Winding device and winding method

Abstract

To provide a winding device and a winding method.SOLUTION: The winding device includes: a wire supply pulley that rotates according to a wire supply speed to supply a wire; a tension rod around which the wire is wound at one end; a tension control motor that is disposed at the other end of the tension rod and rotates the tension rod; and a load cell that detects an actual tension value of the wire at a wire winding end, wherein the tension control motor controls the tension rod to rotate clockwise or counterclockwise based on a tension error existing between a target tension value and the actual tension value of the wire so as to match the actual tension value with the target tension value of the wire.SELECTED DRAWING: Figure 4

Description

Technical Field

[0001] The present invention relates to a winding device and a winding method, and particularly to a winding device and a winding method that provide dual-motor tension.

Background Art

[0002] Currently, in commercially available electronic components and electrical products, a very large number of wound components are used as drive sources and energy conversion applications. The wound components wind an enameled copper wire around a workpiece using fully automatic or semi-automatic equipment. In the winding process, a tensiometer is used so that the copper wire is wound stably with the same tension.

[0003] FIG. 1 is a diagram showing a related-art tension control structure. As shown in FIG. 1, the tension source of the winding device used in the related art is often the spring force generated by a spring 11. When the length of the spring 11 is fixed, the winding device can provide a stable tension. Such a winding device connects a tension rod 12 using the spring 11. A wire 2 is wound around one end of the tension rod 12, and an angle sensor 13 is disposed at the other end. The angle sensor 13 is used to detect the actual angle of the tension rod 12. Such a winding device can control the tension by controlling the wire supply speed used to trigger the wire supply pulley 14 to supply the wire based on the actual angle of the tension rod 12.

[0004] Refer to FIGS. 2A, 2B, and 2C together. FIGS. 2A, 2B, and 2C are schematic diagrams showing the related-art tension control structure when the supply speed is too fast, when the supply speed is appropriate, and when the supply speed is too slow, respectively.

[0005] As shown in FIG. 2A, when the actual angle of the tension rod 12 is greater than the preset target angle of the winding device (the angle error is A), the wire supply pulley 14 provides a faster wire supply speed V2 so as to return the actual angle of the tension rod 12 to the target angle. As shown in FIG. 2B, when the actual angle of the tension rod 12 is equal to or close to the target angle, the wire supply pulley 14 maintains the wire supply speed V2. As shown in FIG. 2C, when the actual angle of the tension rod 12 is smaller than the target angle (the angle error is A), the wire supply pulley 14 provides a slower wire supply speed V2 so as to return the actual angle of the tension rod 12 to the target angle.

[0006] The winding device of the related art can dynamically provide an appropriate wire supply speed V2 by controlling the wire supply speed of the wire supply pulley 14 using the above principle, and can further maintain the tension balance of the wire.

[0007] As shown in FIG. 2C, in the structure of the winding device of the related art, when the actual angle of the tension rod 12 is smaller than the target angle (there is an angle error A), the winding device needs to reduce the wire supply speed V2. At this time, since the wire winding speed V1 of the wire at the wire winding end is greater than the wire supply speed V2 of the wire at the wire supply end, the winding device can use the transportation of the wire to pull back the tension rod 12 to the target angle. In other words, such a winding device can only passively control the tension rod 12, and the maximum moving speed of the tension rod 12 is equal to the wire winding speed V1 of the wire. The slower the wire winding speed V1, the longer the time required for the tension rod 12 to be pulled back to the target angle. Also, since the tension value of the wire is directly related to the actual angle of the tension rod 12, such a winding device takes a long time to return the tension value of the wire to the target tension value. Therefore, such a winding device is very unsuitable for equipment that needs to always maintain a certain tension value.

[0008] Furthermore, a delay also occurs when the wire supply pulley 14 controls the wire supply speed V2 according to the angular error A of the tension rod 12. Specifically, the winding device starts to correct the wire supply pulley 14 to increase or decrease the wire supply speed V2 only when the angular error A is not zero. That is, with this correction method, when the wire rod is suddenly disturbed, it cannot be corrected in real time, and the tension becomes unstable.

