Wire winding device and wire winding method

Abstract

A winding device (20) is provided with: a rotating plate (27) that is rotationally driven by an electric motor (26); a pair of columnar members (28, 29) that are provided to the rotating plate (27) in a manner so as to straddle a rotation center axis (C) of the rotating plate (27); winding cores (39) that are respectively mounted to the pair of columnar members (28, 29); and a holding mechanism (43) that is capable of changing and holding a distance between the pair of columnar members (28, 29), the pair of columnar members (28, 29) being provided to the rotating plate (27) in a manner so as to be respectively movable along a straight line that intersects the rotation center axis (C) of the rotating plate (27), the respective distances from the rotation center axis (C) of the rotating plate (27) to the pair of columnar members (28, 29) being held in an equal manner by the holding mechanism (43).

Description

Technical Field

[0001] This invention relates to a winding device and a winding method. Background Technology

[0002] Existing generator and motor mounting components include: a cylindrical stator core having multiple pole teeth (magnetic poles) arranged radially and protruding in the inner diameter direction, and multiple slots opening between the pole teeth; and a stator coil, which is assembled to the stator core by accommodating the coil edges in the slots. Regarding the assembly of the stator core, a so-called insertion method is known, in which the stator coil is prefabricated separately from the stator core, and then the coil is accommodated in the slots of the core (for example, see Japanese Patent Application Laid-Open JP2000-245120A).

[0003] When a coil used in the insertion method is made by winding wire using a winding device, in order to converge the resistance value of the coil to the design value of the generator and motor, the following adjustment is made: by lengthening or shrinking the length of the portion of the coil protruding from the end face of the stator core (the coil end), the total length of the wire is increased or decreased, and the resistance value of the coil is converged to the design value.

[0004] Furthermore, due to inherent deviations in the standard for wire, for example, even wires manufactured within the same timeframe may exhibit variations in coil resistance. Therefore, in the winding device, the wire tension is adjusted to match the designed coil resistance value. However, when the wire resistance varies significantly, it may be impossible to set the coil resistance to the design value solely through wire tension adjustment; it may be necessary to modify the shape of the winding core and thus change the length of the wire wound around it. Summary of the Invention

[0005] When changing the shape of the winding core, multiple cores with different shapes need to be prepared, and the already installed cores need to be replaced with other cores. Since the winding position is different when changing the core, winding adjustments need to be made by changing the winding program each time the core is changed, which is time-consuming.

[0006] The purpose of this invention is to provide a winding device and a winding method that can easily change the length of the wound wire.

[0007] According to one aspect of the present invention, a winding device winds wire in a rotating core, comprising: a rotating plate driven to rotate by a drive mechanism; a pair of columnar members disposed on the rotating plate such that they are spaced apart from the rotational central axis of the rotating plate; the core, which is respectively mounted on the pair of columnar members; and a retaining mechanism capable of changing and retaining the spacing between the pair of columnar members, wherein the pair of columnar members are disposed on the rotating plate such that they are respectively movable along a straight line intersecting the rotational central axis of the rotating plate, and the respective distances from the rotational central axis of the rotating plate to the pair of columnar members are maintained equally by the retaining mechanism.

[0008] According to another aspect of the invention, a winding method uses a device having a rotating plate, a pair of columnar members, and a winding core to perform winding. The rotating plate is driven to rotate by a drive mechanism. The pair of columnar members are disposed on the rotating plate in such a way that they are each movable along a straight line intersecting the rotational central axis of the rotating plate. The winding cores are respectively mounted on the pair of columnar members. In the winding method, after adjusting the interval between the pair of columnar members, the rotating plate is rotated while maintaining the distances from the rotational central axis of the rotating plate to the pair of columnar members in such a way that they are equal, thereby winding the wire into the winding cores that rotate together with the pair of columnar members. Attached Figure Description

[0009] Figure 1 This is an enlarged front view of the winding core portion of the winding device in this embodiment.

[0010] Figure 2 This is an enlarged front view of the winding core portion of the winding device in this embodiment, showing the state after the spacing between the pair of columnar members has been widened.

[0011] Figure 3 A diagram showing the first core moving mechanism, and is Figure 6 CC-line sectional view.

[0012] Figure 4 for Figure 1 A sectional view along line AA.

[0013] Figure 5 for Figure 1 EE line section view.

[0014] Figure 6 for Figure 1 BB line section view.

[0015] Figure 7 This is a front view of the winding device in this embodiment.

[0016] Figure 8 This is a front view of the winding device in this embodiment, showing the initial winding state in which the wire clamp holds the end of the wire.

[0017] Figure 9 This is a front view of the winding device in this embodiment, showing the state in which the wire is wound around the inner core to form an inner coil.

[0018] Figure 10 This is a front view of the winding device in this embodiment, showing the state in which the wire is wound around the first outer core to form the middle coil.

[0019] Figure 11 This is a front view of the winding device in this embodiment, showing the state in which the wire is wound around the second outer core to form an outer coil.

[0020] Figure 12 for Figure 9 DD-line sectional view.

[0021] Figure 13 for Figure 10 FF line section view.

[0022] Figure 14 for Figure 11 GG line sectional view. Detailed Implementation

[0023] Hereinafter, the winding device 20 according to this embodiment will be described with reference to the accompanying drawings.

[0024] exist Figures 1 to 7 The winding device 20 according to this embodiment is shown in the figure. Here, the three axes X, Y, and Z are set to be orthogonal to each other. The X-axis extends in the horizontal direction, the Y-axis extends in the horizontal front-back direction, and the Z-axis extends in the vertical direction.

[0025] The winding device 20 pairs of stator coils 12 used in the stator of a three-phase AC generator (not shown) Figure 14 The winding device 20 is adapted to wind the coil edges 13a, 14a, and 15a of the stator coil 12. Figure 14 The stator coil 12 is manufactured by inserting it into the slots in the stator (not shown).

[0026] Stator coil 12 forms a winding layer. Stator coil 12 makes the coil edges 13a, 14a, 15a ( Figure 14 ) are inserted into three adjacent slots of the stator (not shown), and have three consecutive coils of different sizes (large, medium, and small) with different spacing between their coil edges.

