Wire-shaped material manufacturing apparatus

Abstract

The present invention relates to a linear material manufacturing apparatus. The linear material manufacturing apparatus comprises: an unwinding device; a processing device configured to move between positions along a transport direction in each transport cycle; a transport device configured to move between positions along the transport direction in each of the transport cycles; a cutting device fixed at a predetermined position; and a control device configured to control the positions of the plurality of processing devices and the transport device in each of the transport cycles.

Description

Technical Field

[0001] The present disclosure relates to a linear material manufacturing device. Background Art

[0002] A winding (enameled wire) having an insulating coating formed on the surface of a conductor made of a metal wire is known. The winding is widely used as a coil for various electrical devices. Examples of electrical devices using the coil include reactors and vehicle motors.

[0003] For example, in the coil manufacturing device described in Japanese Unexamined Patent Application Gazette No. 2016-46863 (JP 2016-46863A), the winding is bent into a predetermined coil shape while being fed, wound into a spiral shape, and cut at the terminal end of the coil, thereby manufacturing the coil. The high-efficiency motor includes a segmented coil. The segmented coil is made of a coil material (also called a "wire material") before being bent. When manufacturing the coil material, for example, a portion of a rectangular wire with an insulating coating is subjected to a coating stripping process multiple times while being fed by a feeding device. Where the rectangular wire with the insulating coating is fed, the rectangular wire with the insulating coating is cut to the necessary length. A product requires various coil materials with different lengths. Summary of the Invention

[0004] However, in the aforementioned manufacturing apparatus, the multiple processing devices used to process the windings are generally fixed. To manufacture multiple types of wire materials of different lengths in this manner, it is necessary to first manufacture multiple first-type wire materials, then change the position of the processing devices and the cutting position, and then manufacture a second-type wire material having a length different from that of the first-type wire materials. Therefore, manufacturing wire materials of different lengths is complex. The equipment must be temporarily stopped to switch between wire materials to be manufactured. Consequently, it is impossible to manufacture wire materials of different lengths in a planned sequence with high productivity.

[0005] The present disclosure can be implemented in the following aspects.

[0006] (1) According to one aspect of the present disclosure, a linear material manufacturing device is provided. The linear material manufacturing device is configured to manufacture a plurality of types of linear materials with different lengths according to a planned order by the following steps: feeding the wound wire in the transport direction in each transport cycle; processing the wire; and cutting the wire at the place where the wire is transported. The linear material manufacturing device includes: an unwinding device, the unwinding device is configured to feed the wire in the transport direction; a processing device, the processing device is configured to process the wire and moves between a plurality of positions along the transport direction in each transport cycle; a transport device, the transport device is configured to transport the wire in the transport direction in each transport cycle, is arranged on the downstream side of the processing device in the transport direction, and is configured to move between positions along the transport direction in each transport cycle; a cutting device, the cutting device is fixed at a predetermined position and is configured to cut the wire processed by a plurality of processing devices; and a control device, the control device is configured to calculate the positions of the processing device and the transport device in each transport cycle by using a plurality of information about the length of the linear material, and control the positions of the processing device and the transport device in each transport cycle. According to this aspect of the linear material manufacturing apparatus, the control device calculates the positions of the processing device and the transport device during each transport cycle using the plurality of pieces of information regarding the linear material length, and controls these positions during each transport cycle. Consequently, linear materials of varying lengths can be continuously produced according to a planned sequence by sequentially feeding the wound wire in the transport direction by the unwinding device and cutting the processed wire by the cutting device. This improves productivity.

[0007] (2) In the above aspect, the control device may be configured to calculate the position of the calculation target device by summing the lengths of the linear material inserted between the cutting device and the calculation target device when calculating the position of the calculation target device, wherein the calculation target device is any one of the processing device and the transport device whose position is to be calculated in each transport cycle. According to the linear material manufacturing apparatus of this aspect, the position of the calculation target device can be easily calculated by summing the wire type information of the plurality of wire materials inserted between the cutting device and the calculation target device.

[0008] (3) In the above aspect, the control device may be configured to store a plurality of line length related information in a plurality of data storage boxes set in association with a plurality of steps, the line length related information being related to the length of the linear material used as a processing target in the corresponding steps, the plurality of steps including: a pre-processing step that precedes the processing to be performed by the processing device and is expected to proceed to the processing device; a processing step that is to be performed by the processing device; and a transport step that is to be performed by the transport device. The control device may be configured to calculate the position of the calculation target device by using the stored line length related information. The control device may be configured to perform a transfer process at the end of each transport cycle to transfer the plurality of line length related information stored in the data storage box set for the transport cycle to the data storage box set for the next transport cycle. The control device may be configured to transfer the plurality of line length related information stored in the data storage box associated with the corresponding step in the transport cycle to the data storage box associated with the step after the corresponding step in the next transport cycle when performing the transfer process. The control device may be configured to calculate the position of the calculation target device in the next transport cycle by using the line length related information transferred to the data storage box. According to this aspect of the linear material manufacturing apparatus, a control device stores a plurality of linear length-related information in a data storage box associated with a corresponding step, the linear length-related information being related to the length of the linear material being processed in the corresponding step. Through a transfer process performed at the end of each transport cycle, the plurality of linear length-related information stored in the data storage box associated with the corresponding step in the transport cycle is transferred to the data storage box associated with the step following the corresponding step in the next transport cycle. By using the transferred linear length-related information in the next transport cycle, the position of the target device can be easily calculated.

[0009] (4) In the above aspect, the linear material manufacturing apparatus may include a plurality of processing devices. The processing devices may be configured to perform a plurality of processing steps online. According to the linear material manufacturing apparatus of this aspect, the plurality of processing steps can be performed online by the plurality of processing devices. Therefore, the linear material manufacturing apparatus can manufacture linear materials that require multiple processing steps before being cut.