[0009] FIG. 3 is a schematic diagram of the spring tension of the related art. As shown in FIG. 3, since the tension source of such a winding device is the amount of tension of the spring 11, the tensile force by the spring 11 varies depending on the angle of the tension rod 12. In FIG. 3, the tensile forces are, for example, F1, F2 to Fn, and the corresponding spring deformation amounts are X1, X2 to Xn.

[0010] As can be seen from Hooke's law, Fn = k × Xn. Here, k is the elastic coefficient of the spring 11, and when the spring 11 fixed by the winding device is used, the value of k is constant. In other words, the maximum tension that the spring 11 can provide is fixed and equal to the allowable swing range of the tension rod 12. SUMMARY OF THE INVENTION PROBLEMS TO BE SOLVED BY THE INVENTION

[0011] However, when the target tension value required by such a winding device exceeds the tension that can be provided by the spring 11, the user has to replace the spring 11. In this way, the field in which such a winding device can be used is physically limited by the spring 11, and the potential cost for the user to replace the spring 11 also increases.

[0012] The main object of the present invention is to provide a winding device and a winding method capable of realizing active tension control by rotationally controlling a tension rod by a tension control motor. MEANS FOR SOLVING THE PROBLEMS

[0013] To achieve the above object, the winding device according to the present invention is used in combination with a wire rod, A wire supply pulley disposed at the wire supply end of the winding device, rotating according to the wire supply speed, and supplying the wire rod from the wire supply end; A tension rod around which the wire rod is wound at one end and which turns the wire rod; A tension control motor disposed at the other end of the tension rod for rotating the tension rod; A load cell disposed at the wire winding end of the winding device for detecting the actual tension value of the wire rod at the wire winding end; Based on the tension error between the target tension value and the actual tension value of the wire rod, the tension control motor controls the rotation of the tension rod clockwise or counterclockwise so that the actual tension value of the wire rod matches the target tension value.

[0014] To achieve the above object, the winding method according to the present invention is applied to the above winding device, Step a of controlling the wire supply pulley to rotate according to the wire supply speed and supply the wire rod to the wire supply end; Step b of detecting the actual tension value of the wire rod at the wire winding end by the load cell; Step c of calculating the tension error between the actual tension value and the target tension value of the wire rod; Step d of controlling the tension control motor to rotate the tension rod clockwise or counterclockwise based on the tension error so that the actual tension value of the wire rod matches the target tension value.

Advantages of the Invention

[0015] Compared with the conventional winding device that uses a spring to pull the tension rod, the present invention uses a tension control motor instead of a spring, providing a wider tension range and enabling active tension control.

Brief Description of the Drawings

[0016]

Figure 1

Figure 2A

Figure 2B

Figure 2C

Figure 3

Figure 4

Figure 5

Figure 6

Figure 7

Figure 8

Figure 9

Embodiments for Carrying Out the Invention

[0017] Preferred embodiments of the present invention will be described below with reference to the drawings.

[0018] In order to achieve the purpose of active tension control and solve the problem that the tension control is not immediate and the maximum tension is affected by the physical limit of the spring, the present invention proposes a novel winding device, which will be described below.

[0019] Figure 4 is a schematic diagram showing a first embodiment of the winding device according to the present invention. As shown in Figure 4, the winding device according to the present invention includes at least a tension rod 31, a tension control motor 32, a load cell 4, and a wire supply pulley 5. The wire 6 is wound around the wire supply pulley 5, the tension rod 31, and the load cell 4.

[0020] In one embodiment, the wire 6 may be, for example, an enameled copper wire, but is not limited thereto.

[0021] The winding device according to the present invention realizes active control by changing the tension source from a spring to the tension control motor 32, and overcomes the drawback that the maximum tension is limited.

[0022] As shown in Figure 4, the winding device has a wire supply end N1 and a wire winding end N2. The wire 6 is supplied into the winding device from the wire supply end N1, tension-controlled by internal members (including the wire supply pulley 5, the tension rod 31, the load cell 4, and one or more fixed pulleys), and then output from the wire winding end N2 to the outside of the winding device and wound around a workpiece (not shown) to form a wound component.

