Winding method and winding device

Abstract

The present invention involves executing steps in which: a wire is supplied from a nozzle (6) while a spool (12c) having two or more corner sections on a side surface is rotated; the wire is wrapped diagonally on a surface (S4) sandwiched by two corner sections (K1, K2) among the side surfaces of the spool (12c), whereby the wire is spirally wound on the spool (12c); the diagonal wrapping is performed, in a state in which the wire is pressed toward an already-wound side using a pressing member (34) in the vicinity of the winding-starting-end-side corner section (K1) of the surface (S4), for each single rotation of the spool (12c); while the diagonal wrapping is being performed, the pressing member (34) is rotated synchronously with rotation of the spool (12c); the pressing by the pressing member (34) is released at or after a timing at which the wire is wound on the winding-completion-end-side corner section (K2) of the surface (S4); and the pressing member (34) is then moved close to the winding-starting-end-side corner section (K1) of the surface (S4) until diagonal wrapping starts in a subsequent cycle. This configuration makes it possible to simplify the configuration and control of the winding device, to reduce the cost of the winding device, and to improve the quality of winding.

Description

[Technical Field]

[0001] The present invention relates to a winding method and a winding device, and more particularly to a winding method and a winding device for supplying a wire from a wire supply port while rotating a winding shaft and winding the wire around the side surface of the winding shaft. [Background technology]

[0002] A known winding device for winding a wire around a winding shaft is, for example, one that winds the wire around the winding shaft of a stator of a rotating electric machine. Also known as a stator of a rotating electric machine is a configuration having a cylindrical stator core with a plurality of teeth (magnetic poles) protruding radially inward and a plurality of slots opening between the teeth arranged radially. In such a stator, winding is performed by winding wire around each tooth, and the stator coil formed by the winding is housed in slots on both sides of the tooth. Because it is difficult to wind wire around each tooth of a cylindrical stator core due to many space constraints, the stator core is divided into multiple split cores, each for each tooth, and the stator is constructed by assembling each wound split core into a ring shape. The split core comprises a yoke piece (iron core portion) which is a split piece of the annular yoke portion, and one tooth which is integral with the yoke piece. The tooth comprises a winding shaft having a square cross section on which wire is wound, and a flange portion which is formed at the inner diameter end of the winding shaft and extends circumferentially.

[0003] One known method of winding wire around a split core is the so-called spindle winding method, in which the split core is fixed to a spindle and rotated so that the winding shaft is concentric with the spindle, and wire is supplied from a wire supply port such as a nozzle and wound spirally around the winding shaft. To increase the space factor of the wire around the reel, rectangular wire with a square cross section is sometimes used. However, because rectangular wire has corners, it is more difficult to wind the wire closely and in a regular pattern than round wire, and winding defects often occur. Such winding defects are particularly likely to occur when the wire is wound diagonally from the end of the front row to the start of the rear row.

[0004] To solve this problem, Patent Document 1 discloses a method in which the wound wire is pressed by one pressing member, forming a wedge-shaped gap so that the wire moves away from the unwound side, and then another pressing member is used to press the wire back toward the already wound side, thereby tightly bonding each row of wire. Similarly, in the area where the wire is to be wound obliquely, one pressing member presses the wire located on the winding start side of the area, forming a wedge-shaped gap that becomes larger downstream, and another pressing member located on the winding end side presses the wire back toward the already wound side. In an example of Patent Document 1, two pressing members are used in the area where the wire is to be wound obliquely, and three pressing members are used in other areas. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Patent No. 5610887 Summary of the Invention [Problem to be solved by the invention]

[0006] When multiple pressing members are provided, as in the invention described in Patent Document 1, it is necessary to configure the pressing members to be driven independently, which makes the device configuration more complex and larger, and the control also becomes more complex, resulting in unavoidable high costs. Furthermore, a more complex configuration is likely to lead to a decrease in reliability (winding quality) in the long term. Similar issues arise when winding wire around targets other than the winding shafts of the stator's split cores.

[0007] The present invention has been made in view of the above circumstances, and aims to simplify the configuration and control of a winding device, reduce the cost of the winding device, and improve the winding quality. [Means for solving the problem]

[0008] The present invention relates to a method for winding a split core, which involves supplying a wire rod from a wire rod supply port while rotating a winding shaft having two or more corners on its side, and helically winding the wire rod around the winding shaft by diagonally winding the wire rod in a first region between the two corners of the winding shaft such that the axial positions of the wire rod are different at the winding start and end of the first region. The method further includes the steps of: for each rotation of the winding shaft, pressing the wire rod toward an already wound wire side with a presser member near the winding start corner of the first region while the presser member is rotating in synchronization with the rotation of the winding shaft during the diagonal winding; releasing the presser member after the wire rod is wound around the winding end corner of the first region; and then moving the presser member to the vicinity of the winding start corner of the first region before the diagonal winding begins for the next turn.

[0009] In such a winding method, The diagonal winding may be performed while the wire is pressed toward the already wound wire side by a pressing member at only one location near the corner on the winding start side of the first region.

[0010] Alternatively, even after the pressing by the pressing member is released, the pressing member may be rotated in the same direction as the winding shaft, and before the pressing member reaches a bridge portion of the wire rod positioned between the winding shaft and the wire rod supply port, the pressing member may be retracted so as not to interfere with the bridge portion, and after the pressing member has passed the bridge portion, the pressing member may be moved to a position where it will press the wire rod in the next revolution of the winding shaft. Furthermore, after the pressing member has been retracted, the pressing member may be rotated in the same direction as the rotational direction of the reel at a higher speed than the reel, and after the pressing member has passed the transition portion, the rotation of the pressing member and the rotation of the reel may be synchronized.

[0011] Furthermore, after the pressure by the presser member is released, the presser member may be retracted so as not to interfere with the rotating reel, and then the presser member may be rotated in a direction opposite to the rotation direction of the reel, and the rotation of the presser member may be synchronized with the rotation of the reel near a downstream position of a bridge portion of the wire rod located between the reel and the wire rod supply port in the rotation direction of the reel, after which the presser member may be moved to a position where it will press the wire rod during the next revolution of the reel.

[0012] In each of the above winding methods, it is preferable to arrange two main shafts concentrically facing each other, hold the winding shaft between the two main shafts, provide the presser members corresponding to the main shafts, and perform the above process for each layer of wire wound spirally around the winding shaft using the presser member that has the least amount of movement for retracting. The present invention can be realized as a method as described above, or in any other form, such as a corresponding device, a system, a program for controlling the device, or a recording medium on which such a program is recorded. [Effects of the Invention]

[0013] According to the configuration described above, the configuration and control of the winding device can be simplified, and the cost of the winding device can be reduced and the winding quality can be improved. [Brief explanation of the drawings]

