21 in such a manner that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed obtained by the operation circuit 46c.

[0072] Here, in the winding device 10, there are provided a winding speed detection sensor 70 for detecting the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tensioning device 31, and a winding speed detection sensor 60 for detecting the speed of the wire 13 after passing through the tensioning device 31. Figure 3 (a) shows a case where the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed. Figure 3 (b) The measured unwinding speed of the wire 13 from the wire unwinding mechanism 21, and Figure 3 (c) shows the measured winding speed of the wire 13 onto the winding core 12.

[0073] Here, when the wire 13 is wound around the winding core 12 having a non-circular cross section such as a rectangle, the winding speed of the wire 13 wound on the winding core 12 changes. Therefore, when the unwinding speed of the wire 13 from the wire unwinding mechanism 21 is set to be constant as in the conventional art, Figure 1 As shown by the dotted arrow in FIG, the guide pulley 34 periodically vibrates, and the tension applied to the wire 13 fluctuates due to the vibration.

[0074] In contrast, in the present invention, Figure 3As shown in (a), the wire 13 is supplied from the wire unwinding mechanism 21 to the winding core 12 at a speed equal to the winding speed of the wire 13 wound on the winding core 12. Therefore, when Figure 3 As shown in (c), when the winding speed of the wire 13 wound on the winding core 12 increases, Figure 3 As shown in (b), the supply speed of the wire 13 from the wire winding mechanism 21 also increases with this increase. Similarly, when the winding speed of the winding core 12 decreases, the supply speed of the wire 13 from the wire unwinding mechanism 21 also decreases.

[0075] In this way, when the supply speed of the wire 13 from the wire unwinding mechanism 21 is consistent with the winding speed of the wire 13 of the winding core 12, Figure 1 The periodic vibration of the guide pulley 34 indicated by the dotted arrow 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.

[0076] 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 direction of the rotation axis of the winding core 12, thereby arranging the wires 13 and winding them around the winding core 12. When the wires 13 are wound around the winding core 12 in a multi-layer manner, as shown in FIG. Figure 10 As shown, when the first layer of winding to the winding body portion 12a is completed, the second layer of winding is implemented on the periphery of the first layer of wire 13, as shown in FIG. Figure 11 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.

[0077] In this way, when the wire material 13 is wound in multiple layers on the winding body 12a, as shown in FIG. Figure 8 as well as Figure 9 As shown, the length from the rotation center O of the core 12 to each part for winding the wire 13 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.

[0078] Specifically, if Figure 7 As shown, in the case of the first layer, if the length from the rotation center O of the winding core 12 to each portion where the wire 13 is wound is the outer peripheral shape of the cross section of the winding core 12 itself. Figure 8 As shown, 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. Figure 9 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.

[0079] The data of the wire diameter d of the wire material 13 and the winding width w of the winding body portion 12a, which are added to the cross-sectional shape of the winding core 12, are stored in advance in the memory 46a. 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.

[0080] In addition, if the second layer of winding is Figure 8 As shown in FIG, the lengths (a+d), (b+d), and (c+d) from the rotation center O of the winding core 12 to each portion where the wire 13 is wound are obtained. If the winding of the third layer is obtained, then Figure 9 As 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 the respective locations around which the wire 13 is wound are determined. Then, by multiplying the angular velocity ω of the rotating winding core 12 by the above-mentioned lengths (a+d), (b+d), (c+d), (a+2d), (b+2d), and (c+2d), the calculated winding speed ( Figure 8 (b) Figure 9 (b)).

[0081] 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 winding speed for each layer obtained by the calculation.

[0082] Thus, even after the second layer, the unwinding speed (unwinding amount) of the wire 13 in the wire unwinding mechanism 21 is controlled to balance the winding speed (winding amount) of the wire 13 on the winding core 12 .

[0083] This suppresses periodic vibration of the guide pulley 34 in the tensioner 31 even after the second layer.

[0084] Here, in actual winding, the controller 46 detects the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tensioning device 31, and the speed of the wire 13 toward the winding core through the tensioning device 31. In addition, the unwinding motor 26 is controlled in a manner to eliminate the offset in the time axis direction between the speed change state of the detected measured unwinding speed and the speed change state of the measured winding speed, and the wire 13 is unwound from the wire unwinding mechanism 21.