[0027] like Figure 1as well as Figure 7 As shown, the winding device 20 includes: a rotating plate 27, which is driven to rotate by an electric motor 26 as a drive mechanism; a pair of columnar members 28 and 29, which are disposed on the rotating plate 27 with respect to the rotation center axis C of the rotating plate 27; and a winding core 39, which is respectively mounted on the pair of columnar members 28 and 29. The winding device 20 winds the wire 16 into the winding core 39, which rotates together with the pair of columnar members 28 and 29 by the electric motor 26, thereby producing a stator coil 12. Figure 14 ).

[0028] Wire 16 is a coated conductor and uses a so-called round wire with a circular cross-section. Alternatively, wire 16 can also be a so-called angle wire with a square cross-section. Wire 16 is unwound from wire unwinding member 31.

[0029] The wire 16 is stored in a manner that is wound on a spool (not shown). The wire 16, drawn from the spool, is stretched straight by a stretching machine (not shown) and then guided to the wire unwinding unit 31.

[0030] like Figure 7 As shown, the wire unwinding member 31 is a rod-shaped member with holes through which the wire 16 passes. The wire unwinding member 31 is mounted on the lower worktable 23 by a wire unwinding member moving mechanism 32 that enables the wire unwinding member 31 to move in three axial directions.

[0031] The wire unwinding component moving mechanism 32 has square telescopic actuators 33-35 along the X, Y, and Z axes. Each telescopic actuator 33-35 has a ball screw 33b-35b driven by a servo motor 33a-35a, and a driven member 33c-35c that is screwed into the ball screw 33b-35b and moves parallel to it.

[0032] The follower 35c of the Z-axis telescopic actuator 35 is movable in the vertical direction, and the housing 35d is mounted on the follower 33c of the X-axis telescopic actuator 33. The follower 33c of the X-axis telescopic actuator 33 is movable in the X-axis direction, and the housing 33d is mounted on the follower 34c of the Y-axis telescopic actuator 34.

[0033] The follower 34c of the Y-axis telescopic actuator 34 is movable in the Y-axis direction, and the housing 34d extends in the Y-axis direction and is mounted on the lower worktable 23. A wire unwinding member 31 is mounted on the follower 35c of the Z-axis telescopic actuator 35 in a manner that extends in the X-axis direction.

[0034] In addition, a gripping mechanism (not shown) is provided on the wire unwinding member 31 to grip the wire 16 unwound from the wire unwinding member 31.

[0035] like Figure 1 As shown, the rotating plate 27 is configured to rotate in a horizontal plane, mounted coaxially with the rotation axis 26a of the electric motor 26 at its center. Furthermore, a pair of columnar members 28 and 29 are disposed on the rotating plate 27, separated from its rotational central axis C. The pair of columnar members 28 and 29 are disposed on the rotating plate 27 such that they are each movable along a straight line intersecting the rotational central axis C of the rotating plate 27. Specifically, the pair of columnar members 28 and 29 are each movable along a straight line orthogonal to the rotational central axis C of the rotating plate 27.

[0036] The rotating plate 27 is circular and is horizontally positioned with a rotating shaft 26a of an electric motor 26 mounted at its center. A track 41 is mounted on the lower surface of the rotating plate 27, orthogonal to the central axis of rotation C.

[0037] A pair of columnar components 28 and 29 are arranged parallel to the rotation center axis C of the vertically extending rotating plate 27. Each of these components has a movable block 42 mounted on its upper part, which engages with the track 41 and is capable of reciprocating along the long side of the track 41. By engaging the movable blocks 42 with the track in a movable manner, the pair of columnar components 28 and 29 can move along a straight line intersecting the rotation center axis C of the rotating plate 27.

[0038] The winding device 20 also includes a retaining mechanism 43 that can change and maintain the spacing between a pair of columnar members 28, 29. The distances from the rotation center axis C of the rotating plate 27 to the pair of columnar members 28, 29 are maintained in an equal manner by the retaining mechanism 43.

[0039] The holding mechanism 43 includes: a movable plate 48, which is disposed on the rotation center axis C of the rotating plate 27 and is movable along the direction of the rotation center axis C of the rotating plate 27; a pair of wedge members 44, 44, which have inclined surfaces opposite to a pair of columnar members 28, 29 and are disposed on both sides of the movable plate 48 in a manner that is separated from the rotation center axis C of the rotating plate 27; and a wedge moving mechanism 45, which moves the pair of wedge members 44, 44 together with the movable plate 48 along the direction of the rotation center axis C of the rotating plate 27.

[0040] like Figure 1 as well as Figure 5As shown, a transverse member 50a extending in the diametrical direction of the rotating plate 27 is provided at the upper end of a movable plate 48 on both sides, which has a pair of wedge members 44, 44 installed on both sides. The lower ends of longitudinal members 50b that can move through the rotating plate 27 are installed at both ends of the transverse member 50a. At the upper end of the longitudinal member 50b that protrudes upward toward the rotating plate 27, an annular operating plate 51 that surrounds the rotating shaft 26a of the electric motor 26 is installed in a manner coaxial with the rotating shaft 26a.

[0041] like Figure 7 As shown, multiple support columns 21, arranged to surround the rotating plate 27, support the lower worktable 23, and horizontally support the upper worktable 22 above the rotating plate 27. An electric motor 26 is mounted on the upper worktable 22 with the rotation axis 26a pointing downwards.

[0042] like Figures 1-3 As shown, a control motor 46 constituting the wedge movement mechanism 45 is provided on the upper surface of the upper worktable 22. The control motor 46 can control the rotational speed of its rotating shaft 46a, and a pair of motors 46a are provided with the rotating shaft 46a facing downwards, separated from the electric motor 26. A male thread 47 is provided on the rotating shaft 46a. In addition, an annular control member 49 surrounding the rotating shaft 26a of the electric motor 26 is provided above the operation plate 51, coaxial and parallel to the operation plate 51. The control member 49 is screwed into the male thread 47 and connected to the movable plate 48.

[0043] A engaging member 52 is provided on the control unit 49, which engages with the periphery of the operation plate 51. When the control motor 46 drives the male thread 47 to rotate, the control unit 49, which is engaged with the male thread 47, moves up and down in the direction (Z-axis direction) along the rotation center axis C of the rotating plate 27 by an amount corresponding to the rotational speed of the male thread 47. In this way, the engaging member 52 moves up and down together with the control unit 49.