[0014] [Figure 1] 1 is a schematic front view of a winding device according to an embodiment of the present invention; [Figure 2] FIG. 2 is a left side view of the winding device shown in FIG. [Figure 3] 2 is a right side view of the upper winding device of the winding device shown in FIG. 1. [Figure 4] 2 is an enlarged view of the periphery of a radial movement mechanism of an upper winding device in the winding device shown in FIG. 1. [Figure 5] FIG. 2 is a control block diagram of the winding device shown in FIG. [Figure 6]2 is a plan view of a split core, which is an example of a target to be wound by the winding device shown in FIG. 1. FIG. [Figure 7] Figures 7A to 7E are a series of diagrams showing the winding operation (during winding) in a rotation-synchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figure 7A is a plan view showing the state in which a pressing member is applied to the winding start end side of the surface where diagonal wrapping is performed, Figure 7B is a side view showing the winding state of the surface where diagonal wrapping is performed, Figure 7C is a plan view showing the state in which the pressing member is retracted, Figure 7D is a side view showing the winding state on the surface adjacent to the surface where diagonal wrapping is performed, and Figure 7E is a plan view showing the state in which the split core has made one rotation from the state in Figure 7A. [Figure 8] 8A to 8C are side views illustrating the positional relationship of the pressing member with respect to the split core: Fig. 8A is a side view showing the pressing member in the second retracted position, Fig. 8B is a side view showing the pressing member in the first retracted position, and Fig. 8C is a side view showing the pressing member in the wire pressing position. [Figure 9] Figures 9A to 9E are a series of diagrams showing the winding operation (during winding down) in a rotation-synchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figure 9A is a plan view showing the state in which a pressing member is applied to the winding start end side of the surface where diagonal wrapping is performed, Figure 9B is a side view showing the winding state of the surface where diagonal wrapping is performed, Figure 9C is a plan view showing the state in which the pressing member is retracted, Figure 9D is a side view showing the winding state on the surface adjacent to the surface where diagonal wrapping is performed, and Figure 9E is a plan view showing the state in which the split core has made one rotation from the state in Figure 9A. [Figure 10] Figures 10A to 10E are a series of diagrams showing the winding operation (during winding) of the first rotation asynchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figures 10A to 10E show states corresponding to Figures 7A to 7E, respectively. [Figure 11] Figures 11A to 11E are a series of diagrams showing the winding operation (during winding down) of the first rotation asynchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figures 11A to 11E show states corresponding to Figures 9A to 9E, respectively. [Figure 12]Figures 12A to 12E are a series of diagrams showing the winding operation (during winding) of the second rotation asynchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figures 12A to 12E show states corresponding to Figures 7A to 7E, respectively. [Figure 13] Figures 13A to 13E are a series of diagrams showing the winding operation (during winding down) of the second rotation asynchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figures 13A to 13E show states corresponding to Figures 9A to 9E, respectively. [Figure 14] Figures 14A to 14H are a series of diagrams showing a modified example of the winding operation of the second rotation asynchronous operation pattern by the upper winding device in the winding device shown in Figure 1. Figures 14A to 14E show states corresponding to Figures 12A to 12E, respectively. Figure 14F is a side view showing the winding state on the surface where diagonal hanging is performed during winding down, Figure 14G is a plan view showing the state where winding is being performed on the surface where diagonal hanging is performed with pressure applied by the presser member, and Figure 14H is a side view showing the winding state on the surface adjacent to the surface where diagonal hanging is performed. [Figure 15] FIG. 10 is a front view showing a modified example of a radial movement mechanism in the upper winding device. [Figure 16] 16A to 16C are diagrams for explaining the proper use of the presser member for the upper winding device and the presser member for the lower winding device, respectively. Fig. 16A is a diagram for explaining that the presser member for the upper winding device is suitable for winding up, Fig. 16B is a diagram for explaining that the presser member for the upper winding device is not suitable for winding down, and Fig. 16C is a diagram for explaining that the presser member for the lower winding device is suitable for winding down. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, an embodiment of the present invention will be described with reference to FIGS. First, a winding device according to one embodiment of the present invention will be described with reference to Figures 1 to 6. Figure 1 is a schematic front view of the winding device. Figure 2 is a left side view of the winding device shown in Figure 1. Figure 3 is a right side view of an upper winding device in the winding device shown in Figure 1. Figure 4 is an enlarged view of the periphery of a radial movement mechanism for the upper winding device in the winding device shown in Figure 1. Figure 5 is a control block diagram of the winding device shown in Figure 1. Figure 6 is a plan view of a split core, which is an example of a target to be wound by the winding device shown in Figure 1.

[0016] The winding device 2 shown in Figure 1 etc. is a winding device of the present invention configured as a split core winding device for winding a winding shaft of a split core of a stator of a rotating electric machine, as shown in Figure 6. 1, the winding device 2 has a vertical twin structure including an upper winding device 2A, a lower winding device 2B, a support mechanism 4 that supports them in an opposing state, a nozzle 6 (see FIG. 2) that is a wire supply port for supplying wire to be wound around a split core (described later), and a control unit 50 (see FIG. 5). The control unit 50 can be configured as, for example, a microcomputer equipped with a processor, a memory, and an input / output interface.

[0017] In Fig. 1, arrow Z indicates the up-down direction, arrow X indicates the left-right direction (also called the front-rear direction), and the direction perpendicular to the X direction on a horizontal plane is the depth direction. Furthermore, in this specification, unless otherwise specified, the upper side of Fig. 1 will be described as "upper" and the lower side as "lower," but these do not necessarily coincide with the upper and lower sides based on the direction of gravity.

[0018] The upper winding device 2A has an upper main shaft (driven shaft) 8 that extends vertically and is rotatably supported, and the lower winding device 2B has a lower main shaft (drive shaft) 10 that extends vertically and has a tip that concentrically faces the upper main shaft 8. An upper winding jig 14 for holding one end of the split core 12 is attached to the tip (lower end in the figure) of the upper main shaft 8, and a lower winding jig 16 for holding the other end of the split core 12 is attached to the tip (upper end in the figure) of the lower main shaft 10.

[0019] As shown in Figure 6, split core 12 includes yoke pieces 12a, which are split pieces of the annular yoke portion of the stator core, and teeth 12b integral with yoke pieces 12a. Teeth 12b include winding shaft 12c, which has a rectangular cross section perpendicular to the axial direction, and arc-shaped flange 12d, which extends in the circumferential direction of the stator and is formed on the inner diameter end of winding shaft 12c. A rectangular wire 18 (see Figure 2), which is a wire material with a rectangular cross section, is wound around winding shaft 12c on its flatwise surface (wide surface). Here, yoke pieces 12a are held by lower winding jig 16, and flange 12d is held by upper winding jig 14, so that winding shaft 12c is concentric with upper main shaft 8 and lower main shaft 10. The winding shaft 12c shown in FIG. 6 is the winding shaft around which the wire is wound by the winding device 2.

[0020] The configuration of the winding device 2 will be specifically described below.

[0021] The support mechanism 4 includes a support base 20 that directly supports the lower winding device 2B, a plurality of support pillars 22 extending upward from the support base 20, and two support plates 24, 26 fixed to the upper ends of these support pillars 22 and supporting the upper winding device 2A.

[0022] The upper winding device 2A includes an upper main shaft 8 rotatably supported with its upper end inserted into a guide tube 28 fixed to the upper support plate 24, two support shafts 29 fixed between the support plates 24, 26 and extending in the vertical direction, a movable base plate 32 fixed to a sliding tube 30 slidably mounted on each support shaft 29 in the vertical direction and movable in the vertical direction, and a cylindrical presser unit 36 ​​supported by the movable base plate 32 and integrated with a presser member 34. The upper main shaft 8 is disposed so as to pass through the center of the presser unit 36.

[0023] As shown in Fig. 3, a servo motor 38, which is a drive source for moving the pressure member 34 in the axial direction (up and down) of the reel 12c, is fixed to the upper support plate 24, and a ball screw mechanism 40 driven by the servo motor 38 is provided below the servo motor 38. A movable portion 40a of the ball screw mechanism 40 is connected to the movable base plate 32, and the pressure unit 36 ​​moves up and down when driven by the servo motor 38. In other words, the pressure member 34 moves in the axial direction of the reel 12c. As the pressure unit 36 ​​moves, the tip of the pressure member 34 can move up and down generally within the range indicated by arrow A in Fig. 1. The servo motor 38, ball screw mechanism 40, movable base plate 32, and presser unit 36 ​​constitute an axial movement mechanism 42 (see FIG. 5) that moves the presser member 34 in the axial direction of the winding shaft 12c.

[0024] As shown in Fig. 3, a servo motor 44 is fixed to the movable base plate 32, and a gear 46 is fixed to the rotation shaft of the servo motor 44. The gear 46 meshes with a flange gear 48 provided at the upper end of the presser unit 36. As a result, when the servo motor 44 operates, the presser unit 36 ​​rotates. In other words, the presser member 34 rotates around the axis of the reel 12c (however, Fig. 3 shows a state in which the presser member 34 has been removed so that the configuration in the vicinity of the upper main shaft 8 can be seen).

[0025] 5, the rotation (rotation direction and rotation speed) of the servo motor 44 is controlled by the control unit 50. In this embodiment, the control unit 50 controls the rotation of the servo motor 44 so that the presser member 34 rotates in synchronization with the rotation of the upper main shaft 8. The servo motor 44, gear 46, flange gear 48, presser unit 36, control unit 50, etc. constitute a rotation synchronization mechanism 52 (see FIG. 5).