[0085] That is, in the present invention, the speed of the wire wound by the winding core 12 is calculated in advance, and the unwinding motor 26 is controlled in such a manner that the wire 13 is supplied from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed. Figure 3 As shown, originally, there is no deviation in the time axis direction between the winding and unwinding speeds of the wire rod 13 .

[0086] When the rotation speed of the winding core 12 is increased, the supply speed of the wire 13 from the wire unwinding mechanism 21 changes at a relatively fast rate. Therefore, even if the controller 46 controls the unwinding motor 26 based on the calculated winding speed, there may be a deviation between the actual winding speed of the wire 13 wound on the winding core 12 and the supply amount of the wire 13 supplied by driving the unwinding motor 26.

[0087] Here, the actual speed of the wire 13 being unwound from the wire unwinding mechanism 21 toward the tensioning device 31 is detected by the unwinding speed detection sensor 70, and the actual winding speed of the wire 13 being wound around the winding core 12 is detected by the winding speed detection sensor 60. Thus, the controller 46 constantly compares the state of speed change of the measured winding speed, determined by the detection output of the winding speed detection sensor 60, with the state of speed change of the measured unwinding speed, determined by the detection output of the unwinding speed detection sensor 70. Furthermore, the unwinding motor 26 is controlled in such a manner that the time axis offset between the detected state of speed change of the measured unwinding speed and the detected state of speed change of the measured winding speed is eliminated, and the wire 13 is unwound from the wire unwinding mechanism 21.

[0088] Specifically, when Figure 4 The measured winding speed shown by the solid line in (c) and Figure 4 When a time axis offset T occurs between the speed changes of the measured unwinding speeds shown by the dot-dash line in (b), the controller 46 obtains the time axis offset T. Figure 4 The offset 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.

[0089] In this regard, the controller 46 in this embodiment includes a speed correction unit that calculates the time axis offset T of the speed changes of the measured winding speed and the measured unwinding speed and subtracts the offset T from the calculated winding speed to obtain a corrected winding speed.

[0090] In addition, the controller 46 follows the obtained Figure 4 (a) shows the correction winding speed and controls the unwinding motor 26. Figure 4The unwinding motor 26 is controlled in a state where the calculated winding speed shown by the solid line in (a) is advanced by the amount of the offset T. Figure 4 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 actually supplied from the wire unwinding mechanism 21 are as follows: Figure 4 (b) is consistent with the solid line.

[0091] Thus, even when the rotation speed of the winding core 12 is increased and the winding speed onto the winding core 12 is changed at a relatively high speed, the supply speed of the wire 13 from the wire unwinding mechanism 21 can follow the speed change.

[0092] This eliminates the discrepancy between the actual winding speed of the wire 13 wound on the winding core 12 and the amount of wire 13 supplied by the unwinding motor 26, thereby preventing periodic vibration of the guide pulley 34 in the tensioning device 31. Consequently, even if the rotation speed of the winding core 12 is increased, the elastic member 35 can apply a constant tension that is consistent with the position of the guide pulley 34.

[0093] 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 above-mentioned 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 supply amount of the wire and the wire winding amount are inconsistent.

[0094] In this way, in the tensioning device 31, the guide pulley 34 around which the wire 13 is wound moves along the rail 36, thereby changing the distance 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 take-up 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.

[0095] Here, when the guide pulley 34 moves, the tension applied to the wire 13 gradually changes. Consequently, when the position change of the guide pulley 34 is detected by the detection output of the position sensor 45, the controller 46 increases or decreases the calculated winding speed, which is the supply amount of the wire 13, at a constant ratio so that the guide pulley 34 returns to a predetermined position on the track 36, such as approximately the center. The controller 46 then controls the rotational speed of the unwinding motor 26 based on the corrected winding speed after this increase or decrease. This balances the unwinding speed of the wire 13 in the wire unwinding mechanism 21 with the winding speed of the winding core 12.

