Winding device and winding method of wire

Abstract

To wind a wire around magnetic poles of a stator at high speed with high accuracy.SOLUTION: A winding device comprises a stator core operation mechanism 19 for operating a stator core 13 so that a magnetic pole 13b oscillates, and a nozzle movement mechanism 30 for moving a nozzle 11 in a direction perpendicular to an axis of the magnetic pole 13b, and circulates the tip of the nozzle around the magnetic pole by combination of oscillation of the stator core and movement of the nozzle to wind a wire 12 sent out from the nozzle around the magnetic pole. The nozzle movement mechanism comprises: a first actuator 32 which moves the nozzle; and a second actuator 33 which moves the first actuator in parallel in a movement direction of the nozzle. Each of the first and second actuators consists of a linear motor, the nozzle is attached to a needle of the first actuator, a stator of the first actuator is attached to a needle of the second actuator, and a stator of the second actuator is adjacently attached to the stator core operation mechanism.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a wire winding device and a winding method for winding a wire fed from the tip of a nozzle around magnetic poles formed to protrude in the radial direction of a stator. [Background technology]

[0002] Conventionally, the stator of an inner rotor type motor is formed by winding wire around multiple magnetic poles that protrude on the inner side of a stator core made of multiple stacked annular members, while the stator of an outer rotor type motor is formed by winding wire around multiple magnetic poles that protrude radially from the outer side of the stator core.

[0003] Conventionally, as a winding device for each magnetic pole of this stator core, the applicant has proposed a winding device that includes a stator support means that rotatably supports the stator core around the central axis of the stator as the center of rotation, and a moving mechanism that moves a nozzle in each of the three axial directions (see, for example, Patent Document 1).

[0004] In this winding device, the rotation of the stator core is combined with the axial movement of the stator of the nozzle that pays out the wire, causing the tip of the nozzle, which is the wire payout end, to move around the magnetic pole and wind the wire paid out from the tip around the magnetic pole. By precisely controlling the rotation of the stator core and the axial movement of the nozzle, a stator in which the wire is wound in alignment around each magnetic pole can be obtained. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 10-271774 Summary of the Invention [Problem to be solved by the invention]

[0006] However, in the above-mentioned conventional winding device, the movement mechanism for moving the nozzle in each of the three axial directions is composed of front-back, left-right, and up-down movement mechanisms stacked in order, so the front-back movement mechanism must move the left-right movement mechanism and the up-down movement mechanism together with the nozzle, and the left-right movement mechanism must move the up-down movement mechanism together with the nozzle. As such, since the parts that move with the nozzle are relatively large, the weight of each part is also relatively large, and it is not possible to speed up the front-back movement of the nozzle by the front-back movement mechanism, or the left-right movement of the nozzle by the left-right movement mechanism, which results in an impediment to speeding up the winding work.

[0007] In addition, the vertical movement mechanism in the conventional winding device uses a ball screw, and the screw shaft is rotated by a servo motor to move the movable table to which the nozzle is attached. With this ball screw, when the servo motor rotates the screw shaft once, the nozzle moves up and down by an amount equivalent to the pitch in the longitudinal direction of the spiral groove formed in the screw shaft.

[0008] Furthermore, when winding the magnetic poles of the stator, the nozzle must usually be moved several to several tens of times the pitch of the spiral groove. In order to move this nozzle back and forth to wind the wire, the servo motor must rotate its screw shaft forward several to several tens of times, and then rotate it in the reverse direction several to several tens of times.

[0009] For this reason, in the above-mentioned conventional winding device using a ball screw, when winding is performed by moving the nozzle at a relatively high speed, it is necessary to rotate the screw shaft at high speed by the servo motor and to rapidly accelerate and decelerate the screw shaft. For this reason, a conventional winding device that uses a ball screw for winding requires a so-called high-torque and highly responsive servo motor as a drive source for rotating the screw shaft.

[0010] Such servo motors are very expensive and large, so if winding speed is sought, the cost of the device will increase and the device will become larger.

[0011] SUMMARY OF THE PRESENT INVETION The present invention has been made in view of the above problems, and an object of the present invention is to provide a winding device and a winding method capable of winding a wire around the magnetic poles of a stator with high precision and at high speed. [Means for solving the problem]

[0012] The present invention is an improvement to a winding device that includes a stator core operating mechanism that operates the stator core so that the magnetic poles oscillate, and a nozzle moving mechanism that moves the nozzle in a direction perpendicular to the axis of the magnetic pole, and by combining the oscillation of the stator core and the movement of the nozzle, the tip of the nozzle is caused to circle around the magnetic pole and the wire fed from the nozzle is wound around the magnetic pole.

[0013] Its distinctive configuration is that the nozzle moving mechanism includes a plurality of actuators arranged in stages.

[0014] In this case, the plurality of actuators provided in stages preferably include a first actuator that moves the nozzle, and a second actuator that moves the first actuator parallel to the direction of nozzle movement.

[0015] Furthermore, when the first actuator and the second actuator each include a stator and a movable element that reciprocates along the stator, it is preferable that the nozzle is attached to the movable element of the first actuator, the stator of the first actuator is attached to the movable element of the second actuator, and the stator of the second actuator is disposed adjacent to the stator core operating mechanism.

[0016] The stator core operating mechanism may also be a servo motor with the stator core mounted coaxially to a rotating shaft.

[0017] Another invention is a method for winding wire in which the tip of the nozzle is rotated around the magnetic pole by combining the oscillation of the magnetic poles around the central axis of the stator core and the movement of the nozzle in the slot between the magnetic poles toward the central axis of the stator core, thereby winding the wire unwound from the tip of the nozzle around the magnetic pole.

[0018] A distinctive feature of this method is that the nozzle in the slot is moved by simultaneously driving a plurality of actuators that are arranged in stages.

[0019] In this case, it is preferable that the simultaneous driving of the multiple actuators arranged in stages is carried out by moving the nozzle with a first actuator and further moving the first actuator in the same direction as the movement direction of the nozzle with a second actuator.

[0020] It is preferable that the oscillation of the magnetic poles starts after the nozzle moving through the slot between the magnetic poles has passed the slot, and that the movement of the nozzle into the slot starts after the oscillation of the magnetic poles has stopped.

