Control system, control device, control program, and control method

Abstract

To calculate the used amount of a wire.SOLUTION: The control device 22 includes the bobbin weight acquisition unit 2201 that acquires the weight of the wire bobbin 3 measured by the weight measurement device 21, and the wire used amount calculation unit 2202 that calculates the used amount of the wire 31 per product in the target model by the winding machine 1 from the change in the weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates to a control system, a control device, a control program, and a control method. [Background technology]

[0002] Conventionally, motor winding machines automatically wind wire onto a product (winding core) a specified number of times from a wire bobbin on which the wire is wound. In this winding machine, if the wire in the wire bobbin runs out during winding operation, the winding will stop halfway, and the equipment equipped with the winding machine will issue a "wire out" alarm and stop operation. In this case, the product in which the wire winding has stopped halfway will be deemed defective. After that, in response to the above-mentioned alarm, the worker replaces the wire bobbin, removes the defective product, manually unwinds the wire that is partially wound around the defective product, and puts it back into the equipment, and then resumes operation of the equipment.

[0003] In this way, if the wire in the wire bobbin runs out during the winding operation, the winding machine will stop winding halfway, resulting in a defective product. In this case, it is necessary to remove the defective product, manually unwind the wire that was partially wound around the defective product, and then reinsert it into the machine, resulting in a loss of work.

[0004] In response to this, for example, Patent Document 1 discloses a device that detects the remaining amount of wire wound on a bobbin by extracting a remaining area, which is the area of ​​the bobbin occupied by the wire, from two image data of the bobbin. However, this method requires two separate imaging units to image the bobbin.

[0005] On the other hand, if it were possible to estimate the amount of wire used to wind each product, it would be possible to predict in advance how much wire is left in the wire bobbin, allowing for replacement before it runs out.However, in the past, it was difficult to accurately estimate the amount of wire used. For example, one possible method for estimating wire usage is to measure the amount of wire feed during winding by a winding machine and calculate the amount of wire usage from this amount of wire feed. However, the wire slips when it is fed toward the product by the winding machine, and the amount of slip also varies depending on the condition of the wire (e.g., the condition of the insulating coating) and the condition of the winding by the winding machine (e.g., the tension set for the wire). Therefore, it is difficult to accurately measure the amount of wire feed, and it is also difficult to calculate the amount of wire usage from this amount of wire feed. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent Publication No. 2017-226485 Summary of the Invention [Problem to be solved by the invention]

[0007] Thus, it has been difficult to accurately estimate the amount of wire used.

[0008] The present disclosure has been made to solve the above-mentioned problems, and aims to provide a control system that can calculate the amount of wire used. [Means for solving the problem]

[0009] The control system according to the present disclosure includes a weight measuring device that measures the weight of a wire bobbin used in a winding machine, and a control device. The control device includes a bobbin weight acquisition unit that acquires the weight of the wire bobbin measured by the weight measuring device, and a wire usage calculation unit that calculates the amount of wire used per product of a target model by the winding machine from changes in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit. [Effects of the Invention]

[0010] According to the present disclosure, the above-described configuration makes it possible to calculate the amount of wire used. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a diagram illustrating an example of the configuration of a control system according to a first embodiment. [Figure 2] 1 is a diagram illustrating an example of the configuration of a control device according to a first embodiment. [Figure 3] 4 is a flowchart showing an example of the operation of the control device according to the first embodiment. [Figure 4] FIG. 10 is a diagram illustrating an example of the configuration of a control device according to a second embodiment. [Figure 5] 10 is a flowchart showing an example of the operation of the control device according to the second embodiment. [Figure 6] 6A and 6B are diagrams illustrating an example of a hardware configuration of the control device according to the first and second embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments will be described in detail with reference to the drawings. Embodiment 1 1 is a diagram showing an example of the configuration of a control system 2 according to embodiment 1. In FIG. 1, the control system 2 is mounted on a winding machine 1.

[0013] The winding machine 1 automatically winds the wire 31 from the wire bobbin 3 on which the wire 31 is wound onto the product (winding core) a specified number of times. The number of times the winding machine 1 winds the wire 31 around one product varies depending on the target model. Also, the amount of wire 31 used to wind one product by the winding machine 1 can vary even for the same target model depending on the condition of the wire 31 (e.g., the condition of the insulating coating) and the condition of the winding by the winding machine 1 (e.g., the tension set for the wire 31).

[0014] The control system 2 calculates the amount of wire 31 used per product of the target model by the winding machine 1. The control system 2 according to the first embodiment also has a function of calculating and determining information relating to replacement of the wire bobbin 3 used in the winding machine 1 based on the calculated amount of wire 31 used.

[0015] Although FIG. 1 shows a case where the control system 2 is mounted on the winding machine 1, the control system 2 may be configured separately from the winding machine 1.

[0016] The control system 2 includes, for example, a weight measuring device 21, a control device 22, a storage device 23, and a display device 24, as shown in FIG.