[0096] That is, if Figure 5As 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, as shown in Figure 5 As shown in (b), the calculated winding speed is increased at a constant ratio in such a way that the unwinding amount of the wire 13 implemented by the wire unwinding mechanism 21 increases, and a corrected winding speed that is substantially consistent with the measured winding speed is obtained. Based on the corrected winding speed after the increase, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21, so that Figure 5 As shown in (c), the measured unwinding speed is made consistent with the measured winding speed.

[0097] On the other hand, if Figure 6 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 6 As shown in (b), the calculated winding speed is reduced at a constant rate by reducing the amount of wire 13 unwound by the wire unwinding mechanism 21, and a corrected winding speed that is substantially consistent with the measured winding speed is obtained. Based on the corrected winding speed after the reduction, the controller 46 controls the unwinding motor 26 in the wire unwinding mechanism 21, so that Figure 6 As shown in (c), the measured unwinding speed is made consistent with the measured winding speed.

[0098] 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.

[0099] According to this embodiment, the following effects are achieved.

[0100] The winding device 10 involved in this embodiment includes: a core 12; a wire unwinding mechanism 21, which supplies the wire 13 to the core 12 in a manner that the supply speed can be changed; a tensioning device 31, which applies tension to the wire 13 supplied from the wire unwinding mechanism 21 to the core 12; a winding motor 14, which rotates the core 12 so that the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 is wound on the core 12; a controller 46, which controls the wire unwinding mechanism 21 in a manner that supplies the wire 13 at a speed equal to the winding speed of the wire 13 wound on the rotating core 12.

[0101] In addition, the winding method involved in this embodiment rotates the core 12, thereby winding the wire 13 supplied from the wire unwinding mechanism 21 and given tension by the tensioning device 31 around the core 12, calculates the winding speed of the wire 13 wound around the core 12 to obtain a calculated winding speed, and unwinds the wire 13 from the wire unwinding mechanism 21 at a speed equal to the calculated winding speed.

[0102] According to the above structure, since the wire 13 is unwound from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13 wound on the core 12, even if it is assumed that the tensioning device 31 has a component such as a guide pulley 34 that is hung with the wire 13 and moves due to the elastic component 35, it is possible to prevent the movement of the guide pulley 34 caused by the speed change of the wire 13.

[0103] In this way, since the change in the tension of the wire caused by the movement of components such as the guide pulley 34 can be 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 cores of different diameters changes significantly.

[0104] In addition, in the winding device 10 involved in this embodiment, the wire unwinding mechanism 21 includes: a capstan 24, which is used to wind the wire 13 supplied from the reel 18; a unwinding motor 26, which rotates the capstan 24 to supply the wound wire 13 to the winding core 12, and the controller 46 controls the unwinding motor 26 in a manner that supplies the wire 13 at a speed equal to the winding speed of the wire 13.

[0105] In addition, in the winding method involved in this embodiment, the unwinding motor 26 is used to rotate the capstan 24 on which the wire 13 supplied from the reel 18 is hung, so that the wire 13 is supplied to the core 12, and the unwinding motor 26 is controlled in such a manner that the speed of the wire 13 supplied to the core 12 due to the rotation of the capstan 24 is consistent with the calculated winding speed.

[0106] According to the above configuration, by controlling the unwinding motor 26 that rotates the capstan 24, the speed of the wire 13 supplied to the winding core 12 due to the rotation of the capstan 24 can be made consistent with the calculated winding speed. As a result, the wire 13 can be supplied from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13.

[0107] In addition, the winding device 10 involved in this embodiment is also equipped with: a memory 46a, which stores information related to the core 12; an operation circuit 46c, which calculates the winding speed of the wire 13 wound on the core 12 based on the information related to the core 12, 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 unwinding motor 26 in a manner that supplies the wire 13 according to the calculated winding speed calculated by the operation circuit 46c.

[0108] In addition, in the winding method involved in this embodiment, the memory 46a stores information related to the core 12, and the calculation circuit 46c is used to calculate the winding speed of the wire 13 wound on the core 12 based on the information related to the core 12, and the unwinding motor 26 is controlled in a manner to supply the wire 13 according to the calculated winding speed calculated by the calculation circuit 46c. The tensioning device 31 has: a guide pulley 34, on which the wire 13 is hung; and an elastic component 35, which applies force to the guide pulley 34.