[0010] (5) In the above aspect, the thread may include a mark indicating a defective portion. The thread-like material manufacturing apparatus may further include a detection unit configured to detect the defective portion between the unwinding device and the first processing device, the first processing device being the processing device closest to the unwinding device. The control device may be configured to, when the detection unit detects the front end of the mark in the transport direction, calculate the distance from the first processing device to the front end in each transport cycle. The control device may be configured to, when the distance calculated by comparing the distance with the thread length-related information stored in the data storage box associated with the pre-processing step is less than the length of the thread-like material in the pre-processing step, insert discarded thread type information indicating the type of thread to be discarded as thread length-related information into the data storage box associated with the pre-processing step. According to the thread-like material manufacturing apparatus of this aspect, the detection unit detects the mark indicating the defective portion of the thread. The control device calculates the distance from the first processing device to the front end of the mark and compares the distance with the thread type information stored in the data storage box associated with the pre-processing step. When the distance is less than the length indicated by the thread type information in the pre-processing step, the discarded thread type information is inserted. By performing processing based on the detection of the front end of the mark, it is possible to insert the scrap line type information during production according to the planned sequence.

[0011] (6) In the above aspect, the control device can be configured to store wire length related information in a data storage box associated with the pre-processing step according to a planned sequence when the detection unit detects the terminal of the mark in the transport direction and the terminal is transported downstream with respect to the first processing device in the transport direction, so that the linear material is subsequently processed by the first processing device according to the planned sequence. According to the linear material manufacturing device of this aspect, processing can be performed based on the detection of the marked terminal, and the wire type information can be returned according to the planned sequence. By performing processing based on the detection of the marked front end and the marked terminal, the amount of non-defective parts in the discarded winding can be minimized without stopping the equipment. The discarded part can be minimized.

[0012] (7) In the above aspect, the wire may be an insulatingly coated copper wire having a rectangular cross section and serving as a material for the segment coil. The processing device may be a stripping device configured to strip the insulating coating. According to the linear material manufacturing apparatus of this aspect, by stripping the insulating coating and cutting the insulatingly coated copper wire having a rectangular cross section and serving as a material for the segment coil, the linear material can be manufactured efficiently according to a planned sequence. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Features, advantages, and technical and industrial significance of illustrative embodiments of the present invention will be described below with reference to the accompanying drawings, in which like reference numerals designate like elements, and in which:

[0014] Figure 1is a schematic diagram showing an overall schematic configuration of a linear material manufacturing apparatus according to a first embodiment of the present disclosure;

[0015] Figure 2 is a control block diagram showing a system configuration of a linear material manufacturing apparatus;

[0016] Figure 3 is a flowchart showing a processing procedure of a linear material manufacturing method to be executed by a control device;

[0017] Figure 4 is a table showing the storage form of line type information to be read for each step in each transport cycle;

[0018] Figure 5 is a schematic diagram showing an overall schematic configuration of a linear material manufacturing apparatus according to a second embodiment of the present disclosure;

[0019] Figure 6 is a schematic diagram showing an overall schematic configuration of a linear material manufacturing apparatus according to a second embodiment of the present disclosure;

[0020] Figure 7 is a flowchart showing a processing procedure for marker front end detection to be performed by the control device;

[0021] Figure 8 is a table showing the storage form of line type information to be read for each step in each transport cycle;

[0022] Figure 9 is a flowchart showing a processing procedure for tag terminal detection to be performed by the control device;

[0023] Figure 10 is a table showing the storage form of line type information to be read for each step in each transport cycle;

[0024] Figure 11 is a schematic diagram showing an overall schematic configuration of a linear material manufacturing apparatus according to a third embodiment of the present disclosure;

[0025] Figure 12 is a flowchart showing a processing procedure of a linear material manufacturing method to be executed by a control device;

[0026] Figure 13 is a table showing the storage form of line type information to be read for each step in each transport cycle;

[0027] Figure 14 is a schematic diagram showing an overall schematic configuration of a linear material production apparatus according to a fourth embodiment of the present disclosure;

[0028] Figure 15 is a table showing the storage form of the line type information to be read for each step in each transport cycle; and

[0029] Figure 16 is a table showing the storage form of the thread type information to be read for each step in each transport cycle. DETAILED DESCRIPTION

[0030] A. First embodiment

[0031] A1. Overall configuration of the linear material manufacturing device 1:

[0032] Figure 1 1 is a schematic diagram showing the overall schematic configuration of a linear material manufacturing device 1 according to one embodiment of the present disclosure. Figure 1 As shown in FIG, the linear material manufacturing device 1 includes an unwinding device 11, a straightening device 12, a processing unit 13, a transport unit 14, a cutting device 15, a loading device 16, a stacker 17 and a control device 30 (see FIG. Figure 2 ).

[0033] The linear material manufacturing device 1 of the first embodiment feeds a rectangular copper wire W (hereinafter also simply referred to as "rectangular wire W") wound on a drum 6 in a predetermined amount, performs a plurality of stripping processes, and cuts the wire into predetermined lengths, thereby manufacturing a plurality of types of linear materials having different lengths as materials for segmented coils. The rectangular wire W is a copper wire with an insulating coating having a rectangular cross-section and corresponds to a "wire". Segmented coils are used, for example, in high-efficiency motors, which are used as drive motors for vehicles. The coils of the high-efficiency motors are produced by assembling the segmented coils according to a planned sequence.

[0034] The rectangular copper wire W used as the material for the segmented coil is produced by stretching and softening a fed wire rod into a conductor, and then forming an insulating coating on the surface of the conductor. The rectangular copper wire W is arranged in an unwinding device 11 while being wound on a drum 6. Hereinafter, the rectangular copper wire W wound on the drum 6 will be simply referred to as a "winding."

[0035] The unwinding device 11 feeds the winding from the drum 6 on which the winding is wound in the transport direction. The straightening device 12 corrects the curl of the winding. The processing unit 13 is a device for stripping the insulation coating of the winding and includes a first processing device 21, a second processing device 22, a third processing device 23, a fourth processing device 24, and a fifth processing device 25.

[0036] Examples of processing equipment 21 to 25 include a stripping equipment unit, which includes a punch, a die, and a servo motor (not shown) used as a driving device. A cutting edge is provided at the tip of the punch, and a receiving edge is provided at the die. For example, the eccentric cam is driven to rotate by the drive of the servo motor, and the punch can perform a movement relative to the die, such as a vertical movement, together with the rotational movement of the eccentric cam. The punch is driven toward the rectangular wire W whose posture is maintained, and the cutting edge punches a predetermined portion of the rectangular wire W, thereby stripping the insulating coating of the predetermined portion. The necessary stripping processing (processing 1 to processing 5) is performed in sequence by the processing equipment 21 to 25.