[0017] The weight measuring device 21 is provided at a location where the wire bobbin 3 used in the winding machine 1 is attached, and measures the weight of this wire bobbin 3. In other words, the weight measuring device 21 measures the total weight of the wire bobbin 3 itself and the weight of the wire 31 wound around the wire bobbin 3. Measurement by this weight measuring device 21 is performed continuously or at predetermined intervals.

[0018] The data (time-series data) indicating the weight of the wire bobbin 3 measured by the weight measuring device 21 is output to the control device 22. Furthermore, data (time-series data) indicating the weight of the wire bobbin 3 measured by the weight measuring device 21 may also be output to at least one of the storage device 23 and the display device 24.

[0019] The control device 22 calculates the amount of wire 31 used per product of the target model by the winding machine 1 based on the weight of the wire bobbin 3 measured by the weight measuring device 21. The control device 22 according to the first embodiment also has a function of calculating and determining information related to replacement of the wire bobbin 3 used in the winding machine 1 based on the calculated amount of wire 31 used.

[0020] Data indicating the information obtained by the control device 22 is output to at least one of the storage device 23 and the display device 24 . An example of the configuration of this control device 22 will be described later.

[0021] The storage device 23 stores at least one of the information obtained by the weight measuring device 21 (time-series data on the weight of the wire bobbin 3 used in the winding machine 1) and the information obtained by the control device 22. In embodiment 1, the information obtained by the control device 22 and stored in the memory device 23 includes, for example, one or more of the following: the amount of wire 31 used per product of the target model by the winding machine 1, the weight of the wire bobbin 3 itself (the weight of the wire bobbin 3 at the time of replacement), and information indicating the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1.

[0022] In addition to the above information, the storage device 23 may also store information indicating the set values ​​(for example, set tension values) used when the winding machine 1 winds the wire.

[0023] Examples of this storage device 23 include non-volatile or volatile semiconductor memory such as RAM (Random Access Memory), ROM (Read Only Memory), flash memory, EPROM (Erasable Programmable ROM), EEPROM (Electrically EPROM), magnetic disk, flexible disk, optical disk, compact disk, mini disk, or DVD (Digital Versatile Disc).

[0024] In FIG. 1, the storage device 23 is provided outside the control device 22. In FIG. However, the present invention is not limited to this, and the storage device 23 may be provided inside the control device 22.

[0025] The information stored in the memory device 23 (particularly, the information indicating the amount of wire 31 used, the weight of the wire bobbin 3 itself, or the set tension value) can be used, for example, to set initial values ​​when the wire bobbin 3 is replaced. For example, the storage device 23 stores the above information (particularly, information indicating the amount of wire 31 used, the weight of the wire bobbin 3 itself, or the set tension value) for each target model and type of wire bobbin 3. The control device 22 then acquires the target model and type of wire bobbin 3 for which the winding work will be performed, and based on this information, extracts the above information linked to the corresponding target model and type of wire bobbin 3 from the storage device 23 and may use this as an initial value. Note that the target model and type of wire bobbin 3 for which the winding work will be performed may be acquired in response to an input operation by the worker, or, if a model number is assigned to the wire bobbin 3, the type of wire bobbin 3 may be acquired by automatically reading this information using a reader (not shown) or the like.

[0026] The display device 24 displays at least one of the information obtained by the weight measuring device 21 (time-series data on the weight of the wire bobbin 3 used in the winding machine 1) and the information obtained by the control device 22. In the first embodiment, the information obtained by the control device 22 and displayed on the display device 24 includes, for example, one or more of the following: the amount of wire 31 used per product of the target model by the winding machine 1; the weight of the wire bobbin 3 itself (the weight of the wire bobbin 3 at the time of replacement); the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1; the number of products of the target model that can be wound with wire 31 by the wire bobbin 3 used in the winding machine 1; and information indicating the result of a determination as to whether or not the wire bobbin 3 used in the winding machine 1 needs to be replaced.

[0027] In addition to the above information, the display device 24 may also display information indicating the set values ​​(for example, set tension values) used when the winding machine 1 winds the wire. The display device 24 may be, for example, a touch panel.

[0028] Next, an example of the configuration of the control device 22 according to the first embodiment will be described with reference to FIG. The control device 22 according to the first embodiment includes, for example, a bobbin weight acquisition unit 2201, a wire usage calculation unit 2202, an empty bobbin weight acquisition unit 2203, a remaining wire calculation unit 2204, a number of windable units calculation unit 2205, a bobbin replacement determination unit 2206, and a bobbin replacement notification unit 2207, as shown in FIG. 2 .

[0029] The bobbin weight acquisition unit 2201 acquires the weight of the wire bobbin 3 measured by the weight measuring device 21 .