[0021] In addition, when the stator core is attached coaxially to the rotating shaft of a servo motor, it is preferable to rotate the stator core together with the rotating shaft by driving the servo motor to rotate the magnetic poles at an angle corresponding to the angle between each magnetic pole and an adjacent magnetic pole. Effect of the Invention

[0022] In the wire winding device of the present invention, the tip of the nozzle is rotated around the magnetic pole by combining the oscillation of the magnetic pole and the movement of the nozzle in the slot between the magnetic poles in the central axis direction of the stator core. This makes it possible to wind the wire fed from the nozzle around the magnetic pole of the stator. The linear movement of the nozzle in the slot between the magnetic poles is performed by multiple actuators, making it possible to increase the movement speed.

[0023] In particular, when the multiple actuators each move a mover in the longitudinal direction of the stator, the winding can be made to move at high speed relatively easily by quickly moving the mover relative to the stator.

[0024] In addition, the stator core operating mechanism that operates the stator core to oscillate the magnetic poles performs winding by rotating the stator core forward and backward at an angle corresponding to the angle between the magnetic pole to be wound and the adjacent magnetic pole, and since the angle between the magnetic pole to be wound and the adjacent magnetic pole is relatively small, even if a general servo motor is used as this stator core operating mechanism, the magnetic poles can be oscillated quickly during winding. This eliminates the need for a relatively expensive servo motor with high torque and high response, and does not increase the unit price of the winding device. [Brief description of the drawings]

[0025] [Figure 1] 1 is a side view showing a winding device according to an embodiment of the present invention; [Diagram 2] FIG. 2 is a side view corresponding to FIG. 1, showing the winding device with its nozzle raised. [Diagram 3] FIG. [Figure 4] 2 is a cross-sectional view taken along line BB in FIG. 1, illustrating the operation of the nozzle moving mechanism. [Diagram 5] 2 is a cross-sectional view taken along line AA in FIG. 1, illustrating a state in which the wound magnetic poles oscillate. [Figure 6] 4A and 4B show the movement of the nozzle relative to the magnetic poles. [Figure 7] 1 is a cross-sectional view of an outer rotor type stator core wound by the winding device. [Figure 8] FIG. 11 is a perspective view showing a winding device according to another embodiment of the present invention. [Figure 9] 9 is a cross-sectional view taken along the line CC in FIG. 8, illustrating a state in which the wire is wound around the magnetic pole by the alternative winding device. [Figure 10] 11A to 11C are diagrams illustrating the operation of the alternative nozzle moving mechanism. [Figure 11] 13A and 13B are diagrams showing the movement of the nozzles relative to the poles of the alternative stator core. [Figure 12] 1 is a cross-sectional view of an inner rotor type stator core wound by the different winding device. FIG. [Figure 13] 5 is a view corresponding to FIG. 4 showing the operation of another nozzle moving mechanism having two first actuators and a single second actuator. [Figure 14] 4 is a top view corresponding to FIG. 3 and showing another winding device having the other nozzle moving mechanism. FIG. [Figure 15] FIG. 14 is a view corresponding to FIG. 13 showing another nozzle movement mechanism having three first actuators and a single second actuator. [Figure 16] FIG. 16 is a view corresponding to FIG. 15 showing yet another nozzle movement mechanism having four nozzles, two first actuators and a single second actuator. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] Next, the best mode for carrying out the present invention will be described with reference to the drawings.

[0027] 1 to 3 show a wire winding device 10 according to the present invention. In each drawing, three mutually orthogonal axes, X, Y, and Z, are set, with the X axis extending in a substantially horizontal front-rear direction, the Y axis extending in a substantially horizontal lateral direction, and the Z axis extending in a vertical direction. The configuration of this winding device 10 will now be described. This winding device 10 winds a wire 12 fed from a nozzle 11 around a magnetic pole 13b (FIG. 7) of a stator core 13.

[0028] As shown in FIG. 7, the stator core 13 used in this embodiment is of an outer rotor type, and this outer rotor type stator core 13 has a circular annular portion 13a and a plurality of magnetic poles 13b protruding radially from the outer circumferential surface of this annular portion 13a toward the outside of this annular portion 13a.

[0029] 1 to 3, this winding device 10 includes a machine base 14 that is installed at an installation location. The machine base 14 is provided with a front-rear direction drive unit 17 that moves a table 16 in the front-rear direction, which is the X-axis direction, and the table 16 is provided with a support 18 that supports the stator core 13.

[0030] The front-rear drive unit 17 includes a front-rear guide 17a arranged on the machine base 14 along the X-axis, which is the drive direction, a front-rear rotation shaft 17b arranged parallel to the front-rear guide 17a and having a helical male screw on its surface, a front-rear moving member 17d (FIGS. 1 and 2) that is screwed into the front-rear rotation shaft 17b by a ball screw and can move along the front-rear guide 17a by rotation of the front-rear rotation shaft 17b, and a front-rear drive source 17c that rotates and drives the front-rear rotation shaft 17b.

[0031] In this embodiment, the forward / rearward drive source is a forward / rearward servomotor 17c, and the table 16 is attached to a forward / rearward moving member 17d which is moved by the driving of the servomotor 17c.

[0032] The table 16 is provided with a swing servomotor 19 having a rotation axis 19a in the Z-axis direction, and a mounting plate 21 adjacent to the swing servomotor 19 and shifted from the swing servomotor 19 in the Y-axis direction.

[0033] The support 18 that supports the stator core 13 has a rod-shaped core material 18a extending vertically and placing the stator core 13 horizontally on its upper edge, and a pressing member 18b that presses the stator core 13 placed on the upper edge of the core material 18a from above.

[0034] The rod-shaped core 18a has its lower end attached to the rotating shaft 19a of the swing servomotor 19, and its upper part is formed to have an outer diameter slightly smaller than the outer diameter of the annular portion 13a (FIG. 7) of the stator core 13. A linear motion guide rail 23 is attached to the side of the mounting plate 21 facing the swing servomotor 19, extending in the vertical direction, and a lifting member 22 is attached to this guide rail 23 so as to be movable up and down.

