Winding device

Abstract

To improve a winding accuracy for a coil.SOLUTION: A winding device 100 that windings a wiring material 1 derived from a nozzle 24 to a core 30, comprises: the coil 30 having a nozzle 24 that drives the wiring material 1 from a tip end part 24a, a drum part 31 to which the wiring material 1 derived from the nozzle 24 is wound, and a first flange part 32 provided to one end side of the drum part 31; and a control part 50 that controls a rotation of any one of the nozzle 24 and the coil 30 that become a rotated member. The control part 50 calculates a requirement rotational angle of the rotated member on the basis of a gap length L1 between the wiring material 1 measured in the middle that the wiring material 1 is wound to the drum part 31 toward the first flange part 32 and the first flange part 32, and rotates the rotated member by the requirement rotational angle.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a winding device and a winding method. [Background technology]

[0002] Patent Document 1 discloses a winding device that winds a wire fed from a nozzle onto a winding core. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2010-183041 A Summary of the Invention [Problem to be solved by the invention]

[0004] In the winding device described in Patent Document 1, the influence of the shape error of the wire on the overall length of the coil is reduced, thereby winding the coil so that the overall length is constant. However, when the manufacturing error of the winding core on which the wire is wound is large and the distance between the flanges varies, if the winding is performed so that the overall length of the coil is a target length, when winding is performed on a winding core whose distance between the flanges is shorter than the target length, new wire will ride up on the already wound wire near the flanges, and when winding is performed on a winding core whose distance between the flanges is longer than the target length, a gap will be generated near the flanges, resulting in a risk of a decrease in winding accuracy around the winding core.

[0005] An object of the present invention is to improve the winding accuracy with respect to a winding core. [Means for solving the problem]

[0006] According to one aspect of the present invention, a winding device that winds a wire rod unwound from a nozzle around a winding core includes a nozzle that unwound the wire rod from a tip portion, a winding drum around which the wire rod unwound from the nozzle is wound, and a winding core having a flange portion provided on one end side of the winding drum, and a control unit that controls the rotation of either the nozzle or the winding core, which serve as rotated members, and the control unit calculates a required rotation angle of the rotated member based on a gap length between the wire rod and the flange portion measured while the wire rod is being wound around the winding drum toward the flange portion, and rotates the rotated member by the required rotation angle.

[0007] According to another aspect of the present invention, a winding method in which a wire rod unwound from a nozzle is wound around a winding core by rotating either the nozzle or the winding core, which serve as the rotated member, measures the length of a gap between the wire rod and the flange portion as the wire rod is wound around the winding body portion of the winding core toward the flange portion of the winding core, calculates a required rotation angle of the rotated member based on the length of the gap, and rotates the rotated member by the required rotation angle. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a side view showing the configuration of a winding device according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view taken along the line AA in FIG. [Diagram 3] FIG. 3 is a diagram showing an example of an image captured by the imaging device. [Figure 4] FIG. 4 is a flow chart showing a winding procedure performed by the winding method according to the embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A winding device and a winding method according to an embodiment of the present invention will be described below with reference to the drawings.

[0010] The winding device 100 is a device for manufacturing an aligned wound coil by winding the wire 1 paid out from a nozzle 24 in an aligned manner around a winding core 30, and includes, as shown in Fig. 1, a nozzle 24 that pays out the wire 1 from a tip portion 24a, a winding core 30 having a winding drum portion 31 around which the wire 1 paid out from the nozzle 24 is wound, a nozzle moving device 20 that moves the nozzle 24 at a predetermined pitch speed, a rotating device 15 that rotates the winding core 30 as a rotated member about a rotation axis C1, and a control unit 50 that controls the nozzle moving device 20 and the rotating device 15. Note that Fig. 1 is a side view of the winding device 100, but an imaging device 40 described later is not shown.

[0011] The nozzle 24 is a member formed in a cylindrical shape and has a through hole (not shown) penetrating in the axial direction. The nozzle 24 is attached to the nozzle moving device 20 so that a tip end 24a where one end of the through hole is open faces the winding core 30. The nozzle 24 pays out the wire rod 1 supplied from a wire rod supply source (not shown) from the tip end 24a and guides it to the winding core 30.