[0026] As shown in Figure 2, a servo motor 54 is fixed to the movable base plate 32, and a ball screw mechanism 56 driven by the servo motor 54 is provided below the servo motor 54. A movable portion 56a of the ball screw mechanism 56 is connected to an annular collar member 58 that fits into the upper end of the presser unit 36 ​​and is arranged so as to be movable in the vertical direction. The collar member 58 is independent of the presser unit 36 ​​and does not rotate. An annular groove 58a (see Figure 4) is formed on the outer circumferential surface of the collar member 58.

[0027] As shown in Fig. 4, a linear guide mechanism including a vertical rail member 55 and a slider 57 that slides relative to the vertical rail member 55 is provided integrally with the presser unit 36 ​​on the outer circumferential surface of the presser unit 36. A vertical rack member 60 is fixed to the slider 57. A cam follower 62 is attached to the upper end of the vertical rack member 60, and the cam follower 62 engages with an annular groove 58a of a collar member 58. For ease of understanding, the collar member 58 is shown hatched in Fig. 4. A linear guide mechanism including a horizontal rail member 59 and a slider 61 that slides relative to the horizontal rail member 59 is provided integrally with the presser unit 36 ​​at the lower end of the presser unit 36. The presser member 34 and a horizontal rack member 64 are provided integrally with the slider 61.

[0028] Both the vertical rack member 60 and the horizontal rack member 64 mesh with a pinion gear 66 that is integral with the presser unit 36. A linear guide mechanism is a mechanism that generates smooth linear sliding by interposing rolling elements such as balls or rollers between a linear rail and a slider (carriage) that slides on the rail. In Figure 4, reference numeral 65 denotes a clamper for locking the tip of the wire.

[0029] With the above configuration, when the servo motor 54 operates, the collar member 58 moves up and down, and accordingly, the vertical rack member 60, which is engaged with the collar member 58 via the cam follower 62, also moves up and down at the same time. When the vertical rack member 60 moves, the pinion gear 66 rotates, and accordingly, the horizontal rack member 64 moves in the radial direction of the reel 12c. In other words, when the servo motor 54 operates, the presser member 34 moves in the radial direction of the reel 12c.

[0030] A radial movement mechanism 68 (see FIG. 5) that moves the presser member 34 in the radial direction of the reel 12c is configured by the servo motor 54, ball screw mechanism 56, collar member 58, vertical rail member 55, slider 57, vertical rack member 60, cam follower 62, horizontal rail member 59, slider 61, horizontal rack member 64, and pinion gear 66. A presser member movement mechanism 67 is configured by the axial movement mechanism 42 and the radial movement mechanism 68. 1 to 3, reference numeral 70 denotes an air cylinder, which is a drive source for pressing the upper main shaft 8 downward to pressurize and hold the split core 12 between it and the lower main shaft 10.

[0031] As shown in Figure 5, the nozzle 6, which supplies the wire (in this embodiment, rectangular wire 18) to be wound around the reel 12c, is displaced at least in the axial direction (up and down) of the reel 12c by a nozzle displacement mechanism 74 driven by a servo motor 72. Strictly speaking, the nozzle 6 can be displaced not only up and down but also left and right and in the depth direction, and can also rotate around the axis of the wire to impart a twist to the wire. The nozzle displacement mechanism 74 is controlled by the control unit 50 via the servo motor 72.

[0032] Next, we will explain the configuration of the lower winding device 2B. Since the configuration of the lower winding device 2B is substantially the same as that of the upper winding device 2A, parts corresponding to those of the upper winding device 2A are distinguished by adding the letter B to the same numbers, and duplicate explanations will be omitted where appropriate.

[0033] As shown in Fig. 1, two support shafts 75 are fixed to the lower part of the support base 20, and a servo motor 78 is fixed to a plate 76 supported by these support shafts 75, for driving and rotating the lower main shaft 10 of the lower winding device 2B. As described above, the lower main shaft 10 and the upper main shaft 8 are connected via the split core 12, so that when the lower main shaft 10 is driven and rotated by the servo motor 78, the split core 12 rotates and the upper main shaft 8 is also rotated accordingly. The servo motor 78, the lower main shaft 10, the guide tube 28B, etc. constitute a main shaft drive mechanism 80 (see Fig. 5) that drives and rotates the main shaft.

[0034] Two support cylinders 81 extending in the vertical direction are fixed to the support base 20, and a sliding shaft 82 is inserted into each support cylinder 81. The lower ends of the sliding shafts 82 are connected by a plate 84, allowing them to slide vertically as a unit. As shown in FIG. 2, a servo motor 38B is fixed to the plate 76, and a ball screw mechanism 40B driven by the servo motor 38B is provided below the servo motor 38B. A movable portion 40Ba of the ball screw mechanism 40B is connected to the plate 84, and the two sliding shafts 82 move vertically when driven by the servo motor 38B. A movable base plate 32B supporting a presser unit 36B is fixed to the upper ends of the two sliding shafts 82. The servo motor 38B, the ball screw mechanism 40B, the movable base plate 32B, the presser unit 36B, etc. constitute an axial movement mechanism 42B (see FIG. 5) that moves the presser member 34B in the axial direction of the reel 12c. As the pressing unit 36B moves, the tip of the pressing member 34B can move up and down generally within the range indicated by the arrow B in FIG.

[0035] As shown in FIG. 2, a servo motor 44B is fixed to the underside of the movable substrate 32B, and a gear 46B is fixed to the rotation shaft of the servo motor 44B. The gear 46B meshes with a flange gear 48B provided at the upper end of the presser unit 36B. As a result, when the servo motor 44B operates, the presser unit 36B rotates. That is, the presser member 34B rotates around the axis of the reel 12c. As shown in FIG. 5, the rotation (rotation direction and rotation speed) of the servo motor 44B is controlled by a control unit 50. In this embodiment, the control unit 50 controls the rotation of the servo motor 44B so that the presser member 34B rotates in synchronization with the rotation of the lower main shaft 10 (and the upper main shaft 8). The servo motor 44B, gear 46B, flange gear 48B, presser unit 36B, control unit 50, and the like constitute a rotation synchronization mechanism 52B.

[0036] A servo motor 54B is fixed to the support base 20, and a ball screw mechanism 56B driven by the servo motor 54B is provided above the servo motor 54B. A movable part 56Ba of the ball screw mechanism 56B is connected to an annular collar member 58B fitted to the lower end of the presser unit 36B. The collar member 58B is independent of the presser unit 36B and does not rotate. An annular groove 58Ba is formed on the outer circumferential surface of the collar member 58B.

[0037] 1, a linear guide mechanism including a vertical rail member 55B and a slider 57B that slides along the vertical rail member 55B is integrally provided on the outer peripheral surface of the presser unit 36B. A vertical rack member 60B is fixed to the slider 57B. A cam follower 62B is attached to the lower end of the vertical rack member 60B, and the cam follower 62B engages with an annular groove 58Ba of a collar member 58B. A linear guide mechanism including a horizontal rail member 59B and a slider 61B that slides relative to the horizontal rail member 59B is provided integrally with the presser unit 36B at the upper end side of the presser unit 36B. A presser member 34B and a horizontal rack member 64B are provided integrally with the slider 61B. Both the vertical rack member 60B and the horizontal rack member 64B are in mesh with a pinion gear 66B that is integrally provided on the presser unit 36B.

[0038] With the above configuration, when servo motor 54B operates, collar member 58B moves up and down, and accordingly, vertical rack member 60B, which is engaged with collar member 58B via cam follower 62B, also moves up and down at the same time. When vertical rack member 60B moves, pinion gear 66B rotates, and accordingly, horizontal rack member 64B moves in the radial direction of reel 12c. In other words, when servo motor 54B operates, presser member 34B moves in the radial direction of reel 12c.

