Wire winding device and wire winding method
By measuring and adjusting the gap length between the wire and the flange in the winding device and calculating the necessary rotation angle, the winding accuracy problem caused by core manufacturing errors was solved, and high-precision wire winding was achieved.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- NITTOKU CO LTD
- Filing Date
- 2023-06-27
- Publication Date
- 2026-07-24
Smart Images
Figure CN117980247B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to a winding device and a winding method. Background Technology
[0002] Japanese Patent Application Publication No. JP2010-183041A discloses a winding device for winding wire that is unwound from a nozzle onto a winding core. Summary of the Invention
[0003] In the winding apparatus described in Japanese Patent Application Publication JP2010-183041A, winding is performed with the total length of the coil being a fixed length by reducing the influence of wire shape errors on the overall length of the coil. However, in cases where the manufacturing error of the winding core is large and there are deviations in the distance between the flanges, if winding is performed with the total length of the coil as the target length, when winding a core with a distance between the flanges shorter than the target length, new wire is mounted on the wire already wound near the flanges. When winding a core with a distance between the flanges longer than the target length, gaps are generated near the flanges. As a result, the winding accuracy relative to the core may decrease.
[0004] The purpose of this invention is to improve the winding accuracy relative to the core.
[0005] According to one aspect of the present invention, a winding device for winding wire unwound from a nozzle onto a winding core comprises: a nozzle for unwinding wire from its top end; a winding core having a winding body portion for winding the wire unwound from the nozzle and a flange portion disposed at one end of the winding body portion; and a control unit for controlling the rotation of either the nozzle or the winding core, wherein the control unit calculates a necessary rotation angle of the rotating component based on the gap length between the wire and the flange portion measured midway through the winding of the wire toward the flange portion on the winding body portion, and rotates the rotating component by the necessary rotation angle.
[0006] According to another aspect of the invention, a winding method in which wire unwound from the nozzle is wound around the core by rotating either the nozzle or the core, measures the gap length between the wire and the flange portion midway through the winding body portion of the core as the wire is wound toward the flange portion of the core. Based on the gap length, a necessary rotation angle of the rotating component is calculated, and the rotating component is rotated by the necessary rotation angle. Attached Figure Description
[0007] Figure 1 A side view showing the structure of the winding device according to an embodiment of the present invention.
[0008] Figure 2 To indicate along Figure 1 A cross-sectional view of the section of line AA.
[0009] Figure 3 A diagram illustrating an example of an image captured by a photographic device.
[0010] Figure 4 This is a flowchart illustrating the winding steps performed by the winding method according to an embodiment of the present invention. Detailed Implementation
[0011] Hereinafter, with reference to the accompanying drawings, the winding apparatus and winding method according to embodiments of the present invention will be described.
[0012] The winding device 100 is a device that manufactures an array of wound coils by arranging and winding the wire 1 unwound from the nozzle 24 onto the core 30. Figure 1 As shown, the winding device 100 includes: a nozzle 24 that unwinds wire 1 from a top end 24a; a winding core 30 having a winding body 31 for winding the wire 1 unwound from the nozzle 24; a nozzle moving device 20 that moves the nozzle 24 at a predetermined interval speed; a rotating device 15 that rotates the winding core 30, which is a rotated component, about a rotating axis C1; and a control unit 50 that controls the nozzle moving device 20 and the rotating device 15. Furthermore, Figure 1 This is a side view of the winding device 100; however, the image of the imaging device 40, which will be described later, is omitted.
[0013] The nozzle 24 is a cylindrical component with a through hole (not shown) extending axially. The nozzle 24 is mounted on the nozzle moving device 20 with its top end 24a, which opens at one end of the through hole, facing the core 30. The nozzle 24 unwinds the wire 1 supplied by the wire supply source (not shown) from the top end 24a and guides it toward the core 30.