[0044] When the engaging member 52 and the control member 49 move up and down together, the operating plate 51 and the movable plate 48 move up and down together via the engaging member 52. This causes a pair of wedge members 44, 44, located on both sides of the movable plate 48, to move up and down simultaneously in the same direction at the same speed. Thus, the pair of wedge members 44, 44, move according to the rotation of the control motor 46 via the control member 49, thereby enabling them to move along the direction of the rotation center axis C of the rotating plate 17 with the movable plate 48.

[0045] A pair of wedge components 44, 44 are symmetrically arranged on the movable plate 48 with respect to the rotation center axis C of the rotating plate 27.

[0046] The wedge member 44 includes: a triangular plate 44a as an inclined member, having an inclined surface; and a track 44b disposed on the inclined surface. The triangular plate 44a extends in the direction of the rotation center axis C of the rotating plate 27 and is mounted on the movable plate 48, with its inclined surface facing one of the pair of columnar members 28 and 29. That is, the pair of wedge members 44 and 44 are composed of a pair of triangular plates 44a and 44a and a pair of tracks 44b and 44b, with the inclined surfaces of the pair of triangular plates 44a and 44a facing the pair of columnar members 28 and 29, respectively. The inclined surfaces of the pair of triangular plates 44a and 44a are formed such that the closer they are to the upper end of the movable plate 48, the wider they expand radially outward from the movable plate 48 towards the rotating plate 27, and the closer they are to each other, the closer they are to the lower end of the movable plate 48. In addition, the pair of tracks 44b and 44b are disposed along the inclined surfaces of the pair of triangular plates 44a and 44a, respectively. On a pair of columnar members 28 and 29, movable blocks 28a and 29a, which are movable along the extension direction of track 44b, are mounted via auxiliary plates 28b and 29b. The movable blocks 28a and 29a are fixed to the pair of columnar members 28 and 29 in a non-movable manner via the auxiliary plates 28b and 29b.

[0047] Therefore, when the control motor 46 is driven, the movable plate 48 moves vertically together with the pair of wedge members 44, 44, and the moving blocks 28a, 29a move radially along the inclination of the track 44b on the rotating plate 27. This causes the pair of columnar members 28, 29, to which the moving blocks 28a, 29a are fixed, to move radially on the rotating plate 27, and the interval between the pair of columnar members 28, 29 changes.

[0048] For example, when it rises from the movable plate 48 Figure 1 From the state shown, as Figure 2 As the movable plate 48 moves downwards, as indicated by the solid arrow, the moving blocks 28a and 29a move towards the upper end of the movable plate 48 and upwards. Since the pair of tracks 44b are formed such that the further towards the upper end of the movable plate 48, the wider they expand radially outwards from the movable plate 48 towards the rotating plate 27, the moving blocks 28a and 29a, as well as the pair of columnar members 28 and 29, move radially outwards from the rotating plate 27. This widens the gap between the pair of columnar members 28 and 29. Conversely, when the movable plate 48 moves downwards as indicated by the solid arrow, the moving blocks 28a and 29a move towards the upper end of the movable plate 48 and upwards. Figure 2 When the movable blocks 28a and 29a move upward as shown by the dashed arrow, they move toward the lower end of the movable plate 48 and downward. This reduces the gap between the pair of columnar members 28 and 29.

[0049] Furthermore, the movable plate 48 is mounted on the rotation center axis C, and the pair of wedge members 44 have a symmetrical structure. Therefore, the distances from the rotation center axis C of the rotating plate 27 to the pair of columnar members 28 and 29 are equal. When the lifting and lowering of the movable plate 48, which is controlled by the control motor 46, stops, the movement of the pair of columnar members 28 and 29 also stops, and the interval between the pair of columnar members 28 and 29 is maintained at a predetermined value.

[0050] Furthermore, the engaging component 52 engages with the periphery of the operating plate 51, thereby preventing the operating plate 51 from rising and falling independently, but allowing the operating plate 51 to rotate. Therefore, the operation plate 51 can rotate together with the rotating plate 27 without being hindered by the engaging component 52. In addition, a winding core 39 is respectively installed on a pair of columnar components 28 and 29.

[0051] The core 39 has: an inner core 36, which is respectively mounted on the top of a pair of columnar members 28, 29; a first outer core 37 and a second outer core 38, which are arranged radially outward compared to the inner core 36.

[0052] like Figures 1-5 As shown, the inner core 36 is mounted on the lower ends of a pair of columnar members 28 and 29. The inner core 36 includes: an inner platform 36a, which is mounted horizontally on the lower ends of the pair of columnar members 28 and 29; and a plurality of inner hanging pins 36b, which are respectively erected on the inner platform 36a and on which wire 16 is wound to form an inner coil 13. Figure 12 ).

[0053] Multiple inner hook pins 36b are disposed on the inner platform 36a in a manner that protrudes downward from the lower surface of the inner platform 36a and conforms to the shape of the inner coil 13. In this embodiment, two inner hook pins 36b are respectively disposed on a pair of inner platforms 36a, for a total of four inner hook pins 36b along the fabricated quadrilateral inner coil 13 ( Figure 12 The inner periphery of the shape is set.

[0054] Therefore, when the pair of columnar components 28, 29 are rotated together with the inner core 36, and the wire 16 is wound around multiple (four) inner hanging pins 36b, as Figure 9 as well as Figure 12 As shown, the wire 16 wound around each inner hanging pin 36b forms the coil end 13b of the inner coil 13. In addition, the wire 16 hung between a pair of columnar members 28, 29 forms the coil edge 13a of the inner coil 13.

[0055] The first outer core 37 is for forming the middle coil 14 that surrounds the inner coil 13. Figure 13 It is set by ( ). For example Figure 1 as well as Figure 5 As shown, the first outer core 37 has: a middle plate 37a, which is disposed radially outside the inner plate 36a and has a longer circumferential length than the inner plate 36a; and a plurality of middle hanging pins 37b, which are disposed on the middle plate 37a and have wire 16 wound around them to form a middle coil 14.

[0056] In addition, the second outer core 38 is for forming the outer coil 15 that further surrounds the middle coil 14. Figure 14 The second outer core 38 is provided with: an outer platform 38a, which is provided radially outside the middle platform 37a and has a longer circumferential length than the middle platform 37a; and a plurality of outer hanging pins 38b, which are provided on the outer platform 38a and have wire 16 wound around them to form an outer coil 15.

