Winding device

Abstract

The invention provides a winding device. The distance of a route from a forming part for forming a wire to a winding object is shortened. The winding device (10) of the present invention comprises: a wire supply unit (11) for supplying a circular wire; a molding unit (12) that is provided on the downstream side of the wire supply unit (11) and that forms the shape of the wire into a flat shape; a tension adjustment unit (13) that is provided on the downstream side of the forming unit (12) and that controls the tension during winding; and a winding part (14) which is provided on the downstream side of the tension adjustment part (13) and which winds the wire to a winding target, the forming part (12) forming the wire corresponding to the portion wound to the winding target without forming the portion of the wire corresponding to the head / tail end of the winding target, the tension adjustment part (13) comprising: a tension roller; and a motor for rotating the tension roller, the tension roller having a gripping force for drawing out the wire from the forming part (12) without slipping between the tension roller and the wire.

Description

Technical Field

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

[0002] When a rectangular wire forming device forms a rectangular wire from a round raw material wire and winds the formed rectangular wire around the teeth of a split core, there is a risk that the winding wire may be scratched if the cross-sectional shape of the winding wire changes.

[0003] Therefore, Patent Document 1 discloses a winding device that aims to provide a winding device that can suppress degradation of product quality due to scratches on the winding wire even when the winding wire is wound onto a winding object after deforming its cross-sectional shape midway.

[0004] Specifically, a winding device is disclosed, which supplies the winding from a wire supply source to the side of a winding object and winds it onto the winding object. The winding device is characterized in that it includes: a winding deformation part, which is arranged on the downstream side of the wire supply source, so that the cross-sectional shape of the winding changes; and a scratch detection part, which is arranged on the downstream side of the winding deformation part, to detect scratches on the winding.

[0005] [Prior art literature]

[0006] [Patent Document]

[0007] [Patent Document 1] Japanese Patent Application Laid-Open No. 2023-132628 Summary of the Invention

[0008] [Problems to be solved by the invention]

[0009] In addition, in patent document 1, the flat forming machine serving as the winding deformation part is a structure in which a pair of forming rollers arranged in the vertical direction relative to the wire and a forming roller arranged in the left and right direction relative to the wire are arranged along the long side direction, thereby forming the wire with a circular cross-section into a flat shape.

[0010] Furthermore, in a flat forming machine, the metal wire rod for coils passes between a pair of rollers arranged at a distance such that the wire rod must be deformed in order to advance. Therefore, a large drawing force is required to draw the wire rod out of the flat forming machine.

[0011] Therefore, in an actual device, a flat forming machine includes a take-off roller that takes out the wire rod to the vicinity of the downstream side of the forming roller.

[0012] On the other hand, in a wound object such as a split stator core, both ends (also referred to as leading ends / terminating ends) of the wound coil wire serve as lead wire portions for connection.

[0013] Therefore, it is preferable that the leading end / terminating end of the wire material wound onto the winding object still maintains a circular shape that facilitates the connection operation performed after the winding.

[0014] Furthermore, if it is desired to form such a head end / end that still maintains a circular shape, the wire portion corresponding to the head end / end is not formed using the forming roller, and then the portion wound onto the winding object is formed using the forming roller.

[0015] Specifically, the short length portion at the beginning, which becomes the tip, remains as a round wire, and then is formed into a flat shape to be wound. The round wire at the tip is not wound around the winding object, but is wound around the flat portion.

[0016] Furthermore, the short length of the wire portion corresponding to the end portion of the current winding object and the head end portion of the next winding object (also referred to as the head end / end portion) is not formed again but is made into a circular wire shape, and then, it is formed into a flat shape corresponding to the portion to be wound, and further, the short length of the wire portion that should be the head end / end portion is not formed, and this process is repeated.

[0017] That is, when the wire rod is formed, it is formed so that unformed short portions are repeatedly present, followed by long portions formed into a flat shape.

[0018] Furthermore, when the head end / tail portion reaches the end of the current winding object, it is cut to separate it into the tail portion and the head end portion, and the head end portion later becomes the wire for the next winding object, and this is repeated to continuously perform the winding operation.

[0019] Furthermore, the stator core segments to be wound naturally have variations in shape within the range of manufacturing tolerances.

[0020] That is, the outer shape of the portion to be wound is sometimes small and sometimes large, and the deviation in the outer shape appears as a difference in the length of the wire required to wind the wire with the same number of windings.