[0014] The core 30 is a so-called winding tube formed of resin, and has a cylindrical winding body 31 for winding the wire 1, a first flange portion 32 provided on one end of the winding body 31 as a flange portion, and a second flange portion 33 provided on the other end of the winding body 31.
[0015] The nozzle moving device 20 is an electric slider 21 that enables the movable piece 22 to reciprocate along the rotation axis C1 of the core 30, and the aforementioned nozzle 24 is mounted on the movable piece 22.
[0016] The rotating device 15 consists of an electric motor 16 and a main shaft 17 mounted on the rotating shaft of the electric motor 16. The top end of the main shaft 17 is shaped to hold the winding core 30 of the above structure.
[0017] A rotor encoder (not shown) is installed on the electric motor 16, which can detect the instantaneous rotation angle of the rotating shaft of the electric motor 16. In addition, the instantaneous rotation angle of the winding core 30, which is rotated by the electric motor 16 via the main shaft 17, can also be calculated based on the detection value of the rotor encoder.
[0018] like Figure 1 As shown, the nozzle moving device 20 and the rotating device 15 are supported by a support column 12 erected on the base 10. Alternatively, the support columns supporting the nozzle moving device 20 and the rotating device 15 can be different supports.
[0019] The control unit 50 controls the operation of the nozzle moving device 20 and the rotating device 15 based on the input from the operator via an input device (not shown). The specific control implemented by the control unit 50 will be detailed in the description of the winding method described later.
[0020] Specifically, the controller 50 is composed of a microcomputer including a CPU (Central Processing Unit), ROM (Read-Only Memory), RAM (Random Access Memory), and an I / O interface (Input / Output Interface). The RAM stores data processed by the CPU, the ROM stores the CPU's control program, and the I / O interface is used for inputting and outputting information to and from the nozzle moving device 20, the rotating device 15, the imaging device 40 (described later), the input device (not shown), and the display device (not shown) connected to the controller 50.
[0021] Here, in the case where the core 30 is specifically formed of resin as described above, the positions of the flange portions 32 and 33 may be slightly offset relative to the winding body portion 31 due to manufacturing errors. Therefore, individual differences may occur in the length of the winding body portion 31, that is, in the size of the interval between the first flange portion 32 and the second flange portion 33.
[0022] Therefore, for example, when the first layer of winding is performed from the second flange portion 33 toward the first flange portion 32 such that the total length of the coil manufactured by the winding device 100 is a predetermined target length, when winding is performed on the core 30 whose length of the winding body portion 31 is shorter than the target length, the new wire 1 is mounted on the wire 1 that has already been wound near the first flange portion 32. When winding is performed on the core 30 whose length of the winding body portion 31 is longer than the target length, a gap is generated near the first flange portion 32. As a result, the winding accuracy relative to the core 30 is reduced.
[0023] Therefore, even if the manufacturing error of the core 30 is relatively large, in order to improve the winding accuracy relative to the core 30, the winding device 100 of this embodiment also includes a shooting device 40 as a distance measuring device.
[0024] The imaging device 40 is, for example, a device mounted on the base 10 for capturing images of the first flange 32 and the wire 1 during the winding process of the wire 1 being wound from the second flange 33 side toward the first flange 32 on the winding body 31. Figure 2 As shown, the shooting device 40 mainly includes a camera 41 and a mirror 43 positioned in the shooting direction of the camera 41. In addition to the above-mentioned components, the shooting device 40 may also include a lighting device and a white or metallic-looking component that serves as a background screen.
[0025] The camera 41 is a digital camera with a sufficient number of pixels and field of view to adequately recognize the shapes of the first flange portion 32, the winding body portion 31, and the wire 1 based on the captured image data. The camera 41 is supported by the support column 13 erected on the base 10 so that the height of the shooting center C2 is the same as the height near the upper end of the winding body portion 31 of the core 30. In other words, the height of the shooting center C2 of the camera 41 is set such that at least the wire 1 extending from the nozzle 24 towards the winding body portion 31 and the first flange portion 32 of the core 30 enter the field of view.