[0037] In this embodiment, the rear end of any (n-1)th linear material and the front end of the nth linear material are processed by one stripping device unit. After processing 1 to processing 5 on the rectangular wire W, the center of the processed portion is cut by the cutting device 15 to obtain the linear material.

[0038] The processes 1 to 5 performed by the processing devices 21 to 25 specifically correspond to, for example, peeling of the upper and lower surfaces and the left and right surfaces of a predetermined portion of the rectangular wire W, and chamfering of the corners of the peeled portion. In this embodiment, five processing devices 21 to 25 are provided, but the number of installed processing devices is not limited to five and is appropriately set depending on the product because the required steps and the number of steps vary depending on the product.

[0039] The transport unit 14 is a device that transports the rectangular wire W to the next processing device in sequence. The transport unit 14 includes a first transport device 26 and a second transport device 27. Each of the transport devices 26 and 27 includes a chuck mechanism that can clamp the rectangular wire W and can perform an operation of transporting the rectangular wire W clamped by the chuck mechanism in the transport direction and a return operation for returning to the clamped position. The transport devices 26 and 27 alternately perform the operations of clamping and transporting the rectangular wire W. That is, when the rectangular wire W is clamped by the chuck mechanism of one transport device and sent in the transport direction, the chuck mechanism of the other transport device to which the rectangular wire W is transported is opened. The front and rear parts of the transport devices 26 and 27 are switched in sequence to alternately transport the rectangular wire W.

[0040] The processing devices 21 to 25 and the transport devices 26 and 27 are self-advancing devices and can be moved to a position along the transport route in the transport direction extending along the rectangular line W during each transport cycle of the rectangular line W. Examples of a drive mechanism for self-advancing each device include a rack-and-pinion mechanism driven by a servo motor and a linear actuator mechanism including an electromagnet. The control device 30 calculates the position of the processing devices 21 to 25 and the transport devices 26 and 27 during each transport cycle and controls movement to the calculated position. The details of the calculation of the calculated position and the control of the device to the calculated position will be described below in the linear material manufacturing method.

[0041] The cutting device 15 cuts the rectangular wire W processed by the processing devices 21 to 25 into predetermined product lengths. The cutting device 15 is, for example, a cutter, and cuts the rectangular wire W from the winding. Unlike the processing devices 21 to 25 and the transport devices 26 and 27, the cutting device 15 is fixed at a predetermined position. The loading device 16 loads the rectangular wire W cut by the cutting device 15 into the stacker 17. The stacker 17 temporarily stores the cut rectangular wire W before transferring them to the next bending step. The stacker 17 includes a plurality of loading platforms associated with a bending station (not shown) for transporting after stripping and cutting. The rectangular wire W cut by the cutting device 15 is sorted and loaded onto the loading platform of the stacker 17 by the loading device 16 as needed.

[0042] A2. System configuration of linear material manufacturing device 1:

[0043] Figure 2 1 is a control block diagram showing the system configuration of the linear material manufacturing device 1. Figure 2 As shown in FIG, the control device 30 of the linear material manufacturing apparatus 1 is connected to communicate with the processing mechanism unit 40, which includes the various processing mechanisms described above (the unwinding device 11, the straightening device 12, the processing devices 21 to 25, the transport devices 26 and 27, the cutting device 15, the loading device 16, and the stocker 17). The control device 30 includes a central processing unit (CPU) 31 and a storage unit 32. The control device 30 is a microcomputer including a read-only memory (ROM), a random access memory (RAM), and an input / output port (not shown), and controls the entire linear material manufacturing apparatus 1. The control device 30 is connected to the production management system 50. For example, the control device 30 receives, as an instruction from the production management system 50, the order of vehicle models to be produced and equipped with motors using the linear material.

[0044] The CPU 31 functions as the operation control unit 33, the wire type information transmission / reception unit 34, the position calculation unit 35, and the processing unit 36 by loading various programs stored in the storage unit 32. The operation control unit 33 controls the movement and operation of the processing mechanism unit 40. The wire type information transmission / reception unit 34 transmits and receives wire type information. The "wire type information" is an example of "wire length-related information" related to the length of the wire-like material to be processed, and includes information about the length of the wire-like material. The position calculation unit 35 calculates the positions of the processing devices 21 to 25 and the transport devices 26 and 27 in each transport cycle. The processing unit 36 performs various arithmetic processing and various determination processing associated with the results of the arithmetic processing, as described below, for example.

[0045] A3. The wire-like material manufacturing method performed by the wire-like material manufacturing apparatus 1:

[0046] Figure 3 is a flowchart showing the processing procedure of the wire-like material manufacturing method performed by the control device 30 of the wire-like material manufacturing apparatus 1 detailed above. As shown in Figure 3 the wire-like material manufacturing method includes a wire type information reading step (S10), a position calculation step (S20), a product workpiece loading step (S30), a peeling step (S40), a cutting step (S50), and a wire type information transfer step (S60). Figure 3 The flow in the flowchart shown in

[0047] In the wire type information reading step (S10), a plurality of pieces of wire type information of products to be dealt with by the processing devices 21 to 25 and the transport devices 26 and 27 are read by the wire type information transmission / reception unit 34 from the data storage box Db (hereinafter simply referred to as "storage box"). Figure 4 is a table T1 showing the storage form of the wire type information to be read at each step in each transport cycle. The wire type information is read and assigned in the data storage box Db associated with each step in each transport cycle. As shown in Figure 4 the storage box Db associated with each step stores the wire type information of any one of the products to be manufactured according to the planned order.

[0048] The storage box Db is provided in association with the steps of "pre-processing", "processing 1", "processing 2", "processing 3", "processing 4", "processing 5", "transportation", "before cutting" and "after cutting". These steps are performed sequentially in the transport direction. The "pre-processing" step is a step that is performed before the processing by the first processing device 21 and is expected to be performed to the processing device 21. The storage box Db for "pre-processing" is connected to the imaginary boundary line S (see FIG. 1 ) between the unwinding device 11 and the first processing device 21. Figure 1 ) to an area of ​​the first processing device 21, and stores data for preparing in advance line type information to be subsequently transmitted to the first processing device 21.