[0057] like Figures 1 to 7 As shown, the first outer core 37 and the second outer core 38 are respectively disposed on a pair of columnar members 28 and 29 in a movable manner. On the pair of columnar members 28 and 29, a plurality of tracks 53 extending in the vertical direction parallel to the rotation center axis C of the rotating plate 27 are respectively disposed.

[0058] like Figure 3 as well as Figure 6 As shown, a central platform 37a is mounted on a central movable body 37d, which is mounted on a track 53 in a lifting and lowering manner. A central hanging pin 37b protrudes downwards from the lower surface of the central platform 37a and is connected to the manufactured central coil 14 (…). Figure 13 The shape of the ) is set in accordance with the central platform 37a.

[0059] like Figure 1 , Figure 2 as well as Figure 6 As shown, the outer platform 38a is mounted on the outer movable body 38d, which is mounted on the other track 53 in a lifting and lowering manner. The outer hanging pin 38b protrudes downward from the lower surface of the outer platform 38a and is connected to the manufactured outer coil 15 (…). Figure 14 The shape of the component is appropriately set on the outer platform 38a. For example... Figure 6 As shown, the cross-section of the outer movable body 38d in the XY plane is U-shaped and surrounds the middle movable body 37d.

[0060] Multiple central mounting pins 37b and external mounting pins 38b rise and fall together with the central platform 37a and the outer platform 38a. The central mounting pins 37b and external mounting pins 38b are configured to move in the direction of the rotation center axis C of the rotating plate 27, such as... Figure 5 The position shown is the same as the position of the inner hanging pin 36b, and it is the winding position that can wind up the wire 16, as shown in the figure. Figures 1-3The device moves back and forth between the position offset from the position of the inner hook pin 36b and the standby position where the wire 16 cannot be wound.

[0061] like Figures 1-3 As shown, the winding device 20 includes first and second core moving mechanisms 55 and 65 capable of reciprocating the positions of the first outer core 37 and the second outer core 38 between a winding position and a standby position. The first core moving mechanism 55 and the second core moving mechanism 65 have the same structure. The first core moving mechanism 55 and the second core moving mechanism 65 each have: annular plate members 56 and 66, which are located above the rotating plate 27 and connected to the first outer core 37 and the second outer core 38; and fluid pressure cylinders 57 and 67, which are actuators provided on the upper surface of the upper worktable 22 with the rods 57a and 67a facing downwards.

[0062] Lifting rods 58 and 68, extending vertically, are provided on the rotating plate 27 in a axially penetrating manner. The lifting rods 58 and 68 are connected to the central movable body 37d and the outer movable body 38d, respectively. At the lower end of the lifting rods 58 and 68, clamping plates 59 and 69 are respectively installed to clamp the central movable body 37d and the outer movable body 38d in the rotation direction (Y-axis direction) of the rotating plate 27.

[0063] Elongated holes 59a and 69a extending radially in the rotating plate 27 are formed on the clamping plates 59 and 69, respectively. Figure 1 as well as Figure 3 The movable middle body 37d and the movable outer body 38d are respectively provided with round pins 37e and 38e that can enter the elongated holes 59a and 69a. This prevents the first outer core 37 and the second outer core 38, including the movable middle body 37d and the movable outer body 38d, from rising and falling independently of the clamping plates 59 and 69. Furthermore, it allows the first outer core 37 and the second outer core 38 to move radially toward the rotating plate 27 relative to the lifting rods 58 and 68, together with a pair of columnar members 28 and 29.

[0064] At the upper ends of the lifting rods 58 and 68, there are annular plate components 56 and 66 that coaxially surround the rotating shaft 26a of the electric motor 26 and the operating plate 51. At the lower ends of the rods 57a and 67a of the fluid pressure cylinders 57 and 67, there are engaging components 61 and 71 that engage with the surrounding area of ​​the plate components 56 and 66.

[0065] When the fluid pressure cylinders 57 and 67 move rods 57a and 67a out of and out, the plate members 56 and 66, along with the first outer winding core 37 and the second outer winding core 38, are raised and lowered together by the engaging members 61 and 71 located at their lower ends. Thus, the first outer winding core 37 and the second outer winding core 38 are configured to... Figure 11 The winding position shown is... Figure 7 It moves back and forth between the indicated standby positions.

[0066] Here, engaging components 61 and 71 engage with the periphery of plate components 56 and 66, thereby preventing plate components 56 and 66 from moving up and down independently. Additionally, engaging components 61 and 71 allow plate components 56 and 66 to rotate, and allow the rotating plate 27 to rotate together with plate components 56 and 66.

[0067] Therefore, as Figure 10 as well as Figure 11 As shown, when the electric motor 26 drives the rotating plate 27 to rotate, the first outer core 37 and the second outer core 38 rotate together with a pair of columnar members 28 and 29 disposed on the rotating plate 27. In addition, wire 16 is wound on the central hanging pin 37b and the outer hanging pin 38b of the first outer core 37 and the second outer core 38.

[0068] like Figure 7 As shown, a fluid pressure cylinder 81 is mounted on a lower worktable 23, which is horizontally positioned below a pair of columnar members 28 and 29 and is supported by a support column 21 that supports the upper worktable 22. The cylinder 81a is positioned so that its rod 81a faces upward. A base 72 is mounted on the upper end of the rod 81a of the fluid pressure cylinder 81, and an electric motor 77 is mounted on the base 72 so that its rotation axis 77a faces upward.

[0069] The electric motor 77 is mounted on the base 72 with its rotation shaft 77a coaxial with the rotation shaft 26a of the electric motor 26. A rotary table 73 is mounted on the rotation shaft 77a so that it can rotate in the horizontal plane. A wire clamp 74 is provided on the rotary table 73 to hold the end of the wire 16 unwound from the wire unwinding member 31.

[0070] A wire clamp 74 is mounted near the outer periphery of the upper surface of the rotary table 73. A slot 74a is formed on the wire clamp 74 to allow the wire 16 to enter from above. The slot 74a is formed with an opening at the upper end and has a restraining member (not shown) built in to restrain the wire 16 entering the slot 74a.

[0071] An operating lever 75 for operating the restraint mechanism is provided on the wire clamp 74. The operating lever 75 switches between a restrained state in which the wire 16 entering the cut groove 74a is restrained, and a released state in which the wire 16 entering the cut groove 74a is released in an unrestrained manner. An actuator 76 for operating the operating lever 75 is provided on the lower worktable 23.