[0026] In addition, the camera 41 is connected to the control unit 50, the shooting time is controlled by the control unit 50, and the captured image data is sent to the control unit 50.
[0027] Mirror 43 is a right-angle prism with a reflective surface that converts the direction of the shooting surface 41a of camera 41 (shooting center C2 direction) toward the core 30 side, and is supported by a pillar 14 erected on the base 10 so that the height of its center position is the same as the height of the shooting center C2.
[0028] Specifically, the direction in which the shooting surface 41a of the camera 41 faces (the shooting center C2 direction), the angle and position of the mirror 43 are set such that the analysis image P captured by the camera 41 (described later) includes the portion of the wire 1 that has just been unwound from the nozzle 24 before being wound around the winding body 31, that is, the portion of the wire 1 that appears to extend radially outward from the winding body 31, the winding body 31 of the core 30, and the first flange portion 32.
[0029] Alternatively, the camera 41 can be configured so that the imaging surface 41a directly faces the vicinity of the upper end of the winding body 31 of the winding core 30 without passing through the mirror 43. In this case, although the mirror 43 is not required, the camera body 41, which includes the lens, is arranged in a direction orthogonal to the rotation axis C1, so the overall winding device 100 may become larger. Therefore, in order to make the winding device 100 more compact, it is preferable to use the mirror 43 appropriately.
[0030] Regarding the analytical image P captured by the imaging device 40 with this structure, refer to... Figure 3 Explanation will be provided. In Figure 3 The image shown is an example of an image P for analysis captured by the imaging device 40.
[0031] As will be described later, the camera 41 performs shooting at a timed manner as instructed by the control unit 50, with the cable 1 being wound from the second flange portion 33 toward the first flange portion 32 in the middle of the winding body portion 31 and the cable 1 being included in the analysis image P.
[0032] The control unit 50 performs image processing on the digital data of the analysis image P to extract the end wire on the side of the first flange portion 32 of the wire 1 and the end face 32a of the first flange portion 32, and calculates the gap length L1 between them.
[0033] Specifically, such as Figure 3 As shown, after the first line segment R1 along the end face 32a of the first flange portion 32, the second line segment R2 along the upper end of the winding body portion 31, and the third line segment R3 along the side of the first flange portion 32 of the wire 1 are identified, the distance between the first line segment R1 and the third line segment R3 at the location where they are separated in parallel from the second line segment R2 by a predetermined specified distance D1 is calculated as the gap length L1.
[0034] Furthermore, the method for calculating the gap length L1 is not limited to this. The gap length L1 can also be calculated based on two line segments: the first line segment R1 along the end face 32a of the first flange portion 32 and the third line segment R3 along the side of the first flange portion 32 of the wire 1. Alternatively, the gap length L1 can be calculated within the area photographed by the winding body portion 31. However, since the color and gloss are similar between the winding body portion 31 and the surrounding portion, it may be difficult to accurately identify, for example, the end face 32a of the first flange portion 32 and the end line along the side of the first flange portion 32 of the wire 1. Therefore, it is preferable to calculate the gap length L1 based on the aforementioned line segments R1, R2, and R3, which are relatively easy to identify by setting the background to white, etc.
[0035] The calculation of the gap length L1 can also be performed by the calculation unit provided in the shooting device 40 instead of the control unit 50. In this case, the size of the gap length L1 is sent from the shooting device 40 to the control unit 50.
[0036] Next, regarding the winding method implemented by the winding device 100 with the above-described structure, refer to... Figure 4 The flowchart will be used for illustration.
[0037] When the operator presses the coil manufacturing start button, the control unit 50 begins winding the wire 1 of the core 30 in step S11. Furthermore, the following description pertains to the case where the top end of the wire 1 is held on the second flange 33 side, and the wire 1 is wound from the second flange 33 side toward the first flange 32 onto the winding body 31.
