Defect inspection device for winding, defect inspection system for winding, and defect inspection method for winding

Abstract

A defect inspection device for a winding wire, the winding wire being wound around a wound member (22) and traveling by applying a certain tension, is provided with: an ion generation unit (4) that is disposed along a traveling path of the winding wire (1) reaching the wound member (22) and generates ions surrounding the outer periphery of the winding wire (1), and a defect inspection unit (5) that inspects the defect of the winding wire (1) and that inspects the defect of the winding wire (1), the ion generation unit (4) being disposed along the traveling path of the winding wire (1); a current detection means (31) that detects a current flowing through the winding as a result of the charge of the ions entering from the defect portion of the winding; and a defect presence / absence determination means (33) for determining the presence / absence of a defect in the winding wire (1) on the basis of the result of comparing the output of the current detection means (31) with a predetermined defect presence / absence threshold value, the defect of the winding wire (1) being detected while the winding wire (1) is traveling, and the insulation layer of the winding wire (1) being prevented from being damaged at the time of detection.

Description

Technical Field

[0001] This disclosure relates to a device for inspecting defects in winding, a system for inspecting defects in winding, and a method for inspecting defects in winding. Background Technology

[0002] When the insulation layer of a rotating electric motor's windings is damaged or has pinholes or other defects, the insulation between the windings and the winding core, or between the windings and ground, decreases. This can lead to insulation damage between adjacent windings forming the coil, potentially causing performance degradation, burnout, or leakage in the rotating electric motor. Therefore, it is necessary to inspect the windings for defects in rotating electric motors.

[0003] Defects in the winding can be detected by applying a voltage to the winding while it is in motion and detecting the current generated during discharge at the defective portion of the winding. However, if the discharge current is not limited, the insulation layer of the winding may be damaged, and the defect may further expand. Therefore, it is necessary to prevent damage to the insulation layer when inspecting winding defects.

[0004] Existing winding defect inspection technologies include the following winding defect detection devices: In order to inspect large damage caused by friction between the guide wire tip and the winding, a fixed resistor is added between the power supply used for inspection and the winding to limit the current flowing during the inspection of damage, thereby preventing the winding from burning out (for example, see Patent Document 1).

[0005] Existing technical documents

[0006] Patent documents

[0007] Patent Document 1: Japanese Patent No. 6408229 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] According to the technology disclosed in Patent Document 1, a fixed resistor is added between the power supply for inspection and the winding to limit the current flowing through a large damaged area of ​​about 1 mm caused by friction between the wire tip guiding the winding to the wound component and the winding. This prevents burning of the damaged portion of the winding and allows for inspection of any damage to the winding.

[0010] On the other hand, when inspecting defects inherent in the winding (such as pinholes or thin insulation dents), the required power supply voltage and discharge current vary depending on the size of the defect. Therefore, when using a fixed resistor to inspect large defects, small defects, or thin insulation dents (i.e., weak defects), applying a low voltage can detect large defects but not small or weak ones. Applying a high voltage can detect small and weak defects, but may damage the winding insulation when detecting large defects. Thus, with a fixed resistor, there is a problem of not being able to simultaneously detect all types of defects and prevent damage to the winding insulation.

[0011] This disclosure was made to solve the above-mentioned problems, and its purpose is to provide a winding defect inspection device that can reliably detect defects in a winding during travel.

[0012] Methods for solving problems

[0013] The defect inspection device for winding disclosed in this application is a device for inspecting defects in windings that are wound under a certain tension for winding onto a component. The device includes: an ion generating unit, which is arranged along the travel path of the winding to the component to generate ions that surround the outer periphery of the winding; a current detection unit, which detects the current flowing in the winding as a result of the intrusion of the charge of the ions from the defect portion of the winding; and a defect presence / absence determination unit, which determines whether the winding has defects based on the result of comparing the output of the current detection unit with a predetermined defect presence / absence threshold.

[0014] Invention Effects

[0015] According to the winding defect inspection device disclosed in this application, defects in the winding can be detected with high reliability by detecting the current generated due to the intrusion of the charge of ions generated by the ion generation unit into the defective part of the winding. Attached Figure Description

[0016] Figure 1 This is a block diagram showing the structure of the winding defect inspection device of Embodiment 1.

[0017] Figure 2 This diagram illustrates the principle of using ions for defect detection in wire winding.