[0072] On the other hand, the fluid pressure cylinder 81 constitutes a table moving mechanism capable of raising and lowering the rotary table 73 along the Z-axis direction. The fluid pressure cylinder 81 enables the rotary table 73 to move as follows: Figure 8 The rotating worktable 73 is shown rising so that its upper surface abuts or approaches the lower end of the inner hanging pin 36b of the inner core 36, and as shown in the figure. Figure 7 The lifting and lowering occurs between the separation positions where a gap is created between the lower end of the inner hook pin 36b, as shown.

[0073] Electric motor 26 rotates the pair of columnar members 28, 29, on which the winding core 39 is provided, together with the rotating plate 27. Additionally, electric motor 77, in sync with the pair of columnar members 28, 29, which rotate around the rotational axis C of the rotating plate 27, rotates the rotating worktable 73, on which the wire clamp 74 is provided. Thus, the winding device 20 is configured to wind the wire 16 unwound from the wire unwinding member 31 around the winding core 39 provided on the pair of columnar members 28, 29. Figure 9 , Figure 10 as well as Figure 11 ).

[0074] On the other hand, the wire unwinding member moving mechanism 32 moves the wire unwinding member 31 and the core 39 together in the direction of the rotation center axis C of the rotating plate 27. In this way, the wire unwinding member moving mechanism 32 causes the wire 16 unwound from the wire unwinding member 31 to be wound in a spiral arrangement around the various hook pins 36b, 37b, 38b in the core 39.

[0075] Next, the winding method implemented by the winding device 20 in this embodiment will be described.

[0076] The winding method of this embodiment is a winding method that uses a device having a rotating plate 27, a pair of columnar members 28 and 29, and a winding core 39. The rotating plate 27 is driven to rotate by an electric motor 26, which serves as a drive mechanism. The pair of columnar members 28 and 29 are disposed on the rotating plate 27 such that they can move along a straight line intersecting the rotational center axis C of the rotating plate 27. The winding core 39 is mounted on each of the columnar members 28 and 29. In the winding method of this embodiment, after adjusting the interval between the pair of columnar members 28 and 29, the rotating plate 27 is rotated while maintaining the distance from the rotational center axis C of the rotating plate 27 to the pair of columnar members 28 and 29 in such a way that they are equal, and the wire 16 is wound into the winding core 39, which rotates together with the pair of columnar members 28 and 29.

[0077] The following explains the use of a winding device 20 equipped with a pair of movable columnar components 28 and 29, such as... Figure 14 As shown, this is a case where the stator coil 12 is formed by the continuous inner coil 13, middle coil 14, and outer coil 15. Furthermore, the winding operation is automatically controlled by a controller (not shown). Each process will be described in detail below.

[0078] <Preparation Process>

[0079] First, the preparation process will be described. In the preparation process, the wire 16 is unwound from the wire unwinding member 31. Specifically, the wire 16, which is wound on a spool (not shown) and stored therein, is prepared and drawn off from the spool. Then, the wire 16, which has been stretched straight by a stretching machine (not shown), is inserted into the wire unwinding member 31 and gripped by a gripping mechanism (not shown).

[0080] Next, as Figure 8 As shown, the rotary worktable 73 is rotated by an electric motor 77 mounted on the lower worktable 23, causing the wire clamp 74, which is mounted near the outer periphery, to confront the wire unwinding member 31. Furthermore, the wire unwinding member 31 is moved by the wire unwinding member moving mechanism 32, causing the end of the wire 16 protruding from the wire unwinding member 31 to enter the cut groove 74a of the wire clamp 74, and the wire 16 is restrained by a restraining member (not shown) built into the cut groove 74a.

[0081] <Interval Holding Process>

[0082] Next, the interval holding process will be described. In the interval holding process, the interval between a pair of columnar members 28 and 29 is adjusted and held in such a way that the distances from the rotation center axis C of the rotating plate 27 to the pair of columnar members 28 and 29 are equal. The adjustment and holding of the interval are performed by the holding mechanism 43.

[0083] Specifically, such as Figure 1 As shown, if the movable plate 48 is in the raised state, the holding mechanism 43 is controlled by the motor 46, such as... Figure 2 As indicated by the solid arrow, the movable plate 48 and the pair of wedge members 44, 44 move downwards in a vertical direction. Thus, the moving blocks 28a, 29a and the pair of columnar members 28, 29 move along the inclination of the track 44b. Figure 2 The solid arrow indicates that the rotating plate 27 moves radially. This increases the distance between the pair of columnar members 28 and 29. Thus, the distance between the pair of columnar members 28 and 29 is set to a predetermined distance, and the pair of columnar members 28 and 29 are positioned at equal distances from the rotation center axis C of the rotating plate 27.

[0084] Here, the predetermined interval is such that the stator coil 12 (formed from the wire 16 prepared in the preparation process) is formed in a manner that allows the stator coil 12 (formed from the wire 16 prepared in the preparation process) to be ... to be formed in a manner that allows the Figure 14 The resistance value of the stator coil 12 is converged to the required interval by the design value, and is calculated in advance by the resistance value of the wire 16. The total length of the wire 16 wound on the stator coil 12 is adjusted by setting the interval between a pair of columnar members 28, 29 to a predetermined interval, thereby causing the resistance value of the stator coil 12 to converge to the design value.

[0085] If the interval between the pair of columnar members 28 and 29 reaches a predetermined interval, the lifting and lowering of the movable plate 48, which is controlled by the motor 46, stops. This stops the radial movement of the pair of columnar members 28 and 29 towards the rotating plate 27. Consequently, the distances from the rotation center axis C of the rotating plate 27 to the pair of columnar members 28 and 29 are equal, and the interval between the pair of columnar members 28 and 29 is maintained at a predetermined value.

[0086] In this state, such as Figure 8 As shown, the rotary table 73 is raised by the fluid pressure cylinder 81, so that the upper surface of the rotary table 73 contacts the lower end face of the multiple inner hanging pins 36b in the inner core 36.

[0087] <Winding process>

[0088] Next, the winding process will be described. In the winding process, the wire 16 is wound onto the cores 36, 37, and 38, which rotate together with a pair of columnar members 28 and 29, by rotating the rotating plate 27. In this embodiment, the winding device 20 described above, which includes an inner core 36, a first outer core 37, and a second outer core 38, is used. Therefore, the winding process includes an inner winding process in which the wire 16 is wound onto the inner core 36, a middle winding process in which the wire 16 is wound onto the first outer core 37, and an outer winding process in which the wire 16 is wound onto the second outer core 38. These will be described below.

