Wire winding device
The wire winding device addresses alignment and tension fluctuations by using a shift roller unit to adjust the wire posture continuously, ensuring stable tension and aligned winding without stopping, thus preventing twists and maintaining quality.
Patent Information
- Application Number
- JP2024003118
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-01-12
- Publication Date
- 2025-07-25
AI Technical Summary
Conventional wire winding devices experience issues with wrinkles, twists, and alignment problems due to fluctuating tension, especially when winding carbon fiber reinforced plastic tapes with pitch variations, requiring temporary stops that lead to decreased tension and poor alignment.
A wire winding device with a first drive unit for rotating the workpiece, a second drive unit for reciprocating the workpiece, a wire supply unit, a tension applying unit, and a shift roller unit that adjusts the wire posture, allowing continuous winding without stopping, maintaining tension, and aligning the wire with pitch variations.
Ensures stable tension and aligned winding without stopping, preventing twists and maintaining quality by synchronizing the shift roller unit with the winding operation, ensuring consistent tension from start to finish.
Smart Images
Figure 2025109320000001_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to a wire winding device and a wire winding method for winding a wire around a workpiece.
Background Art
[0002] As a conventional wire winding device, there is a computer-controlled wire winding device equipped with a stepping motor for feeding a bobbin around which a wire is wound, as shown in Patent Document 1. In this device, a plurality of guide wheels are arranged in a straight line on a base between a fixed guide wheel for the wire and the bobbin, the straight line is held perpendicular to the axis of the bobbin, and a swing base that can move freely in the axial direction of the bobbin is provided. When the line of the guide wheels on the swing base is on the same line as the fixed guide wheel, a shift mechanism part having a mechanism for clamping the swing base is provided.
Prior Art Documents
Patent Documents
[0003]
Patent Document 1
Summary of the Invention
Problems to be Solved by the Invention
[0004] However, in this wire winding device, if the tension applied to the wire fluctuates, wrinkles, twists, etc. of the wire will occur in the wound state. The problem of eliminating the defects in the winding state caused by such tension fluctuations has not been solved.
[0005] In addition, when winding a tape-shaped wire made of carbon fiber reinforced plastic (CFRP) around a workpiece corresponding to a winding jig, in order to pitch-wind the tape-shaped wire, it is necessary to wind the wire with an inclination corresponding to the pitch with respect to the workpiece.
[0006] In order to fold the tension device that generates high tension or the winding part that generates winding rotational force with an inclination for one pitch, it is necessary to temporarily stop the winding operation and then resume the winding operation corresponding to the feeding operation and the rotational operation of the workpiece after the stop. Once the winding operation is temporarily stopped, there is a problem that the tension of the wire wound around the workpiece decreases, wrinkles, twists, etc. occur in the winding state, and it becomes difficult to wind in an aligned manner.
[0007] The present invention has been made in view of the above, and an object thereof is to provide a wire winding device and a wire winding method capable of winding a wire around a workpiece in an aligned manner.
Means for Solving the Problems
[0008] The wire winding device of the present invention is a wire winding device that winds a wire around the outer wall of a workpiece, a base (4), a first drive unit (7) that rotates a workpiece (5) around a rotation axis (13) with respect to the base, a second drive unit (8) that reciprocates the workpiece in the rotation axis direction with respect to the base, a wire supply unit (12) provided on the base and supplying a wire (10) to be wound around the outer wall of the workpiece, a tension applying unit (6) provided on the base and applying tension to the wire wound around the outer wall of the workpiece, and a shift roller unit (20) that adjusts the posture or state of the wire supplied from the wire supply unit to the workpiece between the wire supply unit and the workpiece is adopted.
[0009] The wire winding method of the present invention is a wire winding method for winding a wire around the outer wall of a rotating workpiece, a step of supplying a wire to the outer wall of the rotating workpiece, a step of switching the feeding direction of the workpiece along the rotation axis to the reverse feeding direction without stopping the rotation of the workpiece rotating around the rotation axis, When switching the feeding direction of the workpiece in the reverse direction, it includes a step of adjusting the posture or state of the wire wound around the workpiece by the shift roller unit.