[0023] A wire supply pulley 5 is arranged at the wire supply end N1 of the winding device. The wire 6 is wound around the wire supply pulley 5, and the wire supply pulley 5 rotates according to the wire supply speed to supply the wire 6 into the winding device from the wire supply end N1.

[0024] The tension rod 31 is arranged behind the wire supply pulley 5, and the wire 6 is wound around one end to deflect the wire 6.

[0025] The tension control motor 32 is arranged at the other end of the tension rod 31 away from the wire 6, and actively rotates and controls the tension rod 31 clockwise or counterclockwise based on the feedback information of the winding device. The present invention can realize active tension control and improve the maximum tension by replacing the tension spring of the conventional winding device with the tension control motor 32.

[0026] The load cell 4 is disposed at the wire winding end N2 of the winding device and is used to detect the actual tension value of the wire 6 at the wire winding end N2. Specifically, when the wire 6 passes through the load cell 4, it disengages from the winding device at the wire winding end N2. Therefore, the actual tension value detected by the load cell 4 is the same as or extremely close to the tension value when the wire 6 winds up a workpiece outside the winding device.

[0027] In the present invention, the winding device continuously detects the actual tension value of the wire 6 by the load cell 4 and calculates the tension error between the actual tension value and the target tension value of the wire 6. Then, the tension control motor 32 continuously obtains this tension error and rotationally controls the tension rod 31 clockwise or counterclockwise based on the tension error. In the present invention, since the wire 6 is wound around one end of the tension rod 31, by rotating the tension rod 31 clockwise or counterclockwise with the tension control motor 32 as the center of the circle, the actual tension value of the wire 6 can be controlled. Thereby, the winding device can actively control the tension value of the wire 6 so that the actual tension value of the wire 6 output through the wire winding end N2 matches the target tension value.

[0028] For example, the winding device outputs the wire 6 to wind up a workpiece to manufacture a wound component, and this wound component requires a first tension value. In this case, the winding device uses the above-described technical solution to actively control the rotation of the tension rod 31 by the tension control motor 32 to maintain the wire 6 at the first tension value to meet the needs of the wound component.

[0029] Subsequently, refer to FIGS. 4 and 5 together. FIG. 5 is a flowchart of the first embodiment of the winding method according to the present invention. The present invention further discloses a winding method mainly applied to the winding device shown in FIG. 4, but is not limited thereto.

[0030] As shown in FIG. 5, first, the winding device controls the rotation of the wire supply pulley 5 according to a predetermined wire supply speed to supply the wire rod 6 to the wire supply end N1 (step S51). When the wire rod 6 is supplied into the winding device, the winding device detects the actual tension value of the wire rod 6 at the wire take-up end N2 by the load cell 4 (step S52).

[0031] After obtaining the actual tension value, the winding device calculates the tension error between the actual tension value and the target tension value of the wire rod 6 (step S53), and controls the rotation of the tension rod 31 clockwise or counterclockwise according to the tension error by the tension control motor 32, so as to make the actual tension value of the wire rod 6 coincide with the target tension value (step S54).

[0032] In this embodiment, the wire supply pulley 5 rotates continuously to supply the wire rod 6, the load cell 4 continuously detects the actual tension value of the wire rod 6, the winding device continuously calculates the tension error, and the tension control motor 32 continuously rotates the tension rod 31 (or keeps the tension rod 31 from moving) to maintain the tension balance of the wire rod 6. Therefore, the winding device needs to continuously judge whether the wire supply process has ended (step S55), that is, continuously judge whether to stop the supply of the wire rod 6. And before the wire supply process ends, the winding device repeatedly executes steps S51 to S54 to continuously supply the wire rod 6 and maintain the tension balance of the wire rod 6 during the wire supply process.

[0033] As shown in FIG. 4, the winding device according to the present invention further includes a wire supply motor 51 connected to the wire supply pulley 5 and controlling the rotation of the wire supply pulley 5. In the present invention, when calculating and obtaining a desired wire supply speed, the winding device generates a corresponding control signal and outputs it to the wire supply motor 51. In this way, the wire supply motor 51 controls the rotation of the wire supply pulley 5 based on the control signal, and the wire supply pulley 5 rotates based on the wire supply speed.