[0018] Figure 3 This diagram shows the output of the micro-current meter, the output of the inspection signal processing unit, and the output of the defect presence / absence determination unit of the winding defect inspection device in Embodiment 1.

[0019] Figure 4This is a diagram illustrating an example of the circuit structure of the inspection signal processing unit and the defect presence / absence determination unit in Implementation Method 1.

[0020] Figure 5 This is a block diagram showing the structure of the winding defect inspection device of Embodiment 2.

[0021] Figure 6 This is a block diagram showing the structure of the winding defect inspection device of Embodiment 3.

[0022] Figure 7 This is a block diagram showing the structure of the winding defect inspection device of Embodiment 4.

[0023] Figure 8 This is a diagram showing the relationship between the motor coil wound on the core, the ion generation unit, and the encoder during defect detection in the winding defect inspection system of Embodiment 5.

[0024] Figure 9 This is a diagram illustrating the relationship between the distances to the defect location used to calculate the defect detection in the winding defect inspection system of Embodiment 5.

[0025] Figure 10 This is a flowchart illustrating the measurement steps of the defect inspection system in Implementation 5.

[0026] Figure 11 This is a diagram illustrating an example of the hardware structure of the controller of the defect inspection system in Implementation 5. Detailed Implementation

[0027] Hereinafter, a preferred embodiment of the winding defect inspection device of this application will be described with reference to the accompanying drawings. Furthermore, identical symbols will be used to denote the same content and corresponding portions, and detailed descriptions will be omitted. Similarly, in subsequent embodiments, repeated descriptions of structures labeled with the same reference numerals will be omitted.

[0028] Implementation method 1.

[0029] Figure 1 This is a block diagram of the defect inspection device for the winding of a rotary electric motor according to Embodiment 1. The defect inspection device for the winding 1 includes a winding machine body 2 that winds the winding 1 onto a winding component 22 to manufacture a winding component for a rotary electric motor, and a defect inspection unit 3 for the winding 1.

[0030] The winding machine body 2 has: a winding section 21 that winds out the winding 1; a winding component 22 that is wound with the winding 1; a wire nozzle 23 that guides the winding 1 when it is wound onto the winding component 22; and a housing 24 for mounting the wire nozzle 23.

[0031] The defect inspection unit 3 is mainly composed of the following (1) to (4) to detect defects in the winding 1 and to prevent the insulation layer 12 of the winding 1 from being damaged during inspection (see reference). Figure 2 )damage.

[0032] (1) The winding 1 wound on the winding part 21 is tensioned by the tensioner 90 while traveling, and the ion generating unit 4 is arranged in the middle of the path to the winding part 22.

[0033] (2) The micro-current meter 31 detects the current 45 flowing through the winding 1 due to the ions generated by the ion generation unit 4 when there are defects such as pinholes in the winding 1.

[0034] (3) Check the output of the signal processing unit 32 to amplify the micro ammeter 31 and perform noise processing.

[0035] (4) The defect presence or absence judgment unit 33 judges whether there is a defect based on the output of the inspection signal processing unit 32.

[0036] Ion generation unit

[0037] The ion generating unit 4 comprises a discharge needle 43, an ion generator 42 that induces corona discharge in the discharge needle 43, and a power supply 41 that applies voltage to the ion generator 42. A voltage is applied from the power supply 41 to the ion generator 42, causing the discharge needle 43 to induce corona discharge. Through this corona discharge, the air surrounding the discharge needle 43 is ionized, generating positive or negative ions 44. The winding 1 passes through this atmosphere of generated positive or negative ions, thereby surrounding the outer periphery of the winding 1 with ions 44 having arbitrary positive or negative charges 441. Since the ions 44 can surround the entire outer periphery of the winding 1, for example, the discharge needle 43 can be oriented towards the side of the winding 1 opposite to the side where the defect 13 exists. That is, defects can be detected regardless of the orientation of the defect in the winding 1.

[0038] <Defect Detection Action Description>

[0039] Defect detection is performed by the defect inspection unit 3. The defect inspection unit 3 consists of a micro ammeter 31, an inspection signal processing unit 32, and a defect presence / absence determination unit 33.

[0040] First, let's explain the current generation when winding 1 is surrounded by ions 44. For ease of explanation, let's start from... Figure 1 The block diagram will illustrate the necessary parts in a simplified manner. Figure 2 For example, there is a pinhole defect 13 with a width of 100 μm in the winding 1. When the defect 13 passes through the space where ions 44 are present, the charge 441 of the ions 44 enters the winding 1 from the defect 13 and flows along the copper core 11 of the winding 1, thereby generating a current 45.