[0035] The pressing member 18b is attached to the lifting member 22 so that its central vertical axis coincides with the central axis of the rod-shaped core material 18a and can rotate about the vertical axis as the center of rotation. The lower part of the pressing member 18b, which actually presses the stator core 13 placed on the upper end edge of the core material 18a from above, is formed with an outer diameter slightly smaller than the outer diameter of the annular portion 13a of the stator core 13 (FIG. 5), and the annular portion 13a of the stator core 13 is sandwiched between the core material 18a and the pressing member 18b, and the magnetic poles 13b protrude radially outward from the annular portion 13a, allowing the nozzles 11 to revolve around each magnetic pole 13b.

[0036] The rod-shaped core material 18a has its lower end attached to the rotating shaft 19a of the oscillating servo motor 19. Therefore, when the rotating shaft 19a of the servo motor 19 rotates, the rod-shaped core material 18a rotates together with the rotating shaft 19a, and the stator core 13 sandwiched between the rod-shaped core material 19a and the pressing member 18b rotates around the central axis O of the support 18 consisting of the rod-shaped core material 18a and the pressing member 18b (Figure 5).

[0037] Stator core 13 is placed on the upper edge of rod-shaped core material 19a and its center coincides with the central axis of support 18, and magnetic poles 13b around stator core 13 are configured to be able to swing as stator core 13 rotates.

[0038] Therefore, the swing servo motor 19 is configured to function as a stator core operating mechanism that operates the stator core 13 so that the magnetic poles 13b swing. A lifting cylinder 24 is provided on the mounting plate 21 above the lifting member 22 to lift and lower the lifting member 22 together with the pressing member 18b.

[0039] The winding device 10 is also provided with a nozzle moving mechanism 30 that moves the nozzle 11 in a direction perpendicular to the axis of the magnetic pole 13b, which in this embodiment is parallel to the central axis of the stator core 13 extending vertically.

[0040] Nozzle 11 pays out wire 12 wound around magnetic pole 13b from its tip, and in this embodiment nozzle 11 has a large diameter portion 11a whose base end is fixed to movable base 34, and a small diameter portion 11b that protrudes coaxially from the tip of large diameter portion 11a and continues therefrom.

[0041] 5, the small diameter portion 11b is provided coaxially with the large diameter portion 11a, and the small diameter portion 11b is formed with an outer diameter capable of entering a slot 13c between magnetic poles 13b of the stator core 13. The large diameter portion 11a and the small diameter portion 11b are provided with through holes penetrating their central axes, through which the wire 12 can be inserted, and the wire 12 inserted into the through holes can be paid out from the tip of the small diameter portion 11b.

[0042] The nozzle moving mechanism 30 that moves the nozzle 11 in the vertical direction is provided adjacent to the swing servo motor 19, which is the stator core operating mechanism. In the figure, the nozzle moving mechanism 30 is shown to be provided on a base 31 that extends vertically and is directly fixed to the machine base 14 that is spaced in the X-axis direction from the support 18 that supports the stator core 13. The characteristic configuration of the present invention is that the nozzle moving mechanism 30 includes a plurality of actuators 32, 33 that are provided in stages to move the nozzle 11.

[0043] Specifically, the nozzle movement mechanism 30 in this embodiment is shown to include a first actuator 32 that reciprocates a movable table 34 to which the nozzle 11 is fixed, and a second actuator 33 that reciprocates the first actuator 32 parallel to the movement direction of the movable table 34. The first actuator 32 and second actuator 33 in the figure are shown to be made up of linear motors that reciprocate movers 32b, 33b along stators 32a, 33a, respectively.

[0044] Then, on the surface facing the stator core 13 of the base 31 which extends vertically and is directly fixed to the machine base 14, a stator 33a of a second actuator 33 is provided extending vertically so as to be adjacent to the swing servo motor 19 which serves as the stator core operating mechanism.

[0045] On the other hand, the movable table 34 on which the nozzle 11 is provided is attached to the mover 32b of the first actuator 32, and the stator 32a of the first actuator 32 is attached to the mover 33b of the second actuator 33 so that its longitudinal direction is parallel to the stator 33a.

[0046] 1 to 3, the nozzle 11 is mounted horizontally on the movable base 34, and the tip of the nozzle 11 extending in the X-axis direction can be inserted into the slot 13c (FIG. 5) of the stator core 13 supported by the support 18.

[0047] In addition, the movable base 34 is provided with a deflecting pulley 36 that deflects the wire 12, which is fed from above the nozzle 11 in the Z-axis direction toward the nozzle 11, to pass through the nozzle 11. The deflecting pulley 36 deflects the wire 12, which is supplied from a wire supply source (not shown), from the vertical direction to the horizontal direction so that the wire can enter the slot 13c of the stator core 13, which is supported so that its central axis extends in the vertical direction, from the horizontal direction.

[0048] As shown in FIG. 1, this nozzle moving mechanism 30 is configured such that when the mover 33b of the second actuator 33 is positioned below its stator 33a, and the mover 32b of the first actuator 32, to which the stator 32a is attached, is also positioned below its stator 32a, the nozzle 11 attached to the mover 32b passes through the slot 13c of the stator core 13 and reaches below it.

[0049] On the other hand, as shown in FIG. 2, this nozzle moving mechanism 30 is configured such that when the mover 33b of the second actuator 33 is positioned above its stator 33a and the mover 32b of the first actuator 32, to which the stator 32a is attached, is also positioned above the stator 32a, the nozzle 11 attached to the mover 32b passes through the slot 13c of the stator core 13 and reaches above it.

[0050] Next, a winding method of the present invention using this winding device will be described.

[0051] In the winding method using the winding device 10, first, the stator core 13 is supported by the support 18.

[0052] When supporting this stator core 13, as shown in FIG. 1, the front-rear drive unit 17 drives its front-rear servo motor 17c to rotate the front-rear rotation shaft 17b, thereby moving the front-rear moving member 17d together with the table 16 away from the base 31 as shown by the solid arrow.

[0053] In this state, the rod 24a of the lifting cylinder 24 provided on the mounting plate 21 is retracted to lift the lifting member 22, and the pressing member 18b attached to the lifting member 22 is raised as shown by the dashed-dotted arrow to form a space below it and between the rod-shaped core material 18a. Then, the stator core 13 is placed horizontally on the upper edge of the rod-shaped core material 18a through the space.