[0049] The storage box Db of "Processing 1" stores the thread type information of the products to be processed by the first processing equipment 21 in the corresponding cycle. The storage box Db of "Processing 2" stores the thread type information of the products to be processed by the second processing equipment 22 in the corresponding cycle. The storage box Db of "Processing 3" stores the thread type information of the products to be processed by the third processing equipment 23 in the corresponding cycle. The storage box Db of "Processing 4" stores the thread type information of the products to be processed by the fourth processing equipment 24 in the corresponding cycle. The storage box Db of "Processing 5" stores the thread type information of the products to be processed by the fifth processing equipment 25 in the corresponding cycle.

[0050] The "transport" storage box Db stores the wire type information of the product to be transported by the transport unit 14 in the transport step in the corresponding cycle. The "before cutting" step is a step in which the linear material is positioned to be cut in the next transport cycle. The "before cutting" storage box Db is associated with the area from the transport unit 14 to the cutting device 15, and stores data to be subsequently transferred to the cutting device 15. The "after cutting" step is a step in which the cut linear material is transferred to the stacker 17. The "after cutting" storage box Db is associated with the area from the cutting device 15 to the stacker 17 in the corresponding cycle, and stores information about the product cut from the winding. The information in the "after cutting" storage box Db is the wire type information of the product workpiece (any one of A to G) subjected to stripping and cutting by the linear material manufacturing device 1.

[0051] In the position calculation step (S20), the positions of the processing devices 21 to 25 and the transport devices 26 and 27 are calculated by the position calculation unit 35. Specifically, the positions of the processing devices 21 to 25 and the transport devices 26 and 27 during period n are calculated by summing the multiple pieces of wire type information of the wire material inserted into the calculation target device with respect to the position of the fixed cutting device 15. Although the wire material is not separated before cutting, the wire material can be considered to be connected. It can be said that the connected wire material is inserted between the cutting device 15 and the calculation target device.

[0052] The line type information of the product workpiece A is denoted by La. The line type information of the product workpiece B is denoted by Lb. The line type information of the product workpiece C is denoted by Lc. The line type information of the product workpiece D is denoted by Ld. The line type information of the product workpiece E is denoted by Le. The line type information of the product workpiece F is denoted by Lf. The line type information of the product workpiece G is denoted by Lg. The line type information of the product workpiece H is denoted by Lh. The "line type information of the product workpiece" is hereinafter also simply referred to as "line type length". The processing devices 21 to 25 and the transport devices 26 and 27 correspond to "calculation target devices". Specifically, the positions of the processing devices 21 to 25 and the transport devices 26 and 27 during the cycle n are calculated by using the following expressions.

[0053] Position of the second transport device 27: L7 = Lb

[0054] Position of the first transport device 26: L6 = Lb + Lc

[0055] Position of the fifth processing device 25: L5 = Lb + Lc + Ld

[0056] Position of the fourth processing device 24: L4 = Lb + Lc + Ld + Le

[0057] Position of the third processing device 23: L3 = Lb + Lc + Ld + Le + Lf

[0058] Position of the second processing device 22: L2 = Lb + Lc + Ld + Le + Lf + Lg

[0059] Position of the first processing device 21: L1 = Lb + Lc + Ld + Le + Lf + Lg + Lh

[0060] In the product workpiece loading step (S30), the cut workpieces A to H are loaded by the loading device 16 into the stocker 17. The position calculation step (S20) and the product workpiece loading step (S30) are executed substantially simultaneously in parallel.

[0061] In the peeling step (S40), the predetermined processing is executed by the processing devices 21 to 25 which are moved to the positions calculated in S20. In the cutting step (S50), the rectangular wire W is cut from the winding by the cutting device 15. The peeling step (S40) and the cutting step (S50) are executed substantially simultaneously in parallel. In the line type information transfer step (S60), the line type information transfer / reception unit 34 transfers the plurality of line type information of the target product in the current transport cycle to the subsequent step. In Figure 4 In the table T1 of FIG. 10, each slanted arrow indicates the transfer of the line type information to the next step. The line type information transfer step (S60) corresponds to the transfer processing. By the above processing, the processing routine is terminated.

[0062] Through the above processing, Figure 4 As shown in , product workpiece A is completed in cycle n, product workpiece B is completed in cycle n+1, and product workpiece C is completed in cycle n+2. Similarly, products are manufactured in the order of product workpieces D, E, F, G, ... according to the planned sequence in each transportation cycle.

[0063] Effect

[0064] According to the linear material manufacturing device 1 and the linear material manufacturing method of the first embodiment, in the position calculation step (S20), the positions of the processing devices 21 to 25 and the transport devices 26 and 27 are calculated based on the plurality of wire type information read in the wire type information reading step (S10). Then, the processing by the processing unit 13 and the transportation by the transport unit 14 are performed at positions associated with a cycle (e.g., cycle n). After each processing and transportation is completed, the plurality of wire type information is transferred to the next step in S60. In the next transportation cycle (e.g., cycle n+1), the plurality of wire type information is read (S10) and the positions of the processing devices 21 to 25 and the transport devices 26 and 27 are calculated again.

[0065] By repeating the above process, product workpieces A to H of varying lengths can be continuously produced according to a planned sequence. The various product workpieces produced by the linear material manufacturing apparatus 1 are then bent and welded while being sequentially arranged. For example, when producing multiple product workpieces A and then multiple product workpieces B, it may be necessary to rearrange the products to route them to the subsequent steps described above. In this regard, according to the first embodiment, product workpieces A to H of varying lengths are manufactured according to a planned sequence. This eliminates the need for rearrangement, ensuring efficiency.

[0066] B. Second embodiment

[0067] B1. Overall Configuration

[0068] Next, we will refer to Figures 5 to 10 The second embodiment of the present disclosure is described. In the second embodiment and each subsequent embodiment, the overall configuration of the linear material manufacturing device 2 and the schematic configuration of the control device 30 ( Figure 2 ) is substantially the same as that in the first embodiment. Therefore, substantially the same parts are denoted by the same reference numerals, and description thereof is omitted. Figure 5 and Figure 6 1 is a schematic diagram showing the overall schematic configuration of a linear material manufacturing device 2 according to a second embodiment of the present disclosure. The linear material manufacturing device 2 of the second embodiment differs from the linear material manufacturing device 1 of the first embodiment in that a mark detection sensor 28 for detecting a defect mark 41 is further provided.