[0038] Specifically, the control unit 50 moves the movable piece 22 at a pre-inputted pitch speed using the electric slider 21, thereby moving the nozzle 24 toward the first flange portion 32, and drives the core 30 to rotate by rotating the electric motor 16. In this way, the wire 1 is gradually wound around the winding body portion 31 toward the first flange portion 32.
[0039] The electric motor 16 and the electric slider 21 are driven by the control unit 50. When the winding begins, in the subsequent step S12, the control unit 50 determines whether the length of the coil formed on the core 30 has reached the predetermined length of the gap length L1 to be measured.
[0040] Specifically, when the nozzle 24 has moved at least two-thirds of the predetermined total length of the coil along the rotation axis C1 after the winding begins, preferably at least three-quarters, the control unit 50 determines that the state requiring the measurement of the gap length L1 has been reached and proceeds to step S13. On the other hand, if it is determined that the state requiring the measurement of the gap length L1 has not yet been reached, the winding continues. Furthermore, whether the state requiring the measurement of the gap length L1 has been reached can also be determined by whether the total number of rotations of the core 30 or the total number of rotations of the electric motor 16 after the winding begins has reached the predetermined number of rotations.
[0041] In the subsequent step S13, the control unit 50 instructs the imaging device 40 to capture the image P for analysis.
[0042] The shooting device 40, which is instructed to take pictures, captures an analysis image P containing the first flange 32 of the wire 1 as it is wound around the first flange 32 in the middle of the winding body 31, and sends the image to the control unit 50.
[0043] In addition, in step S13, the control unit 50 calculates the rotation angle of the core 30 at the time point when the analysis image P is captured based on the detection value of the rotor encoder, and stores the calculated rotation angle as the starting position for counting the necessary rotation angle RA, which will be described later.
[0044] Furthermore, when the rotation speed of the core 30 is relatively fast, the analysis image P becomes blurry, making it difficult to extract the end wire on the first flange portion 32 side of the wire 1 and the end face 32a of the first flange portion 32. Therefore, when taking the analysis image P in step S13, the rotation speed of the core 30 can be reduced or the rotation of the core 30 can be temporarily stopped.
[0045] As described above, the control unit 50, which receives the analysis image P, calculates the gap length L1 (refer to) through image processing. Figure 3 ).
[0046] In the subsequent step S14, the control unit 50 calculates the necessary rotation angle RA based on the calculated gap length L1. The necessary rotation angle RA is the rotation angle of the core 30 (rotated component) required until the wire 1 wound on the winding body 31 comes into contact with the end face 32a of the first flange 32.
[0047] The necessary rotation angle RA refers to the rotation angle at which the core 30 is rotated from the point in time when the gap length L1 is measured, i.e., the point in time when the analysis image P is captured, so that the wire 1 unwound from the nozzle 24 will be in contact with the end face 32a of the first flange portion 32. In other words, the necessary rotation angle RA refers to the rotation angle of the core 30 required to wind the wire 1 in a manner that is neither too excessive nor too insufficient relative to the measured gap length L.
[0048] Specifically, the necessary rotation angle RA is determined by the following equation (1) based on the moving distance X1 (pitch speed) of the nozzle 24 along the direction of rotation axis C1 during one revolution of the core 30.
[0049] RA=(L1 / X1)·360…(1)
[0050] Alternatively, the integer part of the value obtained by dividing the gap length L1 by the moving distance X1 can be set as the necessary number of rotations RA1, and the remainder can be multiplied by 360 to set as the necessary angle RA2. This is done by dividing the calculation into the number of rotations and the angle of the core 30 (the rotated part). In this case, the value obtained by adding the necessary number of rotations RA1 and the necessary angle RA2 is essentially equivalent to the necessary rotation angle RA mentioned above.
[0051] For example, when the travel distance X1 is 0.2 mm and the gap length L1 is 0.75 mm, the necessary rotation angle RA becomes 1350°. Furthermore, in this case, the necessary number of rotations RA1 becomes three rotations, and the necessary angle RA2 becomes 270°.