[0010] According to the wire winding device and the winding method of the present invention, when winding the wire around the outer wall of the workpiece, at the time of folding back, the wire is continuously wound around the outer wall of the workpiece without stopping the winding operation corresponding to the rotation operation of the workpiece around which the wire is wound. Therefore, since there is no temporary decrease in the tension of the wound wire, it is possible to ensure a tension of a predetermined value or more from the start of winding to the end of winding. It is possible to perform the folding-back winding of the wire without increasing the amount of wire wound around the outer wall of the workpiece.
[0011] According to the wire winding device and the winding method of the present invention, a shift roller unit that generates an inclination corresponding to the pitch is provided in synchronization with the winding operation, and by making the shift roller unit slightly movable with respect to the base, the posture or state of the wire wound around the workpiece is adjusted, so that it is possible to wind the wire while folding it back.
[0012] According to the present invention, the roller group constituting the shift roller unit is a roller set capable of shifting with respect to the base. At a position between when the wire is carried out from the wire supply unit and carried into the workpiece, three rollers are provided at a position close to the workpiece. It is preferable that the roller surfaces of the rollers at both ends on the inlet side and the outlet side have a convex shape, and the roller surface of the central roller has a concave shape or a flat shape. The present invention is preferably applied to a wire having a rectangular cross-sectional shape.
Brief Description of the Drawings
[0013]
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Mode for Carrying Out the Invention
[0014] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In a plurality of embodiments, substantially the same constituent parts are denoted by the same reference numerals, and the description thereof will be omitted.
[0015] (First Embodiment) An embodiment of the present invention will be described with reference to FIGS. 1 to 13. The wire material used in an embodiment of the present invention refers to a tape in the form of a strip made of carbon fiber reinforced plastic (CFRP). In an embodiment of the present invention, the workpiece around which the wire material is wound is a cylindrical object corresponding to the main body of the inner rotor of the motor.
[0016] Specifically, as shown in FIGS. 1 and 13, for the object 1, a plurality of bar-plate-shaped magnets 3 extending in the axial direction of the rotation axis 13 are attached to the outer wall 2 of the cylindrical rotating body, and a plurality of bar-plate-shaped magnets 3 are attached at substantially equal intervals over the entire circumference in the circumferential direction of the outer wall 2. An embodiment of a winding device and a winding method for winding a tape 10 for holding a plurality of magnets 3 attached to the outer wall 2 of a workpiece 5 onto the object 1 will be described.
[0017] The tape 10 used in one embodiment corresponding to the wire material of the present invention refers to a flat belt or a wire material having a square cross-sectional shape. This winding device is a device for winding a carbon fiber reinforced plastic material (CFRP) as the tape 10 around the outer wall 2 of a rotating body so as to hold a plurality of magnets 3 on the outer wall 2 of the rotating body without displacement.
[0018] As shown in the blown-out symbol in FIG. 13, the cross-sectional shape of the tape 10 is square. In this embodiment, the size of the tape is, by way of example, a height of 0.1 mm and a width of 3.2 mm in cross-section. Specific numerical values are described to make it easier to imagine the size of the tape as a wire material. The wire material to which the present invention is applied is not limited in shape, height, and width of the cross-section.
[0019] As shown in FIG. 1, this winding device includes a first drive unit 7 such as a motor that rotationally drives the workpiece 5 with respect to the base 4 in the direction of arrow 14 about the rotation axis 13 as the central axis, and a second drive unit 8 such as a motor that reciprocally moves the workpiece 5 with respect to the base 4 in the direction of arrow 15 along the rotation axis 13.
[0020] The tape 10 wound around the tape supply roll 12 is carried out from the tape supply roll 12 in the direction of arrow 16 while a tension of, for example, 370 N is applied in the direction of arrow 9 by the tension applying unit 6, and is wound around the outer wall 2 of the workpiece 5.
[0021] The workpiece 5 as the object rotates in the direction of arrow 14 around the rotation axis 13. Further, the workpiece 5 can reciprocally move (feed and reverse feed) in the direction of arrow 15 of the rotation axis 13. As the workpiece 5 rotates in the direction of arrow 14 and reciprocally moves in the direction of arrow 15, the tape 10 is wound around the outer wall 2 of the workpiece 5. Between the workpiece 5 and the tape supply roll 12, a shift roller unit 20 for adjusting the supply direction of the tape 10 to the workpiece 5 is provided.