[0069] The winding (rectangular wire W) used in the second embodiment has a defect marker 41 indicating a defective portion. Defect marker 41 is previously attached to the defective portion of the winding. Examples of defects include pinholes and swelling or peeling of the coating. Defect marker 41 is colored in the marking step, and the coloring extends over several millimeters around the defective portion of the winding detected in the defect inspection step.

[0070] Examples of methods for inspecting defective portions of the insulating coating in the event of swelling or peeling include a method of capturing an image of the winding surface with a charge-coupled device (CCD) camera or the like and processing the captured image with an image processing device, and a method of detecting defective portions by measuring the thickness of the insulating coating on the winding surface with a laser displacement meter. Pinholes can be detected, for example, by measuring insulation resistance with a withstand voltage tester (spark tester). In the marking step, for example, the defective portion is marked in black using an inkjet printer.

[0071] The mark detection sensor 28 is provided between the unwinding device 11 and the straightening device 12. The mark detection sensor 28 is a color sensor in this embodiment and reads the defect mark 41 attached to the winding in advance. The mark detection sensor 28 corresponds to a "detection unit".

[0072] Figure 5 A state when the leading end 42 of the defective mark 41 is detected is shown. Figure 6 The state when the terminal 43 of the defective mark 41 is detected is shown. As the time of "when detected", Figure 5 and Figure 6 The state when the defective mark 41 is detected during transportation of the winding is shown, and the transportation cycle in which the mark 41 is detected is terminated and stopped, rather than the moment when the mark detection sensor 28 described below detects the defective mark 41 during transportation of the winding.

[0073] In the second embodiment, the mark detection sensor 28 performs the same control as in the first embodiment ( Figure 3 ) simultaneously detects the leading end 42 and trailing end 43 of the defective mark 41. Since a portion with a defective surface 41 cannot be included in a product, information indicating the type of discarded wire is assigned to the corresponding portion of the winding including the defective mark 41 in the second embodiment. Portions subsequent to the corresponding portion of the winding including the defective mark 41 and capable of being manufactured into a product are sequentially manufactured by restoring the wire type information according to the planned sequence. In other words, these processes are skipped for the winding portion with the defective mark 41, and the minimum necessary portion of the winding is discarded. Details will also be described below with reference to the flowchart.

[0074] B2. Detection of the marking front end 42:

[0075] Figure 7 1 is a flowchart showing a processing procedure of the mark front end detection to be executed by the control device 30 of the linear material manufacturing apparatus 2 of the second embodiment. The mark front end detection is executed simultaneously with the start of transportation. Figure 7 As shown in FIG, the processing unit 36 ​​determines in S101 whether the leading end 42 of the defective mark 41 is detected by the mark detection sensor 28. When the leading end 42 of the defective mark 41 is not detected (S101: NO), the process returns and repeats the control routine.

[0076] When the leading end 42 of the defective mark 41 is detected (S101: Yes), the process proceeds to S102, and the processing unit 36 ​​calculates the distance L from the first processing device 21 (process 1) to the leading end 42 of the mark 41. In S103, the processing unit 36 ​​determines whether the calculated distance L is less than the length of the product workpiece in the pre-processing step. When the distance L is equal to or less than the length of the product workpiece in the pre-processing step (S103: Yes), the process proceeds to S104, and the waste thread type Z is inserted into the pre-processed storage box Db. When the distance L is greater than the length of the product workpiece in the pre-processing step in S103 (S103: No), the process returns to S102, and the process of calculating the distance L is repeated.

[0077] Figure 8 : is a table T21 showing the storage form of the line type information to be read for each step in each transport cycle (including the cycle in which the marking front end 42 is detected). In this example, eight types of product workpieces A to H are manufactured according to the planned sequence, the marking front end 42 is detected in cycle n, and then the marking front end 42 reaches the pre-processing step in four cycles. Figure 8 As shown in FIG, in cycle n+4, the data to be stored in the pre-processed bin Db should be "E", but a discarded line type Z is inserted. This is because the defect mark 41 reaches the first processing device 21 in the next cycle "n+5".

[0078] In this way, the distance L is always calculated, and when the length of the product workpiece to be processed later cannot be ensured due to the defective mark 41, the discarded line type Z is stored as the discard information. The discarded line type Z is inserted until the mark terminal 43 passes, that is, reaches the first processing device 21.

[0079] Method for calculating the distance L from the first processing device 21 (process 1) to the marking front end 42

[0080] Next, a method of calculating the distance L from the first processing device 21 (process 1) to the marker front end 42 will be described. The marker front end 42 is detected during the transport of the rectangular wire W. Assuming that ΔL represents the amount of movement from the time of detection to the end of transport in the transport cycle involving detection, the distance Ln from the first processing device 21 to the marker front end 42 at the end of cycle n in which the marker is detected is expressed as follows.

[0081] Ln=LS-L1-ΔL

[0082] (L1: distance from the cutting device 15 to the first processing device 21)

[0083] Symbol "LS" (see Figure 5 ) is the distance from the cutting device 15 to the mark detection sensor 28, and is a fixed value.

[0084] The transport distance of the rectangular wire W in each cycle is the length of the wire type to be cut in the post-cutting step in the next transport cycle. In other words, the length of the wire type in the pre-cutting step in the previous transport cycle is the transport distance. Assuming that LI represents the length of the wire type before cutting, the distance L between the marking front end 42 and the first processing device 21 in the next cycle is n+1 It is expressed as follows.

[0085] L n+1 =Ln-LI=LS-L1-ΔL-LI

[0086] When the length of each line type is represented by a lowercase letter of the line type (e.g., La), the line type in the pre-cutting step in cycle n is based on "B" ( Figure 8 ). Therefore, the following expression holds.

[0087] L n+1 =LS-L1-ΔL-LI=LS-L1-ΔL-Lb

[0088] This value is compared with the line type length (denoted by L0) in a preprocessing step.