[0052] Furthermore, the control unit 50 compares the number of turns when the winding core 30 rotates by a necessary rotation angle RA from the rotation angle of the winding core 30 at the time point when the analysis image P is captured, and the number of turns for the first layer is compared with the pre-planned number of turns for the first layer, and the difference is stored as the number of over- or under-wound turns. Alternatively, the number of turns can be converted into the winding length of the wire 1, and the number of over- or under-wound turns can be stored as the over- or under-wound wire length.
[0053] In step S14, when the necessary rotation angle RA is calculated, the control unit 50 causes the core 30 to rotate further by the necessary rotation angle RA in the subsequent step S15.
[0054] Specifically, the core 30 is rotated by driving the electric motor 16 to rotate until the rotation angle of the core 30, which has been counted since the time point when the image P for analysis was captured, becomes the necessary rotation angle RA. The movable piece 22 is moved at a pre-inputted pitch speed by the electric slider 21.
[0055] In this way, the wire 1 unwound from the nozzle 24 is wound onto the winding body 31 in a manner that is not mounted on the wire 1 already wound near the first flange portion 32, until it is almost in contact with the end face 32a of the first flange portion 32.
[0056] Furthermore, if the winding process continues until the rotation angle of the core 30, which was counted from the time point when the analysis image P was captured, finally becomes the necessary rotation angle RA, then the winding process after the analysis image P was captured in step S13 can either restart without waiting for the measurement of the gap length L and the completion of the calculation of the necessary rotation angle RA, or it can restart after the above calculations are completed.
[0057] Since the wire 1 is wound in such a way that there is almost no gap between it and the end face 32a of the first flange portion 32, when the first layer of winding is completed, the process moves to step S16 to start the winding of the second layer and thereafter.
[0058] The number of windings for the second and subsequent layers is the same as that for the first layer, without calculating the necessary rotation angle RA. In addition, the number of windings for the outermost layer is set to be the same as that for the first layer, after adding or subtracting the amount of over- or under-winding stored in step S14 relative to the pre-planned number of windings.
[0059] Here, when performing the second layer or subsequent winding, the gap between the wires 1 may slightly increase or decrease due to errors in the wire diameter, the shape of the wire 1, and the accuracy of the conveying speed of the nozzle 24. This results in a situation where the winding width is different from the winding width of the first layer. In this case, even if the same number of windings as the first layer is used, there is a possibility that the new wire 1 may be mounted on the wire 1 that has already been wound near the flanges 32 and 33, or that a gap may be created near the flanges 32 and 33.
[0060] Therefore, the measurement of the gap length L and the calculation of the necessary rotation angle RA are not only performed in the first layer of winding, but also in the winding of the second layer and thereafter. For example, they can be performed when winding layers in a predetermined sequence such as the third layer and the seventh layer, or when winding all layers.
[0061] Furthermore, when the wire 1 unwound from the nozzle 24 is wound around the second and fourth layers of the winding body 31 towards the second flange 33 instead of the first flange 32, the imaging device 40 measures the gap length L and calculates the necessary rotation angle RA. The imaging device 40 then captures an analysis image P containing the wire 1 in a single image, showing the second flange 33 winding around the winding body 31 towards the second flange 33. In this case, the second flange 33 corresponds to the flange portion, and the gap length L1 is the distance between the end line of the wire 1 on the second flange 33 side and the end face of the second flange 33. Additionally, the imaging device 40 that captures images near the second flange 33 can be, for example, an imaging device that can capture images near both the first flange 32 and the second flange 33 by switching the position of the mirror 43, or it can be an imaging device separately provided from the imaging device 40 that captures images near the first flange 32.
[0062] In this way, by also measuring the gap length L and calculating the necessary rotation angle RA when performing the winding of the second layer and subsequent layers, it is also possible to wind the wire 1 relative to the core 30 in a way that is neither too much nor too little when performing the winding of each layer.