[0109] According to the above structure, the supply speed of the wire 13 from the wire unwinding mechanism 21 and the winding speed of the wire 13 wound on the winding core 12 are made consistent, thereby eliminating the periodic vibration of the guide pulley 34 and maintaining the tension of the wire 13 supplied to the winding core 12 at a constant level. As a result, a high-quality coil can be manufactured.

[0110] In addition, the winding device 10 involved in this embodiment is also equipped with: a unwinding speed detection sensor 70, which detects the speed of the wire 13 unwound from the wire unwinding mechanism 21 toward the tensioning device 31; a winding speed detection sensor 60, which detects the speed of the wire 13 passing through the tensioning device 31 toward the winding core 12, and the controller 46 controls the unwinding motor 26 in a manner that eliminates the offset in the time axis direction between the state of speed change of the measured winding speed determined by the detection output of the winding speed detection sensor 60 and the state of speed change of the measured unwinding speed determined by the detection output of the unwinding speed detection sensor 70.

[0111] In addition, in the winding method involved in this embodiment, the unwinding speed of the wire 13 from the wire unwinding mechanism 21 toward the tensioning device 31 and the winding speed of the wire 13 wound by the winding core 12 through the tensioning device 31 are detected, and the wire 13 is unwound from the wire unwinding mechanism 21 in a manner that eliminates the offset in the time axis direction between the speed change state of the detected measured unwinding speed and the speed change state of the measured winding speed.

[0112] According to the above configuration, even when the rotational speed of the winding core 12 is increased, causing the winding speed onto the winding core 12 to change at a relatively rapid rate, the supply speed of the wire 13 from the wire unwinding mechanism 21 can be adjusted to follow this speed change. Consequently, the difference between the actual winding speed of the wire 13 wound onto the winding core 12 and the amount of wire 13 supplied by the unwinding motor 26 is eliminated, thereby preventing periodic vibration of the guide pulley 34 in the tensioning device 31. Therefore, even when the rotational speed of the winding core 12 is increased, the elastic member 35 can apply a constant tension that remains constant according to the position of the guide pulley 34.

[0113] 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 configured as follows. Figure 12 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 distal end of the tension arm 4 .

[0114] Even if Figure 12 The tensioning device shown with the tension arm 4 can also prevent the movement of the guide pulley 5 associated with changes in the speed of the wire 13 wound around the winding core 12 when the wire is unwound from the wire unwinding mechanism 21 at a speed equal to the winding speed of the wire 13 wound around the winding core 12. As a result, since changes in the wire tension associated with the movement of the guide pulley 5 are avoided, the tension of the wire wound around the winding core 12 can be maintained constant.

[0115] In the above embodiment, the elastic member 35 that urges the guide pulley 34 in the tensioner 31 is illustrated as a coil spring. However, a fluid pressure cylinder that utilizes fluid pressure, such as air pressure, to urge the rod in the direction of sinking or protruding can also be used as the elastic member. When such a fluid pressure cylinder is used as the elastic member, the elastic force can be easily changed by varying the fluid pressure, such as compressed air, in the cylinder.

[0116] In the above embodiment, the controller 46 is provided with a calculation circuit 46c, and the calculation circuit 46c calculates the winding speed from the information or data stored in the memory 46a. However, the calculation circuit 46c may be omitted, and the winding speed may be calculated separately from the controller 46 in advance, and the memory 46a may store the calculated winding speed.

[0117] In this case, the controller 46 controls the unwinding motor 26 to supply the wire 13 according 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.

[0118] 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 are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

[0119] This application claims priority based on Japanese Patent Application No. 2020-004193 filed with the Japan Patent Office on January 15, 2020, the entire contents of which are incorporated herein by reference.