[0041] When the defect 13 in the winding 1 is, for example, as large as 100 μm, the amount of charge 441 entering the copper core 11 of the winding 1 increases, such as... Figure 3 As shown in (a), the current 45 increases to, for example, 4μA, as with signal 45a. Figure 3 In (a), the vertical axis represents the magnitude of the current 45, and the horizontal axis represents the elapsed time. Furthermore, when generating ions 44, in order not to damage the insulation layer 12 of the winding 1, the concentration of ions 44 (in other words, the total amount of charge 441 possessed by ions 44) is reduced, for example, to 20 μA.

[0042] In contrast, when the defect 13 in the winding 1 is small, for example, 50 μm, the amount of charge 441 entering the copper core 11 of the winding 1 is small. Therefore, the magnitude of the current 45 is, for example, as small as 2 μA, as shown in signal 45b. Furthermore, when the winding 1 has no defect 13, as shown in signal 45c, the magnitude of the current 45 is 0 μA.

[0043] Next, the detection of defect 13 in winding 1 will be explained. Regarding the current 45, Figure 3 Signals 45a and 45b from (a) flow to ground via the micro-ammeter 31, thus the current 45 can be detected by the micro-ammeter 31. The micro-ammeter 31, for example, converts a current of 1 μA into a voltage of 100 mV and outputs it.

[0044] The signal processing unit 32 performs amplification and noise removal on the voltage output converted by the micro-ammeter 31. Figure 3 (b) represents the voltage waveform signals 32a and 32b after the current waveform signals 45a and 45b are converted by the micro-ammeter 31 and processed by the inspection signal processing unit 32. The defect presence / absence judgment unit 33 inputs the signals 32a and 32b processed by the inspection signal processing unit 32, and judges whether there is a defect in the winding 1 by comparing them with the defect presence / absence threshold 32d. Figure 3 In (b), the vertical axis represents the magnitude of the voltage, and the horizontal axis represents the voltage relative to the horizontal axis. Figure 3 (a) The same elapsed time. Signal 32a is larger than the defect presence / absence threshold 32d during time t2~t3, therefore, as Figure 3As shown in (c), a high-level "H" defect presence / absence signal 33a, indicating a defect, is output to the controller 34 of the winding machine body 2. Furthermore, the signal 32b during the time interval t4~t5 is also greater than the defect presence / absence threshold 32d; therefore, a high-level "H" defect presence / absence signal 33b, indicating a defect, is output. The controller 34 can also receive the high-level "H" signal to generate a warning sound, display an indicator, etc., to attract the operator's attention. The defect location can be determined based on the timing of the defect presence / absence signals 33a and 33b; therefore, countermeasures such as stopping the winding machine body 2 can be taken to remove or repair the defective part. Figure 3 In (c), the vertical axis represents the signal "H" or "L", and the horizontal axis represents the signal related to... Figure 3 of (a) Figure 3 (b) The same elapsed time.

[0045] The defect presence / absence threshold 32d is pre-selected using preliminary tests. In the preliminary tests, for example, (A) a winding determined to be defect-free using a JIS pinhole test, and (B) a winding determined to be defective are prepared. The defect-free winding (A) is wound using a defect inspection device, and the current measured by the micro-ammeter 31 and the voltage converted from the current are recorded. In this case, since only noise is recorded, to avoid misdetecting noise as a defect, a voltage higher than the noise voltage is set as the defect presence / absence threshold 32d. Furthermore, the voltage applied to the ion generator 42 of the ion generation unit 4 is set such that the minimum value of the output of the micro-ammeter 31 when the defective winding (A) is wound using the defect inspection device—that is, the voltage that determines a defect—is greater than the defect presence / absence threshold 32d.

[0046] <Detailed structure of the micro-galvanometer, inspection signal processing unit, and defect presence / absence judgment unit>

[0047] The micro current meter 31 only needs to be able to detect a small current and convert it into voltage. For example, the commercially available micro current meter 5450 can also be used.

[0048] Furthermore, terminal 311 of the micro-ammeter 31 does not output voltage. That is, by setting the voltage at terminal 311 to 0V, charge 441 can naturally flow to ground.