[0039] Servo motor 54B, ball screw mechanism 56B, collar member 58B, vertical rail member 55B, slider 57B, vertical rack member 60B, cam follower 62B, horizontal rail member 59B, slider 61B, horizontal rack member 64B, pinion gear 66B, and the like constitute a radial movement mechanism 68B (see FIG. 5) that moves presser member 34B in the radial direction of reel 12c. The axial direction moving mechanism 42B and the radial direction moving mechanism 68B constitute a pressing member moving mechanism 67B (see FIG. 5).

[0040] Next, the winding operation of the winding device 2 will be described for each pattern with reference to Figures 7 to 14. Each of the winding operations according to these patterns is an embodiment of the winding method of the present invention. Although winding around split core 12 can be performed by either upper winding device 2A or lower winding device 2B due to the configuration of winding device 2 described above, the following describes winding using upper winding device 2A. As shown in Fig. 5, a program for executing each pattern is stored in nonvolatile memory 50a of control unit 50, and control unit 50, which has the functionality of a microcomputer, controls the operation of each servo motor of rotation synchronization mechanism 52, presser member moving mechanism 67, nozzle displacement mechanism 74, and main shaft drive mechanism 80 based on this program, thereby causing winding device 2 to perform the winding operation of each pattern described below.

[0041] [Rotation synchronous operation pattern (when winding): Figures 7A to 8C] First, the rotation-synchronized operation pattern during winding will be described with reference to FIGS. 7A to 8C. 7A to 7E are a series of diagrams showing the winding operation (during winding) in the rotation synchronous operation pattern by the upper winding device 2A in the winding device 2. FIGS. 8A to 8C are side views for explaining the positional relationship of the pressing member 34 with respect to the split core 12. The rotation-synchronized operation pattern described here is an operation pattern in which the rotation of the presser member 34 is synchronized with the rotation of the main shafts (upper main shaft 8 and lower main shaft 10). During winding, the flat wire 18, which is a wire rod, is wound from bottom to top in the axial direction of the winding shaft 12c.

[0042] 7A to 7E show the winding operation of the first layer as an example of the operation of the rotation synchronous operation pattern during winding. As shown in FIG. 7A, the single pressing member 34 is disposed near corner K1 on the winding start side (starting position of diagonal hanging) of surface S4 (corresponding to the first region sandwiched between two corners K1 and K2) where diagonal hanging is performed, out of the four surfaces (S1, S2, S3, S4) of the winding shaft 12c, which has a rectangular cross section in a plane perpendicular to the axial direction. Oblique winding refers to a winding method in which the starting and ending ends of the winding on one surface of the winding shaft 12c are at different positions in the axial direction (axial direction of the winding shaft). The ending end may be either above or below the starting end. In the example of Figure 7, oblique winding is performed on surface S4. Surface S1 is the starting surface where the rectangular wire 18 is first wound.

[0043] The position indicated by the unhatched square is the first retracted position P1 (see FIG. 8B) where the pressure member 34 has retracted in the radial direction of the reel 12c. By control of the radial movement mechanism 68 and the axial movement mechanism 42 by the control unit 50, the pressure member 34 moves from the first retracted position P1 as indicated by the arrow to the wire pressing position P2 (see FIG. 8C) indicated by the hatched square, and then descends slightly, allowing it to press the rectangular wire 18 from above. This position is the wire pressing position P3 shown in FIG. 7B, and is the position of the pressure member 34 when the diagonal winding begins. The surface of the reel 12c shown in FIG. 7B is surface S4.

[0044] The pressing member 34 starts pressing the rectangular wire 18 after the winding has progressed to the corner K1 of the surface S3 before the surface S4 where the diagonal hanging is performed (the corner between the surfaces S4 and S3), i.e., after the rectangular wire 18 has contacted the corner K1 but before the rectangular wire 18 has contacted the surface S4. This pressing start timing is called the "pressing start point." It is preferable that the pressing start point be as close as possible to the timing when the rectangular wire 18 contacts the corner K1.

[0045] The split core 12 rotates clockwise from the state shown in Fig. 7A, and diagonal hanging is performed as shown in Fig. 7B. Diagonal hanging is performed by displacing the nozzle 6 upward from the position during winding on the side that is not diagonally hung, under the control of the nozzle displacement mechanism 74 by the control unit 50, so that the angle θ required for diagonal hanging is achieved, while the flat wire 18 is pressed toward the already wound side by the pressing member 34. The pressing member 34 has a shape including a strip-shaped main body 34a extending in the axial direction of the winding shaft 12c and a pressing piece 34b that protrudes in an L-shape from the tip (the bottom end in the figure) of the main body 34a in the radial direction of the winding shaft 12c. The pressing member 34 presses the upper surface of the rectangular wire 18 with a surface 34b-1 on the lower side (the direction in which the main body 34a extends) of the tip of the pressing piece 34b. The "already wound side" refers to the side on which winding has already been performed, and no wound wire exists in the first axial row.

[0046] As shown in Figure 7C, as the rotation of the split core 12 progresses and the flat wire 18 is wound around the corner K2 located at the end of the winding on the surface S4 (the end position of the diagonal winding), the control unit 50 releases the pressure from the pressing member 34 and controls the nozzle 6 to return to the position it was in when the flat wire 18 was wound around the surface without the diagonal winding. When the flat wire 18 is wound around the corner K2, the contact friction with the corner K2 in the bent state makes it difficult for the flat wire 18 to shift in position along the axial direction of the winding shaft 12c. In other words, once the winding around the corner K2 is complete, the corner K2 can be considered to function to prevent the flat wire 18 from shifting in position, similar to when it is pressed, without the pressure of a pressing member such as the pressing member 34.

[0047] Based on this idea, in this embodiment, on the surface S4 where diagonal wrapping is performed and where winding defects are likely to occur, the state in which the rectangular wire 18 is wound around the corner K2 can be replaced by pressing with a pressing member, and the number of pressing members is reduced. When winding on surfaces S1 to S3 other than the surface S4 where diagonal wrapping is performed, the rectangular wire 18 is wound in a horizontal state, so if the displacement control of the nozzle 6 is performed with a certain degree of precision, the problem of misalignment is unlikely to occur. This makes it possible to solve the problem of winding defects even with a configuration in which the wire is held down by only one pressing member 34.

[0048] As the split core 12 rotates and reaches the position where the flat wire 18 is wound around the corner K2, there is no risk of the flat wire 18 becoming misaligned, as described above. Therefore, when the flat wire 18 is wound around the corner K2, the control unit 50 controls the presser member 34 to move slightly axially upward to the wire pressing position P2 to release the pressure and avoid damaging the insulating coating of the flat wire 18. The presser member 34 is then moved radially back to the first retracted position P1. Then, as shown in Figure 7D, with the nozzle 6 positioned for winding on a non-diagonal surface, winding of the wire onto the surfaces S1, S2, and S3 of the reel 12c proceeds as the split core 12 rotates. Surface S3 of the reel 12c is shown in Figure 7D.

[0049] The timing when the rectangular wire 18 is wound around the corner K2 is, more specifically, any timing after the rectangular wire 18 touches the corner K2 during the winding. In this embodiment, this timing is called the "pressure end" because the pressure on the rectangular wire 18 by the pressing member 34 is released at this timing. The pressurizing end is preferably as close as possible to the timing when the rectangular wire 18 touches the corner K2, but it should at least be the timing when the rectangular wire 18 is bent at the corner K2 to such an extent that it is expected that the position of the rectangular wire 18 in the axial direction of the winding shaft 12c will not be displaced due to contact friction with the corner K2 as described above. This pressing end point is the end of the period during which the pressing member 34 holds down the rectangular wire 18 while winding it, in other words, it is the timing at which the pressing by the pressing member 34 that began in the state of Fig. 7A is no longer necessary. Therefore, after passing the pressing end point, the pressing member 34 can retreat to the first retreat position P1.