[0021] Therefore, even if the number of windings on the winding target is the same, the required length of the wire to be wound may vary.

[0022] Furthermore, for example, in a case where the distance of the route from the forming roller to the winding object is equivalent to the length of the wire wound onto the winding object, when the winding of the wire onto the winding object begins, the wire portion that should be the head end / tail end portion that becomes the boundary with the next winding object will be located at the forming roller.

[0023] Therefore, at the same time as the winding begins, the next head end / end part (unformed circular wire part) enters the route, so it is determined halfway that if the length of the wire is designed, the number of windings is insufficient, and even if the head end / end part is offset to the rear, it cannot be achieved.

[0024] Furthermore, when the number of windings is insufficient, it means that the wire needs to be extended in order to achieve the original number of windings. If the required number of windings is to be achieved, the head end / tail end portion will enter the winding portion.

[0025] If this occurs, not only will it cause the winding to collapse, but the flat portion will be located at the portion that should be the end, thereby increasing the defective rate in the subsequent connection step.

[0026] On the other hand, in recent years, the variety of motors has continued to increase, and the variation in the length of the wire wound on the split stator core has gradually increased, and types with shorter winding lengths have also appeared.

[0027] Therefore, it is considered important to shorten the route while producing the head end / end that is not formed so that the above-mentioned problem will not occur. At the time when it is determined that the number of windings is insufficient, the head end / end portion has not yet entered the route and the head end / end portion can be set in a position offset to the rear.

[0028] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a winding device that shortens the distance of a route from a shaping section that shapes a wire material to a winding target.

[0029] [Technical means to solve the problem]

[0030] In order to achieve the above-mentioned object, the present invention is realized by the following configuration.

[0031] The winding device of the present invention is a winding device for winding a wire onto a winding object, and the winding device includes: a wire supply part, which supplies the circular wire; a forming part, which is provided on the downstream side of the wire supply part, and shapes the wire into a flat shape; a tension adjustment part, which is provided on the downstream side of the forming part, and controls the tension during winding; and a winding part, which is provided on the downstream side of the tension adjustment part, and winds the wire onto the winding object, the forming part does not shape the part of the wire corresponding to the head end / tail end of the winding object but shapes the wire corresponding to the part wound onto the winding object, the tension adjustment part includes: a tension roller; and a motor, which rotates the tension roller, and the tension roller has a gripping force that can lead the wire out of the forming part without slipping between the wire and the forming part.

[0032] [Effects of the Invention]

[0033] According to the present invention, it is possible to provide a winding device that shortens the distance of a route from a shaping section that shapes a wire material to a winding target. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 It is a perspective view of a brushless motor having split cores that can be suitably used in a winding device according to an embodiment of the present invention.

[0035] Figure 2 This is a side view of a portion corresponding to one split core according to the embodiment of the present invention.

[0036] Figure 3 It is a top view for explaining the winding device according to the embodiment of the present invention.

[0037] Figure 4 It is a diagram for explaining the forming operation in the forming section according to the embodiment of the present invention.

[0038] Figure 5 This is a side view of a portion of an encoder according to an embodiment of the present invention as viewed from the side.

[0039] Explanation of Figure Numbers

[0040] 1: Brushless motor

[0041] 2: Stator

[0042] 3: Rotor

[0043] 4: stator core

[0044] 5: Insulator

[0045] 6: Coil

[0046] 7: Split core

[0047] 8: Coil wire

[0048] 8A, 8B: Partial

[0049] 10: Winding device

[0050] 11: Wire supply department

[0051] 12: Forming department

[0052] 12A: First forming section

[0053] 12B: Second forming section

[0054] 13: Tension adjustment unit

[0055] 13A: First tension roller

[0056] 13B: Second tension roller

[0057] 14: Winding part

[0058] E1: Rotating disk

[0059] E2: Light Sensor

[0060] ENC: Encoder

[0061] NZ: Nozzle

[0062] R: Roller

[0063] S:Slit DETAILED DESCRIPTION

[0064] Hereinafter, a form for carrying out the present invention (hereinafter referred to as “embodiment”) will be described in detail with reference to the drawings.

[0065] In addition, throughout the description of the embodiments, the same elements are denoted by the same numbers or symbols.

[0066] Figure 1 The winding device 10 (see Figure 3 ) is a perspective view of the brushless motor 1 with split core 7.

[0067] Figure 2 It is a side view of a portion corresponding to one split core 7 according to the embodiment of the present invention.