[0030] The wire usage calculation unit 2202 calculates the usage amount of wire 31 per product of the target model by the winding machine 1 from the change in weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201. Here, the feed amount of the wire 31 in the winding machine 1 is not always constant, but changes at least at the timing of switching the product to be wound. Therefore, by monitoring the change in weight of the wire bobbin 3, it is possible to distinguish between a period when the product is being wound and a period when the product to be wound is being switched. Therefore, the wire usage calculation unit 2202 can calculate the amount of wire 31 used per product of the target model by the winding machine 1 from the change in weight of the wire bobbin 3.

[0031] Furthermore, in general, the amount of wire 31 used per product of the target model wound by the winding machine 1 is often very small compared to the amount of wire 31 wound around a new wire bobbin 3. For example, the amount of wire 31 wound around a new wire bobbin 3 may be several to several dozen kilograms, while the amount of wire 31 used per product of the target model wound by the winding machine 1 may be around 100 g. Therefore, although it depends on the accuracy of the weight measuring device 21, it may be difficult to calculate the amount of wire 31 used per product from the change in weight of the wire bobbin 3 when winding is performed on one product. Therefore, it is generally desirable that the wire usage calculation unit 2202 calculates the amount of wire 31 used per product of the target model by the winding machine 1 from the average value based on the change in weight of the wire bobbin 3 when winding is performed on multiple products.

[0032] The empty bobbin weight acquisition unit 2203 acquires the weight of the wire bobbin 3 when no wire 31 is wound around it (the weight of the empty wire bobbin 3). That is, the empty bobbin weight acquisition unit 2203 acquires the weight of the wire bobbin 3 itself. At this time, the empty bobbin weight acquisition unit 2203 may acquire the weight of the wire bobbin 3 in a state where the wire 31 is not wound thereon, which is measured in advance. In addition, the empty bobbin weight acquisition unit 2203 may acquire the weight of the wire bobbin 3 at the time of replacement (when the bobbin replacement determination unit 2206 determines that the wire bobbin 3 needs to be replaced) as the weight of the wire bobbin 3 when no wire 31 is wound on it, based on the measurement results from the weight measuring device 21.

[0033] The remaining wire amount calculation unit 2204 calculates the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201 and the weight of the wire bobbin 3 in a state where no wire 31 is wound thereon acquired by the empty bobbin weight acquisition unit 2203. At this time, the remaining wire amount calculation unit 2204 calculates the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1 by subtracting the weight of the wire bobbin 3 without wire 31 wound thereon, which is acquired by the empty bobbin weight acquisition unit 2203, from the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201.

[0034] The winding capacity calculation unit 2205 calculates the number of products of the target model that can be wound with wire 31 using the wire bobbins 3 used in the winding machine 1, based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204. At this time, the windable number calculation unit 2205 divides the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204 by the used amount of wire 31 calculated by the used wire amount calculation unit 2202, and calculates the quotient as the windable number of units.

[0035] The bobbin replacement determination unit 2206 determines whether the wire bobbin 3 used in the winding machine 1 needs to be replaced based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the wire remaining amount calculation unit 2204. In this case, the bobbin replacement determination unit 2206 may determine that the wire bobbin 3 used in the winding machine 1 needs to be replaced if the amount of wire 31 remaining minus the amount of wire 31 used is less than a predetermined amount. Furthermore, the bobbin replacement determination unit 2206 may determine that the wire bobbin 3 used in the winding machine 1 needs to be replaced when the number of products of the target model that can have the wire 31 wound thereon by the wire bobbin 3 used in the winding machine 1 is equal to or less than a predetermined number. In this case, the bobbin replacement determination unit 2206 may make the above determination by utilizing the calculation result by the windable number calculation unit 2205.

[0036] Furthermore, as a preliminary step of determining whether the wire bobbin 3 used in the winding machine 1 needs to be replaced, the bobbin replacement determination unit 2206 may determine whether preparations for replacement of the wire bobbin 3 used in the winding machine 1 need to be made based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204.

[0037] In this case, for example, first, the bobbin replacement determination unit 2206 uses a first threshold value to determine whether preparation for replacement of the wire bobbin 3 used in the winding machine 1 is necessary based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204. This determination is made to ensure a preparation period for an operator to replace the wire bobbin 3. For example, when the unit of the threshold value is the number of units, the first threshold value is, for example, 10 units. Thereafter, the bobbin replacement determination unit 2206 uses a second threshold value that is smaller than the first threshold value to determine whether the wire bobbin 3 used in the winding machine 1 needs to be replaced, based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204. This determination is made to prompt an operator to replace the wire bobbin 3. For example, when the unit of the threshold value is the number of units, the second threshold value is, for example, 1 unit. This allows the worker to know the timing for preparing to replace the wire bobbin 3 and the timing for replacing the wire bobbin 3, thereby enabling a smooth replacement operation.