[0050] Then, before the split core 12 completes one rotation, specifically, before the pressing member 34 reaches the crossover portion 18a of the rectangular wire 18 located between the split core 12 and the nozzle 6 (while moving through the range R1 shown in FIG. 7E), the control unit 50 controls the pressing member 34 to retract by a distance h1 upward in the axial direction of the reel 12c to a second retracted position P4 as shown in FIG. 7D so that the pressing member 34 does not interfere with the crossover portion 18a and can pass through the crossover portion 18a. Furthermore, after the pressing member 34 passes the crossover portion 18a, the control unit 50 controls the pressing member 34 to move to a wire pressing position P3 after one rotation by the time the split core 12 completes one rotation from the state shown in FIG. 7A.

[0051] Specifically, after the pressing member 34 passes through the crossover portion 18a, the control unit 50 lowers the pressing member 34 by a distance h2 slightly shorter than the dimension h1 (see FIG. 8A) to the first retracted position P1 as shown in FIG. 8B while the split core 12 makes one rotation (while the pressing member 34 moves from R2 to R3 in FIG. 7E), or while lowering the pressing member 34, as shown in FIG. 8C, the control unit 50 positions the pressing member 34 at a wire pressing position P2 where there is a small gap g between the pressing member 34 and the top surface of the rectangular wire 18. Thereafter, the control unit 50 further lowers the pressing member 34 to the wire pressing position P3 as shown in FIG. 7B simultaneously with or after the split core 12 makes one rotation, thereby pressing the rectangular wire 18 from the pressing start end in the next winding.

[0052] The second retraction position P4 shown in FIG. 8A is a position where the pressing member 34 is retracted so as not to interfere with the crossover portion 18a, and the first retraction position P1 shown in FIG. 8B is a preparation position for moving the pressing member 34 to the wire pressing position P2. The first layer of the winding is formed by repeating the above-described operation for each rotation of the split core 12. As shown in Fig. 8C, the pressing member 34 is positioned at the wire pressing position P2 where there is a gap g between the pressing member 34 and the wound rectangular wire 18, and then the pressing member 34 is moved downward in the axial direction of the winding shaft 12c to press the rectangular wire 18, thereby making it possible to press the rectangular wire 18 without damaging its insulating coating.

[0053] In the operation pattern described here, when the pressing member 34 is retracted from the wire rod pressing position P3 to the second retraction position P4 where it can pass without interfering with the crossover portion 18a, the pressing member 34 is moved from the wire rod pressing position P2 to the first retraction position P1 and then further moved upward in the axial direction of the reel 12c. However, without retracting the pressing member 34 to the first retraction position P1, it is also possible to simply move the pressing member 34 upward from the wire rod pressing position P2 shown in Fig. 8C to an extent where it can pass without interfering with the crossover portion 18a (it is sufficient to simply retract the pressing member 34 to such a position instead of the second retraction position P4).

[0054] However, with this retraction method, as the winding progresses and the flat wire 18 approaches the yoke piece 12a, there is insufficient space for the retraction of the presser member 34. At that point, the presser member 34 must be retracted to the second retraction position P4. Therefore, from the perspective of standardizing the control amount and simplifying control, the retraction path described above retracts the presser member 34 to the second retraction position P4 for every turn. The second retraction position P4 may also serve as the first retraction position P1. That is, the initial position of the presser member 34 in FIG. 7A may be the second retraction position P4.

[0055] Furthermore, the timing at which the pressure on the flat wire 18 by the pressing member 34 is released does not have to be the same as the timing at which the flat wire 18 is wound around the corner K2. If the pressure on the flat wire 18 is released at a timing later than the timing at which the flat wire 18 is wound around the corner K2, the time available to move the pressing member 34 to the second retracted position P4 before the pressing member 34 reaches the crossing portion 18a of the flat wire 18 will be shortened by the amount of the later timing, but there is no problem as long as this retraction is in time.

[0056] [Rotational synchronization operation pattern (lowering): Figures 9A to 9E] Next, the rotation-synchronized operation pattern during lowering will be described with reference to FIGS. 9A to 9E. 9A to 9E are a series of diagrams showing the winding operation (during winding down) in the rotation synchronous operation pattern by the upper winding device 2A in the winding device 2. During winding down, the rectangular wire 18 is wound from top to bottom in the axial direction of the winding shaft 12c.

[0057] 9A to 9E show the winding operation of the second layer as an example of the operation of the rotation-synchronized operation pattern during winding down. This winding operation differs from the winding operation during winding up explained using Fig. 7A to 7E only in the winding direction, etc., and therefore explanations of parts that overlap with the winding operation during winding up will be omitted as appropriate. 9B, the nozzle 6 is displaced downward from the position of the non-diagonally hung surface during winding so as to have the angle θ required for diagonal hanging under the control of the nozzle displacement mechanism 74 by the control unit 50. Another difference is that the pressing member 34 presses the lower surface of the rectangular wire 18 with the upper surface 34b-2 of the tip of the pressing piece 34b (the surface opposite to that in FIG. 7B).

[0058] [First rotation asynchronous operation pattern (winding): Figures 10A to 10E] Next, the first rotation asynchronous operation pattern during winding will be described with reference to FIGS. 10A to 10E. 10A to 10E are a series of diagrams showing the winding operation (during winding) by the upper winding device 2A in the winding device 2 in the first rotation asynchronous operation pattern. The rotation asynchronous operation pattern described here (including the second rotation asynchronous operation pattern described next) is an operation pattern in which the rotation of the pressing member 34 is not synchronized with the rotation of the main shafts (upper main shaft 8 and lower main shaft 10) in some rotation ranges. 10A to 10E show the winding operation of the first layer as an example of the operation of the first rotation asynchronous operation pattern during winding. Explanation of parts that overlap with the winding operation of the rotation synchronous operation pattern described using FIGS. 7A to 7E will be omitted as appropriate.

[0059] In the first rotation asynchronous operation pattern, the rotation of the pressing member 34 is synchronized with the rotation of the main shaft from the pressing start point in Fig. 10A to the pressing end point in Fig. 10C, as in the rotation synchronous operation pattern. Thereafter, as shown in Fig. 10C, when the winding of the rectangular wire 18 progresses to the corner K2 on the winding end side of the surface S4 and the rectangular wire 18 is wound around the corner K2, the control unit 50 moves the pressing member 34 in the radial direction of the winding shaft 12c so as not to interfere with the rotating split core 12, i.e., so as to be outside the range of the rotation locus of the split core 12, and retracts the pressing member 34 to the first retract position P1.

[0060] The control unit 50 then desynchronizes the rotation of the pressing member 34 with the rotation of the main shaft, rotating the pressing member 34 in the same direction as the rotation of the main shaft at a higher speed than the rotation of the main shaft. The control unit 50 also functions as a means for arbitrarily releasing and restoring the synchronization of the rotation of the pressing member 34 with the rotation of the main shaft. For example, if a motor with a function for detecting its own rotation angle is used, the synchronization can be released and restored arbitrarily. Such a motor may be used as the servo motor 78 for rotating the split core 12.

[0061] Furthermore, the control unit 50 moves the holding member 34 upward in the axial direction of the winding spindle 12c to a second retracted position P4 so that the holding member 34 does not interfere with the transition portion 18a before the holding member 34 reaches the crossover portion 18a of the wire that is located between the split core 12 and the nozzle 6. Next, after the holding member 34 passes the crossover portion 18a, the control unit 50 synchronizes the rotation of the holding member 34 with the rotation of the main shaft, and moves the holding member 34 from the second retracted position P4 downward in the axial direction of the winding spindle 12c, passing through the first retracted position P1 and the wire rod pressing position P2, and then to the wire rod pressing position P3 after the split core 12 has made one rotation.

[0062] In this way, by rotating the pressing member 34 faster than the rotation of the main shaft (rotation of the split core 12), the descent from the second retraction position P4 to the first retraction position P1 shown in Figure 8B can be performed independently of the rotation of the split core 12, thereby shortening the time for the winding operation.