[0049] Alternatively, a positive voltage of, for example, 50V can be output through terminal 311 to actively introduce charge 441 into the micro-ammeter 31. As a result, the amount of charge 441 flowing to the micro-ammeter 31 increases, thus increasing the detection signal and improving detection accuracy.

[0050] Figure 4This illustrates an example of the circuitry for the inspection signal processing unit 32 and the defect presence / absence determination unit 33. The inspection signal processing unit 32 uses an amplifier 321 (full name: amplifier, external components other than resistors omitted) for signal amplification to amplify the voltage signal output from the signal converted from the voltage of the micro-ammeter 31. The defect presence / absence determination unit 33 uses a comparator 331 (external components omitted) to compare the output of the amplifier 321 with a defect presence / absence threshold 32d. When the output of the amplifier 321 is greater than the defect presence / absence threshold 32d, the comparator 331 becomes high ("H"), for example, outputting a 5V signal. When the output of the amplifier 321 is less than the defect presence / absence threshold 32d, the comparator 331 becomes low ("L"), for example, outputting a 0V signal. Figure 3 (c) represents the output of comparator 331. A filter (e.g., a low-pass filter) can also be configured between amplifier 321 and comparator 331 to remove noise superimposed on the current detected by micro-ammeter 31.

[0051] As described above, since the charge from the ion generating unit 4 penetrates the defective portion of the winding, defects in the traveling winding can be detected with high reliability, and damage to the insulation layer of the winding can be prevented during defect detection. Furthermore, as the winding 1 passes through the ion generating unit 4, ions 44 surround the outer periphery of the wire. Therefore, even if the discharge needle 43 is not oriented towards the defect 13, for example, if the discharge needle 43 is oriented towards the outer peripheral surface of the winding opposite to the defect 13, defect detection can be performed regardless of the defect's orientation. Moreover, compared to methods that detect defects in the winding by irradiating the winding with an electron beam, no equipment for creating a vacuum environment is required, thus offering advantages such as simplified structure.

[0052] Implementation method 2.

[0053] Figure 5 This is a block diagram showing the defect inspection device for the winding of the rotary electric machine according to Embodiment 2. In this diagram, [the following text is incomplete and likely refers to a different device:] ...and... Figure 1 The same label indicates the same or equivalent parts.

[0054] The defect inspection unit 3 is mainly composed of the following (1) to (4) to detect defects 13 in the winding 1 and to prevent damage to the insulation layer 12 of the winding 1 during inspection.

[0055] (1) The winding 1 wound on the winding part 21 is tensioned by the tensioner 90 while traveling, and the ion generating unit 4a is arranged in the middle of the path to the winding part 22.

[0056] (2) The micro-current meter 31 detects the current 45 flowing through the winding 1 due to the ions generated by the ion generation unit 4a when there are defects such as pinholes in the winding 1.

[0057] (3) Check the output of the signal processing unit 32 to amplify the micro ammeter 31 and perform noise processing.

[0058] (4) The defect presence or absence judgment unit 33 judges whether there is a defect based on the output of the inspection signal processing unit 32.

[0059] <Ion Generation Unit of Embodiment 2>

[0060] The ion generating unit 4a of Embodiment 2, similar to that of Embodiment 1, comprises a discharge needle 43, an ion generator 42 that induces corona discharge in the discharge needle 43, and a power supply 41 that applies voltage to the ion generator 42. Furthermore, the ion generating unit 4a of Embodiment 2 includes a shielding box 46 made of a non-conductive material for limiting the generation range of ions 44. The shielding box 46 is formed to extend from the ion generator 42 toward the winding 1 in a manner that surrounds the discharge needle 43, and may also be cylindrical or square in shape. Figure 5 As shown, when the shielding box 46 extends around the winding 1, a through hole 461 is formed in the shielding box 46 for the winding 1 to pass through, and a cover 462 is provided for enclosing the ions 44 in the shielding box 46.

[0061] By limiting the generation range of ions 44 using the shielding box 46, the concentration of ions 44 can be increased. Therefore, even if the amount of ions 44 generated is the same as in Embodiment 1, the charge entering the copper core 11 from the defect 13 of the winding 1 can be increased. As a result, the signal detected by the micro-galvanometer 31 also becomes larger. Therefore, for example, even small defects that cannot be detected in Embodiment 1 can be detected by the micro-galvanometer 31. In addition, since the generation range of ions 44 is limited, it also has the advantage that when a defect 13 is detected, it is easier to determine the location of the defect 13 based on the detection time, the travel speed of the winding 1, and the width of the shielding box 46 compared to Embodiment 1.