[0120] (Explanation of Reference Numerals)

[0121] 10: Winding device

[0122] 12: Core

[0123] 13: Wire

[0124] 14: Winding motor (core rotation unit)

[0125] 18: Reel (wire source)

[0126] 21: Wire unwinding mechanism

[0127] 24: Winch

[0128] 26: Unwinding motor

[0129] 31: Tensioning device

[0130] 46: Controller

[0131] 46a: Memory (storage unit)

[0132] 46c: Arithmetic circuit (arithmetic unit)

[0133] 60: Winding speed detection sensor (winding speed detection unit)

[0134] 70: Unwinding speed detection sensor (unwinding speed detection unit)

Claims

1. A winding device comprising: A core having a rectangular cross section; a wire unwinding mechanism that feeds the wire to the winding core at a variable feeding speed; 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 that controls the wire unwinding mechanism so as to supply the wire at a speed equal to a calculated winding speed of the wire wound around the rotating winding core, The calculated winding speed is calculated based on the length from the rotation center of the core to the long side of the core, the length from the rotation center of the core to the short side of the core, the distance from the rotation center of the core to the corner of the core, the rotational angular velocity of the core, and the wire diameter of the wire.

2. The winding device according to claim 1, wherein The wire unwinding mechanism comprises: a capstan on which the wire supplied from a wire source is wound; a drive unit for unwinding that rotates the capstan to supply the wound wire to the winding core, The controller controls the unwinding drive unit so as to supply the wire rod at a speed equal to the calculated winding speed of the wire rod.

3. The winding device according to claim 2, wherein further comprising a storage unit configured to store the calculated winding speed, which is the winding speed of the wire wound around the rotating winding core; The tensioning device comprises: a guide pulley for the wire to be hung around; a force applying unit, which applies force to the guide pulley, The controller controls the unwinding drive unit so as to supply the wire rod according to the calculated winding speed stored in the storage unit.

4. The winding device according to claim 2, wherein Also features: a storage unit for storing information related to the winding core; a calculation unit, which calculates the winding speed, The tensioning device comprises: a guide pulley for the wire to be hung around; a force applying unit, which applies force to the guide pulley, The controller controls the unwinding drive unit so as to supply the wire rod according to the calculated winding speed calculated by the calculation unit.

5. The winding device according to any one of claims 2 to 4, wherein Also features: an unwinding speed detection unit for detecting a speed of the wire being unwound from the wire unwinding mechanism toward the tensioning device; a winding speed detection unit for detecting the speed of the wire material passing through the tensioning device toward the winding core, The controller controls the unwinding drive unit in such a manner 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.

6. A winding method comprising rotating a winding core having a rectangular cross section so as to wind a wire supplied from a wire unwinding mechanism and having tension applied by a tensioning device around the winding core. The winding speed of the wire wound on the core is calculated based on the length from the rotation center of the core to the long side of the core, the length from the rotation center of the core to the short side of the core, the distance from the rotation center of the core to the corner of the core, the rotational angular velocity of the core, and the wire diameter of the wire, thereby obtaining a calculated winding speed. The wire is unwound from the wire unwinding mechanism at a speed equal to the calculated winding speed.

7. The winding method according to claim 6, wherein: The unwinding drive unit rotates a capstan around which the wire supplied from the wire source is wound, thereby supplying the wire to the winding core. The unwinding drive unit is controlled so that a speed of the wire material supplied to the winding core due to the rotation of the capstan matches the calculated winding speed.

8. The winding method according to claim 7, wherein: causing a storage unit to store the calculated winding speed, controlling the unwinding drive unit so as to supply the wire rod according to the calculated winding speed stored in the storage unit, The tensioning device comprises: a guide pulley for the wire to be hung around; A force applying unit applies force to the guide pulley.

9. The winding method according to claim 7, wherein: causing the storage unit to store information related to the winding core, Calculate the winding speed using the calculation unit, controlling the unwinding drive unit so as to supply the wire rod according to the calculated winding speed calculated by the calculation unit, The tensioning device comprises: a guide pulley for the wire to be hung around; A force applying unit applies force to the guide pulley.

10. The winding method according to any one of claims 6 to 9, wherein: detecting a speed of unwinding the wire from the wire unwinding mechanism toward the tensioning device and a speed of winding the wire by the winding core after passing through the tensioning device, The wire is unwound from the wire unwinding mechanism so that a shift in the time axis direction between a detected state of speed change of the actually measured unwinding speed and a detected state of speed change of the actually measured winding speed is eliminated.

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