[0063] That is, it takes a certain amount of time to move the pressure member 34 from the second retracted position P4 to the first retracted position P1, and this time is considered to be the rate-limiting factor in the methods shown in Figures 7A to 7E. Therefore, the rotation speed of the split core 12 can only be increased to the extent that the time required for rotation from R2 to R3 in Figure 7E is longer than the time required for the pressure member 34 to move from the second retracted position P4 to the first retracted position P1. However, with the method shown in Figures 10A to 10E, the pressure member 34 can begin to descend to the first retracted position P1 at an earlier timing (rotational phase) than the time at which the pressure member 34 passes through the crossover portion 18a in the example shown in Figures 7A to 7E. Therefore, even if the split core 12 is rotated faster, the time required to move the pressure member 34 from the second retracted position P4 to the first retracted position P1 can be secured, thereby shortening the overall winding operation time.

[0064] As is clear from the above description, the first retracted position P1 is a position where the pressing member 34 does not interfere with the rotating split core 12, and the second retracted position P4 is a position where the pressing member 34 does not interfere with the transition portion 18a and does not interfere with the rotating split core 12. Therefore, the second retracted position P4 may be used instead of the first retracted position P1 as a position where the pressing member 34 does not interfere with the rotating split core 12 (the same applies to the operation patterns described below).

[0065] [First rotation asynchronous operation pattern (lowering): Figures 11A to 11E] Next, the first rotation asynchronous operation pattern during lowering will be described with reference to FIGS. 11A to 11E. 11A to 11E are a series of diagrams showing the winding operation (during winding down) by the upper winding device 2A of the winding device 2 in the first rotation asynchronous operation pattern.

[0066] 11A to 11E show the second layer winding operation as an example of the operation of the first rotation asynchronous operation pattern during winding down. This winding operation differs from the winding operation during winding up explained using FIGS. 10A to 10E only in the winding direction, etc., and therefore explanations of parts that overlap with the winding operation during winding up will be omitted as appropriate. 11B, the nozzle 6 is displaced downward from the position of the non-diagonally hung surface during winding so as to have the angle θ required for diagonal hanging under the control of the nozzle displacement mechanism 74 by the control unit 50. Another difference is that the pressing member 34 presses the lower surface of the rectangular wire 18 with the upper surface 34b-2 of the tip of the pressing piece 34b (the surface opposite to that in FIG. 10B).

[0067] [Second rotation asynchronous operation pattern (winding): Figures 12A to 12E] Next, the second rotation asynchronous operation pattern during winding will be described with reference to FIGS. 12A to 12E. 12A to 12E are a series of diagrams showing the winding operation (during winding) by the upper winding device 2A in the winding device 2 in the second rotation asynchronous operation pattern. 12A to 12E show the winding operation of the first layer as an example of the operation of the second rotation asynchronous operation pattern during winding. Explanation of parts that overlap with the winding operation of the rotation synchronous operation pattern described using FIGS. 7A to 7E will be omitted as appropriate.

[0068] In the second rotation asynchronous operation pattern, the rotation of the pressing member 34 is synchronized with the rotation of the main shaft from the pressing start point in Fig. 12A to the pressing end point in Fig. 12C, as in the rotation synchronous operation pattern. Thereafter, as shown in Fig. 12C, the control unit 50 controls the pressing member 34 to retract to the first retract position P1 (a position that does not interfere with the rotating split core 12) at the timing when the winding of the rectangular wire 18 progresses to the corner K2 on the winding end side of the surface S4 and the rectangular wire 18 is wound around the corner K2, and then controls the pressing member 34 to be out of sync with the rotation of the main shaft and rotate in the direction opposite to the rotation direction of the main shaft.

[0069] The control unit 50 then synchronizes the rotation of the holding member 34 with the rotation of the main shaft again near the downstream side of the transition portion 18a in the rotation direction of the main shaft (synchronization start position R4 in FIG. 12E), and then moves the holding member 34 to the wire pressing position P3 after one rotation of the split core 12. The rotation speed of the holding member 34 in the reverse direction may be any speed that allows the holding member 34 to wait at the synchronization start position before the holding member 34 passes the transition portion 18a, assuming that the rotation of the holding member 34 and the rotation of the main shaft are not lost from synchronization. As long as this condition is satisfied, the rotation speed may be faster, slower, or the same as the rotation of the main shaft (only the rotation direction is different). Because the rotation angle from the first retract position P1 to the transition portion 18a is shorter in the opposite direction (counterclockwise) than in the same direction as the main shaft, the above condition can be satisfied even if the rotation speed is slower than that of the main shaft.

[0070] Specifically, the control unit 50 rotates the pressing member 34 in the direction opposite to the rotation direction of the main shaft, and then synchronizes the rotation of the pressing member 34 with the rotation of the main shaft at a synchronization start position R4. Furthermore, at an appropriate timing after the start of synchronization, the control unit 50 controls the pressing member 34 to move from the first retracted position P1 to the wire pressing position P2, and then to move the pressing member 34 to the wire pressing position P3 after the split core 12 has rotated one revolution.

[0071] In this operation pattern, the rotation of presser member 34 does not interfere with connecting portion 18a, so there is no problem with rotating presser member 34 in the first retracted position P1, as shown in Fig. 12D (surface S3 of reel spindle 12c appears in Fig. 12D). In other words, there is no need to retract presser member 34 to second retracted position P4, as in the examples of Figs. 7A to 7E and 10A to 10E.

[0072] 12E, which corresponds to the rotation from R2 to R3 in Fig. 7E, the pressing member 34 only needs to move a short distance from the first retracted position P1 to the wire pressing position P3 via the wire pressing position P2, so that the movement of the pressing member 34 can be appropriately controlled even if the split core 12 is rotated faster, thereby shortening the time required for the winding operation. However, even if the configuration in which the presser member 34 is retracted to the second retract position P4 in the second rotation asynchronous operation pattern is adopted, the winding itself can be performed without any problems.

[0073] [Second rotation asynchronous operation pattern (lowering): Figures 13A to 13E] Next, the second rotation asynchronous operation pattern during lowering will be described with reference to FIGS. 13A to 13E. 13A to 13E are a series of diagrams showing the winding operation (during winding down) by the upper winding device 2A in the winding device 2 in the second rotation asynchronous operation pattern.

[0074] 13A to 13E show the second layer winding operation as an example of the operation of the second rotation asynchronous operation pattern during winding down. This winding operation differs from the winding operation during winding up described using FIGS. 12A to 12E only in the winding direction, etc., and therefore explanations of parts that overlap with the winding operation during winding up will be omitted as appropriate. 13B, the nozzle 6 is displaced downward from the position of the non-diagonally hung surface during winding so as to have the angle θ required for diagonal hanging under the control of the nozzle displacement mechanism 74 by the control unit 50. Another difference is that the pressing member 34 presses the lower surface of the rectangular wire 18 with the surface 34b-2 of the tip of the pressing piece 34b opposite to that in FIG. 12B (the upper surface in the drawing).

[0075] [Modifications of the second rotation asynchronous operation pattern: Figures 14A to 14H] Next, a modified example of the second rotation asynchronous operation pattern will be described with reference to FIGS. 14A to 14H. 14A to 14H are a series of diagrams showing the winding operation in a modified example of the second rotation asynchronous operation pattern by the upper winding device 2A in the winding device 2. Explanations of parts that overlap with the winding operation of the second rotation asynchronous operation pattern explained using FIGS. 12A to 13E will be omitted as appropriate. 14A to 14H show the winding operation of the Nth layer (winding up) and the N+1th layer (winding down) as an example of the operation of a modified example of the second rotation asynchronous operation pattern. N is a natural number. Figs. 14A to 14E show the winding operation, and Figs. 14F to 14H show the winding operation.

[0076] In this modified example, the operation during winding is the same as in the second rotation asynchronous operation pattern. However, during winding, on the surface S4 where the diagonal hanging is performed, the axial positions of the rectangular wire 18 at the winding start and end are made to differ by a larger amount than the width of the rectangular wire 18, resulting in a winding method with gaps between adjacent rows of the rectangular wire 18 (such a winding method is referred to as a "jump" here), which is different from the second rotation asynchronous operation pattern.