[0062] The shielding box 46 is equipped with a cover 462, but the cover 462 may not be required as long as the ions 44 can be sealed within the shielding box 46.

[0063] As described above, in addition to the effects of Embodiment 1, the defect inspection device of Embodiment 2 is also equipped with a shielding box that limits the range of ion generation. Therefore, the detection accuracy of defects can be further improved, and the determination of the detection location of defects becomes easier.

[0064] Implementation method 3.

[0065] Figure 6 This is a block diagram showing the defect inspection device for the winding of the rotary electric machine according to Embodiment 3. In this diagram, [the following text appears to be incomplete and requires further context: "and..."] Figure 1The same label indicates the same or equivalent parts.

[0066] The defect inspection unit 3 is mainly composed of the following (1) to (4) to detect defects 13 in the winding 1 and to prevent damage to the insulation layer 12 of the winding 1 during inspection.

[0067] (1) The winding 1 wound on the winding part 21 is tensioned by the tensioner 90 while traveling, and the ion generating unit 4b is arranged in the middle of the path to the winding part 22.

[0068] (2) The micro-current meter 31 detects the current 45 flowing through the winding 1 due to the ions generated by the ion generation unit 4b when there are defects such as pinholes in the winding 1.

[0069] (3) Check the output of the signal processing unit 32 to amplify the micro ammeter 31 and perform noise processing.

[0070] (4) The defect presence or absence judgment unit 33 judges whether there is a defect based on the output of the inspection signal processing unit 32.

[0071] <Ion Generation Unit of Embodiment 3>

[0072] The ion generating unit 4b of Embodiment 3 is similar to that of Embodiment 1, consisting of a discharge needle 43, an ion generator 42 that causes corona discharge in the discharge needle 43, and a power supply 41 that applies voltage to the ion generator 42. Furthermore, the ion generating unit 4b of Embodiment 3 includes, between the discharge needle 43 and the winding 1: a metal plate 47 that accumulates ions 44; a brush 49 that contacts the winding 1; and a conductor 48 for directing the charge 441 of the ions 44 accumulated on the metal plate 47 to the brush 49.

[0073] By setting the metal plate 47, ions 44 actively move towards the metal plate 47, thus accumulating on the metal plate 47. This increases the amount of charge 441 entering the defect 13 of the winding 1 via the conductor 48 and the brush 49. Consequently, the signal detected by the micro-ammeter 31 also increases, improving the detection accuracy of minute defects without damaging the insulation layer 12 of the winding 1. Furthermore, since the generation range of ions 44 is limited to the contact area between the brush 49 and the winding 1, it also has the advantage that, when a defect 13 is detected, the location of the defect 13 is more easily determined based on the detection time, the travel speed of the winding 1, and the width of the brush 49 compared to Embodiment 1. In addition, similar to Embodiments 1 and 2, defects can be detected regardless of the direction of the discharge needle 43 toward the winding 1.

[0074] Furthermore, even if the amount of charge 441 flowing to defect 13 is relatively large, it is only about 20 μA, so it will not damage the insulation layer 12 of the winding 1. In addition, since no high voltage is applied to the winding 1, it is possible to avoid discharge between the defect 13 of the winding 1 and the components of the winding machine body 2, such as the wire nozzle 23.

[0075] As described above, in addition to the effects of Embodiment 1, the defect inspection device of Embodiment 3 can further improve the detection accuracy of defects and make it easier to determine the location of defect detection.

[0076] Implementation method 4.

[0077] Figure 7 This is a block diagram showing the defect location inspection device for the winding of the rotary electric machine according to Embodiment 4. In this diagram, [the following text appears to be incomplete and requires further context: "and..."] Figure 1 The same label indicates the same or equivalent parts.

[0078] The defect inspection unit 3 is mainly composed of the following (1) to (5) to detect defects 13 in the winding 1 and to prevent damage to the insulation layer 12 of the winding 1 during inspection.

[0079] (1) The winding 1 wound on the winding part 21 is tensioned by the tensioner 90 while traveling, and ion generating units 4a1 and 4a2 are arranged in the middle of the path to the winding part 22.