[0089] <Inner winding process>

[0090] First, the inner winding process will be explained. In the inner winding process, the wire 16 is wound into the inner core 36. Therefore, as... Figure 8 As shown, the first outer core 37 and the second outer core 38 are raised and positioned above the inner core 36. Specifically, the first core moving mechanism 55 and the second core moving mechanism 65 move to the standby position by submerging the rods 57a and 67a of the fluid pressure cylinders 57 and 67 respectively, and raising the first outer core 37 and the second outer core 38, thereby releasing the outer radius of rotation of the inner hanging pin 36b of the inner core 36.

[0091] Then, the clamping mechanism of the wire unwinding member 31 is used to release the clamping of the wire 16, and the electric motor 26 is driven, so that the inner core 36 and the rotating plate 27 rotate together a predetermined number of times. At the same time, the electric motor 77 provided on the lower worktable 23 is driven, so that the rotating worktable 73, which is provided with wire clamps 74 for restraining the ends of the wire 16, rotates synchronously with the inner core 36 in the same direction and at the same speed a predetermined number of times.

[0092] In this way, such as Figure 9 As shown, the wire 16 unwound from the wire unwinding member 31 is wound around the inner core 36 a predetermined number of times. At this time, the wire unwinding member moving mechanism 32 can also move the wire unwinding member 31 axially along the rotating plate 27 together with the rotation of the inner core 36. In this way, the wire 16 unwound from the wire unwinding member 31 is wound in a spiral shape around a plurality of inner hook pins 36b, so that adjacent wires 16 are wound in an arrangement that is parallel and close to each other.

[0093] Furthermore, after the first layer of coil, formed by the wire 16 directly wound around the inner hook pin 36b, is formed, the wire 16 is further wound and arranged as needed to form the second and subsequent layers of coil. Thus, as... Figure 12As shown, in the inner winding process, an inner coil 13 with a polygonal shape including a coil end 13b and a coil side 13a is formed. The coil end 13b is composed of wire 16 wound on an inner hanging pin 36b provided on an inner platform 36a, and the coil side 13a is composed of wire 16 wound between a pair of columnar members 28 and 29.

[0094] <Middle Winding Process>

[0095] Next, the intermediate winding process will be described. In the intermediate winding process, the wire 16 is wound around a plurality of intermediate hook pins 37b of the first outer core 37 to form the intermediate coil 14. The inner coil 13 obtained in the previous process is surrounded by a plurality of intermediate hook pins 37b in the first outer core 37.

[0096] Specifically, such as Figure 10 As shown, rod 57a protrudes from the fluid pressure cylinder 57 of the first core moving mechanism 55, and the first outer core 37 is moved downward from the standby position. Furthermore, the plurality of center hook pins 37b of the first outer core 37 are moved in the direction of the rotation center axis C of the rotating plate 27 to the same position as the inner hook pin 36b of the inner core 36 (the position surrounding the inner hook pin 36b), i.e., the winding position.

[0097] At this time, the position of the wire unwinding member 31 is adjusted by the wire unwinding member moving mechanism 32 so that the wire 16 extending from the inner coil 13 to the wire unwinding member 31 enters between the desired center-hanging pins 37b. In this way, the wire 16 is guided from the inner coil 13 to the outside of the plurality of center-hanging pins 37b.

[0098] Then, rotate the first outer core 37 together with the inner core 36, as follows: Figure 13 As shown, the wire 16 unwound from the wire unwinding member 31 is wound around a plurality of center hook pins 37b in the first outer core 37 to form a center coil 14.

[0099] That is, such as Figure 10 As shown, the stopped electric motor 26 is driven again, causing the first outer winding core 37 to rotate further together with the rotating plate 27 and the pair of columnar members 28 and 29 a predetermined number of times. Simultaneously, the electric motor 77, which is mounted on the lower worktable 23, is driven, causing the rotating worktable 73, equipped with wire clips 74 that restrain the ends of the wire 16, to rotate synchronously with the first outer winding core 37 in the same direction and at the same speed a predetermined number of times. In this way, the wire 16, unwound from the wire unwinding member 31, is wound around the plurality of intermediate winding pins 37b of the first outer winding core 37 a predetermined number of times.

[0100] At this time, the wire unwinding member moving mechanism 32 can also move the wire unwinding member 31 axially along the rotating plate 27 together with the rotation of the first outer core 37. Here, the wire 16 unwound from the wire unwinding member 31 is spirally wound around a plurality of central winding pins 37b, resulting in adjacent wires 16 being wound in a parallel and close-fitting arrangement. Furthermore, after the first layer of coils formed by the wires 16 directly wound around the central winding pins 37b is formed, the wires 16 are further wound in an arranged manner as needed to form second and subsequent layers of coils.

[0101] Thus, as Figure 13 As shown, in the winding process, a polygonal coil 14 is formed, including a coil end 14b and a coil side 14a. The coil end 14b is composed of wire 16 wound on a winding pin 37b provided on a central platform 37a, and the coil side 14a is composed of wire 16 wound between a pair of columnar members 28 and 29.

[0102] <Outer winding process>

[0103] Next, the outer winding process will be described. In the outer winding process, the wire 16 is wound around the multiple outer hooks 38b of the second outer core 38 to form the outer coil 15. The middle coil 14 obtained in the previous process is surrounded by the multiple outer hooks 38b in the second outer core 38.

[0104] Specifically, such as Figure 11 As shown, this causes rod 67a to protrude from the fluid pressure cylinder 67 in the second core moving mechanism 65, and causes the second outer core 38 to... Figure 7 The standby position shown is moved downwards. In addition, the multiple outer winding pins 38b are moved in the direction of the rotation center axis C of the rotating plate 27 to the same position as the middle winding pin 37b of the first outer core 37 (the position surrounding the middle winding pin 37b), i.e., the winding position.

[0105] At this time, the position of the wire unwinding member 31 is adjusted by the wire unwinding member moving mechanism 32 so that the wire 16 extending from the center coil 14 to the wire unwinding member 31 enters between the desired outer hooks 38b. In this way, the wire 16 is guided from the center coil 14 to the outside of the multiple outer hooks 38b.