[0034] In the present invention, the winding device further includes a first encoder 33 for detecting the actual angle of the tension rod 31.

[0035] In one embodiment, when the tension control motor 32 controls the rotation of the tension rod 31, the motor position changes, and the first encoder 33 can correspondingly calculate the actual angle of the tension rod 31 based on the current position of the tension control motor 32.

[0036] In the present invention, the wire supply motor 51 can continuously acquire the actual angle of the tension rod 31 from the first encoder 33 and control the wire supply speed of the wire supply pulley 5 based on the actual angle. In this way, the tension control motor 32 controls the rotation of the tension rod 31 to achieve tension balance. However, when the actual angle of the tension rod 31 deviates from the target angle, the winding device can pull or release the wire rod 6 by controlling the wire supply speed so that the tension rod 31 returns to the target angle again after rotation. In other embodiments, the winding device can pull or release the wire rod 6 by controlling the wire supply speed so as to maintain that the angle error between the actual angle after the rotation of the tension rod 31 and the target angle is smaller than the allowable threshold.

[0037] As shown in FIG. 4, the winding device according to the present invention further includes a second encoder 7 disposed at the wire winding end N2 of the winding device.

[0038] In one embodiment, the second encoder 7 is disposed on one of a plurality of fixed pulleys close to the wire take-up end N2 of the winding device. In this embodiment, this fixed pulley winds the wire 6 and deflects the wire 6. When the wire 6 moves to rotate the fixed pulley, the second encoder 7 can detect the actual wire take-up speed of the wire 6 at the wire take-up end N2 based on the rotation of the fixed pulley. As described above, since the second encoder 7 is disposed at the wire take-up end N2 and the wire 6 detaches from the wire take-up end N2 of the winding device to wind the workpiece, the actual wire take-up speed detected by the second encoder 7 is the same as or extremely close to the wire take-up speed of the wire 6 when winding the workpiece.

[0039] In the present invention, the wire supply motor 51 acquires the actual wire take-up speed of the wire 6 from the second encoder 7 in real time, and controls the wire take-up speed of the wire supply pulley 5 based on this actual wire take-up speed. The present invention uses the actual wire take-up speed of the wire 6 as the second feedback source of the wire supply motor 51 (the first feedback source is the actual angle of the tension rod 31), so that a stable speed source can be obtained for the wire supply motor 51, and the change in the wire speed can also be immediately responded to. In this way, the influence of disturbances on the stability of wire supply can be effectively reduced.

[0040] FIG. 6 is a schematic diagram showing a second embodiment of the winding device according to the present invention. Referring to this figure, the winding device according to the present invention further includes one or more controllers, and the one or more controllers are connected to at least one of the tension control motor 32, the first encoder 33, the load cell 4, the wire supply motor 51, and the second encoder 7, and perform control on the tension rod 31 and / or the wire supply pulley 5.

[0041] In the embodiment of FIG. 6, the controller includes a PI controller (Proportional-Integral Controller) 8 and a feed-forward controller 9. In one embodiment, the PI controller 8 is realized by a tension control motor 32 or a first encoder 33, and the feed-forward controller 9 is realized by a second encoder 7. In other embodiments, the PI controller 8 and the feed-forward controller 9 are realized by independent controllers and can be connected to various members within the winding device.

[0042] FIG. 7 is a schematic diagram showing a specific embodiment of the first control structure of the present invention. In the embodiment of FIG. 7, the PI controller 8 is connected to a load cell (L1) and receives the actual tension value of the wire 6 detected by the load cell (L1). Also, the PI controller 8 (or other members in the winding device) calculates a tension error (Err) between the actual tension value and the target tension value of the wire 6, and calculates an output control command signal (Out) based on the tension error to use as an input parameter for the tension control motor 32. In this way, the tension control motor 32 controls the corresponding rotation of the tension rod 31 based on this input parameter, so that the tension value of the wire 6 can be controlled to match the target tension value.

[0043] In one embodiment, the winding device obtains the above tension error (Err) by subtracting the actual tension value from the target tension value and taking the absolute value. Also, the PI controller 8 calculates the above output control command signal (Out) based on the tension error and a proportional relationship, but is not limited thereto.