[0054] Thereafter, the rod 24a of the lifting cylinder 24 is extended to lower the lifting member 22 as shown by the dashed double-dotted arrow, and the pressing member 18b, which descends together with the lifting member 22, presses down the stator core 13 placed on the upper edge of the rod-shaped core material 18a from above, as shown in Figure 1.

[0055] 1. Thereafter, the front-rear drive unit 17 drives the front-rear servo motor 17c to rotate the front-rear rotation shaft 17b in the reverse direction, and moves the front-rear moving member 17d together with the table 16 closer to the base 31 as indicated by the dashed arrow in FIG.

[0056] Then, when starting the actual winding, the nozzle 11 is moved in three dimensions relative to the stator core 13 by the front-rear drive unit 17 which moves the stator core 13 in the X-axis direction, the nozzle moving mechanism 30 which moves the nozzle in the Z-axis direction, and the swing servo motor 19 which functions as a stator core operating mechanism which operates the stator core 13 so that the magnetic pole 13b swings. The end of the wire 12 unwound from the tip of the nozzle 11 is then tied and fixed to a tying pin or wire clamp device (not shown).

[0057] Next, the actual winding is performed. In this winding, the nozzle 11 is moved back and forth in the Z-axis direction by the nozzle moving mechanism 30, and the stator core 13 is rotated alternately in the forward and reverse directions by the swing servo motor 19 so that the magnetic pole 13b to be wound swings.

[0058] That is, the winding method of the present invention is a method in which the tip of the nozzle 11 is wound around the magnetic pole 13b as shown in FIG. 6 by combining the oscillation of the magnetic pole 13b as shown in FIG. 5 with the movement of the nozzle 11 in the axial direction of the stator core 13 in the slot 13c between the magnetic poles, and the wire 12 fed from the tip of the nozzle 11 is wound around the magnetic pole 13b.

[0059] The oscillation of the magnetic pole 13b around the central axis O (Figure 5) of the stator core 13 is performed with the tip of the nozzle 11 removed from the slot 13c, as shown in Figures 1 and 2, and the oscillation ends when the tip of the nozzle 11 faces the slot 13c between the wound magnetic pole 13b and the adjacent magnetic pole 13b, as shown in Figure 5.

[0060] On the other hand, the movement of the nozzle 11 in the axial direction of the stator core 13 is achieved by moving the nozzle 11 in the Z-axis direction by the nozzle moving mechanism 30 when the tip of the nozzle 11 is in the slot 13c sandwiched between the wound magnetic pole 13b and the adjacent magnetic pole 13b, without oscillating the magnetic pole 13b by the oscillating servo motor 19.

[0061] By alternately repeating such movement of the nozzle 11 and the oscillation of the magnetic pole 13b, the nozzle 11 moves circularly around the magnetic pole 13b along the cross-sectional shape of the magnetic pole 13b, as shown in Figure 6, and the wire 12 paid out from the tip of the nozzle 11 is wound around the magnetic pole 13b.

[0062] As shown in Figure 4, the movement of the nozzle 11 in the slot 13c in the present invention is characterized in that the movable base 34 to which the nozzle 11 is fixed is moved by the first actuator 32, and simultaneously with this movement, the first actuator 32 is further moved in the same direction as the movement direction of the movable base 34 by the second actuator 33.

[0063] That is, as shown in Figures 2 and 4(a), when the nozzle 11 located above the stator core 13 is to be moved downward, the movable base 34 to which the nozzle 11 is fixed is moved downward by the first actuator 32 as shown in Figure 4(b), and simultaneously with this movement, the first actuator 32 is lowered by the second actuator 33, so that the movement of the nozzle 11 stops when it passes through the slot 13c and reaches below the stator core 13 as shown in Figures 1 and 4(c).

[0064] On the other hand, when moving the nozzle 11 located below the stator core 13 upward as shown in Figures 1 and 4(c), the movable base 34 to which the nozzle 11 is fixed is moved upward by the first actuator 32 as shown in Figure 4(d), and simultaneously with this movement, the first actuator 32 is raised by the second actuator 33, so that the nozzle 11 passes through the slot 13c and stops moving when it reaches above the stator core 13 as shown in Figures 2 and 4(e).

[0065] As a result, the movement speed Zv of the nozzle 11 in the slot 13c in the Z-axis direction by the nozzle movement mechanism 30 is the sum of the movement speed Z1v at which the first actuator 32 moves the nozzle 11 and the movement speed Z2v at which the second actuator 33 further moves the first actuator 32 together with the nozzle 11 in the same direction, as shown in Figures 4(b) and (d).

[0066] Therefore, compared to the conventional method in which the nozzle 11 is moved by a single actuator, the winding method of the present invention makes it possible to double the moving speed Zv of the nozzle 11 in the Z-axis direction.

[0067] On the other hand, the oscillation of the wound magnetic poles 13b is achieved by rotating the stator core 13 back and forth, and the rotation is achieved by rotating the rod-shaped core material 18a (Figure 1) of the support 18 about its central axis by the oscillation servo motor 19.

[0068] This rod-shaped core material 18a is attached to the rotating shaft 19a of the swing servo motor 19. Therefore, as shown in FIG. 5, this rotation is achieved by rotating the rotating shaft 19a of the swing servo motor 19 in the forward and reverse directions at an angle corresponding to the angle θ formed between the magnetic pole 13b which is the subject of the winding and the adjacent magnetic pole 13b, so that the nozzle 11 swings from the state shown in FIG. 5(a) where it faces one of the slots 13c to the state shown in FIG. 5(b), and the swing is stopped when the nozzle 11 faces the other adjacent slot 13c as shown in FIG. 5(c). Since the rotation angle θ is relatively small, the swing of the magnetic pole 13b can be achieved quickly.

[0069] Therefore, by simply moving the nozzle 11 back and forth once using the nozzle moving mechanism 30 and rotating the rotating shaft 19a of the swing servo motor 19 forward and backward by a small angle, the nozzle 11 can be rotated once in a square shape around the magnetic pole 13b, and the winding speed can be significantly increased compared to the conventional method in which the servo motor had to be rotated several or several tens of times to rotate the nozzle once.