[0022] The configuration of the shift roller unit 20 is shown in FIGS. 2 and 3. The shift roller unit 20 is provided with a first roller 22 for carrying in the tape 10 supplied from the tape supply roll 12, a second roller 27, and a third roller 32 in this order in the direction of carrying out.
[0023] The first roller 22, the second roller 27, and the third roller 32 are free rollers, and the respective rotation axes 23, 28, and 33 are parallel to the rotation axis 13 of the workpiece 13. The first roller 22 and the third roller 32 are rotatably provided on the same surface side with respect to the tape 10, and the second roller 27 is rotatably provided on the opposite surface side with respect to the tape 10.
[0024] The first roller 22 has a convex curved surface 221 around which the tape 10 is wound, the second roller 27 has a concave curved surface 271 around which the tape 10 is wound, and the third roller 32 has a convex curved surface 321 around which the tape 10 is wound. By pressing the second roller 27 in the direction of arrow 29 from the opposite side with respect to the tape 10 wound around the first roller 22 and the third roller 32, the conveyance path of the tape 10 is bent, the contact area with each of the rollers 22, 27, and 32 is increased, and the centripetal force of the tape 10 is improved.
[0025] FIG. 5 shows each part as viewed from arrows A, B, and C in FIG. 3. As shown in FIGS. 3 and 5, the tangent distance I between the first roller 22 and the second roller 27 and the tangent distance II between the second roller 27 and the third roller 32 in the shift roller unit 20 are equal in length in the tape traveling direction as shown by the arrow groups 34 and 35 in the tape width direction, respectively. Thereby, it is possible to prevent the occurrence of deviation of the tape and to prevent the meandering of the tape path.
[0026] The tape 10 wound around the first roller 22, the second roller 27, and the third roller 32 is, as shown in FIG. 4, on the first roller 22 having a convex curved surface 221 and the third roller 32 having a convex curved surface 321, drawn toward the center side (maximum outer diameter side) of the convex portion of the tape width in the directions of arrows 17 and 18, and the feeding speed of the tape becomes faster toward the center side in the width direction as shown by arrow 19.
[0027] As shown in FIG. 1, the shift roller portion 20 is movable a minute distance in the direction of arrow 36 or the reverse arrow 37 with respect to the base 4 in the axial direction of the rotation axes 13, 23, and 28 of the first roller 22, the second roller 27, and the third roller 32 in conjunction with the feeding amount of the workpiece 5 in the direction of arrow 15 or the reverse direction. The shift roller portion 20 is movable a minute distance in the direction of arrow 36 or the reverse arrow 37 with respect to the base 4 when folding and winding the tape around the outer wall 2 of the workpiece 5. The shift roller portion 20 generates an inclination corresponding to the pitch in synchronization with the winding operation of the tape 10 by the first driving portion and the second driving portion.
[0028] As shown in FIG. 6, when the original pitch of the tape 10 wound around the workpiece 5 is p, and the pitches at both ends of the workpiece 5 are p1, p2, p3, and p4, the relationships are p1 < p2 < p and p4 < p3 < p.
[0029] Next, the operation of this embodiment will be described. In FIG. 1, when the workpiece 5 is rotationally driven in the direction of arrow 14 and simultaneously fed in the direction of arrow 15 along the rotation axis 13, a tension (for example, 370 N) is applied to the tape 10 in the direction of arrow 9 by the tension applying portion 6, and the tape 10 carried out from the shift roll portion 20 is tilted by an inclination angle θ1, and the tape 10 is wound around the outer wall 2 of the workpiece 5 in the right direction shown in FIG. 1.
[0030] Next, when reaching the folding point at the end of the workpiece 5, as shown in FIGS. 7 and 8, without stopping the rotation operation (tape winding rotation operation) of the workpiece 5, the feeding operation is decelerated and stopped (see the embodiment of FIG. 7), the shift roll portion 20 is moved a minute distance in the direction of arrow 37, the shift is returned to zero, and the inclination angle of the tape is restored.