[0044] Subsequently, refer to FIGS. 8 and 9 together. FIG. 8 is a schematic diagram showing a specific embodiment of the second control structure of the present invention. FIG. 9 is a flowchart of the second embodiment of the winding method according to the present invention.

[0045] In the embodiment of FIG. 8, the PI controller 8 is connected to the first encoder (E2) and receives the actual angle of the tension rod 31 detected by the first encoder (E2). The feedforward controller 9 is connected to the second encoder 7 and the wire supply pulley 5, receives the actual wire winding speed V1 detected by the second encoder 7, and controls the wire supply speed V2 of the wire supply pulley 5.

[0046] Specifically, as shown in FIG. 9, when the winding device performs the wire supply process, first, the PI controller 8 obtains the actual angle of the tension rod 31 from the first encoder (E2) (step S91), and calculates the angle error (Err) between the actual angle and the target angle (step S92). In one embodiment, the winding device obtains the degree error (Err) by subtracting the actual angle from the target angle by the PI controller 8 and taking the absolute value. In another embodiment, the winding device obtains the angle error (Err) by subtracting the actual angle from the target angle by another controller (not shown) and taking the absolute value.

[0047] Next, the PI controller 8 generates a first output (Out1) based on the angle error (Err) (step S93). Specifically, the PI controller 8 generates the first output (Out1) based on the angle error (Err) and a proportional relationship, but is not limited thereto.

[0048] Next, the winding device obtains the actual wire winding speed (V1) of the wire 6 at the wire winding end N2 from the second encoder 7 by the feedforward controller 9 (step S94), and generates a second output (Out2) based on the actual wire winding speed (V1) (step S95). Specifically, the feedforward controller 9 generates the second output (Out2) based on the actual wire winding speed (V1) and a proportional relationship, but is not limited thereto.

[0049] Next, the winding device adds the first output (Out1) and the second output (Out2) by the feed-forward controller 9 or another controller (not shown), generates the wire supply speed (V2), and uses it as the input to the wire supply pulley 5 (step S96). In this way, the wire supply motor 51 can rotationally control the wire supply pulley 5 according to the received wire supply speed (V2) (step S97).

[0050] Similar to the embodiment of FIG. 4, in the wire supply process of the winding device, since the tension rod 31 is continuously rotationally controlled and the wire supply pulley 5 is continuously rotationally controlled, the winding device continuously determines whether the wire supply process has ended (step S98), that is, it is necessary to continuously determine whether to stop the supply of the wire rod 6. And before the wire supply process ends, the winding device repeatedly executes steps S91 to S97, so that the PI controller 8 and the feed-forward controller 9 continuously control the wire supply speed (V2) adopted by the wire supply pulley 5, and maintain the tension balance in the wire rod 6 during the wire supply process.

[0051] The present invention can achieve active tension control by rotationally controlling the tension rod 31 by the tension control motor 32 and rotationally controlling the wire supply pulley 5 by the wire supply motor 51 according to the feedback signal of the winding device. In addition, since the winding device according to the present invention does not use a spring, the maximum tension range is not physically limited by the spring, and the costs required for the use and replacement of the spring can be avoided.

[0052] As described above, the preferred embodiments of the present invention have been described in detail, but they do not limit the scope of the present invention. The entire scope of the present invention is based on the following claims, and similar modifications applying the specification and drawings of the present invention should be included in the scope of the present invention.

Explanation of Reference Numerals

[0053] 11 Spring 12 Tension Rod 13 Angle Sensor 14 Wire Supply Pulley 2 Wire 31 Tension Rod 32 Tension Control Motor 33, E2 First Encoder 4, L1 Load Cell 5 Wire Supply Pulley 51 Wire Supply Motor 6 Wire 7 Second Encoder 8 PI Controller 9 Feedforward Controller A Angle Error V1 Wire Winding Speed V2 Wire Supply Speed N1 Wire Supply End N2 Wire Winding End Err Error Out Output Control Command Signal Out1 First Output Out2 Second Output X1, X2 Spring Deformation Amount F1, F2 Tensile Force