[0012] The winding core 30 is a so-called bobbin made of resin, and has a cylindrical winding drum 31 around which the wire 1 is wound, a first flange 32 provided at one end of the winding drum 31, and a second flange 33 provided at the other end of the winding drum 31.

[0013] The nozzle moving device 20 is an electric slider 21 capable of reciprocating a movable piece 22 along the direction of the rotation axis C1 of the winding core 30, and the above-mentioned nozzle 24 is attached to the movable piece 22.

[0014] The rotating device 15 is composed of an electric motor 16 and a spindle 17 attached to the rotating shaft of the electric motor 16, and the tip of the spindle 17 is shaped so as to be able to hold the winding core 30 configured as described above.

[0015] The electric motor 16 is provided with a rotary encoder (not shown), which is capable of detecting the instantaneous rotation angle of the rotating shaft of the electric motor 16. In addition, the instantaneous rotation angle of the winding core 30 rotated by the electric motor 16 via the spindle 17 can also be obtained from the detection value of the rotary encoder.

[0016] 1, the nozzle moving device 20 and the rotation device 15 are supported by a support 12 standing on a base 10. Note that the support supporting the nozzle moving device 20 and the support supporting the rotation device 15 may be different supports.

[0017] The control unit 50 controls the operation of the nozzle moving device 20 and the rotation device 15 in accordance with the contents input by an operator via an input device (not shown). The specific control performed by the control unit 50 will be described in detail later in the description of the winding method.

[0018] Specifically, the control unit 50 is composed of a microcomputer equipped with a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), and an I / O interface (Input / Output Interface). The RAM stores data for CPU processing, the ROM stores the CPU control program and the like in advance, and the I / O interface is used for inputting and outputting information between the nozzle moving device 20 and the rotation device 15 connected to the control unit 50, the imaging device 40 described below, an input device (not shown), and a display device (not shown).

[0019] Here, when the winding core 30 is formed, particularly from resin, as described above, manufacturing errors may cause the positions at which the flange portions 32, 33 are provided relative to the winding drum portion 31 to shift slightly, which may result in individual differences in the length of the winding drum portion 31, i.e., the size of the distance between the first flange portion 32 and the second flange portion 33.

[0020] For this reason, for example, when a first layer of winding is performed from the second flange 33 side toward the first flange 32 so that the overall length of the coil manufactured by the winding device 100 becomes a preset target length, when winding is performed around a winding core 30 whose winding body 31 is shorter than the target length, the new wire material 1 will ride up on the already wound wire material 1 near the first flange 32, and when winding is performed around a winding core 30 whose winding body 31 is longer than the target length, a gap will be generated near the first flange 32, resulting in a decrease in winding accuracy around the winding core 30.

[0021] Therefore, the winding device 100 of the present embodiment further includes an imaging device 40 as a distance measuring device in order to improve the winding accuracy around the winding core 30 even when the manufacturing error of the winding core 30 is relatively large.

[0022] The imaging device 40 is a device provided on the base 10 to capture an image of the first flange 32 and the wire 1 while the wire 1 is being wound around the winding drum 31 from the second flange 33 side toward the first flange 32, and as shown in Fig. 2, mainly includes a camera 41 and a mirror 43 installed in the imaging direction of the camera 41. In addition to these, the imaging device 40 may also include a lighting device and a white or metallic member that serves as a background screen.

[0023] The camera 41 is a digital camera having a pixel count and a field of view large enough to sufficiently distinguish the shapes of the first flange 32, the winding drum 31, and the wire 1 from the captured image data, and is supported by a support 13 standing on the base 10 so that the height of the imaging center C2 is approximately the same as the height of the vicinity of the upper end of the winding drum 31 of the core 30. In other words, the height of the imaging center C2 of the camera 41 is set so that at least the wire 1 extending from the nozzle 24 to the winding drum 31 and the first flange 32 of the winding core 30 are included in the imaging field of view.

[0024] Moreover, the camera 41 is connected to the control unit 50, and the image capturing timing is controlled by the control unit 50, and the captured image data is transmitted to the control unit 50.

[0025] Mirror 43 is a right-angle prism mirror having a reflective surface that changes the direction in which imaging surface 41a of camera 41 faces (towards imaging center C2) toward the winding core 30, and is supported by a support 14 erected on base 10 so that the height of its center position is approximately the same as the height of imaging center C2.