[0038] The bobbin replacement notification unit 2207 issues a notification to replace the wire bobbin 3 when the bobbin replacement determination unit 2206 determines that the wire bobbin 3 needs to be replaced. Furthermore, the bobbin replacement notification unit 2207 issues a notification of preparation for replacement of the wire bobbin 3 when the bobbin replacement determination unit 2206 determines that preparation for replacement of the wire bobbin 3 is necessary. At this time, for example, the bobbin replacement notification unit 2207 may cause the display device 24 to display a screen, may cause an audio output device (not shown) to output audio, or may cause a light source device (not shown) to emit light.

[0039] In addition, FIG. 2 shows a case where the control device 22 includes a bobbin weight acquisition unit 2201, a wire usage calculation unit 2202, an empty bobbin weight acquisition unit 2203, a remaining wire calculation unit 2204, a number of windable units calculation unit 2205, a bobbin replacement determination unit 2206, and a bobbin replacement notification unit 2207. However, the present invention is not limited to this, and the control device 22 may include at least the bobbin weight acquisition unit 2201 and the wire usage amount calculation unit 2202.

[0040] Next, an example of the operation of the control device 22 according to the first embodiment shown in Fig. 2 will be described with reference to Fig. 3. In the following, the bobbin replacement determination unit 2206 does not determine whether the wire bobbin 3 needs to be prepared for replacement, but only determines whether the wire bobbin 3 needs to be replaced.

[0041] In an operation example of the control device 22 according to the first embodiment shown in Fig. 2, first, as shown in Fig. 3, for example, the bobbin weight acquisition unit 2201 acquires the weight of the wire bobbin 3 measured by the weight measuring device 21 (step ST101). The weight of the wire bobbin 3 is acquired constantly or at regular intervals.

[0042] Next, the wire usage calculation unit 2202 calculates the usage amount of wire 31 per product of the target model by the winding machine 1 from the change in weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201 (step ST102). It is desirable to calculate the usage amount of wire 31 for each wire bobbin 3 or for each lot of wire bobbins 3.

[0043] Furthermore, the empty bobbin weight acquisition unit 2203 acquires the weight of the wire bobbin 3 when the wire 31 is not wound thereon (the weight of the empty wire bobbin 3) (step ST103).

[0044] Next, the remaining wire amount calculation unit 2204 calculates the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201 and the weight of the wire bobbin 3 in a state where no wire 31 is wound thereon acquired by the empty bobbin weight acquisition unit 2203 (step ST104). This calculation of the remaining amount of wire 31 is performed constantly or at regular intervals.

[0045] Next, the windable number calculation unit 2205 calculates the number of products of the target model that can be wound with the wire 31 using the wire bobbins 3 used in the winding machine 1, based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204 (step ST105). This calculation of the windable number is performed constantly or at regular intervals.

[0046] Next, the bobbin replacement determination unit 2206 determines whether or not the wire bobbin 3 used in the winding machine 1 needs to be replaced based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204 (step ST106). This determination of whether or not the wire bobbin 3 needs to be replaced is performed constantly or at regular intervals.

[0047] In step ST106, if the bobbin replacement determination unit 2206 determines that the wire bobbin 3 needs to be replaced, the bobbin replacement notification unit 2207 issues a notification to replace the wire bobbin 3 (step ST107).

[0048] On the other hand, if the bobbin replacement determination unit 2206 determines in step ST106 that replacement of the wire bobbin 3 is not necessary, the sequence returns to step ST104.

[0049] As described above, according to this embodiment 1, the control system 2 includes a weight measuring instrument 21 that measures the weight of the wire bobbin 3 used in the winding machine 1, and a control device 22. The control device 22 includes a bobbin weight acquisition unit 2201 that acquires the weight of the wire bobbin 3 measured by the weight measuring instrument 21, and a wire usage calculation unit 2202 that calculates the amount of wire 31 used per product of the target model by the winding machine 1 from changes in the weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201. This enables the control system 2 according to the first embodiment to calculate the amount of wire 31 used. Note that the amount of wire 31 used can vary even for the same target model depending on the condition of the wire 31 (e.g., the condition of the insulating coating) and the condition of the winding by the winding machine 1 (e.g., the tension set for the wire 31). However, the control system 2 according to the first embodiment can also handle this variation by monitoring the change in weight of the wire bobbin 3, and can easily and accurately calculate the amount of wire 31 used.

[0050] Furthermore, according to this embodiment 1, the control device 22 includes an empty bobbin weight acquisition unit 2203 that acquires the weight of the wire bobbin 3 when no wire 31 is wound on it, and a remaining wire amount calculation unit 2204 that calculates the remaining amount of wire 31 wound on the wire bobbin 3 used in the winding machine 1 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201 and the weight of the wire bobbin 3 when no wire 31 is wound on it acquired by the empty bobbin weight acquisition unit 2203. As a result, the control system 2 according to the first embodiment can calculate the remaining amount of wire 31 in the wire bobbin 3. Furthermore, in the control system 2 according to the first embodiment, the user can determine the timing to replace the wire bobbin 3 based on the amount of wire 31 used and the remaining amount of wire 31, thereby preventing the occurrence of defective products. As a result, work such as unwinding the wire 31 from defective products is no longer necessary, and work loss can be reduced.