[0089] L n+1 =Ln-L1-LI=LS-L1-ΔL-Lb>L0=La

[0090] The comparison in the above expression corresponds to the processing of S103. This is repeated in each cycle, and the marking front end 42 is marked when the distance L from the first processing device 21 to the marking front end 42 is less than the line type length L0 in the pre-processing step (i.e., when L <L0)时已经到达预处理步骤。此时,将预处理步骤中的计划顺序的线类型信息替换为废弃线类型。

[0091] B3. Detection of Marking Terminal 43:

[0092] Next, detection of the tag terminal 43 will be described. Figure 9 1 is a flowchart showing a processing procedure for detecting the marking terminal 43 to be executed by the control device 30 of the linear material manufacturing apparatus 2 of the second embodiment. Figure 9 The process in the flowchart shown in Figure 7 The flowchart shown in FIG is executed after the tag front end 42 is detected. Figure 9 As shown in FIG, the processing unit 36 ​​determines S111 whether the terminal end 43 of the defective mark 41 is detected by the mark detection sensor 28. When the terminal end 43 of the defective mark 41 is not detected (S111: No), the process is terminated.

[0093] When the marking terminal 43 is detected (S111: Yes), the processing proceeds to S112, and the processing unit 36 ​​calculates the distance L' from the first processing device 21 (processing 1) to the marking terminal 43. In S113, the processing unit 36 ​​determines whether the calculated distance L' is less than zero. When the distance L' is less than zero (S113: Yes), the processing proceeds to S114, and the line type information according to the planned order is stored in the pre-processed storage box Db. That is, the discarded line type Z is returned to the original line type information according to the planned order. When the distance L' is equal to or greater than zero in S113 (S113: No), the processing returns to S112, and the process of calculating the distance L' is repeated.

[0094] Figure 10 Table T22 shows the storage form of the wire type information to be read in the storage box Db of each step in each transport cycle (including the cycle in which the mark terminal 43 is detected). In this example, eight types of product workpieces A to H are manufactured according to the planned sequence, the mark terminal 43 is detected in cycle m, and then the mark terminal 43 reaches the pre-processing step in four cycles. The number of discards is two. Figure 10 As shown in FIG, during cycle m+4, the thread type information "E" according to the planned order is stored in the pre-process storage box Db instead of the "discarded thread type Z". This is because the marking terminal 43 has already reached the process 1 in cycle "m+4" and the product workpiece can be manufactured from the next cycle.

[0095] Method for calculating the distance L' from the first processing device 21 (process 1) to the tag terminal 43

[0096] Next, calculation of the distance L' (see FIG. 1 ) from the first processing device 21 (process 1) to the tag terminal 43 will be described. Figure 6). The terminal 43 that detected the defect mark 41 in the transport processing of the rectangular line W, assuming that ΔL' represents the amount of movement from the time of detection to the end of transport in the transport cycle in which the detection was made, the distance I'm from the first processing device 21 to the mark terminal 43 at the end of the cycle in which the mark was detected is expressed as follows.

[0097] L'm = LS - LI - ΔL'

[0098] The transport distance of the rectangular line W in each transport cycle is the length of the line type to be cut in the cut-after step in the next transport cycle. That is, the transport distance is the length of the line type in the cut-before step in the previous transport cycle. Assuming that L'I represents the length of the line type before cutting, the distance L' m+1 from the first processing device 21 to the mark terminal 43 in the next transport cycle is expressed as follows.

[0099] L' m+1 = L'm - L'I = LS - LI - ΔL' - L'I

[0100] When the length of each line type is represented by a lowercase letter of the line type (e.g., La), the line type in the cut-before step is "D" ( Figure 10 ) based on the table T22. Therefore, the following expression holds.

[0101] L' m+1 = L'm - L'I = LS - LI - ΔL' - L'I = LS - LI - ΔL' - Ld

[0102] It is checked whether this value is less than zero.

[0103] L' m+1 = L'm - L'I = LS - LI - ΔL' - Ld < 0?

[0104] The comparison in the above expression corresponds to the processing of S113. This is repeated in each cycle. When the distance L' from the first processing device 21 to the mark terminal 43 is less than zero (when L' < 0), the mark terminal 43 has reached the processing 1. At this time, the scrap line type information in the pre-processing step is returned to the line type information of the planned order. That is, in the above processing, when the terminal 43 is detected by the mark detection sensor 28 and the first processing device 21 is transported downstream in the transport direction (S113: Yes), the line length related information according to the planned order is stored in the data storage box associated with the pre-processing step, so that the line-like material to be subsequently processed in the first processing device 21 follows the planned order.

[0105] Effects

[0106] The second embodiment achieves similar effects to the first embodiment. By executing the detection process based on the marking front end 42 as detailed above, discarded wire type information can be inserted during production according to the planned sequence. By executing the detection process based on the marking terminal 43, the wire type information can be returned according to the planned sequence. Therefore, by executing the detection process based on the marking front end 42 and the marking terminal 43, the amount of non-defective parts of the rectangular wire W that are discarded can be minimized without stopping the equipment. The discarded part can be minimized.

[0107] C. Third embodiment:

[0108] Next, we will refer to Figures 11 to 13 A third embodiment of the present disclosure is described. Figure 11 This is a schematic diagram illustrating the overall schematic configuration of a linear material manufacturing apparatus 3 according to a third embodiment of the present disclosure. This linear material manufacturing apparatus 3 differs from the linear material manufacturing apparatus 2 of the second embodiment in that it further includes a discard chute 18 for automatically discarding discarded wire type Z. The remaining configuration is identical. The discard chute 18 is located downstream of the cutting device 15 in the transport direction and stores the cut material corresponding to discarded wire type Z.

[0109] Figure 12 1 is a flowchart showing a processing procedure of the linear material manufacturing method to be executed by the control device 30 of the linear material manufacturing apparatus 3. Figure 3 The flowchart shown in FIG. 1 is different in that processing steps S11 and S12 are added after S10. The other processes are the same. In the third embodiment, before the product workpiece loading step (S30) performed by the loading device 16, the processing unit 36 ​​determines in S11 whether the type of thread cut from the workpiece is the waste thread type Z. The information on the waste thread type has been transmitted to the previous step similarly to the above embodiment.

[0110] When the wire type of the workpiece is the discard wire type Z (S11: YES), the process proceeds to S12, and the cut workpiece is discharged by the loading device 16 to the discard chute 18 instead of the stocker 17. When the wire type of the cut workpiece is not the discard wire type Z (S11: NO), the process proceeds to S30, and the cut workpiece is loaded into the stocker 17 by the loading device 16.