[0026] Specifically, the direction in which the imaging surface 41a of the camera 41 faces (towards the imaging center C2) and the angle and position of the mirror 43 are set so that the analysis image P captured by the camera 41, which will be described later, includes the portion of the wire 1 being unwound from the nozzle 24 just before it is wound around the winding drum 31, i.e., the wire 1 that appears to extend radially outward from the winding drum 31, and the winding drum 31 and first flange 32 of the winding core 30.

[0027] The camera 41 may be disposed so that the imaging surface 41a directly faces the vicinity of the upper end of the winding drum 31 of the winding core 30, without the mirror 43. In this case, the mirror 43 is unnecessary, but the main body of the camera 41 including the lens is disposed in a direction perpendicular to the rotation axis C1, which may increase the size of the entire winding device 100. Therefore, in order to make the entire winding device 100 compact, it is preferable to use the mirror 43 appropriately.

[0028] The analysis image P captured by the imaging device 40 having such a configuration will be described with reference to Fig. 3. Fig. 3 shows an example of the analysis image P captured by the imaging device 40.

[0029] As described below, the camera 41 captures images at a timing instructed by the control unit 50 so that the first flange 32 and the wire 1 are included in the analysis image P while the wire 1 is being wound around the winding drum 31 from the second flange 33 side toward the first flange 32.

[0030] The control unit 50 processes the digital data of the analysis image P to extract the end line of the wire 1 on the first flange portion 32 side and the end face 32a of the first flange portion 32, and calculates the gap length L1 between them.

[0031] Specifically, as shown in FIG. 3, a first line segment R1 along the end face 32a of the first flange portion 32, a second line segment R2 along the upper end of the winding drum portion 31, and a third line segment R3 along the first flange portion 32 side of the wire 1 are recognized, and then the distance between the first line segment R1 and the third line segment R3 at a point parallel to and separated from the second line segment R2 by a preset specified distance D1 is calculated as the gap length L1.

[0032] The method of calculating the gap length L1 is not limited to this, and the gap length L1 may be calculated from two line segments, the first line segment R1 along the end face 32a of the first flange 32 and the third line segment R3 along the first flange 32 side of the wire rod 1. The gap length L1 may also be calculated within the range in which the winding drum 31 is shown. However, since the color and gloss of the winding drum 31 are similar to that of the surrounding area, it may be difficult to accurately recognize, for example, the end face 32a of the first flange 32 or the end line of the wire rod 1 on the first flange 32 side. For this reason, it is preferable to calculate the gap length L1 based on the above-mentioned line segments R1, R2, and R3, which are relatively easy to recognize by making the background white, etc.

[0033] The calculation of the gap length L1 may be performed by a calculation unit provided in the imaging device 40 instead of the control unit 50. In this case, the imaging device 40 transmits the size of the gap length L1 to the control unit 50.

[0034] Next, a winding method performed by the winding device 100 having the above configuration will be described with reference to the flowchart of FIG.

[0035] When an operator operates a coil production start button or the like, the control unit 50 starts winding the wire 1 around the winding core 30 in step S11. In the following, a case will be described in which the tip end of the wire 1 is held on the second flange portion 33 side, and the wire 1 is wound around the winding drum portion 31 from the second flange portion 33 side toward the first flange portion 32.

[0036] Specifically, the control unit 50 moves the movable piece 22 by the electric slider 21 at a pitch speed input in advance, thereby moving the nozzle 24 toward the first flange 32, and rotates the electric motor 16 to rotate the winding core 30. As a result, the wire 1 is gradually wound around the winding drum 31 toward the first flange 32.

[0037] The control unit 50 controls the drive of the electric motor 16 and the electric slider 21 and starts winding. In the subsequent step S12, the control unit 50 determines whether or not the length of the coil formed on the winding core 30 has reached a predetermined length at which the gap length L1 should be measured.

[0038] Specifically, when the distance traveled by the nozzle 24 along the direction of the rotation axis C1 after the start of winding is at least two-thirds, preferably at least three-quarters, of the expected total length of the coil, the control unit 50 determines that the gap length L1 should be measured and proceeds to step S13. On the other hand, if it is determined that the gap length L1 should not be measured yet, the winding is continued. Note that whether the gap length L1 should be measured or not may be determined based on whether the total number of rotations of the winding core 30 or the total number of rotations of the electric motor 16 after the start of winding has reached a predetermined number of rotations.