[0051] Furthermore, according to the first embodiment, the control device 22 includes a winding capacity calculation unit 2205 that calculates the number of products of the target model that can be wound with the wire 31 using the wire bobbins 3 used in the winding machine 1, based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the remaining wire amount calculation unit 2204. As a result, the control system 2 according to the first embodiment can calculate the number of units for which winding is possible. Furthermore, in the control system 2 according to the first embodiment, the user can determine the timing to replace the wire bobbin 3 based on the number of wires that can be wound, thereby preventing the occurrence of defective products. As a result, the need to unwind the wire 31 from defective products is eliminated, and work loss can be reduced.

[0052] Furthermore, according to this embodiment 1, the control device 22 includes a bobbin replacement determination unit 2206 that determines whether the wire bobbin 3 used in the winding machine 1 needs to be replaced based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 and the remaining amount of wire 31 calculated by the wire remaining amount calculation unit 2204, and a bobbin replacement notification unit 2207 that notifies the user to replace the wire bobbin 3 used in the winding machine 1 when the bobbin replacement determination unit 2206 determines that the wire bobbin 3 needs to be replaced. As a result, in the control system 2 according to the first embodiment, the user can more easily determine the timing for replacing the wire bobbin 3, thereby making it possible to avoid the occurrence of defective products. As a result, work such as unwinding the wire 31 from defective products becomes unnecessary, making it possible to reduce work loss.

[0053] Moreover, according to the first embodiment, the storage device 23 for storing at least one of the information obtained by the weight measuring device 21 and the information obtained by the control device 22 is provided. Moreover, according to the first embodiment, the display device 24 for displaying at least one of the information obtained by the weight measuring device 21 and the information obtained by the control device 22 is provided. As a result, in the control system 2 according to the first embodiment, at least one of the information obtained by the weight measuring instrument 21 and the information obtained by the control device 22 can be visualized.

[0054] Furthermore, according to this embodiment 1, the control device 22 includes a bobbin weight acquisition unit 2201 that acquires the weight of the wire bobbin 3 measured by the weight measuring device 21 that measures the weight of the wire bobbin 3 used in the winding machine 1, and a wire usage calculation unit 2202 that calculates the amount of wire 31 used per product of the target model by the winding machine 1 from changes in the weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201. This allows the control device 22 according to the first embodiment to calculate the amount of wire 31 used.

[0055] Furthermore, according to the first embodiment, the control program causes the computer to function as the control device 22. As a result, the control program according to the first embodiment can calculate the amount of wire 31 used.

[0056] Furthermore, according to this embodiment 1, the control method includes a step in which the bobbin weight acquisition unit 2201 acquires the weight of the wire bobbin 3 measured by the weight measuring device 21 that measures the weight of the wire bobbin 3 used in the winding machine 1, and a step in which the wire usage calculation unit 2202 calculates the usage amount of wire 31 per product of the target model by the winding machine 1 from the change in the weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201. As a result, the control method according to the first embodiment makes it possible to calculate the amount of wire 31 used.

[0057] Embodiment 2 The control system 2 (control device 22) according to the first embodiment has the function of calculating and determining information relating to replacement of the wire bobbin 3 based on the calculated amount of use of the wire 31.

[0058] Here, in the winding machine 1, in order to reduce the amount of wire 31 used, winding is performed while applying tension to the wire 31 and pulling it. On the other hand, if too much tension is applied, the insulating coating of the wire 31 will break, resulting in a defective product. Therefore, it is desirable that winding be performed in the winding machine 1 while applying a large amount of tension to the wire 31 so that the insulating coating will not break. In contrast, conventionally, the tension value for the wire 31 during winding by the winding machine 1 has been set empirically. Furthermore, this tension value can be calculated from the elongation of the wire 31 during winding, but conventionally it has not been possible to measure the elongation of the wire 31. Note that the elongation of the wire 31 can vary even with the same set tension value depending on the condition of the wire 31 (for example, the condition of the insulating coating), etc.

[0059] Therefore, the control system 2 (control device 22) of embodiment 2 also has the function of calculating and controlling information regarding the tension value for the wire 31 when winding by the winding machine 1, based on the calculated amount of wire 31 used.

[0060] Fig. 4 is a diagram showing an example of the configuration of the control device 22 according to embodiment 2. In the control device 22 according to embodiment 2 shown in Fig. 4, the empty bobbin weight acquisition unit 2203, the remaining wire amount calculation unit 2204, the available winding number calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207 are removed from the control device 22 according to embodiment 1 shown in Fig. 2, and a wire elongation calculation unit 2208 and a tension value control unit 2209 are added. Other configuration examples of the control device 22 according to the second embodiment shown in FIG. 4 are the same as the configuration example of the control device 22 according to the first embodiment, and the same reference numerals are used and the description thereof will be omitted.