[0068] like Figure 1 As shown, for example, a brushless motor 1 (also simply referred to as a motor) includes a stator 2 press-fitted into a housing (not shown) and a rotor 3 arranged radially inside the stator 2 and rotatable relative to the stator 2 .

[0069] The stator 2 includes a stator core 4 , an insulating insulator 5 mounted on the stator core 4 , and a coil 6 .

[0070] The stator core 4 is a split core type stator core 4 formed by connecting a plurality of split cores 7 (an example of a winding object of the present invention) split in the circumferential direction in an annular shape.

[0071] like Figure 2 As shown, the coil 6 is formed by winding a coil wire 8 (an example of a wire material of the present invention) around the split core 7. However, the coil wire 8 wound around the portion 8A of the split core 7 is flattened so as to be wound with as little gap as possible, thereby increasing the density and improving the performance of the motor.

[0072] On the other hand, the coil wire 8 of the portion 8B (hereinafter also referred to as the leading end, trailing end, or collectively referred to as the leading end / trailer) led out from the split core 7 is formed into a circular shape, thereby making it less likely to cause defects during connection work such as welding to a bus bar.

[0073] in addition, Figure 2 Since this is a side view, the tip of the head / tip is depicted, and the head that overlaps in the depth direction of the paper cannot be seen.

[0074] Furthermore, the winding device 10 of this embodiment is suitable for forming the head end / tail end into a circular shape and winding the portion to be wound into a flat shape while winding it onto the split core 7. Figures 3 to 5 While explaining.

[0075] Figure 3 It is a top view for explaining the winding device 10 according to the embodiment of the present invention.

[0076] like Figure 3 As shown, the winding device 10 of this embodiment includes: a wire supply unit 11, which supplies a circular coil wire 8; a forming unit 12, which is provided on the downstream side of the wire supply unit 11 and forms the shape of the coil wire 8 into a flat shape; a tension adjustment unit 13, which is provided on the downstream side of the forming unit 12 and controls the tension during winding; and a winding unit 14, which is provided on the downstream side of the tension adjustment unit 13 and uses a rotating mechanism (not shown) to rotate the split core 7 to rotate the split core 7 while winding the coil wire 8.

[0077] The upstream side (upstream) refers to the wire supply unit 11 side where the supply of the coil wire 8 is started, and the downstream side (downstream) refers to the winding unit 14 side which is the opposite side, and the same applies hereinafter.

[0078] Moreover, the mechanism for winding the coil wire 8 onto the split core 7 is not limited to this. However, in the present embodiment, the winding portion 14 includes a rotating mechanism (not shown) that winds the supplied coil wire 8 onto the split core 7 by rotating while holding the split core 7 and the head end of the coil wire 8 .

[0079] The winding device 10 of this embodiment includes an encoder ENC provided just downstream of the shaping section 12 (at a position between the tension adjusting section 13 ) and a nozzle NZ for supplying the coil wire 8 to the winding section 14 .

[0080] The wire supply unit 11 is a bobbin around which a circular so-called magnet wire serving as the coil wire 8 is wound.

[0081] The forming section 12 includes: a first forming section 12A, which has a pair of forming rollers for forming the coil wire 8 by clamping it from a first direction (upper and lower directions) perpendicular to the coil wire 8 (in addition, only the forming rollers located on the upper side can be seen in the figure); and a second forming section 12B, which has a pair of forming rollers for forming the coil wire 8 by clamping it from a second direction (left and right directions) perpendicular to the coil wire 8 and the first direction.

[0082] Figure 4 These are diagrams for explaining the forming operation in the forming section 12 according to the embodiment of the present invention, and are shown from the left side to the right side and from the upstream side to the downstream side.

[0083] like Figure 4 As shown, the coil wire 8 supplied from the wire supply unit 11 is a circular coil wire 8 .

[0084] Furthermore, when the coil wire 8 passes through the first forming section 12A whose width is limited by the upper and lower rollers, the width in the vertical direction is formed into a width X. Furthermore, when the coil wire 8 passes through the second forming section 12B whose width is limited by the left and right rollers, the width in the left and right directions is formed into a width Y. By passing through the forming section 12, the coil wire 8 is formed into a flat shape with a width of X in the vertical direction and a width of Y in the left and right directions, as shown on the right.

[0085] In addition, the upper roller and the lower roller can be moved in a direction of approaching and a direction of moving away from each other by a driving mechanism (not shown), so that the distance between the upper roller and the lower roller can be changed.