[0031] Next, while continuing the rotation operation of the workpiece 5, reverse feeding of the workpiece 5 is started along the rotation axis 13, and the reverse winding rotation is started. At the start of this reverse feeding, the shift roll portion 20 is moved a minute distance in the direction of arrow 36, and then the shift is returned to zero.
[0032] In order to ensure the inclination corresponding to the pitch of the pitch winding operation during the acceleration and deceleration of the feeding operation, the shift roller portion 20 is moved a minute distance in the axial directions of the rotation axes 23, 28, and 33. Since the shift roller portion 20 is provided at a position close to the workpiece 2, it is sufficient to move the shift roller portion 20 a minute distance in the direction of arrow 36 or 37 at the folding point of the tape 10 wound around the workpiece 5, resulting in the effect of good operability.
[0033] In the present embodiment, without the tilting operation of the tape supply roll, the pitch tilt angle can be adjusted by the minute movement of the shift roll portion 20 close to the workpiece 5, resulting in good operability. In the present embodiment, pitch winding is realized with the tension of the tape 10 in a stable state, and the tension of the tape 10 is also stabilized and switched even at the folding point, so that the pitch can be aligned and wound.
[0034] As shown in FIG. 8, in the embodiment, variations in the tension of the tape are suppressed. There is no rotation stop at the time of folding. The quality requirement tension force appropriately falls between the upper limit and the plus and minus. Thereby, the quality requirements are satisfied. In one embodiment, the shift roller portion 20 provided at a position adjacent to the workpiece 5 reciprocates a minute distance in the direction of the rotation axis 13 of the workpiece 5 with respect to the base 4. Therefore, since the distance for the shift roller portion 20 to reciprocate is sufficient as a minute distance, the drive unit (not shown) of the shift roller portion 20 can be made lightweight. Also, it is possible to synchronize with the main shaft rotation in the feeding direction 15 of the workpiece 5.
[0035] (Comparative form) The configuration and operation of the comparative form will be described with reference to FIGS. 10 to 12. The configuration of the comparative form does not include a shift roller section. In FIGS. 10 to 12, the same reference numerals are given to substantially the same parts as in the embodiment. Regarding the operation of the comparative form, in FIG. 10, when the work 5 is rotationally driven in the direction of arrow 14 and at the same time fed in the direction of arrow 15 along the rotation axis 13, a tension (for example, 370 N) is applied to the tape 10 in the direction of arrow 9, the tape supply roll 12 is tilted by an inclination θ2, and the tape 10 is wound around the outer wall 2 of the work 5 in the right direction shown in FIG. 10.
[0036] Next, when reaching the folding point at the end of the work 5, as shown in FIG. 11, the rotational operation and the feeding operation of the work 5 are stopped (see the comparative form in FIG. 7), and the tape supply roll 10 is tilted by θ3 in the opposite direction. Then, as shown in FIG. 12, the reverse feeding of the work 5 is started in the direction of arrow 21 along the rotation axis 13, and the folding winding rotation is started. In this comparative form, the rotation of the work 5 is stopped when folding the end of the work 5. As shown in FIGS. 10 and 11, during the stop period of the work 5, the tension device of the tape supply roll 12 shifts from the left inclination angle θ2 to the right inclination angle θ3.
[0037] In the comparative form, when the position where the tape 10 is wound reaches the end of the work 5, the winding rotation of the work 5 is stopped when the tape 10 is wound and folded back. After folding back, the winding rotation direction of the work 5 is started to rotate in the same direction again. Regarding the feeding direction, feeding is started in the reverse feeding direction that reverses at the time of folding back. In the comparative form, in order to stop rotating as shown in FIG. 9, the tension of the tape rapidly decreases during the folding operation when stopped. This rapid decrease in tension occurs, making it difficult to neatly wind the tape 10.
[0038] On the other hand, in the above-described embodiment, as shown in the upper part of FIG. 7 and FIG. 8, when folding back, the shift roller section 20 moves a minute distance in the feeding and reverse feeding directions with respect to the base 4, so that the tension changes stably, and thus it is possible to perform aligned winding even at the time of folding back.