[0061] The wire elongation calculation unit 2208 calculates the elongation of the wire 31 wound by the winding machine 1 based on the amount of wire 31 used calculated by the wire usage calculation unit 2202. Here, when the tension value set in the winding machine 1 is large, the pulling force on the wire 31 during winding is strong, so the elongation of the wire 31 increases and the amount of wire 31 used decreases. Conversely, when the tension value set in the winding machine 1 is small, the pulling force on the wire 31 during winding is weak, so the elongation of the wire 31 decreases and the amount of wire 31 used increases. Therefore, from this relationship, the wire elongation calculation unit 2208 can calculate the elongation of the wire 31 by monitoring the amount of wire 31 used.

[0062] The tension value control unit 2209 controls the tension value applied to the wire 31 when the winding machine 1 winds the wire 31 based on the elongation of the wire 31 calculated by the wire elongation calculation unit 2208 . At this time, if the elongation of the wire 31 calculated by the wire elongation calculation unit 2208 is smaller than the desired elongation, the tension value control unit 2209 controls the winding machine 1 to increase the tension value for the wire 31. On the other hand, if the elongation of the wire 31 calculated by the wire elongation calculation unit 2208 is larger than the desired elongation, the tension value control unit 2209 controls the winding machine 1 to decrease the tension value for the wire 31. The desired elongation is, for example, 3%.

[0063] 4 shows a case where the control device 22 includes a wire elongation calculation unit 2208 and a tension value control unit 2209. However, the control device 22 is not limited to this, and the function of controlling the tension value is not an essential function, and the control device 22 may not have this function. In other words, the control device 22 may not have the tension value control unit 2209.

[0064] Next, an example of the operation of the control device 22 according to the second embodiment shown in FIG. 4 will be described with reference to FIG.

[0065] In an example of the operation of the control device 22 according to the second embodiment shown in Fig. 4, first, as shown in Fig. 5, for example, the bobbin weight acquisition unit 2201 acquires the weight of the wire bobbin 3 measured by the weight measuring device 21 (step ST201). The weight of the wire bobbin 3 is acquired constantly or at regular intervals.

[0066] Next, the wire usage calculation unit 2202 calculates the usage amount of wire 31 per product of the target model by the winding machine 1 from the change in weight of the wire bobbin 3 based on the weight of the wire bobbin 3 acquired by the bobbin weight acquisition unit 2201 (step ST202). It is desirable to calculate the usage amount of wire 31 for each wire bobbin 3 or for each lot of wire bobbins 3.

[0067] Next, the wire elongation calculation unit 2208 calculates the elongation of the wire 31 wound by the winding machine 1 based on the amount of wire 31 used calculated by the wire usage calculation unit 2202 (step ST203). It is desirable to calculate the elongation of the wire 31 for each wire bobbin 3 or for each lot of wire bobbins 3.

[0068] Next, the tension value control unit 2209 controls the tension value of the wire 31 when the winding machine 1 winds the wire 31 based on the elongation of the wire 31 calculated by the wire elongation calculation unit 2208 (step ST204). It is desirable to control the tension value for each wire bobbin 3 or for each lot of wire bobbins 3.

[0069] In addition, the control system 2 (control device 22) according to embodiment 2 may be added with a function of calculating and determining information regarding replacement of the wire bobbin 3 based on the calculated amount of wire 31 used, as shown in the control system 2 (control device 22) according to embodiment 1. That is, some or all of the empty bobbin weight acquisition unit 2203, remaining wire amount calculation unit 2204, number of available windings calculation unit 2205, bobbin replacement determination unit 2206, and bobbin replacement notification unit 2207 may be added to the control system 2 (control device 22) according to embodiment 2.

[0070] As described above, according to this embodiment 2, the control device 22 includes a wire elongation calculation unit 2208 that calculates the elongation of the wire 31 being wound by the winding machine 1 based on the usage amount of the wire 31 calculated by the wire usage calculation unit 2202. As a result, the control system 2 according to the second embodiment can calculate the elongation rate of the wire 31.

[0071] Furthermore, according to this embodiment 2, the control device 22 is provided with a tension value control unit 2209 that controls the tension value for the wire 31 during winding by the winding machine 1 based on the elongation rate of the wire 31 calculated by the wire elongation rate calculation unit 2208. As a result, the control system 2 according to the second embodiment can control the tension value of the wire 31 to an appropriate value when the winding machine 1 winds the wire.