Claims

1. A winding device used in combination with a wire, comprising: A wire supply pulley disposed at a wire supply end of the winding device, rotating according to a wire supply speed, and supplying the wire from the wire supply end; A tension rod having the wire wound around one end thereof and deflecting the wire; A tension control motor disposed at the other end of the tension rod for rotating the tension rod; A load cell disposed at a wire take-up end of the winding device for detecting an actual tension value of the wire at the wire take-up end; A first encoder for detecting a current position of the tension control motor and calculating an actual angle of the tension rod; A wire supply motor connected to and rotating the wire supply pulley, wherein the tension control motor rotates the tension rod clockwise or counterclockwise based on a tension error between a target tension value and the actual tension value of the wire so as to make the actual tension value of the wire coincide with the target tension value; and the wire supply motor adjusts the wire supply speed based on the actual angle so that after the tension rod rotates, the actual angle coincides with a target angle of the tension rod, or an angle error between the actual angle and the target angle is made smaller than a threshold value.

2. The winding device according to claim 1, wherein the first encoder calculates the actual angle of the tension rod based on a motor position of the tension control motor.

3. The winding device further comprises a second encoder disposed at a wire take-up end of the winding device for detecting an actual wire take-up speed of the wire at the wire take-up end; and the wire supply motor controls the wire supply speed based on the actual wire take-up speed.

4. The second encoder is disposed on a fixed pulley close to the wire take-up end of the winding device; and the wire is wound around the fixed pulley and deflected.

5. The winding device further comprises a PI controller connected to the load cell, receiving the actual tension value from the load cell, calculating the tension error between the actual tension value and the target tension value, and generating an output control command signal as an input parameter of the tension control motor based on the tension error. The winding device according to claim 1, wherein the tension control motor controls the rotation of the tension rod based on the input parameter.

6. A PI controller connected to the first encoder, calculating the angle error between the actual angle and the target angle of the tension rod, and generating a first output based on the angle error; A feedforward controller connected to the second encoder and the wire supply pulley, generating a second output based on the actual wire winding speed of the wire at the wire winding end, adding the first output and the second output, and generating the wire supply speed as an input to the wire supply pulley; The winding device according to claim 3, further comprising.

7. A winding method applied to the winding device according to claim 1, comprising: Step a of controlling the wire supply pulley to rotate according to the wire supply speed so as to supply the wire to the wire supply end; Step b of detecting the actual tension value of the wire at the wire winding end by the load cell; Step c of calculating the tension error between the actual tension value and the target tension value of the wire; Step d of controlling the tension control motor to rotate the tension rod clockwise or counterclockwise based on the tension error so as to make the actual tension value of the wire coincide with the target tension value; Step e of adjusting the wire supply speed by the wire supply motor based on the actual angle, making the actual angle coincide with the target angle of the tension rod after the tension rod rotates, or maintaining the angle error between the actual angle and the target angle to be smaller than the threshold value, wherein the actual angle is calculated by the first encoder detecting the current position of the tension control motor.

8. The winding device further includes a second encoder disposed at the wire winding end; The winding method includes: Step f of detecting the actual wire winding speed of the wire at the wire winding end by the second encoder; The winding method according to claim 7, further comprising step g of controlling the wire supply speed by the wire supply motor based on the actual wire winding speed.

9. The winding device further includes a PI controller connected to the load cell. Step c includes receiving the actual tension value from the load cell by the PI controller, calculating the tension error between the actual tension value and the target tension value, and generating an output control command signal as an input parameter of the tension control motor based on the tension error. Step d includes controlling and rotating the tension rod based on the input parameter by the tension control motor. The winding method according to claim 8.

10. The winding device further includes a PI controller connected to the first encoder, and a feedforward controller connected to the second encoder and the wire supply pulley. The winding method is as follows. Step h of obtaining the actual angle of the tension rod. Step i of calculating the angle error between the actual angle and the target angle by the PI controller. Step j of generating a first output based on the angle error. Step k of obtaining the actual wire winding speed of the wire at the wire winding end. Step l of generating a second output based on the actual wire winding speed by the feedforward controller. Step m of adding the first output and the second output to generate the wire supply speed as an input to the wire supply pulley. The winding method according to claim 8 further includes step n of continuously executing steps h to m before stopping the supply of the wire.

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