[0111] Figure 13 is a table T3 showing the storage form of the line type information to be read for each step in each transport cycle. Figure 13 In the example shown in , eight types of product workpieces A to H are manufactured according to the planned sequence, and discarded workpieces arrive at the post-cutting step during cycle n and cycle n+1. The number of discards is two.

[0112] exist Figure 13In the example shown in Table T3, the scrapped workpieces are in the post-severance stage in cycles n and n+1. Therefore, the loader 16 discharges the scrapped workpieces into the scrap chute 18. Starting in cycle n+2, the finished workpieces (of the planned sequence of line types) are again sent to the post-severance stage. Therefore, the loader 16 begins loading the finished workpieces into the stocker 17.

[0113] Effect

[0114] The third embodiment achieves similar effects to the first embodiment. Since the loading device 16 discharges waste workpieces into the waste chute 18 based on waste line type information, waste workpieces can be automatically discharged from the equipment. This eliminates the need to remove waste workpieces, which would require equipment to stop. Consequently, productivity can be increased by improving equipment operation.

[0115] D. Fourth embodiment

[0116] Next, we will refer to Figure 14 and Figure 15 A fourth embodiment of the present disclosure is described. Figure 14 is a schematic diagram showing the overall schematic configuration of the linear material manufacturing device 4 according to the fourth embodiment of the present disclosure. The linear material manufacturing device 4 differs from the linear material manufacturing device 3 of the third embodiment in that the mark detection sensor 28 also functions as a terminal detection sensor for detecting the terminal 44 of the winding. The other configurations are the same. The terminal detection sensor detects the terminal 44, which is the end point of the winding turns. In the third embodiment, when the terminal detection sensor detects the terminal 44 of the winding, the product is manufactured until the remaining length reaches the limit length of the winding that can be discharged as a waste workpiece by the loading device 16, and the terminal copper wire is automatically discarded without stopping the equipment. The details will be described below.

[0117] Figure 15 It is Table T4, which shows the storage form of the wire type information to be read for each step in each transport cycle. In Table T4, the discarded wire type is represented by Z', the terminal discarded wire type is represented by Z", and no wire type (after the terminal passes) is represented by N. To be picked up and discarded into the discard chute 18 by the loading device 16, it is necessary to ensure the minimum length of the terminal 44 from the winding to perform the operation. The discarded wire type that is the last part including the terminal 44 is "terminal discarded wire type Z". The discarded wire type before the terminal discarded wire type Z" is "discarded wire type Z'". In Figure 15 In the example shown in , eight types of product workpieces A to H are manufactured according to a planned sequence, and the discarded workpieces (discarded line type Z') at the terminal 44 arrive at the pre-processing step during cycle n and arrive at the post-cutting step during cycle m.

[0118] Method for calculating the distance L" from the first processing device 21 (process 1) to the winding terminal 44

[0119] Next, calculation of the distance L from the first processing device 21 (process 1) to the winding terminal 44 will be described (see Figure 14 ) method. The winding terminal 44 is detected during the transport process of the rectangular wire W. Assuming that ΔL" represents the amount of movement from the detection moment to the end of the transport in the transport cycle involving detection, the distance L"k from the first processing device 21 to the terminal 44 at the end of the cycle k in which the terminal 44 is detected is expressed as follows.

[0120] L"k=L"S-L1-ΔL"

[0121] Symbol “L”S” is the distance from the cutting device 15 to the terminal detection sensor, and is a fixed value.

[0122] Since the transport distance of the rectangular wire W in each cycle is the length of the wire type cut in the post-cutting step in the next transport cycle, the transport distance is the length of the wire type in the pre-cutting step in the previous transport cycle. Assuming that L"I represents the length of the wire type before cutting, the distance L" from the first processing device 21 to the winding terminal 44 in the next transport cycle is k+1 It is expressed as follows.

[0123] L" k+1 =L"kL"I=L"S-L1-ΔL"-L"I

[0124] Assuming that the final workpiece length is represented by L"E in order to safely discharge the winding terminal 44, it is necessary to set a variable length for the discarded workpiece immediately before the final workpiece. Since the shortest length of the workpiece that the equipment can produce is LZ, the total discarded length L"Z at the terminal 44 needs to meet the following conditions.

[0125] 2×LZ+L"E≥L"Z>LZ+L"E

[0126] That is, the change timing from the planned sequence line type to the discarded line type can be understood by checking whether the distance L" from the first processing device 21 to the winding terminal 44 in each cycle satisfies the above conditions. When the determination is made based on the transmission timing of the line type information in the pre-processing step (see Figure 12 ), the following expression holds true.

[0127] 2×LZ+L"E≥L"-L0>LZ+L"E (L0: line type length in the preprocessing step)...Condition (1)

[0128] At this time, the line length L'Z' of the discarded line type "Z'" (the discarded workpiece immediately before the final workpiece) is expressed as follows.

[0129] L'Z'=L"-L0-L"E

[0130] When the above condition (1) is satisfied, the line type information in the pre-processing step can be changed to the discarded line type "Z'". Assuming that the discarded line type has reached the pre-processing step in cycle n as shown in Table T4, the following condition is satisfied at the end of cycle n-1.

[0131] 2×LZ+L"E≥L" n-1 -La>LZ+L"E (La: line type A in the preprocessing step)

[0132] At this time, the line length L'Z' of the discarded line type "Z'" is represented by L'Z'=L"-La-L"E.

[0133] In the next cycle (cycle n+1), the terminal waste wire type "Z'" as the final workpiece is stored in the preprocessing step, and the processing is performed at the wire length L"E. Since no rectangular wire W is supplied from the next cycle onward, the wireless type "N" is stored, and the operation stops. In this way, information about the waste wire type "Z'", the terminal waste wire type "Z"" and the wireless type "N" is stored, and the loading device 16 automatically discharges the waste workpiece at the terminal 44 when the waste wire type reaches the post-cutting step.

[0134] Effect

[0135] The fourth embodiment achieves similar effects to those of the first embodiment. Product workpieces can be produced close to the winding terminal 44 fed from the bobbin. Consequently, the winding yield can be improved and the need for work involving equipment stoppages can be eliminated, thereby improving productivity and operating efficiency.