[0039] In the following step S13, the control unit 50 instructs the imaging device 40 to capture an image P for analysis.

[0040] When instructed to capture an image, the imaging device 40 captures an analysis image P in which the first flange portion 32 and the wire 1 are included in a single image while the wire 1 is being wound around the winding drum portion 31 toward the first flange portion 32, and transmits the image to the control unit 50.

[0041] Furthermore, in step S13, the control unit 50 determines the rotation angle of the winding core 30 at the time the analysis image P was captured from the detection value of the rotary encoder, and stores the determined rotation angle as the starting position for starting counting the required rotation angle RA described below.

[0042] If the rotation speed of the winding core 30 is high, the analysis image P becomes blurred, and it may become difficult to extract the end line of the wire 1 on the first flange portion 32 side or the end face 32a of the first flange portion 32. For this reason, when capturing the analysis image P in step S13, the rotation speed of the winding core 30 may be reduced or the rotation of the winding core 30 may be temporarily stopped.

[0043] The control unit 50 receives the analysis image P and calculates the gap length L1 by image processing as described above (see FIG. 3).

[0044] In the next step S14, the control unit 50 calculates a required rotation angle RA, which is the rotation angle of the winding core 30 (rotated member) required until the wire 1 wound around the winding drum 31 comes into contact with the end face 32a of the first flange portion 32, based on the calculated gap length L1.

[0045] The required rotation angle RA is a rotation angle that indicates how much further the winding core 30 needs to be rotated from the rotation angle of the winding core 30 at the time when the gap length L1 is measured, i.e., at the time when the analysis image P is captured, so that the wire 1 unwound from the nozzle 24 comes into contact with the end face 32a of the first flange portion 32, and is the rotation angle of the winding core 30 required to wind the wire 1 just enough for the measured gap length L.

[0046] Specifically, the required rotation angle RA is calculated from the movement distance X1 (pitch speed) that the nozzle 24 moves along the direction of the rotation axis C1 during one rotation of the winding core 30 and the gap length L1 according to the following formula (1).

[0047] RA = (L1 / X1) 360 (1)

[0048] Note that the integer part of the value obtained by dividing the gap length L1 by the movement distance X1 is the required number of rotations RA1, and the decimal part is multiplied by 360 to obtain the required angle RA2, and the calculation may be divided into the number of times to rotate the winding core 30 (the rotated member) and the angle. In this case, the sum of the required number of rotations RA1 and the required angle RA2 essentially corresponds to the above-mentioned required rotation angle RA.

[0049] For example, when the moving distance X1 is 0.2 mm and the gap length L1 is 0.75 mm, the required rotation angle RA is 1350°. In this case, the required number of rotations RA1 is 3 rotations, and the required angle RA2 is 270°.

[0050] Furthermore, the control unit 50 compares the number of turns when the first layer is wound by rotating the winding core 30 by the required rotation angle RA from the rotation angle of the winding core 30 at the time when the analysis image P was captured with the number of turns of the first layer that was planned in advance, and stores the difference as the number of turns that is excess or deficiency. Note that the number of turns may be converted into the winding length of the wire 1, and the number of turns that is excess or deficiency may be stored as the wire length that is excess or deficiency.

[0051] When the required rotation angle RA is calculated in step S14, the control unit 50 further rotates the winding core 30 by the required rotation angle RA in the following step S15.

[0052] Specifically, by rotating the electric motor 16, the rotation angle of the winding core 30 is rotated until the rotation angle of the winding core 30, which starts counting from the rotation angle of the winding core 30 at the time the analysis image P is captured, becomes the required rotation angle RA, and the electric slider 21 moves the movable piece 22 at a pitch speed that has been input in advance.

[0053] As a result, the wire 1 unwound from the nozzle 24 is wound exactly around the winding drum 31 until it is almost in contact with the end face 32a of the first flange 32, without riding onto the already wound wire 1 near the first flange 32.

[0054] In addition, if winding is performed until the rotation angle of the winding core 30, from which counting begins from the rotation angle of the winding core 30 at the time the analysis image P is captured, finally becomes the required rotation angle RA, the winding after the analysis image P is captured in step S13 may be resumed without waiting for the measurement of the gap length L and the calculation of the required rotation angle RA to be completed, or may be resumed after these calculations, etc. are completed.