[0080] (2) The micro-current meter 31 detects the current 45 flowing through the winding 1 due to the ions generated by the ion generating units 4a1 and 4a2 when there are defects such as pinholes in the winding 1.

[0081] (3) Check the output of the signal processing unit 32 to amplify the micro ammeter 31 and perform noise processing.

[0082] (4) The defect presence or absence judgment unit 33 judges whether there is a defect based on the output of the inspection signal processing unit 32.

[0083] (5) Ion generating units 4a1 and 4a2 have the same structure as ion generating unit 4a shown in Embodiment 2, and have a shielding box 46 for limiting the generation range of ions 44. The shielding box 46 is formed to extend from the ion generator 42 toward the winding wire 1 in a manner that surrounds the discharge needle 43, and may also be cylindrical or square in shape. Figure 7 As shown, when the shielding box 46 extends around the winding 1, a through hole 461 is formed in the shielding box 46 for the winding 1 to pass through, and a cover 462 is provided for enclosing the ions 44 in the shielding box 46.

[0084] The difference between Embodiment 4 and Embodiment 1 is that, as described above, two ion generating units 4a1 and 4a2 are arranged at different positions along the travel direction of the winding 1, surrounding the outer periphery of the winding 1. The operation of the defect inspection device for the winding 1 in Embodiment 4 is the same as that described in Embodiments 1 and 2, except that, in addition to ion generating unit 4a1, ion generating unit 4a2 also detects the defect 13 by passing ions 44 surrounding the outer periphery of the winding 1.

[0085] The procedure for inspecting defects in winding 1 is explained. Ion generating units 4a1 and 4a2 are arranged, for example, at a distance of 10 cm. The traveling speed of winding 1 is 500 mm / s. In this case, defect 13 of winding 1 passes through the shielding box 46 of ion generating unit 4a1 and then through the shielding box 46 of ion generating unit 4a2 0.2 seconds later; therefore, the micro-current meter 31 detects it twice. Figure 3 The detection time difference for signals 45a or 45b shown is also 0.2 seconds.

[0086] The detected current after voltage conversion by the micro current meter 31 is amplified by the inspection signal processing unit 32 and compared with the defect presence / absence threshold 32d by the defect presence / absence judgment unit 33, and the presence / absence of defects is judged as follows (1) to (3).

[0087] (1) The defect detection unit 33 detected the defect only once. Figure 3 In the case of whether the defect shown in (c) has signal 33a or signal 33b, that is, when a signal is detected for any ion 44 of ion generating units 4a1 and 4a2, it is assumed that there is no defect 13 in the winding 1.

[0088] (2) Two defects were detected in the defect presence / absence judgment unit 33. Figure 3 In the case of defect presence or absence signal 33a or defect presence or absence signal 33b shown in (c), that is, when a signal is detected in the ions 44 of both ion generating units 4a1 and 4a2, the controller 34 calculates the time difference between the two detected defect presence or absence signals 33a or defect presence or absence signal 33b (for example, the time difference of the rising edge of the defect presence or absence signal). If the time difference is 0.2 seconds, it is assumed that there is a defect 13 in the winding 1. Similar to the case described in Embodiment 1, the operator's attention can be drawn by generating a warning sound, displaying a screen, etc., and countermeasures such as stopping the winding machine body 2 can be taken to remove or repair the defective part.

[0089] (3) In contrast, if the time difference is not 0.2 seconds, it is considered that the micro-galvanometer 31 detected noise, and the winding 1 is assumed to have no defects 13.

[0090] Furthermore, while this embodiment describes the case of two ion generating units 4a1 and 4a2, it is also possible to configure two or more ion generating units along the travel direction of the winding 1. In this case, the determination based on the presence or absence of signals from multiple defects can also be performed using a majority decision circuit or the like.

[0091] Furthermore, the structures of ion generating units 4a1 and 4a2 in this embodiment can also be the same as those of ion generating unit 4b shown in embodiment 3.

[0092] As described above, in addition to the effects of Embodiment 1, the defect inspection device of Embodiment 4 also detects the same defects in the winding 1 by using multiple ion generation units, thus further improving the detection probability and detection accuracy of defects.

[0093] Implementation method 5.