[0106] Then, the second outer core 38 is rotated together with the first outer core 37, so that the wire 16 unwound from the wire unwinding member 31 is wound around the multiple outer hooks 38b of the second outer core 38, thereby forming the outer coil 15.

[0107] That is, such as Figure 11As shown, the stopped electric motor 26 is driven again, causing the second outer winding core 38 to rotate further a predetermined number of times. Simultaneously, the rotary table 73, equipped with wire clamps 74 that restrain the ends of the wire 16, is rotated synchronously with the second outer winding core 38 in the same direction and at the same speed a predetermined number of times. In this way, the wire 16, unwound from the wire unwinding member 31, is wound around the multiple outer hooks 38b of the second outer winding core 38 a predetermined number of times.

[0108] At this time, the wire unwinding member moving mechanism 32 can also move the wire unwinding member 31 axially along the rotating plate 27 together with the rotation of the second outer core 38. Here, the wire 16 unwound from the wire unwinding member 31 is spirally wound around a plurality of outer hooks 38b, resulting in adjacent wires 16 arranged parallel and closely wound together. Furthermore, after the first layer of coils formed by the wires 16 directly wound around the outer hooks 38b is formed, the wires 16 are further wound in an arranged manner as needed to form second and subsequent layers of coils.

[0109] Thus, as Figure 14 As shown, in the outer winding process, a polygonal outer coil 15 is formed, including a coil end 15b and a coil side 15a. The coil end 15b is composed of wire 16 wound on an outer hanging pin 38b provided on an outer platform 38a, and the coil side 15a is composed of wire 16 wound between a pair of columnar members 28 and 29.

[0110] Here, as Figure 14 As shown, the outer winding pin 38b of the second outer winding core 38 is located at the location where it covers the coil end 14b of the middle coil 14 from the radial outside, and the middle winding pin 37b of the first outer winding core 37 is located at the location where it covers the coil end 13b of the inner coil 13 from the radial outside. Therefore, the outer coil 15 becomes a coil of the size that surrounds the middle coil 14 from the radial outside at predetermined intervals, and the middle coil 14 becomes a coil of the size that surrounds the inner coil 13 from the radial outside at predetermined intervals.

[0111] As a result, the inner coil 13, the middle coil 14, and the outer coil 15 are of different sizes. Thus, in the winding device 20 of this embodiment, a stator coil 12 with different lengths at the coil ends 13b, 14b, and 15b, and with the inner coil 13, the middle coil 14, and the outer coil 15 being continuous, can be manufactured.

[0112] Here, the resistance value of the stator coil 12 must converge to a pre-set design value. In the winding device 20 and winding method of this embodiment, a pair of columnar members 28 and 29, on which the core 39 is divided and mounted, are configured to move along a straight line intersecting the rotation center axis C of the rotating plate 27. Therefore, by adjusting the interval between the pair of columnar members 18 and 19, the resistance value of the stator coil 12 can be adjusted. In addition, the length of the wire 16 wound on the divided core 39 can be changed without replacing the core 39.

[0113] Furthermore, the holding mechanism 43 maintains the wire at equal distances from the rotation center axis C of the rotating plate 27 to the pair of columnar members 28 and 29. Therefore, the rotation center of the divided core 39 can be aligned with the rotation center axis C of the rotating plate 27. This suppresses wobbling during rotation caused by the eccentricity of the core 39, thus enabling rapid winding of the wire 16.

[0114] Furthermore, after the inner coil 13, middle coil 14, and outer coil 15 are formed, they are transported separately from the inner core 36, the first outer core 37, and the second outer core 38. In subsequent processes, the coil edges 13a, 14a, and 15a are inserted into slots in the core (not shown) using a currently used insertion method.

[0115] Here, the steps for detaching the inner coil 13, middle coil 14, and outer coil 15 from the inner core 36, the first outer core 37, and the second outer core 38 will be described. First, the wire 16 is held by a gripping mechanism (not shown) in the wire unwinding member 31, thereby preventing the wire 16 from being rewound from the wire unwinding member 31.

[0116] Furthermore, the inner coil 13, middle coil 14, and outer coil 15 formed on the inner core 36, the first outer core 37, and the second outer core 38 are held by a shape-holding member (not shown), and while maintaining their shape, the wire 16 extending from the wire unwinding member to the outer coil 15 is cut by a cutting device or the like. In this way, the inner coil 13, middle coil 14, and outer coil 15 are removed from the wire unwinding member 31.

[0117] At this point, the wires 16 constituting the inner coil 13, middle coil 14, and outer coil 15 can be bundled using adhesive tape as needed. This allows the wires 16 floating between the hanging pins 36b, 37b, and 38b to be bundled.

[0118] Additionally, the fluid pressure cylinder 81 lowers the rotary table 73, thereby releasing it from below the lower end faces of the inner hanging pin 36b, the middle hanging pin 37b, and the outer hanging pin 38b. Then, the retaining mechanism 43 reduces the spacing between the pair of columnar members 28 and 29.

[0119] Specifically, the motor 46 for controlling the drive holding mechanism 43, such as Figure 2 As indicated by the dashed arrow, the movable plate 48 and the pair of wedge members 44, 44 move vertically upwards together. This causes the moving blocks 28a, 29a to move along the inclination of the track 44b, and the pair of columnar members 28, 29 to move radially in the direction of the rotating plate 27. This reduces the distance between the pair of columnar members 28, 29.

[0120] In addition, by maintaining mechanism 43, the distance between the core 39 and the pair of columnar members 28, 29 is reduced, thereby bringing the winding pins 36b, 37b, 38b of the core 39 closer to each other.

[0121] In this way, such as Figure 14 As shown, the inner coil 13, middle coil 14, and outer coil 15 formed by the wire 16 wound on the inner hanging pin 36b, the middle hanging pin 37b, and the outer hanging pin 38b are relaxed. Furthermore, the wire 16 is detached from the inner hanging pin 36b, the middle hanging pin 37b, and the outer hanging pin 38b respectively.

[0122] Then, the inner coil 13, middle coil 14 and outer coil 15, held by the shape retainer (not shown), are moved downward together with the shape retainer and pulled downward from the released lower end faces of the inner hanging pin 36b, middle hanging pin 37b and outer hanging pin 38b.