[0070] In this way, the winding device 10 of the present invention does not use the ball screw system that has been used in the past to rotate the nozzle 11 around the magnetic pole 13b for winding. Therefore, there is no need for sudden acceleration and deceleration from high speed, which was previously required by a servo motor to rotate the screw shaft of the ball screw.

[0071] As described above, the nozzle moving mechanism 30 in the present invention is a linear motor that can quickly reciprocate the nozzle 11 in the Z-axis direction, and the swing servo motor 19 can swing the magnetic pole 13b by repeatedly rotating forward and backward by a small angle. This eliminates the need for a high-torque, high-response servo motor that was previously required for high-speed winding.

[0072] On the other hand, in order to wind the wire 12 in an aligned manner around the magnetic pole 13b, it is necessary to rotate the nozzle 11 around the magnetic pole 13b and move the stator core 13 in the X-axis direction by the front-rear direction drive unit 17 by the diameter of the wire 12 for each turn of the wire 12. The movement of the stator core 13 in the X-axis direction is performed by rotating the front-rear direction rotation shaft 17b by the front-rear direction servo motor 17c of the front-rear direction drive unit 17.

[0073] However, the amount of movement of the stator core 13 is extremely small, being only the diameter of the wire 12 for each turn of the wire 12, and so there is no need to rotate the front-rear rotation shaft 17b at high speed. Therefore, a standard servo motor available on the market can be used for the front-rear servo motor 17c that rotates the front-rear rotation shaft 17b, and the winding speed for aligned winding can be increased without increasing the unit price of the winding device 10.

[0074] This winding is performed on all of the magnetic poles 13b, and after winding has been completed on all of the magnetic poles 13b as shown in Fig. 7, the stator core 13 is removed from the support 18. During this removal, the front-rear drive unit 17 drives the front-rear servo motor 17c to rotate the front-rear rotation shaft 17b, and moves the support 18 together with the table 16 away from the base 31 as shown by the solid arrow in Fig. 1.

[0075] In this state, rod 24a of lifting cylinder 24 provided on mounting plate 21 is retracted, and pressing member 18b is raised together with lifting member 22 as shown by the dashed-dotted arrow, releasing pressing member 18b from stator core 13 and forming a space above stator core 13. Stator core 13 placed on the upper end of rod-shaped core material 18a is then removed from rod-shaped core material 18a through that space, completing a series of winding operations.

[0076] Another embodiment of the present invention is shown in Figures 8 to 12. In this another embodiment, the same reference numerals as those in the previous embodiment denote the same parts, and repeated explanations will be omitted.

[0077] As shown in FIG. 12, the stator core 63 in this alternative embodiment is of an inner rotor type and includes a circular annular portion 63a and a plurality of magnetic poles 63b protruding from the inner circumferential surface of the annular portion 63a toward the center of the annular portion 63a.

[0078] 8, the machine base 14 is provided with a support device 68 for mounting such a stator core 63. This support device 68 includes a fixed base 68a arranged on the machine base 14, a rotating base 68b that is rotatably attached to the fixed base 68a in a horizontal plane and can mount and fix the stator core 63 on its upper side, and a swing servo motor (not shown) that rotates the rotating base 68b.

[0079] The winding device 60 in this alternative embodiment includes a machine base 14 that is provided with the support device 68 and installed at an installation location, and a driving means 70 that is provided on the machine base 14 and drives the nozzle movement mechanism 30 in three axial directions. The driving means 70 is made up of a combination of three axial direction driving units 71, 72, and 73, and includes a front-rear direction driving unit 71, a left-right direction driving unit 72, and a top-bottom direction driving unit 73. These driving units 71, 72, and 73 are substantially the same driving mechanism along the driving directions X, Y, and Z.

[0080] First, the vertical drive unit 73 will be described. This vertical drive unit 73 is provided with a vertical guide 73a arranged along the drive direction Z, a vertical rotation shaft 73b arranged parallel to the vertical guide 73a and having a male screw on its surface, a vertical movement unit 73c that is screwed into the vertical rotation shaft 73b by a ball screw and can move along the vertical guide 73a, a vertical connection unit 73d connected to the vertical movement unit 73c, and a vertical drive source 73e that rotates and drives the vertical rotation shaft 73b.

[0081] The vertical rotation shaft 73b is connected to a vertical drive source 73e by a universal joint 73f. The movement range of the vertical moving part 73c in the drive direction Z is set by the range of a male screw arranged on the vertical rotation shaft 73b.

[0082] The front-rear direction drive unit 71 and the left-right direction drive unit 72 are arranged along drive directions X and Y shown in Fig. 8 as a structure similar to that of the up-down direction drive unit 73. The front-rear direction drive unit 71 is fixed to the machine base 14 and equipped with a front-rear direction drive source 71e, and the left-right direction drive unit 72 is arranged to be movable in the front-rear direction relative to the front-rear direction drive unit 71 via a front-rear direction connection part 71d.

[0083] The left-right drive unit 72 includes a left-right drive source 72e, and the up-down drive unit 73 is arranged to be movable left-right relative to the left-right drive unit 72 via a left-right connection unit 72d. Each of the drive sources 71e, 72e, and 73e may be, for example, a servo motor that can be controlled with high precision. The up-down connection unit 73d of the up-down drive unit 73 is provided with a nozzle movement mechanism 30 that moves the nozzle 11 in the Z-axis direction, which is a direction perpendicular to the axis of the magnetic pole 63b for winding.

[0084] This nozzle movement mechanism 30 has the same structure as that described in the previous embodiment, and as shown in Figures 8 to 10, this nozzle movement mechanism 30 includes a first actuator 32 that reciprocates a movable table 34 to which the nozzle 11 is fixed, and a second actuator 33 that reciprocates the first actuator 32 parallel to the movement direction of the movable table 34 (Z-axis direction).

[0085] The first actuator 32 and the second actuator 33 are linear motors that respectively move movable elements 32b, 33b back and forth along stators 32a, 33a, and the stator 33a of the second actuator 33 extends vertically at a portion of the vertical connection portion 73d facing the stator core 63, and the stator 32a of the first actuator 32 is attached to the movable element 33b of the second actuator 33.