[0086] Similarly, the left roller and the right roller can also be moved in a direction of approaching and a direction of moving away by a driving mechanism (not shown), thereby changing the distance between the left roller and the right roller.

[0087] Therefore, the driving mechanism not shown in the figure is driven in a manner to widen the spacing distance between the upper roller and the lower roller and the spacing distance between the left roller and the right roller so that the coil wire 8 corresponding to the head end / tail end portion is not formed. As a result, the circular coil wire 8 supplied from the wire supply section 11 is not formed but passes directly through, thereby setting the head end / tail end portion in the state of the circular coil wire 8.

[0088] like Figure 3 As shown, the tension adjustment unit 13 includes tension rollers (a first tension roller 13A and a second tension roller 13B) and a motor (not shown) for rotating the tension rollers.

[0089] When the forming lead-out rollers are arranged in front of the downstream side of the forming section 12, the diameter of the two tension rollers is 130 mmφ. However, when the forming lead-out rollers are simply abolished in order to make the forming section 12 closer to the downstream side, slippage frequently occurs between the tension rollers and the coil wire 8, resulting in the problem of being unable to stably lead out the coil wire 8 from the forming section 12.

[0090] Therefore, in order to make the two tension rollers of the tension adjustment section 13 function well as forming and drawing rollers, the two tension rollers of the present embodiment are set to have a large diameter of 150 mmφ.

[0091] In this way, by increasing the diameter of the tension rollers (the first tension roller 13A and the second tension roller 13B), the contact area with the coil wire 8 passing through the first tension roller 13A and the second tension roller 13B is increased, so that the tension rollers (the first tension roller 13A and the second tension roller 13B) obtain a high gripping force to draw the coil wire 8 out of the forming part 12 without slipping between themselves and the coil wire 8.

[0092] In order to ensure a sufficient contact area, the diameter of the tension roller may be 140 mmφ or more. However, if it is too large, space is required, so it may be 200 mmφ or less.

[0093] Moreover, when the forming lead-out roller is arranged in front of the downstream side of the forming section 12, the material of the tension rollers (the first tension roller 13A and the second tension roller 13B) is urethane with a Shore hardness equivalent to A90. In order to delete the forming lead-out roller and make the two tension rollers of the tension adjustment section 13 also serve as the forming lead-out rollers, the raw material is changed to natural rubber with a Shore hardness equivalent to A90 with higher gripping force.

[0094] In this way, a material with high friction is used for at least the portion of the tension roller (the first tension roller 13A and the second tension roller 13B) that contacts the coil wire 8, so that the tension roller (the first tension roller 13A and the second tension roller 13B) obtains a high gripping force to pull the coil wire 8 out of the forming portion 12 without slipping between the tension roller and the coil wire 8.

[0095] As described above, the two tension rollers accompanying the tension adjustment section 13 also serve as forming lead-out rollers, making it possible to implement a structure in which no forming lead-out roller for leading the coil wire 8 from the forming section 12 is provided between the tension rollers (the first tension roller 13A and the second tension roller 13B) and the forming section 12. This allows the forming section 12 to be arranged much closer to the downstream side, and the distance of the route from the forming section 12 to the split core 7 to be wound can be greatly shortened.

[0096] Although not shown, the first tension roller 13A and the second tension roller 13B are connected by a belt, and the belt is driven by a motor, so that the first tension roller 13A and the second tension roller 13B rotate in synchronization.

[0097] Furthermore, in the case of this structure, both the first tension roller 13A and the second tension roller 13B become driving rollers, so unlike when one of them is a driven roller and simply rotates in conjunction with the movement of the coil wire 8, the driven roller works as a load relative to the driving roller, thereby helping to suppress slippage between the coil wire 8.

[0098] Furthermore, since the encoder ENC is also located upstream of the tension adjustment unit 13 , it is a member having low friction resistance and contributes to suppressing slippage between the tension rollers (the first tension roller 13A and the second tension roller 13B) and the coil wire 8 .

[0099] Figure 5 This is a side view of a portion of the encoder ENC according to the embodiment of the present invention as viewed from the side.

[0100] in addition, Figure 5 The figure with the bubble frame portion is a plan view showing only the rotating disk E1.

[0101] and, Figure 5 In FIG. 1 , the illustration of a unit for calculating the supplied length of the coil wire 8 based on a detection result of a detection unit (see a dotted-line frame portion) described later of the encoder ENC is omitted.