[0063] Since the performance of a coil generally varies depending on the number of windings and the length of the winding wire, when the second layer or subsequent windings begin, in step S17, in order to achieve the required performance, the control unit 50 determines whether the number of windings of the coil has reached the pre-set design number of windings, or whether the length of the wire 1 used in the winding of the coil has reached the pre-set design length.
[0064] When it is determined that the number of coil windings has reached the pre-set design number of windings, or when it is determined that the length of wire 1 used in the coil winding has reached the pre-set design length, the control unit 50 stops the electric motor 16 and the electric slider 21, and ends the winding.
[0065] Through the above processes, the winding of the wire 1 to the core 30 is completed, and a winding coil with predetermined parameters is formed on the core 30.
[0066] The above implementation method achieves the following effects.
[0067] In the winding device 100 with the above structure, the control unit 50 calculates the necessary rotation angle RA of the core 30, which is a rotating component, based on the gap length L between the wire 1 unwound from the nozzle 24 and the first flange 32, which is wound around the winding body 31 as a flange portion. The core 30 is then rotated by the necessary rotation angle RA.
[0068] In this way, by determining the necessary rotation angle RA of the core 30 required to wind the wire 1 in a manner that is neither too excessive nor too insufficient, in order to wind the wire 1 in a way that is neither too excessive nor too insufficient, based on the measured gap length L between the wire 1 and the first flange 32 as it is wound around the winding body 31 towards the first flange 32, and by rotating the core 30 by this necessary rotation angle RA, even if there are individual differences in the length of the winding body 31 due to manufacturing errors of the core 30, it is possible to prevent new wire 1 from being mounted on wire 1 already wound near the first flange 32, and to prevent gaps from forming near the first flange 32. As a result, the winding accuracy relative to the core 30 can be improved.
[0069] Furthermore, according to the winding device 100 with the above-described structure, even in cases where the manufacturing error of the core 30 is relatively large, or where the guide groove for the position of the first layer of wire 1 is not formed on the winding body 31, the wire 1 can still be wound relative to the core 30 in a manner that is neither too much nor too little. Therefore, the manufacturing cost of the core 30 can be reduced, and the manufacturing cost of the coil formed on the core 30 can also be reduced.
[0070] Furthermore, the following modifications are also within the scope of the present invention, and it is possible to combine the structures shown in the modifications with the structures described in the above embodiments, or to combine the structures described in the following different modifications with each other.
[0071] In the above embodiment, the winding device 100 is described as an arrangement winding machine in which the core 30 is the rotating component. Alternatively, the winding device may be an arrangement winding machine in the form of a flywheel in which the nozzle 24 is the rotating component. In this case, the control unit 50 controls the rotation of the nozzle 24, which rotates around the core 30 while unwinding the wire 1.
[0072] Furthermore, in the above embodiment, the measurement of the gap length L and the calculation of the necessary rotation angle RA are performed when the first layer of winding is carried out on the core 30. In addition, the measurement of the gap length L and the calculation of the necessary rotation angle RA are performed not only when the first layer of winding is carried out on the core 30, but also when the second layer or subsequent layers of winding are carried out. Alternatively, if a guide groove is formed on the winding body 31 to define the position of the first layer of wire 1, these calculations may not be performed when the first layer of winding is carried out on the core 30, but rather when the second layer or subsequent layers of winding are carried out.
[0073] Furthermore, in the above embodiment, the cross-sectional shape of the wire 1 is circular. Alternatively, the cross-sectional shape of the wire 1 can also be rectangular or polygonal. Additionally, in the above embodiment, the outer peripheral surface of the winding main body 31 around which the wire 1 is wound has a circular cross-sectional shape. Alternatively, the cross-sectional shape of the winding main body 31 can also be rectangular or polygonal.
[0074] In addition, in the above embodiment, the core 30 is made of resin. Alternatively, the core 30 can also be a metal winding tube.