[0077] That is, the operations of Figures 14A to 14E are substantially the same as those of Figures 12A to 12E. The operations of Figures 14F to 14H correspond to those of Figures 13A to 13E, except that in Figure 14F, the downward displacement of the nozzle 6 relative to the position of the non-diagonally wound surfaces S1 to S3 during winding is greater than in Figure 13B. Therefore, the inclination ψ of the rectangular wire 18 is greater than the θ of Figure 13B. Also, as shown in Figure 14H, in the row where the jump occurs, a gap G occurs between adjacent rows of the rectangular wire 18. Even in this case, by performing the diagonal winding while pressing the rectangular wire 18 toward the already wound side with the pressing member 34, it is possible to prevent misalignment of the rectangular wire 18 using only one pressing member 34, as in the second non-synchronous rotation operation pattern, and thus eliminate the problem of poor winding.

[0078] When split cores 12 are assembled in a ring shape in a stator, there is more winding space on the outer diameter side, so if the wire is wound evenly in the axial direction around winding shaft 12c to fit the space on the inner diameter side, wasted space will remain on the outer diameter side. Therefore, by making the above-mentioned jump on the inner diameter side, for example, more wire can be wound on the outer diameter side, allowing for a more flexible winding design.

[0079] Of course, the jump does not have to be performed along the entire axial length, nor does it have to be performed on every layer. The size of the gap between adjacent rows of rectangular wire 18 is arbitrary (for example, it can be 1 or 2 times the width of rectangular wire 18, but is not limited to an integer multiple), and may vary depending on the axial position or layer. The jump may also be performed on the winding side. Furthermore, the above-mentioned jump may be performed in the above-mentioned rotation-synchronous operation pattern or the first rotation-asynchronous operation pattern.

[0080] [Modification of winding device: Figure 15] Next, a modified example of the radial movement mechanism 68 in the upper winding device 2A of the winding device 2 will be described with reference to FIG. Fig. 15 is a front view showing the configuration of a modified example of the radial movement mechanism 68. In Fig. 15, the same reference numerals are used for parts common to the configuration shown in Figs. The radial movement mechanism 68 in the configuration shown in Figures 1 to 4 etc. was configured to move the presser member 34 in the radial direction (front-to-back direction) of the reel 12c using a rack and pinion mechanism, but this modified example is configured using a link mechanism.

[0081] 15, a ring unit 86 is disposed in a fitted state on the upper end side of the presser unit 36. The ring unit 86 has a base ring 88 that is connected to the ball screw mechanism 56 and is movable up and down independently of the presser unit 36, and a radial bearing 90 that is coupled to the base ring 88. A link mechanism 92 that is connected to the radial bearing 90 is provided integrally with the presser unit 36.

[0082] Link mechanism 92 includes a first link 94 connected to radial bearing 90 and an L-shaped second link 98 rotatably supported by shaft 96. One end of second link 98 is connected to first link 94 by cam follower 100 via elongated hole 98a. The other end of second link 98 is connected to slider 106, which is integral with pressing member 104, by cam follower 102 via elongated hole 98b.

[0083] The slider 106 is fitted to a rail member 108 fixed to the lower end of the presser unit 36 ​​to form a linear guide mechanism, and is slidable in the axial direction of the rail member 108. When the movable part 56a of the ball screw mechanism 56 moves downward, the first link 94 is pushed down, causing the pressure member 104 to move radially to the left in the figure, and when the movable part 56a moves upward, the first link 94 is pulled up, causing the pressure member 104 to move radially to the right in the figure. The radial movement mechanism using the link mechanism shown in FIG. 15 can be similarly implemented in the radial movement mechanism 68B of the lower winding device 2B.

[0084] [Regarding the use of the holding member 34 and the holding member 34B: Figures 16A to 16C] Next, with reference to the explanatory diagrams of Figures 16A to 16C, we will explain how the pressing member 34 provided in the upper winding device 2A and the pressing member 34B provided in the lower winding device 2B are alternately used for each layer of wire wound spirally around the winding shaft 12c (when winding up and when winding down). When the pressing member 34 provided on the upper winding device 2A is used, as shown in FIG. 16A, during winding, as explained using FIG. 7B etc., the lower surface 34b-1 of the pressing piece of the pressing member 34 of the upper winding device 2A presses the rectangular wire 18. Therefore, in the case of retraction, which can be achieved by simply moving the pressing member 34 in the axial direction of the reel 12c, interference between the pressing member 34 and the crossover portion 18a can be avoided by simply moving it upward slightly larger than the thickness of the wire, as shown by the two-dot chain line.

[0085] However, during unwinding, as explained using Fig. 9B etc., the upper surface 34b-2 of the pressing piece presses the rectangular wire 18, so even if the pressing member 34 is moved axially downward, the main body 34a interferes with the crossover portion 18a, as shown by the two-dot chain line in Fig. 16B. Therefore, the pressing member 34 needs to be retracted to the second retracted position P4, and the movement path for retraction and return to the pressing position becomes long, and the movement takes time.

[0086] On the other hand, as shown in FIG. 16C, if the pressing member 34B of the lower winding device 2B is used during winding down, interference between the pressing member 34B and the crossover portion 18a can be avoided by simply moving it downward slightly larger than the thickness of the wire, as shown by the two-dot chain line, as in the case shown in FIG. 16A. In this way, by selectively using the presser member 34 of the upper winding device 2A and the presser member 34B of the lower winding device 2B for each layer of wire wound around the winding shaft 12c depending on whether it is winding up or winding down, the retraction movement of each presser member 34, 34B can be kept to the minimum necessary, which ultimately contributes to improving the efficiency of the winding work.

[0087] Furthermore, when winding diagonally, if the wire is wound up at the same angle, a problem occurs in which the wire hits the flange 12d near the top end. In this case, the problem can be solved by reducing the angle of inclination so that the wire does not hit the flange 12d, and by pressing the starting end with the upper pressing member 34 while pushing up the ending end with the lower pressing member 34B. The same applies to winding down. In this way, by using the upper and lower pressing members 34, 34B simultaneously, the difficulty of winding at the top and bottom ends can be alleviated.

[0088] As described above, in this embodiment, the presser member is provided to be rotatable around the axis of the main shaft and movable in the axial and radial directions of the winding shaft, the wire is wound diagonally while being pressed by the presser member toward the already wound side, and the pressure from the presser member is released when the wire is wound around the corner that is the winding end side on the surface where diagonal wrapping is performed. Therefore, even when winding the wire spirally around the winding shaft using diagonal wrapping, poor winding can be prevented with a simple configuration that has one presser member.

[0089] Furthermore, by configuring the presser members to rotate faster by desynchronizing their rotation with the spindle after the pressure is released, the winding time can be shortened. Furthermore, because presser members 34 and 34B can be positioned as desired when they are not pressing the wire, a variety of operating patterns can be achieved with a single presser member. For example, this increases the degree of freedom in terms of whether the presser members rotate in the same direction as the winding shaft or in the opposite direction, and at what speed.

[0090] [Other variations] In addition, while the above embodiment illustrates a twin-configuration winding device 2 including an upper winding device 2A and a lower winding device 2B, a winding device including only one of these may also be used. In addition, in the above embodiment, the rotation of the presser member is synchronized with the rotation of the main shaft by control of the servo motor by the control unit 50. However, if desynchronization is not required, the presser unit may be fixed to the main shaft so that the presser member rotates integrally with the main shaft. Furthermore, while a rectangular wire with a rectangular cross section is used as the wire material, the above-described effects can also be achieved with round wire or wire material with a polygonal cross section other than a rectangular cross section. This effect is particularly significant in the case of rectangular wire, which is prone to misalignment when hung diagonally.

[0091] Furthermore, the target of the winding according to the present invention is not limited to the winding shaft of the split core of the stator as in the above-described embodiment, but may of course be any winding shaft. Furthermore, the shape of the reel is not limited to a rectangular cross section like reel 12c, but may be any polygonal shape. Of course, the angles formed by the surfaces on both sides of a corner do not necessarily have to be right angles. All or part of the side surface of reel 12c may be curved. Regardless of the shape of the side surface of the reel, the same effect as in the above-described embodiment can be achieved as long as the region of the side surface of the reel where the wire is hung diagonally is sandwiched between two corners. The corners may also be somewhat rounded, as long as a frictional force is obtained between the wound wire and the corners that makes it less likely for the wire to shift in the axial direction of the reel.