[0094] The method for determining the location of defects by using core 6 for the wound component 22, with the winding 1 as motor coil 5 wound around the teeth of core 6 through insulator 7, will be explained. Figure 8 (a) is a diagram showing the relationship between the motor coil 5 wound around the core 6, the ion generating unit 4, and the encoder E in defect detection. In this diagram, the winding 1 of the motor coil 5 is viewed as the teeth of the core 6 in the protruding direction towards the back of the core. The coil distance T1 is the length along the circumference of the motor, and the coil distance T2 is the length along the axial direction of the motor. Figure 8 (b) is a perspective view showing the state in which the winding 1 is wound onto the core 6 of the insulator 7, which serves as the motor coil 5. The winding of the motor coil 5 is performed by rotating the spindle on which the core 6 is mounted.

[0095] The distance L1 from the discharge needle 43 of the ion generating unit 4 to the front end of the nozzle 23, the distance L2 from the front end of the nozzle 23 to the motor coil 5, the distance T1 in the short side direction of the motor coil 5, the distance T2 in the long side direction, and the elongation of the winding 1 under winding tension are known in advance. An encoder E is installed between the discharge needle 43 and the nozzle 23, and the distance (length) is measured according to the speed at which the winding 1 passes through the encoder E.

[0096] The controller 34 receives signals from the defect presence / absence determination unit 33 and the encoder E, sets the starting distance of the winding of the motor coil 5 to zero, and records the winding distance before and after the defect is detected. Therefore, based on the winding distance data from the encoder E and the pre-known distances L1, L2, T1, T2, and the elongation of the winding 1 under winding tension, by executing the measurement procedure, the position of the defect on the motor coil 5, within which turn, can be determined through calculation.

[0097] Figure 9 This describes the flow of the measurement steps for such a defect inspection system. Simultaneously with the start of winding via the winding machine body 2, the distance count of the encoder E begins (step S1). If a defect is detected (step S2), the distance E1 counted at the time of detection is acquired and stored in the controller 34 (step S3). Simultaneously with acquiring distance E1, a new count for acquiring distance E2 begins (step S4). The total winding distance R required to complete winding 1 is compared. total And the distance E1 at which the defect was detected (step S5). In the case of comparison, add the known distances L1 and L2 at the start of winding (refer to...) to the distance E1. Figure 10 (The relationships between the various distances).

[0098] The distance E1 + distance L1 + distance L2 is compared to the total distance R. total After one hour (step S5 "Yes"), calculate the defect position on motor coil 5 corresponding to distance E1 + distance L1 + distance L2 and record it in controller 34 (step S6). Add the distance E1 from the detected defect to the distance E2 from the defect detection to the present as the distance E1 from the start of winding to the present (step S7), and continue counting distance E1. In this case, reset distance E2 (step S8).

[0099] The distance E1 + distance L1 + distance L2 equals the total distance R. total Or greater than the total distance R total When (No in step S5), it is estimated that a defect occurred at any position within the range from the end of winding to the point after backtracking by distance L1 + distance L2. Together with the workpiece replacement (step S10), the defect position on motor coil 5 corresponding to distance L1 + distance L2 - distance E2 is calculated (refer to...). Figure 10 The distance relationships are recorded in the controller 34 (step S11). After recording, the counted distances E1 and E2 are reset (step S12).

[0100] This measurement process allows for accurate identification of defects on the wound motor coil 5. For example, in the case of a disposable motor, by pre-selecting only defective teeth, the defect rate in subsequent processes can be suppressed, leading to an expected reduction in overall costs. Furthermore, even with defective motor coils, by arranging them in a manner where their positions are not adjacent during stator assembly, defects can be avoided and the product can be used without causing problems, thus improving yield.

[0101] Alternatively, the distance L1 from the discharge needle 43 to the tip of the wire nozzle 23 can be replaced with a distance L1A = L1 ± α / 2 that takes into account the generation range α of ions from the discharge needle 43 along the direction of the winding 1. Thus, the location of defects on the motor coil 5 can be determined based on the detection range that takes into account the generation range of ions in the winding 1.

[0102] Figure 11 This illustrates an example of the hardware of controller 34. It comprises a processor 100 and a storage device 200. Although not shown, the storage device 200 includes volatile storage devices such as random access memory and non-volatile auxiliary storage devices such as flash memory. Alternatively, a hard disk can be used as an auxiliary storage device instead of flash memory. The processor 100 executes a program input from the storage device 200, for example, executing... Figure 9 The measurement process is shown. In this case, the program is input from the auxiliary storage device to the processor 100 via the volatile storage device. In addition, the processor 100 can output the measured values ​​and calculated defect locations, etc., to the volatile storage device of the storage device 200, or it can save the data to the auxiliary storage device via the volatile storage device.