[0055] When the first layer of winding is completed by winding the wire 1 around the end face 32a of the first flange portion 32 with almost no gap between them, the process proceeds to step S16, where the second and subsequent layers of winding are started.

[0056] The second and subsequent layers are wound in the same manner as the first layer and with the same number of turns as the first layer, without calculating the required rotation angle RA. The number of turns of the outermost layer is set to a number that is increased or decreased by the number of turns stored in step S14 relative to the previously planned number of turns.

[0057] Here, when winding the second and subsequent layers, the size of the gaps between the wire rods 1 may slightly expand or contract during winding depending on the error in the wire diameter of the wire rod 1, the shape of the wire rod 1, and the accuracy of the feed speed of the nozzle 24, resulting in a winding width different from that of the first layer. In such a case, even if the same number of turns as the first layer are wound, the new wire rod 1 may ride up on the already wound wire rod 1 near the flanges 32 and 33, or a gap may be generated near the flanges 32 and 33.

[0058] For this reason, the measurement of the gap length L and the calculation of the required rotation angle RA may be performed not only for the first winding layer, but also for the second and subsequent winding layers; for example, they may be performed when winding layers in a predetermined order, such as the third or seventh layer, or they may be performed when winding all layers.

[0059] When the gap length L is measured and the required rotation angle RA is calculated in the second or fourth winding layer in which the wire 1 unwound from the nozzle 24 is wound around the winding drum 31 toward the second flange 33 instead of the first flange 32, the imaging device 40 captures an analysis image P in which the second flange 33 and the wire 1 are included in one image while the wire 1 is being wound around the winding drum 31 toward the second flange 33. In this case, the second flange 33 corresponds to the flange, and the gap length L1 is the distance between the end line of the wire 1 on the second flange 33 side and the end face of the second flange 33. In addition, the imaging device 40 that images the area near the second flange 33 may be, for example, an imaging device that can image both the area near the first flange 32 and the area near the second flange 33 by switching the position of the mirror 43, or may be an imaging device provided separately from the imaging device 40 that images the area near the first flange 32.

[0060] In this way, by measuring the gap length L and calculating the required rotation angle RA even when winding the second layer and thereafter, it is possible to wind the wire 1 around the winding core 30 without excess or deficiency when winding each layer.

[0061] Since the performance of a coil generally varies depending on the number of turns and the length of the winding, when winding of the second layer or subsequent layers is started, in step S17, the control unit 50 determines whether the number of turns of the coil has reached a preset design number of turns or whether the length of the wire 1 used to wind the coil has reached a preset design length in order to achieve the required performance.

[0062] When it is determined that the number of turns of the coil has reached a preset design number of turns, or when it is determined that the length of the wire 1 used to wind the coil has reached a preset design length, the control unit 50 stops the electric motor 16 and the electric slider 21, and ends the winding.

[0063] Through the steps described above, the winding of the wire 1 around the winding core 30 is completed, and an aligned wound coil with predetermined specifications is formed around the winding core 30.

[0064] The above embodiment provides the following advantages.

[0065] In the winding device 100 configured as described above, the control unit 50 calculates a required rotation angle RA of the winding core 30 as the rotated member based on the gap length L between the wire 1 unwound from the nozzle 24 and the first flange 32 measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32 serving as a flange, and rotates the winding core 30 by the required rotation angle RA.

[0066] In this way, the necessary rotation angle RA of the winding core 30 required for winding the wire 1 without excess or deficiency with respect to the gap length L between the wire 1 and the first flange 32 measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32 is obtained, and the winding core 30 is rotated by this necessary rotation angle RA. Even if there is an individual difference in the length of the winding drum 31 due to a manufacturing error of the winding core 30 or the like, it is possible to prevent new wire 1 from riding on the already wound wire 1 near the first flange 32 and to prevent a gap from being generated near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0067] Furthermore, according to the winding device 100 having the above configuration, even if the manufacturing error of the winding core 30 is relatively large or if a guide groove or the like that defines the position of the wire 1 in the first layer is not formed in the winding drum 31, it is possible to wind the wire 1 just right around the winding core 30. Therefore, the manufacturing cost of the winding core 30 can be reduced, and the manufacturing cost of the coil formed on the winding core 30 can also be reduced.