[0086] The movable base 34 on which the nozzle 11 is provided is attached to the lower end of a lift plate 74 extending in the Z-axis direction, and the upper end of this lift plate 74 is attached to the mover 32b of the first actuator 32. The nozzle 11 is fixed to a portion of the movable base 34 located in the X-axis direction of the stator core 13 so as to extend in the X-axis direction, and the movable base 34 is provided with a pulley 36 that redirects the wire 12 passing through the nozzle 11 toward the vertical connection part 73d, as shown in Fig. 9.

[0087] Furthermore, this nozzle moving mechanism 30 is configured so that, when the vertical connection part 73d to which the nozzle moving mechanism 30 is attached is stopped at a predetermined position, as shown in Figure 10(a), the mover 33b of the second actuator 33 is positioned above the second stator 33a, and the first mover 32b of the first actuator 32, having the first stator 32a attached to the second mover 33b, is also positioned above the first stator 32a, and the nozzle 11 attached to the first mover 32b via the lift plate 74 is positioned above and passing through the slot 63c of the stator core 63.

[0088] On the other hand, when the vertical connection part 73d to which the nozzle moving mechanism 30 is attached is stopped at a predetermined position, as shown in Figure 10(c), the second movable element 33b of the second actuator 33 is positioned below the second stator 33a, and the first movable element 32b of the first actuator 32, having the first stator 32a attached to the second movable element 33b, is also positioned below the first stator 32a, so that the nozzle 11 attached to the first movable element 32b via the lifting plate 74 reaches a position below where it passes through the slot 13c of the stator core 13.

[0089] Next, a method for winding a wire using such a winding device will be described.

[0090] First, the wire 12 is passed through the nozzle 11 and fed out from the tip of the nozzle 11. Then, when winding is to begin, the driving means 70 moves the nozzle 11 in three dimensional directions together with the nozzle moving mechanism 30, and the end of the wire 12 is hooked and fixed to a hooking pin or a wire clamp device (not shown). Thereafter, the driving means 70 is driven to move the nozzle 11, which is in a horizontal position, to the slot 63c between the magnetic pole 63b on the stator core 63 where winding is to be performed and the adjacent magnetic pole 63b, as shown in FIG.

[0091] Next, the actual winding is performed. In this actual winding, the nozzle 11 is moved back and forth in the Z-axis direction by the nozzle moving mechanism 30, and the rotating table 68b is rotated forward and backward together with the stator core 63 by a swing servo motor (not shown) of the support device 68 so that the magnetic pole 63b to be wound swings.

[0092] That is, the winding method of the present invention is a method in which the tip of the nozzle 11 is wound around the magnetic pole 63b by combining the oscillation of the magnetic pole 63b and the movement of the nozzle 11 in the axial direction of the stator core 63 in the slot 63c between the magnetic poles, as shown in FIG. 11, and the wire 12 fed from the tip of the nozzle 11 is wound around the magnetic pole 63b.

[0093] The oscillation of the magnetic pole 63b starts when the tip of the nozzle 11 has come out of the slot 63c, and ends when the tip of the nozzle 11 faces the adjacent slot 63c. The oscillation of the magnetic pole 63b is performed by driving an oscillation servo motor (not shown) in the support device 68.

[0094] On the other hand, the movement of the nozzle 11 in the axial direction of the stator core 63 is not performed by oscillating the magnetic pole 63b by a swing servo motor (not shown) in the support device 68, but by moving the nozzle 11 in the Z-axis direction by the nozzle moving mechanism 30 when the tip of the nozzle 11 faces the slot 63c sandwiched between the wound magnetic pole 63b and the adjacent magnetic pole 63b.

[0095] By alternately moving the nozzle 11 in the slot 63c and swinging the magnetic pole 63b in this manner, it is possible to rotate the nozzle 11 around the magnetic pole 63b along the cross-sectional shape of the magnetic pole 63b, as shown in Figure 11.

[0096] The movement of the nozzle 11 by the nozzle movement mechanism 30 of the present invention is achieved by, with the vertical connection part 73d to which the nozzle movement mechanism 30 is attached stopped at a predetermined position, moving the movable table 34 to which the nozzle 11 is fixed back and forth together with the lift plate 74 by the first actuator 32, as shown in Figure 10, and, simultaneously with this movement, further moving the first actuator 32 in the same direction as the movement of the movable table 34 and the lift plate 74 by the second actuator 33.

[0097] That is, when the nozzle 11 located above the stator core 63 is to be moved downward as shown in Fig. 10(a), the movable base 34 to which the nozzle 11 is fixed is moved downward together with the lift base 74 by the first actuator 32 as shown in Fig. 10(b). At the same time as this movement, the first actuator 32 is lowered by the second actuator 33, and as shown in Fig. 10(c), the nozzle 11 passes through the slot 63c and stops moving when it reaches below the stator core 63.

[0098] On the other hand, when the nozzle 11 located below the stator core 63 is to be moved upward as shown in Fig. 10(c), the movable base 34 to which the nozzle 11 is fixed is moved upward together with the lift plate 74 by the first actuator 32 as shown in Fig. 10(d). At the same time as this movement, the first actuator 32 is raised by the second actuator 33, and the movement of the nozzle 11 is stopped when it passes through the slot 63c and reaches above the stator core 63 as shown in Fig. 10(e).

[0099] 10(b) and 10(d), the moving speed Zv of the nozzle 11 in the slot 63c by the nozzle moving mechanism 30 is the sum of the moving speed Z1v at which the first actuator 32 moves the nozzle 11 and the moving speed Z2v at which the second actuator 33 further moves the first actuator 32 in the same direction. Therefore, compared to the conventional method in which the nozzle 11 is moved by a single actuator, the winding method of the present invention makes it possible to double the moving speed Zv of the nozzle 11 in the Z-axis direction.

[0100] On the other hand, the oscillation of the wound magnetic pole 63b is achieved by reciprocatingly rotating the stator core 63, and this rotation is performed by an oscillation servo motor (not shown) in the support device 68. This reciprocating rotation of the stator core 63 is achieved by rotating the oscillation servo motor (not shown) forward and backward at an angle corresponding to the angle formed by the magnetic pole 63b that is the subject of the winding and the adjacent magnetic pole 63b.