[0103] This application describes various exemplary implementation methods and embodiments, but the various features, methods and functions described in one or more embodiments are not limited to the application of a specific embodiment and can be applied to the embodiment alone or in various combinations.

[0104] Therefore, numerous variations not illustrated are assumed within the scope of the technology disclosed in this application. For example, these include variations, additions, or omissions of at least one constituent element, as well as extraction of at least one constituent element and combination with constituent elements of other embodiments.

[0105] Label Explanation

[0106] 1: Winding; 2: Winding machine body; 3: Defect inspection unit; 11: Copper core; 12: Insulation layer; 13: Defect; 21: Winding-out section; 22: Winded component; 23: Wire nozzle; 24: Housing; 31: Micro ammeter; 32: Inspection signal processing unit; 33: Defect presence / absence judgment unit; 34: Controller; 4, 4a, 4b, 4a1, 4a2: Ion generation unit; 41: Power supply; 42: Ion generator; 43: Discharge needle; 44: Ion; 45: Current; 46: Shielding box; 47: Metal plate; 48: Conductor; 49: Brush; 90: Tensioner; 100: Processor; 200: Storage device; 311: Terminal; 441: Charge.

Claims

1. A defect inspection device for a winding, wherein the winding is traveled under tension for winding onto a component, wherein, The defect inspection device for the winding includes: An ion generating unit, which is configured along the travel path of the winding to the wound component, generates ions that surround the outer periphery of the winding. A current detection unit detects the current flowing within the winding as a result of the charge of the ions penetrating from a defect in the winding. as well as The defect presence / absence determination unit determines whether the winding has defects based on the result of comparing the output of the current detection unit with a predetermined defect presence / absence threshold.

2. The winding defect inspection device according to claim 1, wherein, The threshold for the presence or absence of the defect is a value greater than the noise voltage.

3. The winding defect inspection device according to claim 1, characterized in that, The ion generating unit includes a discharge needle, an ion generator that causes corona discharge in the discharge needle, and a power source that applies voltage to the ion generator.

4. The winding defect inspection device according to claim 3, wherein, The voltage applied to the ion generator is set such that the minimum voltage at which a defect is determined in the defect presence / absence determination unit is greater than the defect presence / absence threshold.

5. The winding defect inspection device according to claim 3 or 4, characterized in that, The defect inspection device for the winding is equipped with a shielded box that surrounds the discharge needle and the winding surrounded by the ions.

6. The winding defect inspection device according to claim 5, wherein, The shielding box is made of a non-conductive material.

7. The winding defect inspection device according to any one of claims 3 to 6, characterized in that, The defect inspection device for the winding includes: a metal plate that accumulates the ions between the discharge needle and the winding; a brush that contacts the winding; and a conductor for directing the charge of the ions accumulated on the metal plate to the brush.

8. The winding defect inspection device according to any one of claims 3 to 7, characterized in that, The defect inspection device for the winding is configured with multiple ion generating units along the travel path of the winding, and determines the defects of the winding based on the result of comparing multiple current outputs of the current detection unit with the threshold for the presence or absence of defects.

9. The winding defect inspection device according to any one of claims 1 to 8, characterized in that, The input terminal of the current detection unit to the current flowing in the winding is configured such that the charge flows to ground without outputting a voltage.

10. The winding defect inspection device according to any one of claims 1 to 8, characterized in that, The current sensing unit is input to the terminal of the current flowing in the winding, and the charge is introduced into the current sensing unit by the output voltage.

11. A winding defect inspection system, the winding defect inspection system comprising: A winding machine that winds up wire as a motor coil; The defect inspection device according to any one of claims 3 to 8; An encoder, configured between the discharge needle of the defect inspection device and the motor coil, detects the speed of the winding; and The controller calculates the defect location of the winding in which the motor coil is wound, based on the output of the encoder and the defect detection signal output by the defect inspection device.

12. A method for inspecting defects in wire winding, wherein, Using a winding machine that winds a wire into a motor coil, a defect inspection device according to any one of claims 3 to 8, and an encoder that detects the speed of the winding between the discharge needle of the defect inspection device and the motor coil, the distance at which the winding begins is set to zero, and the defect position of the winding is calculated based on the winding distance before the defect is detected and the winding distance after the defect is detected.

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