[0068] In addition, the following modified examples are also within the scope of the present invention, and it is possible to combine the configuration shown in the modified example with the configuration described in the above embodiment, or to combine the configurations described in the different modified examples below.

[0069] In the above embodiment, a description has been given of the case where the winding device 100 is an alignment winding machine in which the winding core 30 is the rotated member. Alternatively, the winding device may be a flyer-type alignment winding machine in which the nozzle 24 is the rotated member, and in this case, the control unit 50 controls the rotation of the nozzle 24 which rotates around the winding core 30 while unwinding the wire 1.

[0070] In the above embodiment, the measurement of the gap length L and the calculation of the required rotation angle RA are performed when the first layer is wound around the winding core 30. In addition to this, the measurement of the gap length L and the calculation of the required rotation angle RA may be performed not only when the first layer is wound around the winding core 30, but also when the second and subsequent layers are wound. Alternatively, if a guide groove that defines the position of the wire 1 for the first layer is formed in the winding drum 31, the measurement of the gap length L and the calculation of the required rotation angle RA may not be performed when the first layer is wound around the winding core 30, but may be performed when the second and subsequent layers are wound.

[0071] In the above embodiment, the cross-sectional shape of the wire 1 is circular. Alternatively, the cross-sectional shape of the wire 1 may be rectangular or polygonal. In the above embodiment, the cross-sectional shape of the outer circumferential surface of the winding drum 31 around which the wire 1 is wound is circular. Alternatively, the cross-sectional shape of the winding drum 31 may be rectangular or polygonal.

[0072] In the above embodiment, the winding core 30 is made of resin. Alternatively, the winding core 30 may be a metal bobbin.

[0073] In the above embodiment, the winding core 30 is formed integrally with the winding drum 31 and both flanges 32, 33. Alternatively, the winding core 30 may be formed of separate members, such that the winding drum 31 and both flanges 32, 33 are separate members. The winding core 30 may be formed of the winding drum 31 and either one of the flanges 32, 33, or a portion of the spindle 17 may be used as the winding drum 31 of the winding core 30.

[0074] In the above embodiment, the travel distance X1 used in calculating the required rotation angle RA is a preset value. Alternatively, the travel distance X1 may be found from the analysis image P, similar to the gap length L1. Specifically, the width of the wire 1 in the direction along the rotation axis C1 when the wire 1 is wound around the winding drum 31 may be measured from the analysis image P, and the required rotation angle RA may be calculated by regarding the measured width as the travel distance X1 that the nozzle 24 travels along the rotation axis C1 while the winding core 30 makes one rotation.

[0075] In the above embodiment, the gap length L1 is measured using the analysis image P captured by the camera 41. Alternatively, the gap length L1 may be measured using a laser distance measuring device such as a 2D-LiDAR (Light Detection and Ranging) sensor. For example, a laser may be irradiated onto a portion of the wire 1 unwound from the nozzle 24 immediately before it is wound around the winding drum 31 and onto the first flange 32, or a laser may be irradiated from the first flange 32 toward the second flange 33 along the rotation axis C1 to determine the shape of the winding core 30 including the wire 1.

[0076] The configuration, operation, and effects of the embodiment of the present invention will be described below.

[0077] The winding device 100 includes a nozzle 24 that pays out the wire 1 from a tip 24a, a winding drum 31 around which the wire 1 paid out from the nozzle 24 is wound, and a winding core 30 having a first flange 32 provided on one end side of the winding drum 31, and a control unit 50 that controls the rotation of either the nozzle 24 or the winding core 30, which serve as rotated members. The control unit 50 calculates a required rotation angle RA of the rotated member based on a gap length L1 between the wire 1 and the first flange 32 measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32, and rotates the rotated member by the required rotation angle RA.

[0078] In this configuration, a required rotation angle RA of the rotated member required to wind the wire 1 without excess or deficiency with respect to a gap length L between the wire 1 and the first flange 32 measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32 is obtained, and the rotated member is rotated by the required rotation angle RA. Even if there is an individual difference in the length of the winding drum 31 due to a manufacturing error of the winding core 30 or the like, it is possible to prevent new wire 1 from riding on the already wound wire 1 near the first flange 32 and to prevent a gap from being generated near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0079] The required rotation angle RA is the rotation angle of the rotated member from the point at which the gap length L1 is measured, and is set to the rotation angle of the rotated member required until the wire 1 wound around the winding drum 31 comes into contact with the first flange 32.