[0136] E. Other Embodiments

[0137] E1

[0138] In the above embodiment, workpieces A through H are manufactured as materials for motors to be installed in specific vehicles. By setting multiple lines of information, it is possible to continuously manufacture workpieces A through H into materials for different motors to be installed in different vehicles after they have been produced. In other words, by setting multiple lines of information, continuous manufacturing can be performed without stopping equipment, thereby achieving so-called mixed-flow production, in which motors for multiple vehicle models are manufactured in a mixed manner.

[0139] Will refer to Figure 16 A specific example is described. Figure 16 Table T5 shows the storage form of the line type information to be read for each step in each transport cycle. Figure 16 In the form shown in FIG. 6, product workpieces A to H that are used as material for product P1 and product workpieces A' to H' that are used as material for product P2 are alternately manufactured. Figure 16 An example of switching product is shown in FIG. 7. Products P1 and P2 can be manufactured by the same winding. As shown in FIG. 7, product P1 starts switching to product P2 in cycle n. The wire type of product P2 gradually fills the equipment as the cycle progresses. In cycle m+2, the wire type is switched to the wire type of product P2 in all steps. Thus, the switching is completed. It is not necessary to stop the equipment during this period. Automatic switching can be similarly performed and mixed production can be achieved in the case of switching product P2 to product P1, or in the case of any other product that can be manufactured by the same winding. Figure 16

[0140] E2

[0141] In the above-described embodiment, the transport unit 14 includes two transport devices 26 and 27, but can include one transport device. The operation of gripping and transporting the rectangular wire W, releasing the rectangular wire W, and returning to the next gripping position can be repeated for one transport device.

[0142] E3

[0143] In the above-described embodiment, the processing unit 13 includes processing devices 21 to 25, but can include one processing device.

[0144] E4

[0145] In the fourth embodiment, the mark detection sensor 28 also functions as a terminal detection sensor for detecting the terminal 44 of the winding, but the terminal detection sensor can be provided separately from the mark detection sensor 28.

[0146] E5

[0147] In the above-described embodiment, the rectangular wire W used as the wire is a band-insulated copper wire used as a wire-like material for a segmented coil of a vehicle motor, but the wire is not limited thereto. The processing devices 21 to 25 are stripping devices that strip the insulation coating, but can perform other processing.

[0148] The present disclosure is not limited to each of the above-described embodiments, and can be implemented in various configurations without departing from the spirit thereof. For example, the technical features in each of the embodiments corresponding to the technical features in each of the aspects described in the "SUMMARY" can be replaced or combined as necessary to solve some or all of the above-described problems or achieve some or all of the above-described effects. When a technical feature is not described as essential herein, the feature can be deleted as necessary.​

Claims

1. A linear material manufacturing apparatus configured to manufacture a plurality of types of linear materials having different lengths according to a planned sequence by the following steps: feeding a wound wire in a transport direction in each transport cycle; processing the wire; and cutting the wire at the location to which it is transported, The linear material manufacturing device is characterized by comprising: an unwinding device configured to feed the wire in the transport direction; a processing device configured to process the wire and to move between positions along the transport direction during each transport cycle; a transport device configured to transport the wire in the transport direction in each transport cycle, the transport device being disposed on a downstream side of the processing device in the transport direction, and configured to move between positions along the transport direction in each transport cycle; a cutting device fixed at a predetermined position and configured to cut the wire processed by the plurality of processing devices; and a control device configured to calculate, in each transport cycle, positions of the processing device and the transport device by using a plurality of pieces of information related to the length of the linear material, and to control the positions of the processing device and the transport device in each transport cycle, wherein the control device is configured to calculate the position of a calculation target device by summing the lengths of the linear material inserted between the cutting device and the calculation target device when calculating the position of the calculation target device, wherein the calculation target device is any one of the processing device and the transport device whose position is to be calculated in each transport cycle, wherein the control device is configured to store a plurality of line length related information in a plurality of data storage boxes provided in association with a plurality of steps, the line length related information being related to the length of the line-shaped material serving as a processing target in the corresponding steps, wherein the plurality of steps include: a pre-processing step that precedes processing to be performed by the processing device and is expected to proceed to the processing device; a processing step to be performed by the processing device; and a transporting step to be performed by the transporting device; The control device is configured to calculate the position of the calculation target device by using the stored line length related information; The control device is configured to perform a transfer process at the end of each transport cycle, the transfer process being for transferring the plurality of line length related information stored in the data storage box set for the transport cycle to a data storage box set for a next transport cycle; The control device is configured to: when performing the transfer process, transfer the plurality of line length related information stored in the data storage box associated with the corresponding step in the transport cycle to the data storage box associated with a step subsequent to the corresponding step in the next transport cycle; and The control device is configured to calculate the position of the calculation target device in the next transportation cycle by using the line length related information transmitted to the data storage box, Wherein, the linear material manufacturing device further comprises: a detection unit configured to detect a defective portion between the unwinding device and a first processing device, the first processing device being a processing device closest to the unwinding device, wherein The line includes a mark indicating the defective portion, and The control device is configured to: When the detection unit detects the front end of the marker in the transport direction, calculating the distance from the first processing device to the front end in each transport cycle; and When the distance is less than the length of the linear material in the preprocessing step by comparing the distance with the line length related information stored in the data storage box associated with the preprocessing step, discarded line type information indicating the line type to be discarded is inserted into the data storage box associated with the preprocessing step as the line length related information.

2. The linear material manufacturing device according to claim 1, characterized in that: The linear material manufacturing apparatus includes a plurality of the processing devices, and the plurality of the processing devices are configured to perform a plurality of the processing steps on the wire.

3. The linear material manufacturing device according to claim 1, wherein: The control device is configured to: When the detection unit detects the terminal end of the marker in the transport direction and the terminal end is transported downstream in the transport direction relative to the first processing equipment, The wire length related information is stored in the data storage box associated with the pre-processing step according to the planned sequence, so that the wire-shaped material is subsequently processed by the first processing device according to the planned sequence.

4. The linear material manufacturing device according to claim 1, characterized in that: The wire is an insulation-coated copper wire having a rectangular cross-section and serving as a material for the segmented coils; and The processing device is a stripping device configured to strip the insulating coating.

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