[0102] The encoder ENC is a measuring unit that monitors the length of the coil wire 8 supplied to the split core 7. For example, based on the measured length of the coil wire 8, a control unit (not shown) issues control instructions to the forming unit 12 for spacing the forming rollers for the head end / tail end.

[0103] like Figure 3 As shown, the encoder ENC has two rollers R, between which the coil wire 8 passes.

[0104] One roller R is connected to a detection unit described later, and the other roller R serves to bring the coil wire 8 into contact with the roller R side so that slippage does not occur between the roller R connected to the detection unit and the coil wire 8 .

[0105] The pair of rollers R contacts the coil wire 8 so as not to cause slippage therebetween. Therefore, when the structure of the detection unit has a large load, the load is applied to the coil wire 8 via the pair of rollers R.

[0106] Furthermore, when viewed from the tension adjusting portion 13 , the load acts as a force that inhibits the coil wire 8 from being pulled toward the tension adjusting portion 13 . As a result, a greater pulling force is required to pull the coil wire 8 out of the forming portion 12 .

[0107] Therefore, reducing the load on the coil wire 8 by the structure of the detection portion has the same effect as increasing the gripping force of the tension roller.

[0108] That is, if the load on the coil wire 8 caused by the structure of the detection portion is reduced, the gripping force of the tension roller required to also function as the forming and drawing roller can be reduced accordingly.

[0109] Therefore, if Figure 5As shown, as the structure of the detection part, the encoder ENC includes: a rotating disk E1, which is installed on the rotating axis of one of the rollers R and has slits S on the outer peripheral side that are evenly spaced when viewed in the circumferential direction; and a light sensor E2, which detects the passage of the slits S of the rotating disk E1 in a non-contact manner. The encoder ENC strives to reduce the load generated in the detection part.

[0110] In addition, this structure uses the passage of the slit S to detect the rotation state (rotation speed) of the roller R, and calculates the length of the coil wire 8 that has passed based on the rotation speed of the roller R and the circumference (circumferential length) of the contact part between the roller R and the coil wire 8, thereby measuring the length of the coil wire 8 that has been supplied.

[0111] As described above, in this embodiment, by setting the tension rollers (the first tension roller 13A and the second tension roller 13B) to have a high gripping force that allows the coil wire 8 to be drawn out from the forming section 12 without slipping between the coil wire 8 (wire), the structure of the forming lead-out rollers that were previously set to draw out the coil wire 8 from the forming section 12 is not provided between the tension rollers and the forming section 12, and the forming section 12 can be arranged on the downstream side.

[0112] Therefore, the route from the forming section 12 to the split core 7 (winding object) can be shortened, so compared with previous winding devices, it is also easier to cope with the following control, that is, when it is determined that the number of windings is insufficient, the head end / tail end portion has not entered the route in most cases, and the head end / tail end portion is set in a position offset to the rear.

[0113] As mentioned above, although this invention was demonstrated based on the specific embodiment, this invention is not limited to these embodiments.

[0114] For example, although the case where two tension rollers are used in the tension adjustment section 13 is shown, three or more tension rollers may be provided.

[0115] In this case, it is also preferable that both tension rollers are drive rollers that are driven synchronously.

[0116] Thus, the contents that can be understood from the embodiments and the contents in which the embodiments are changed or improved are also included in the technical scope of the invention, and this will be clear to those skilled in the art from the description of the claims.

Claims

1. A winding device for winding a wire material onto a winding object. The winding device is characterized by comprising: a wire material supplying portion for supplying the circular wire material; a shaping section, provided on a downstream side of the wire material supply section, for shaping the wire material into a flat shape; a tension adjustment section, disposed on the downstream side of the forming section, for controlling the tension during winding; as well as A winding portion, provided on the downstream side of the tension adjustment portion, winds the wire material onto the winding object. The shaping section does not shape the portion of the wire corresponding to the leading end / terminating end of the winding object, but shapes the wire corresponding to the portion wound onto the winding object. The tension adjustment unit includes: Tension roller; as well as a motor to rotate the tension roller, The tension roller has a gripping force capable of pulling the wire material out of the forming portion without slipping between the tension roller and the wire material.

2. The winding device according to claim 1, wherein The gripping force is achieved by increasing the diameter of the tension roller.

3. The winding device according to claim 1 or 2, characterized in that The gripping force is obtained by using a material having high friction for at least the portion of the tension roller that contacts the wire rod.

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