[0123] Here, after the inner coil 13, middle coil 14, and outer coil 15 are detached from the inner core 36, the first outer core 37, and the second outer core 38, the aforementioned interval holding process can be restarted. This improves productivity.

[0124] Furthermore, although the above embodiment describes the case where the wire unwinding member 31 is used to pass through a single wire 16, the wire unwinding member 31 can also pass through multiple wires 16 in a side-by-side, close-fitting state. When the wire unwinding member 31 unwinds multiple wires 16, it is preferable to use a rod-shaped member with elongated holes through which multiple wires 16 can pass.

[0125] Furthermore, in the above embodiment, the following situation was described: as a winding core that is separately mounted on a pair of columnar members 28, 29, a winding core consisting of an inner winding core 36, a first outer winding core 37, and a second outer winding core 38 is used, and the inner coil 13, the middle coil 14, and the outer coil 15 are continuously produced. However, although not shown, in the case of obtaining a single coil, a single winding core can also be separately mounted on a pair of columnar members 28, 29. In the case of obtaining a coil in which the inner coil 13 and the outer coil 15 are continuous, one of the inner winding core 36, the first outer winding core 37, and the second outer winding core 38 can be separately mounted on a pair of columnar members 28, 29, without mounting the other of the first outer winding core 37 and the second outer winding core 38.

[0126] Furthermore, in the above embodiment, the case where the wedge member 44 has a triangular plate 44a provided on the movable plate 48 in a manner extending in the moving direction has been described. However, although not shown, the wedge member 44 may not have a triangular plate 44a as long as it has an inclined surface facing the columnar members 28 and 29. In addition, it may have a trapezoidal plate or the like provided on the movable plate 48 in a manner extending in the moving direction instead of a triangular plate 44a. When using a trapezoidal plate, a track 44b can be provided on the inclined surface of the trapezoidal plate facing the columnar members.

[0127] Furthermore, in the above embodiment, it is explained that two hanging pins 36b, 37b, and 38b are respectively erected on the inner plate 36a, the middle plate 37a, and the outer plate 38a, and the wires 16 wound on the four hanging pins 36b, 37b, and 38b form a quadrilateral inner coil 13, a middle coil 14, and an outer coil 15.

[0128] Therefore, if coils 13, 14, and 15 of the necessary shape can be formed, the number of hanging pins 36b, 37b, and 38b is not limited to four; a total of six hanging pins can be placed on the platform to obtain a hexagonal coil. Alternatively, a total of eight hanging pins can be placed on the platform to obtain an octagonal coil. Furthermore, even more than one number of hanging pins can be placed on the platform.

[0129] The embodiments of the present invention have been described above. However, the above embodiments are merely some examples of the application of the present invention and are not intended to limit the technical scope of the present invention to the specific structures of the above embodiments.

[0130] This application claims priority based on Japanese Patent Application 2020-118466, filed with the Japan Patent Office on July 9, 2020, the entire contents of which are incorporated herein by reference.

Claims

1. A winding device for winding wire onto a rotating core, wherein, have: A rotating plate, which is driven to rotate by a drive mechanism; A pair of columnar components are disposed on the rotating plate with respect to the rotational central axis of the rotating plate; The core is respectively mounted on the pair of columnar components; A retaining mechanism that can change and maintain the spacing between the pair of columnar components. The pair of columnar members are disposed on the rotating plate in such a way that they are each movable along a straight line intersecting the rotational central axis of the rotating plate. The distances from the rotational center axis of the rotating plate to the pair of columnar members are maintained equally by the retaining mechanism. The retaining mechanism has: A movable plate is disposed on the rotation center axis of the rotating plate and is capable of moving along the direction of the rotation center axis of the rotating plate; A pair of wedge components having inclined surfaces opposite the pair of columnar components, and disposed on both sides of the movable plate in such a manner as to be separated from the rotational central axis of the rotating plate; A wedge-moving mechanism that causes the pair of wedge components to move together with the movable plate along the direction of the rotation center axis of the rotating plate. A driven member is mounted on the pair of columnar members, which moves along the inclined surface of the pair of wedge members.

2. The winding device as described in claim 1, wherein, The pair of wedge components have: The track, which is set on the inclined surface, On the pair of columnar members, a driven member is mounted that moves along the extension direction of the track.

3. The winding device as described in claim 1, wherein, The wedge moving mechanism has: The control motor has a male threaded portion on its rotating shaft; A control component, which engages with the male threaded portion and is connected to the movable plate. The control component moves according to the rotation of the control motor, thereby enabling the pair of wedge components to move together with the movable plate along the direction of the rotation center axis of the rotating plate.

4. The winding device as described in claim 1, wherein, The core has: The inner cores are respectively mounted on the top of the pair of columnar components; The outer cores, which are respectively mounted on the pair of columnar members in a manner movable along the rotational central axis of the rotating plate, are configured to be radially outward compared to the inner cores. The winding device also includes a core moving mechanism that enables the position of the outer core in the direction of the rotation center axis of the rotating plate to reciprocate between the winding position and the standby position. The winding position refers to the position that is the same as the position of the inner winding core and that allows the wire to be wound up. The standby position refers to the position offset from the position of the inner core, and the position where the wire cannot be wound up.

5. A winding method, comprising winding using a device having a rotating plate, a pair of columnar members, a core, and a holding mechanism. The rotating plate is driven to rotate by a drive mechanism. The pair of columnar members are disposed on the rotating plate in such a way that they are each movable along a straight line intersecting the rotational central axis of the rotating plate. The cores are respectively mounted on the pair of columnar members. The retaining mechanism is capable of changing and maintaining the spacing between the pair of columnar components. The retaining mechanism has: A movable plate is disposed on the rotation center axis of the rotating plate and is capable of moving along the direction of the rotation center axis of the rotating plate; A pair of wedge-shaped components, each having an inclined surface opposite to the pair of columnar components, are disposed on both sides of the movable plate with respect to the rotational central axis of the rotating plate. A driven member is mounted on the pair of columnar members, which moves along the inclined surface of the pair of wedge members. In the winding method, The pair of wedge members and the movable plate are moved together along the direction of the rotation center axis of the rotating plate, thereby moving the driven member along the inclined surface of the pair of wedge members. After adjusting the interval between the pair of columnar members, the rotating plate is rotated while maintaining the distances from the rotation center axis of the rotating plate to the pair of columnar members as equal, and the wire is wound onto the core that rotates together with the pair of columnar members.

Images