[0075] Furthermore, in the above embodiment, the winding body portion 31 and the two flange portions 32 and 33 of the core 30 are integrally formed. Alternatively, the winding body portion 31 and the two flange portions 32 and 33 of the core 30 can also be formed from different components. In addition, the core 30 can be composed of the winding body portion 31 and either of the flange portions 32 and 33, or a portion of the main shaft 17 can be used as the winding body portion 31 of the core 30.
[0076] Furthermore, in the above embodiment, the moving distance X1 used in calculating the necessary rotation angle RA is a pre-set value. Alternatively, the moving distance X1 can also be calculated from the analysis image P in the same way as the gap length L1. Specifically, the width of the wire 1 in the direction along the rotation axis C1 when the wire 1 is wound on the winding body 31 can be measured based on the analysis image P, and the measured width can be regarded as the moving distance X1 of the nozzle 24 along the rotation axis C1 during one revolution of the winding core 30, thereby calculating the necessary rotation angle RA.
[0077] Furthermore, in the above embodiment, the measurement of the gap length L1 is performed using an analysis image P captured by the camera 41. Alternatively, the measurement of the gap length L1 can also be performed using a laser distance measuring machine such as a 2D-LiDAR (Light Detection and Ranging) sensor. For example, the gap length L1 can be calculated based on the shape of the core 30 including the wire 1, determined by irradiating the portion of the wire 1 just before it is wound around the winding body 31 from the nozzle 24 and the first flange 32 with laser light, or irradiating the first flange 32 towards the second flange 33 along the rotation axis C1.
[0078] The structure, function, and effects of the embodiments of the present invention are summarized and explained below.
[0079] The winding device 100 includes: a nozzle 24 that unwinds wire 1 from a top end 24a; a core 30 having a winding body 31 for winding the wire 1 unwound from the nozzle 24, and a first flange 32 disposed at one end of the winding body 31; and a control unit 50 that controls the rotation of either the nozzle 24 or the core 30, which are the rotating components. The control unit 50 calculates the necessary rotation angle RA of the rotating component based on the gap length L1 between the wire 1 and the first flange 32 measured midway through the winding of the wire 1 toward the first flange 32 on the winding body 31, and rotates the rotating component by the necessary rotation angle RA.
[0080] In this structure, since the necessary rotation angle RA of the rotating component is determined for winding the wire 1 in a manner that is neither too excessive nor too insufficient, in order to wind the wire 1 in a way that is neither too excessive nor too insufficient, as measured midway between the wire 1 and the first flange 32 when the wire 1 is wound toward the first flange 32 and the first flange 32 is wound around, and the rotating component is rotated by this necessary rotation angle RA, even if there are individual differences in the length of the winding body 31 due to manufacturing errors of the core 30, it is possible to prevent new wire 1 from being mounted on wire 1 already wound near the first flange 32, and to prevent gaps from forming near the first flange 32. As a result, the winding accuracy relative to the core 30 can be improved.
[0081] In addition, the necessary rotation angle RA is set as the rotation angle of the rotated component starting from the time point when the gap length L1 is measured, and is set as the rotation angle of the rotated component required until the wire 1 wound on the winding body 31 is connected to the first flange 32.
[0082] In this structure, the necessary rotation angle RA is set to the rotation angle of the rotated component required until the wire 1 wound on the winding body 31 comes into contact with the first flange 32. By rotating the rotated component by such a set necessary rotation angle RA, the wire 1 can be wound in a manner that is neither too much nor too little relative to the gap length L. As a result, even if there are individual differences in the length of the winding body 31 due to manufacturing errors of the core 30, it is possible to prevent new wire 1 from being mounted on the wire 1 already wound near the first flange 32, and to prevent gaps from forming near the first flange 32.
[0083] In addition, at least one of the wound body portion 31 and the first flange portion 32 is made of resin.