[0101] Therefore, by simply reciprocating the nozzle 11 once and rotating the swing servo motor (not shown) forward and backward by a small angle, the nozzle 11 can be rotated once around the magnetic pole 63b. As a result, the winding speed can be increased compared to the conventional method in which the nozzle could not be rotated once around the magnetic pole without rotating the screw shaft multiple times.

[0102] Moreover, the winding device 60 in this alternative embodiment includes a driving means 70 for moving the nozzle 11 in three-dimensional directions together with the nozzle moving mechanism 30. However, this driving means 70 is used when the nozzle 11 is to be moved significantly, such as when changing the magnetic pole 63b to be wound, or when the end of the wire 12 fed from the tip of the nozzle 11 is to be fixed by tying it to a tying pin or a wire clamp device (not shown).

[0103] For this reason, although the driving means 70 includes a vertical driving unit 73 that moves the nozzle 11 up and down along the Z axis together with the nozzle movement mechanism 30, the vertical driving unit 73 is not used when rotating and moving the nozzle 11 around the magnetic pole 63b for winding. Therefore, it is not necessary to use a high-torque, highly responsive servo motor capable of rapid acceleration and deceleration from high speed as the vertical driving source 73e in the vertical driving unit 73.

[0104] In addition, the magnetic pole 63b can be swung by repeatedly rotating forward and backward through a small angle in a swing servo motor (not shown). Therefore, by using a servo motor that is commercially available as a standard product as the vertical drive source 73e of this separate winding device 60 and as the swing servo motor (not shown), it is possible to increase the winding speed without increasing the unit price of the winding device 60.

[0105] In addition, in order to wind the wire 12 in an aligned manner around the magnetic pole 63b, it is necessary to rotate the nozzle 11 around the magnetic pole 63b and move the nozzle 11 together with the nozzle moving mechanism 30 in the X-axis direction by the diameter of the wire 12 for each turn of the wire 12 using the forward / backward drive unit 71.

[0106] To move the nozzle 11 in the X-axis direction, the front-rear direction drive source 71e of the front-rear direction drive unit 71 is driven to move the front-rear direction connection unit 71d in the X-axis direction. However, the amount of movement is extremely small, being only the diameter of the wire 12 for each turn of the wire 12, and so there is no need to drive the front-rear direction drive source 71e at high speed.

[0107] Therefore, even when a servo motor is used as the forward / rearward drive source 71e, a standard product available on the market can be used, and a winding device 60 capable of high-speed, aligned winding can be obtained without increasing the unit price of the winding device 60.

[0108] In the above-described embodiment, a case has been described in which the nozzle moving mechanism 30 attaches the stator 32b of a single first linear motor 32 to the mover 33b of a single second linear motor 33, and moves a single nozzle 11 in the axial direction of a single stator core 13, 63.

[0109] However, the nozzle moving means 30 of the present invention, which has multiple actuators 32, 33, may be such that multiple first actuators 32, each of which moves one or more nozzles 11, are moved simultaneously or separately in the axial direction of the stator cores 13, 63 by a single second actuator 33.

[0110] 13 and 14, for example, a bridge plate 81 perpendicular to the moving direction of the mover 33b of the second linear motor 33 serving as the second actuator may be provided, the stators 32a of the first actuator 32 may be attached to both sides of the bridge plate 81, and the movable bases 34 having the nozzles 11 may be attached to the movers 32b of the first actuator 32. In this way, the nozzle moving mechanism 30 moves two nozzles 11.

[0111] Fig. 14 shows a winding device 80 having the nozzle movement mechanism 30 shown in Fig. 13. The winding device 80 shown in Fig. 14 shows the nozzle movement mechanism 30 attached to the machine base 14 via a front-rear direction drive unit 87 that moves the nozzle movement mechanism 30 along the X-axis. The front-rear direction drive unit 87 includes a front-rear direction guide 87a that is arranged on the machine base 14 along the X-axis, which is the driving direction, a front-rear direction rotation shaft 87b that is arranged parallel to the front-rear direction guide 87a and has a helical male screw on its surface, and a front-rear direction drive source 87c that rotationally drives the front-rear direction rotation shaft 87b.

[0112] The nozzle moving mechanism 30 shown in FIG. 13 moves two nozzles 11, and therefore the winding device 80 shown in FIG. 14 having this nozzle moving mechanism 30 has two tables 16 provided on the machine base 14 facing the two nozzles 11 moved by the nozzle moving mechanism 30. The tables 16 are provided with a support for supporting the stator core and a swing servo motor 19 which serves as a stator core operating mechanism that rotates the support and swings the magnetic poles of the stator core.

[0113] With this type of winding device 80, it is possible to rotate and move the nozzles 11 around the magnetic poles along the cross-sectional shape of the magnetic poles by alternately moving the nozzles 11 in the slots of a stator core (not shown) and oscillating the magnetic poles in the stator core. And with this type of winding device 80, even though it is equipped with only a single nozzle moving mechanism 30, it is possible to simultaneously wind two stator cores 13, the same number as the number of nozzles 11.

[0114] As shown in Fig. 13(a), when the nozzle 11 located above the stator core 63 is moved downward by the nozzle moving mechanism 30, the movable base 34 to which the nozzle 11 is fixed is moved downward by the first actuators 32 on both sides of the crossing plate 81 as shown by the solid arrow in Fig. 13(b), and simultaneously with this movement, the first actuators 32 on both sides are lowered together with the crossing plate 81 by the second actuator 33. Then, as shown in Fig. 13(c), the movement of those nozzles 11 is stopped when they reach the downward position.

[0115] On the other hand, as shown in Fig. 13(c), when the nozzle 11 located at the bottom is moved upward, the movable platform 34 to which the nozzle 11 is fixed is moved upward by the first actuators 32 on both sides of the crossing plate 81 as shown by the dashed arrow in Fig. 13(b), and simultaneously with this movement, the first actuators 32 on both sides are raised together with the crossing plate 81 by the second actuator 33. Then, as shown in Fig. 13(a), the movement of the nozzle 11 is stopped when it reaches the top.