[0072] Finally, an example of the hardware configuration of the control device 22 according to the first and second embodiments will be described with reference to Fig. 6. Although an example of the hardware configuration of the control device 22 according to the first embodiment will be described below, the same applies to an example of the hardware configuration of the control device 22 according to the second embodiment. The functions of the control device 22, including the bobbin weight acquisition unit 2201, wire usage calculation unit 2202, empty bobbin weight acquisition unit 2203, remaining wire calculation unit 2204, available winding number calculation unit 2205, bobbin replacement determination unit 2206, and bobbin replacement notification unit 2207, are realized by a processing circuit 51. The processing circuit 51 may be dedicated hardware as shown in Fig. 6A, or may be a CPU (also referred to as a central processing unit, processing unit, arithmetic unit, microprocessor, microcomputer, processor, or DSP (Digital Signal Processor)) 52 that executes a program stored in a memory 53 as shown in Fig. 6B.

[0073] When the processing circuit 51 is dedicated hardware, the processing circuit 51 corresponds to, for example, a single circuit, a composite circuit, a programmed processor, a parallel programmed processor, an ASIC (Application Specific Integrated Circuit), an FPGA (Field Programmable Gate Array), or a combination thereof. The functions of each of the bobbin weight acquisition unit 2201, the wire usage calculation unit 2202, the empty bobbin weight acquisition unit 2203, the remaining wire calculation unit 2204, the available winding number calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207 may be realized individually by the processing circuit 51, or the functions of each unit may be realized collectively by the processing circuit 51.

[0074] When the processing circuit 51 is a CPU 52, the functions of the bobbin weight acquisition unit 2201, the wire usage calculation unit 2202, the empty bobbin weight acquisition unit 2203, the remaining wire calculation unit 2204, the available winding number calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207 are realized by software, firmware, or a combination of software and firmware. The software and firmware are written as programs and stored in the memory 53. The processing circuit 51 realizes the functions of each unit by reading and executing the programs stored in the memory 53. That is, the control device 22 includes the memory 53 for storing a program that, when executed by the processing circuit 51, results in the execution of, for example, each step shown in FIG. 3. It can also be said that these programs cause the computer to execute the procedures and methods of the bobbin weight acquisition unit 2201, the wire usage calculation unit 2202, the empty bobbin weight acquisition unit 2203, the remaining wire calculation unit 2204, the number of available windings calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207. Here, the memory 53 may be, for example, a non-volatile or volatile semiconductor memory such as RAM, ROM, flash memory, EPROM, or EEPROM, a magnetic disk, a flexible disk, an optical disk, a compact disk, a minidisk, or a DVD.

[0075] Note that the functions of the bobbin weight acquisition unit 2201, the wire usage calculation unit 2202, the empty bobbin weight acquisition unit 2203, the remaining wire amount calculation unit 2204, the available winding number calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207 may be partially implemented by dedicated hardware and partially implemented by software or firmware. For example, the function of the bobbin weight acquisition unit 2201 may be implemented by the processing circuit 51 as dedicated hardware, and the functions of the wire usage calculation unit 2202, the empty bobbin weight acquisition unit 2203, the remaining wire amount calculation unit 2204, the available winding number calculation unit 2205, the bobbin replacement determination unit 2206, and the bobbin replacement notification unit 2207 may be implemented by the processing circuit 51 reading out and executing programs stored in the memory 53.

[0076] In this way, the processing circuitry 51 can realize each of the above-described functions by hardware, software, firmware, or a combination of these.

[0077] It should be noted that the embodiments may be freely combined, or any of the components in each embodiment may be modified, or any of the components in each embodiment may be omitted.

[0078] Various aspects of the present disclosure are summarized below as appendices.

[0079] (Appendix 1) The winding machine is provided with a weight measuring device for measuring the weight of a wire bobbin used in the winding machine, and a control device, The control device a bobbin weight acquisition unit that acquires the weight of the wire bobbin measured by the weight measuring device; and a wire usage calculation unit that calculates the amount of wire used per product of a target model by the winding machine from a change in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit. A control system comprising: (Appendix 2) The control device an empty bobbin weight acquisition unit that acquires the weight of the wire bobbin when no wire is wound thereon; and a wire remaining amount calculation unit that calculates the remaining amount of wire wound on the wire bobbin used in the winding machine based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit and the weight of the wire bobbin in a state where no wire is wound thereon acquired by the empty bobbin weight acquisition unit. 2. The control system of claim 1. (Appendix 3) The control device and a winding capacity calculation unit that calculates the number of products of a target model that can be wound with wire using a wire bobbin used in the winding machine based on the amount of wire used calculated by the wire usage calculation unit and the remaining amount of wire calculated by the remaining wire calculation unit. 3. The control system according to claim 2. (Appendix 4) The control device a bobbin replacement determination unit that determines whether a wire bobbin used in the winding machine needs to be replaced based on the amount of wire used calculated by the wire usage calculation unit and the remaining amount of wire calculated by the remaining wire amount calculation unit; and a bobbin replacement notification unit that notifies the user to replace the wire bobbin used in the winding machine when the bobbin replacement determination unit determines that the wire bobbin needs to be replaced. 4. The control system according to claim 2 or 3. (Appendix 5) The control device a wire elongation calculation unit that calculates an elongation rate of the wire being wound by the winding machine based on the amount of wire used calculated by the wire usage calculation unit; 5. The control system according to any one of claims 1 to 4, (Appendix 6) The control device and a tension value control unit that controls a tension value for the wire during winding by the winding machine based on the wire elongation calculated by the wire elongation calculation unit. 6. The control system according to claim 5, (Appendix 7) a storage device for storing at least one of the information obtained by the weight measuring device and the information obtained by the control device; 7. The control system according to any one of claims 1 to 6, (Appendix 8) a display device that displays at least one of the information obtained by the weight measuring instrument and the information obtained by the control device; 8. The control system according to any one of claims 1 to 7, (Appendix 9) a bobbin weight acquisition unit that acquires the weight of the wire bobbin measured by a weight measuring device that measures the weight of the wire bobbin used in the winding machine; a wire usage calculation unit that calculates the amount of wire used per product of a target model by the winding machine from a change in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit; A control device comprising: (Appendix 10) A control program for causing a computer to function as the control device described in Supplementary Note 9. (Appendix 11) a step in which a bobbin weight acquisition unit acquires a weight of the wire bobbin measured by a weight measuring device that measures the weight of the wire bobbin used in the winding machine; a wire usage amount calculation unit calculating a wire usage amount per product of the target model by the winding machine from a change in weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit; A control method comprising: [Explanation of symbols]