[0084] In this structure, since at least one of the winding body portion 31 and the first flange portion 32 is made of resin, individual differences may occur in the length of the winding body portion 31 and the size of the interval between the first flange portion 32 and the second flange portion 33 due to manufacturing errors, etc. However, since the wire 1 is wound in a manner that is neither too excessive nor too insufficient for the gap length L1 measured for each core 30, the winding accuracy for the core 30 can be improved regardless of manufacturing errors.
[0085] In addition, the winding device 100 includes a camera 40 capable of capturing images of the first flange portion 32 and the wire 1 during the winding of the wire 1 toward the first flange portion 32 in the winding body portion 31, and the control unit 50 calculates the gap length L1 based on the image captured by the camera 40.
[0086] In this structure, the gap length L1 is calculated based on the image captured by the imaging device 40. Thus, by using a relatively simple system to measure the gap length L1, the increase in manufacturing cost of the winding device 100 can be suppressed.
[0087] Furthermore, by rotating either the nozzle 24, which is the rotating component, or the winding core 30, the wire 1 unwound from the nozzle 24 is wound around the winding body 31 of the winding core 30. The gap length L1 between the wire 1 and the first flange 32 is measured midway through the winding body 31 of the winding core 30, the necessary rotation angle RA of the rotating component is calculated based on the gap length L1, and the rotating component is rotated by the necessary rotation angle RA.
[0088] In this structure, since the necessary rotation angle RA of the rotating component is determined for winding the wire 1 in a manner that is neither too excessive nor too insufficient, in order to wind the wire 1 in a way that is neither too excessive nor too insufficient, as measured midway between the wire 1 and the first flange 32 when the wire 1 is wound toward the first flange 32 and the first flange 32 is wound around, and the rotating component is rotated by this necessary rotation angle RA, even if there are individual differences in the length of the winding body 31 due to manufacturing errors of the core 30, it is possible to prevent new wire 1 from being mounted on wire 1 already wound near the first flange 32, and to prevent gaps from forming near the first flange 32. As a result, the winding accuracy relative to the core 30 can be improved.
[0089] 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.
Claims
1. A winding device for winding wire unwound from a nozzle onto a core, wherein, have: The nozzle unwinds the wire from its top end; The winding core has a winding body portion for winding the wire that is unwound from the nozzle, and a flange portion provided at one end of the winding body portion. A photographing device capable of capturing images of the flange and the wire midway through the winding of the wire toward the flange portion; The control unit controls the rotation of either the nozzle or the winding core, which are the rotating components. The control unit extracts the end line of the wire on the flange side and the end face of the flange from the image midway as the wire is wound toward the flange portion, calculates the distance between them as the gap length between the wire and the flange portion, calculates the necessary rotation angle of the rotated component based on the gap length, and rotates the rotated component by the necessary rotation angle.
2. The winding device as described in claim 1, wherein, The necessary rotation angle is the rotation angle of the rotated component starting from the time point when the gap length is measured, and is set to the rotation angle of the rotated component required until the wire wound on the winding body comes into contact with the flange.
3. The winding device as described in claim 1, wherein, At least one of the wound body portion and the flange portion is made of resin.
4. A winding method comprising winding wire unwound from the nozzle onto the core by rotating either a nozzle, which is a rotating component, or a core, wherein... Midway through the winding body of the core, as the wire is wound around the flange portion of the core, the end wire on the flange side and the end face of the flange portion of the wire are extracted from the image captured by an imaging device capable of capturing images of the flange portion and the wire, and the distance between them is measured as the gap length between the wire and the flange portion. The necessary rotation angle of the rotated component is calculated based on the gap length. The rotated component is rotated by the necessary rotation angle.
5. The winding method as described in claim 4, wherein, The necessary rotation angle is the rotation angle of the rotated component starting from the time point when the gap length is measured. The necessary rotation angle is set to the rotation angle of the rotated component required until the wire wound on the winding body comes into contact with the flange.