[0080] In this configuration, the required rotation angle RA is set to a rotation angle of the rotated member required until the wire 1 wound around the winding drum 31 comes into contact with the first flange 32. By rotating the rotated member by the required rotation angle RA set in this way, it becomes possible to wind the wire 1 without excess or deficiency with respect to the gap length L. As a result, even if there is an individual difference in the length of the winding drum 31 due to a manufacturing error of the winding core 30 or the like, it is possible to prevent new wire 1 from riding on the already wound wire 1 near the first flange 32 and to prevent a gap from being generated near the first flange 32.

[0081] At least one of the winding body 31 and the first flange 32 is made of resin.

[0082] In this configuration, at least one of the winding drum 31 and the first flange 32 is made of resin, so there is a risk of individual differences in the length of the winding drum 31 and the size of the gap between the first flange 32 and the second flange 33 due to manufacturing errors, etc.; however, because the wire 1 is wound just enough with respect to the gap length L1 measured for each winding core 30, it is possible to improve the winding accuracy around the winding core 30 regardless of manufacturing errors.

[0083] The winding device 100 also includes an imaging device 40 capable of capturing images of the first flange portion 32 and the wire 1 while the wire 1 is being wound around the winding drum portion 31 toward the first flange portion 32, and the control unit 50 calculates the gap length L1 from the image captured by the imaging device 40.

[0084] In this configuration, the gap length L1 is calculated from the image captured by the imaging device 40. In this manner, by measuring the gap length L1 using a relatively simple system, an increase in the manufacturing cost of the winding device 100 can be suppressed.

[0085] In addition, in a winding method in which the wire 1 unwound from the nozzle 24 is wound around the winding core 30 by rotating either the nozzle 24 or the winding core 30, which are the rotated members, a gap length L1 between the wire 1 and the first flange 32 is measured while the wire 1 is being wound around the winding body 31 of the winding core 30 toward the first flange 32 of the winding core 30, a required rotation angle RA of the rotated member is calculated based on the gap length L1, and the rotated member is rotated by the required rotation angle RA.

[0086] In this configuration, a required rotation angle RA of the rotated member required to wind the wire 1 without excess or deficiency with respect to a gap length L between the wire 1 and the first flange 32 measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32 is obtained, and the rotated member is rotated by the required rotation angle RA. Even if there is an individual difference in the length of the winding drum 31 due to a manufacturing error of the winding core 30 or the like, it is possible to prevent new wire 1 from riding on the already wound wire 1 near the first flange 32 and to prevent a gap from being generated near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0087] Although the embodiments of the present invention have been described above, the above-mentioned embodiments merely show some of the application examples of the present invention, and it is not intended that the technical scope of the present invention be limited to the specific configurations of the above-mentioned embodiments.

Claims

1. A winding device that winds wire material dispensed from a nozzle onto a winding core, The nozzle that feeds out the wire from the tip, A spindle capable of holding the winding core at its tip, having a winding drum portion around which the wire material unwound from the nozzle is wound, and a flange portion provided on one end of the winding drum portion, An imaging device comprising: a camera capable of capturing images of the flange and the wire while the wire is being wound onto the winding drum toward the flange; and a mirror installed in the imaging direction of the camera; The system comprises a control unit that controls the rotation of either the nozzle or the winding core, which are to be rotated members, The camera is positioned such that the direction in which the imaging surface faces is parallel to the rotation axis direction of the winding core held by the spindle. The mirror is positioned to change the direction in which the imaging surface faces toward the winding core. Winding device.

2. A winding device according to claim 1, The aforementioned mirror is a right-angle prism mirror. Winding device.

3. A winding device according to claim 1, The system further comprises a lighting device and a white or metallic background screen. Winding device.

4. A winding device according to claim 1, The height of the imaging center of the camera is set so that the wire extending from the nozzle to the winding core and the flange portion are within the field of view. Winding device.

5. A winding device according to any one of claims 1 to 4, The control unit, while the wire is being wound onto the winding drum toward the flange, extracts the flange-side end line of the wire and the flange end face from the image, calculates the distance between them as the gap length between the wire and the flange, calculates the required rotation angle of the rotating member based on the gap length, and rotates the rotating member by the required rotation angle. Winding device.

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