[0039] Regarding the shift roller unit 20, when winding the tape 10 in the right direction in FIG. 6, at the start, the tape 10 is tilted to the left, and then returned to the center. When it reaches the other end, it is tilted to the left again to reduce the width. Then, the shift roller unit is moved to the right, and then the shift distance is set to zero. When it comes to the left end of the starting point again, it is shifted to the right and returned. As a result, the pitch is reduced and aligned winding is performed without stopping the winding rotation at both ends. At the central part, it rotates at a predetermined pitch. When switching at the other end, without stopping the winding rotation, by slightly moving the shift roller unit 20 in the opposite direction, the tape is wound and rotated at a small pitch at the end, and then the shift is set to zero. When reaching the end point of the fold-back, the shift roller unit 20 is moved a minute distance to the right again. Thus, aligned winding can be performed without stopping the rotation of the first drive unit 7.
[0040] Generally, when the tension of the tape wound around the workpiece decreases, there is a risk that the tape will be twisted and the quality of holding the magnet will deteriorate. However, in this embodiment, since the tension of the tape 10 is stable without stopping the winding operation of the tape 10 around the workpiece 5, the magnet 3 can be reliably held on the outer wall 2 of the workpiece 5.
[0041] (Other Embodiments) In the above-described embodiment of the present invention, regarding the tape corresponding to the wire, a strip made of carbon fiber reinforced plastic (CFRP) was used. The shape of the wire of the present invention is an elongated strip shape, and basically, a square cross-section is preferable.
[0042] The wire used in the winding device and winding method of the present invention is not limited to a strip or a rectangular cross-section. As long as it is a wire that can be wound around an object, the cross-sectional shape is not limited and can be any cross-sectional shape. The material of the wire of the present invention may be any material such as cloth, paper, resin, metal, etc., as long as the shape is determined.
[0043] In one embodiment, the shift roller unit 20 of the present invention comprises a first roller 22, a second roller 27, and a third roller 32. In the present invention, for the first roller and the third roller, the convex curved surface may have a shape such as a drum shape or a crown shape, but is not limited thereto. In the present invention, for the second roller, in one embodiment, a concave curved surface is used, but it may also be a flat surface.
[0044] In the above embodiment, the shift roller unit of the present invention shows an embodiment of reciprocating linear motion, but it may also be an embodiment of pivoting and tilting with respect to the base within a predetermined rotation angle range. In one embodiment, a form that reciprocates a small distance with respect to the base 4 in the direction of the rotation axis 13 of the workpiece is shown. However, as another embodiment of the present invention, it may also be an embodiment in which the tilt angle of the shift roller unit can be changed to pivot with respect to the base so as to adjust the tape loading angle onto the workpiece. Also in this other embodiment, since the shift roller unit is provided at a position adjacent to the workpiece, it is sufficient to change the shift roller unit by a small tilt angle at the tape folding point, so there is an effect that the operability is good.
[0045] In the present invention, in other embodiments, the roller surface of the second roller may be a flat surface. The shift roller group is preferably positioned close to the workpiece. The pitch angle can be changed with a small feed distance. The first roller and the second roller with convex roller surfaces include those with a crown-shaped or drum-shaped roller surface. In the present invention, the first drive unit and the second drive unit may be the same drive source. The first drive unit and the second drive unit can also be made the same drive source by combining, for example, a link mechanism, a control unit, etc.
[0046] The wire winding device of the present invention may be configured such that the shift roller unit has a first free roller (22) that winds around one surface (F1) side of the wire from an inlet (40) for carrying in the wire toward an outlet (42) for carrying out the wire, a second free roller (27) that winds around the other surface (F2) side of the wire, and a third free roller (32) that winds around the one surface (F1) side of the wire, wherein the first free roller and the third free roller have convex roller surfaces (221, 321), and the second free roller has a concave or flat roller surface (271).
[0047] The wire winding device of the present invention may be configured to switch the work feed direction on the work rotation axis (13) to the reverse feed direction by the second drive unit without stopping the rotation of the work by the first drive unit when switching the work feed direction.
[0048] The wire winding device of the present invention may be configured to suppress a decrease in the tension of the wire without stopping the rotation of the work around the rotation axis when reversing the feed direction of the wire wound around the work.