[0116] Therefore, even if two nozzles 11 are moved by the nozzle movement mechanism 30, the movement speed Zv of the nozzles 11 will be the sum of the movement speed at which the first actuator 32 moves the nozzle 11 and the movement speed at which the second actuator 33 further moves the first actuator 32 in the same direction, as shown in Figure 13(b), making it possible to double the movement speed Zv of the nozzles 11 compared to the conventional method, and making it possible to improve the winding speed compared to the conventional method.

[0117] In this way, when the nozzle movement mechanism 30 is equipped with multiple first actuators 32 that move the nozzles 11 and a single second actuator 33 that moves them, it becomes possible to quickly move more nozzles 11 than the number of first actuators 32, and to simultaneously wind a number of stator cores equal to that number.

[0118] Therefore, as shown in FIG. 15, if three first actuators 32 are moved by a single second actuator 33, it becomes possible to move three nozzles 11 quickly, and it becomes possible to wind three stator cores, equal to the number of nozzles 11, simultaneously.

[0119] Furthermore, as shown in FIG. 16, two nozzles 11 are provided on each of the movers 32b of the two first actuators 32 via crossover pieces 82, so that the two first actuators 32 each move two nozzles 11 simultaneously, and these two first actuators 32 are further moved by a single second actuator 33. This makes it possible to move the four nozzles 11 quickly, and makes it possible to wind four stator cores, which is equal to the number of nozzles 11, simultaneously, which is expected to further improve the tact time.

[0120] In the above-described embodiment, the first and second actuators 32 and 33 constituting the nozzle movement mechanism 30 are linear motors that move the movers 32b and 33b in the longitudinal direction of the stators 32a and 33a, respectively. However, these actuators may be combined with conventional actuators that rotate a ball screw to move a movable base (mover) screwed thereto, as long as they are provided in stages and can move the nozzle at a relatively high speed.

[0121] Furthermore, in the winding device 60 of the other embodiment described above, a driving means 70 is provided that moves the nozzle 11 in three dimensions together with the nozzle moving mechanism 30, and the vertical driving unit 73 in this driving means 70 is used when the nozzle 11 is to be moved significantly, and this vertical driving unit 73 is not used when the nozzle 11 is rotated around the magnetic pole 63b to perform winding.

[0122] However, the vertical drive unit 73 may be used when winding by rotating the nozzle 11 around the magnetic pole 63b. In this case, the vertical drive unit 73 becomes an actuator (vertical drive unit 73) that moves the nozzle 11 up and down along the Z axis together with the first and second actuators 32, 33 during winding. In this case, the nozzle movement mechanism 30 is composed of these three actuators, and it is expected that the winding speed will be further increased. [Explanation of symbols]

[0123] 10,60,80 Winding device 11 Nozzle 12 Wire rod 13,63 Stator core 13b,63b magnetic pole 19 Oscillating servo motor (stator operating mechanism) 19a Rotation axis 30 Nozzle movement mechanism 32 First actuator (first linear motor) 33 Second actuator (second linear motor) 32a,33a Stator 32b,33b Mover

Claims

1. a stator core operating mechanism (19) that operates a stator core (13, 63) so that magnetic poles (13b, 63b) oscillate; and a nozzle moving mechanism (30) that moves a nozzle (11) in a direction perpendicular to an axis of the magnetic poles (13b, 63b), wherein a tip of the nozzle (11) is wound around the magnetic poles (13b, 63b) by a combination of the oscillation of the stator core (13, 63) and the movement of the nozzle (11), thereby winding a wire (12) fed from the nozzle (11) around the magnetic poles (13b, 63b), The nozzle moving mechanism (30) includes a plurality of actuators (32, 33) arranged in stages at positions perpendicular to the axes of the magnetic poles (13b, 63b). A wire winding device characterized by:

2. 2. The wire winding device according to claim 1, wherein the plurality of actuators (32, 33) arranged in stages comprise a first actuator (32) that moves the nozzle (11) and a second actuator (33) that moves the first actuator (32) parallel to the movement direction of the nozzle (11).

3. The first actuator (32) and the second actuator (33) each include a stator (32a, 33a) and a mover (32b, 33b) that reciprocates along the stator (32a, 33a), The nozzle (11) is attached to the movable element (32b) of the first actuator (32), a stator (32a) of the first actuator (32) is attached to a mover (33b) of the second actuator (33); 3. The wire winding device according to claim 2, wherein the stator (33a) of the second actuator (33) is provided adjacent to the stator core operating mechanism (19).

4. A wire winding device as described in claim 2 or 3, wherein the stator core operating mechanism (19) comprises a servo motor (19) in which the stator core (13) is attached to a rotating shaft (19a) coaxially with the rotating shaft (19a).

5. A wire winding method for winding a wire (12) fed from a tip of the nozzle (11) around the magnetic pole (13b, 63b) by combining oscillation of the magnetic pole (13b, 63b) about a central axis (O) of a stator core (13) as a center of rotation and movement of the nozzle (11) in a slot (13c, 63c) between the magnetic poles in the direction of the central axis (O) of the stator core (13), wherein the tip of the nozzle (11) is wound around the magnetic pole (13b, 63b), The nozzle (11) is moved in the slot (13c, 63c) by simultaneously driving a plurality of actuators (32, 33) arranged in stages. A method for winding a wire, comprising:

6. 6. The wire winding method according to claim 5, wherein simultaneously driving the plurality of actuators (32, 33) arranged in stages comprises moving the nozzle (11) by a first actuator (32) and further moving the first actuator (32) by a second actuator (33) in the same direction as the movement direction of the nozzle (11).

7. A wire winding method as described in claim 6, wherein the magnetic pole (13b, 63b) starts to oscillate after the nozzle (11) moving through the slot (13c, 63c) passes through the slot (13c, 63c), and the nozzle (11) starts to move into the slot (13c, 63c) after the magnetic pole (13b, 63b) stops oscillating.

8. A moving speed (Zv) of the nozzle (11) in the slot (13c, 63c) in the direction of the central axis (O) of the stator core (13) by the nozzle moving mechanism (30) is 8. The wire winding method according to claim 6 or 7, characterized in that the speed (Z1v) is the sum of the speed (Z1v) at which the first actuator (32) moves the nozzle (11) and the speed (Z2v) at which the second actuator (33) further moves the first actuator (32) together with the nozzle (11) in the same direction.

Images