[0080] 1 Winding machine, 2 Control system, 3 Wire bobbin, 21 Weight measuring device, 22 Control device, 23 Storage device, 24 Display device, 31 Wire, 51 Processing circuit, 52 CPU, 53 Memory, 2201 Bobbin weight acquisition unit, 2202 Wire usage calculation unit, 2203 Empty bobbin weight acquisition unit, 2204 Wire remaining amount calculation unit, 2205 Number of available windings calculation unit, 2206 Bobbin replacement determination unit, 2207 Bobbin replacement notification unit, 2208 Wire elongation calculation unit, 2209 Tension value control unit.

Claims

1. The winding machine is provided with a weight measuring device for measuring the weight of a wire bobbin used in the winding machine, and a control device, The control device a bobbin weight acquisition unit that acquires the weight of the wire bobbin measured by the weight measuring device; a wire usage calculation unit that calculates the amount of wire used per product of a target model by the winding machine from a change in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit. A control system comprising:

2. The control device an empty bobbin weight acquisition unit that acquires the weight of the wire bobbin when no wire is wound thereon; and a wire remaining amount calculation unit that calculates the remaining amount of wire wound on the wire bobbin used in the winding machine based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit and the weight of the wire bobbin in a state where no wire is wound thereon acquired by the empty bobbin weight acquisition unit.

2. The control system of claim 1.

3. The control device and a winding capacity calculation unit that calculates the number of products of a target model that can be wound with wire using a wire bobbin used in the winding machine based on the amount of wire used calculated by the wire usage calculation unit and the remaining amount of wire calculated by the remaining wire calculation unit.

3. The control system according to claim 2.

4. The control device a bobbin replacement determination unit that determines whether a wire bobbin used in the winding machine needs to be replaced based on the amount of wire used calculated by the wire usage calculation unit and the remaining amount of wire calculated by the remaining wire amount calculation unit; and a bobbin replacement notification unit that notifies the user to replace the wire bobbin used in the winding machine when the bobbin replacement determination unit determines that the wire bobbin needs to be replaced.

3. The control system according to claim 2.

5. The control device a wire elongation calculation unit that calculates an elongation rate of the wire being wound by the winding machine based on the amount of wire used calculated by the wire usage calculation unit; 2. The control system of claim 1.

6. The control device and a tension value control unit that controls a tension value for the wire during winding by the winding machine based on the wire elongation calculated by the wire elongation calculation unit.

6. The control system according to claim 5.

7. a storage device for storing at least one of the information obtained by the weight measuring device and the information obtained by the control device; 2. The control system of claim 1.

8. a display device that displays at least one of the information obtained by the weight measuring instrument and the information obtained by the control device; 2. The control system of claim 1.

9. a bobbin weight acquisition unit that acquires the weight of the wire bobbin measured by a weight measuring device that measures the weight of the wire bobbin used in the winding machine; a wire usage calculation unit that calculates the amount of wire used per product of a target model by the winding machine from a change in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit; A control device comprising:

10. A control program for causing a computer to function as the control device according to claim 9.

11. a step in which a bobbin weight acquisition unit acquires a weight of the wire bobbin measured by a weight measuring device that measures the weight of the wire bobbin used in the winding machine; a wire usage amount calculation unit calculating a wire usage amount per product of the target model by the winding machine from a change in the weight of the wire bobbin based on the weight of the wire bobbin acquired by the bobbin weight acquisition unit; A control method comprising:

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