[0049] The wire winding device of the present invention may be configured such that the state of the wire adjusted by the shift roller unit is one or more of the elements of the winding start position of the wire on the work, the winding start angle, or the pitch angle. The wire winding device of the present invention may be configured such that the wire is a tape having a rectangular cross-sectional shape.
[0050] The wire winding method of the present invention is a winding method for winding a wire around the outer wall of a rotating work, and includes a step of supplying the wire to the outer wall of the rotating work, a step of switching the feed direction of the work along the rotation center axis to the reverse feed direction without stopping the rotation of the work rotating around the rotation center axis, and a step of adjusting the posture or state of the wire wound around the work by a shift roller unit when switching the feed direction of the work to the reverse direction.
[0051] The wire winding method of the present invention can apply the wire to a tape. In the method for winding a wire of the present invention, the posture or state of the wire can be specified by any one or more of the winding start position of the tape on the workpiece, the winding start angle, or the pitch angle.
[0052] As described above, the present invention is not limited to the above embodiments, and can be implemented in various forms without departing from the gist thereof.
Explanation of Reference Numerals
[0053] 1 Object, 2 Outer wall, 3 Magnet, 4 Base, 5 Workpiece, 6 Tension applying part, 7 First drive part, 8 Second drive part, 10 Tape (wire), 12 Tape supply roll (wire supply part), 13 Axis of rotation, 20 Shift roller part, 22 First roller, 27 Second roller, 32 Third roller, 221 Convex curved surface (convex surface), 271 Concave curved surface (concave surface or flat surface), 321 Convex curved surface (convex surface).
Claims
1. A wire winding device for winding a wire around the outer wall of a workpiece, comprising: a base (4); a first drive unit (7) that rotates a workpiece (5) around a rotation axis (13) with respect to the base; a second drive unit (8) that reciprocates the workpiece in the direction of the rotation axis with respect to the base; a wire supply unit (12) provided on the base for supplying a wire (10) to be wound around the outer wall (2) of the workpiece; a tension applying unit (6) provided on the base for applying tension to the wire wound around the outer wall of the workpiece; and a shift roller unit (20) for adjusting the posture of the wire supplied from the wire supply unit to the workpiece between the wire supply unit and the workpiece. A wire winding device for a wire.
2. The shift roller unit includes a first free roller (22) that winds around one surface (F1) side of the wire, a second free roller (27) that winds around the other surface (F2) side of the wire, and a third free roller (32) that winds around the one surface (F1) side of the wire, from an inlet (40) for carrying in the wire to an outlet (42) for carrying out the wire. The first free roller and the third free roller have convex roller surfaces (221, 321), and the second free roller has a concave or flat roller surface (271). The wire winding device according to claim 1.
3. When switching the workpiece feed direction, the workpiece feed direction on the workpiece rotation axis (13) is switched to the reverse feed direction by the second drive unit without stopping the rotation of the workpiece by the first drive unit. The wire winding device according to claim 1.
4. When the feed direction of the wire wound around the workpiece is reversed, the wire winding device according to claim 2, which suppresses a decrease in the tension of the wire without stopping the rotation of the workpiece around the rotation axis.
5. The posture of the wire adjusted by the shift roller unit is a posture determined by one or more elements of a winding start position, a winding start angle, or a pitch angle of the wire on the workpiece. The wire winding device according to claim 1.
6. The wire is a tape having a rectangular cross-sectional shape. The wire winding device according to claim 5.
7. A wire winding method for winding a wire around the outer wall of a rotating workpiece, comprising: a step of supplying a wire to the outer wall of the rotating workpiece; a step of switching the feed direction of the workpiece along the rotation center axis to the reverse feed direction without stopping the rotation of the workpiece rotating around the rotation center axis; A wire winding method including a step of adjusting the posture or state of a wire wound around a workpiece by a shift roller unit when switching the feeding direction of the workpiece in the reverse direction.
8. The wire winding method according to claim 7, wherein the wire is a tape.
9. The wire winding method according to claim 7, wherein the posture or state of the wire is the winding start position of the tape on the workpiece, the winding start angle, or the pitch angle.
Citation Information
Patent Citations
Winding method of coil, winding apparatus of coil, and coil
JP1998144553A