[0092] Although preferred embodiments of the present invention have been described above, the present invention is not limited to such specific embodiments and various modifications and variations are possible. The configurations of the present invention described above may be implemented by extracting only a portion thereof, and the modifications described in the above description may be applied in any combination as long as they are not mutually contradictory. The effects described in the embodiments of the present invention are merely examples of the effects obtained by the embodiments, and the effects of the present invention are not limited to those described in the embodiments of the present invention. [Explanation of symbols]

[0093] 2 Winding device 2A upper winding device 2B Lower Winding Device 6 nozzles 8, 10 spindle 12 split cores 12c winding shaft 34, 34B Presser member 34a Main body 34b Presser foot 34b-1 Lower surface of the tip of the presser piece 34b-2 Upper surface of the tip of the presser piece 42, 42B Axial movement mechanism 50 control section 52, 52B rotation synchronization mechanism 67, 67B Presser member moving mechanism 68, 68B Radial movement mechanism 74 Nozzle displacement mechanism 80 Spindle drive mechanism K1 Corner where the diagonal hanging starts K2 Corner where the diagonal hanging ends

Claims

1. a winding shaft having two or more corners on a side surface is rotated, and a wire rod is supplied from a wire rod supply port; and the wire rod is helically wound around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a start point and an end point of the winding in the first region; For each rotation of the winding shaft, The diagonal winding is performed in a state where the wire is pressed toward the already wound wire side by a pressing member only at one location near the corner on the winding start end side of the first region, During the diagonal hanging, the pressing member is rotated in synchronization with the rotation of the reel, the pressing member is released after the wire is wound around the corner portion on the winding end side of the first region; Thereafter, the winding method includes a step of moving the pressing member to the vicinity of the corner portion on the winding start end side of the first region before the start of the diagonal winding in the next turn.

2. a winding shaft having two or more corners on a side surface is rotated, and a wire rod is supplied from a wire rod supply port; and the wire rod is helically wound around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a start point and an end point of the winding in the first region; For each rotation of the winding shaft, The diagonal winding is performed while the wire is pressed toward the already wound wire side by a pressing member near a corner on the winding start end side of the first region, During the diagonal hanging, the pressing member is rotated in synchronization with the rotation of the reel, the pressing member is released after the wire is wound around the corner portion on the winding end side of the first region; Thereafter, a step of moving the pressing member to the vicinity of the corner portion on the winding start end side of the first region is performed before the start of the diagonal hanging in the next turn. Even after the pressing by the pressing member is released, the pressing member is rotated in the same direction as the winding shaft, and before the pressing member reaches a crossover portion of the wire rod positioned between the winding shaft and the wire rod supply port, the pressing member is retracted so as not to interfere with the crossover portion, and after the pressing member has passed the crossover portion, the pressing member is moved to a position where it will press the wire rod in the next revolution of the winding shaft, after the presser member has been retracted, the presser member is rotated in the same direction as the rotation of the winding shaft at a speed faster than that of the winding shaft, and after the presser member has passed the connecting portion, the rotation of the presser member and the rotation of the winding shaft are synchronized.

3. a winding shaft having two or more corners on a side surface is rotated, and a wire rod is supplied from a wire rod supply port; and the wire rod is helically wound around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a start point and an end point of the winding in the first region; For each rotation of the winding shaft, The diagonal winding is performed while the wire is pressed toward the already wound wire side by a pressing member near a corner on the winding start end side of the first region, During the diagonal hanging, the pressing member is rotated in synchronization with the rotation of the reel, the pressing member is released after the wire is wound around the corner portion on the winding end side of the first region; Thereafter, a step of moving the pressing member to the vicinity of the corner portion on the winding start end side of the first region is performed before the start of the diagonal hanging in the next turn. the winding method comprising: releasing the pressure from the presser member, retracting the presser member so as not to interfere with the rotating reel; rotating the presser member in a direction opposite to the rotation of the reel; synchronizing the rotation of the presser member with the rotation of the reel near a downstream position of the wire rod crossing portion located between the reel and the wire rod supply port in the rotation direction of the reel; and then moving the presser member to a position where it will press the wire rod during the next revolution of the reel.

4. a winding shaft having two or more corners on a side surface is rotated, and a wire rod is supplied from a wire rod supply port; and the wire rod is helically wound around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a start point and an end point of the winding in the first region; For each rotation of the winding shaft, The diagonal winding is performed while the wire is pressed toward the already wound wire side by a pressing member near a corner on the winding start end side of the first region, During the diagonal hanging, the pressing member is rotated in synchronization with the rotation of the reel, the pressing member is released after the wire is wound around the corner portion on the winding end side of the first region; Thereafter, a step of moving the pressing member to the vicinity of the corner portion on the winding start end side of the first region is performed before the start of the diagonal hanging in the next turn. Even after the pressing by the pressing member is released, the pressing member is rotated in the same direction as the winding shaft, and before the pressing member reaches a crossover portion of the wire rod positioned between the winding shaft and the wire rod supply port, the pressing member is retracted so as not to interfere with the crossover portion, and after the pressing member has passed the crossover portion, the pressing member is moved to a position where it will press the wire rod in the next revolution of the winding shaft, a winding method comprising: arranging two main shafts concentrically facing each other, holding the winding shaft between the two main shafts, providing a presser member corresponding to each of the main shafts, and performing the above-mentioned process for each layer of wire wound spirally around the winding shaft using one of the presser members that has a smaller amount of movement for retraction.

5. A winding device that supplies a wire rod from a wire rod supply port while rotating a winding shaft having two or more corners on a side surface of the winding shaft, and helically winds the wire rod around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a winding start point and a winding end point in the first region, One pressing member; a movement mechanism that moves the pressing member at least in the axial direction of the reel; a rotation mechanism capable of rotating the pressing member in synchronization with the rotation of the reel; and a control unit that controls the movement mechanism and the rotation mechanism so that, for each rotation of the winding shaft, the diagonal wrapping is performed with the presser member pressing the wire toward an already wound wire at only one location near the corner on the winding start side of the first region, the presser member rotates in synchronization with the rotation of the winding shaft during the diagonal wrapping, the pressure by the presser member is released after the wire is wound around the corner on the winding termination side of the first region, and thereafter, the presser member is moved to the vicinity of the corner on the winding start side of the first region before the diagonal wrapping of the next turn begins.

6. A winding device that supplies a wire rod from a wire rod supply port while rotating a winding shaft having two or more corners on a side surface of the winding shaft, and helically winds the wire rod around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a winding start point and a winding end point in the first region, One pressing member; a movement mechanism that moves the pressing member at least in the axial direction of the reel; a rotation mechanism capable of rotating the pressing member in synchronization with the rotation of the reel; a control unit that controls the movement mechanism and the rotation mechanism so that, for each rotation of the winding shaft, the oblique wrapping is performed with the presser member pressing the wire toward an already wound wire side near a corner on the winding start end side of the first region, the presser member rotates in synchronization with the rotation of the winding shaft while the oblique wrapping is being performed, the presser member is released from the pressure after the wire is wound around the corner on the winding end end side of the first region, and thereafter, the presser member is moved to the vicinity of the corner on the winding start end side of the first region before the oblique wrapping of the next turn begins, the control unit controls the moving mechanism and the rotating mechanism to continue rotating the presser member in the same direction as the winding shaft even after the pressing by the presser member is released, to retract the presser member so as not to interfere with a crossover portion of the wire rod positioned between the winding shaft and the wire rod supply port before the presser member reaches the crossover portion, and to move the presser member to a position where it will press the wire rod in the next revolution of the winding shaft after the presser member has passed the crossover portion; the control unit, after retracting the presser member, rotates the presser member in the same direction as the rotation direction of the reel at a speed faster than that of the reel, and controls the movement mechanism and the rotation mechanism so that the rotation of the presser member and the rotation of the reel are synchronized after the presser member has passed the connecting portion.

7. A winding device that supplies a wire rod from a wire rod supply port while rotating a winding shaft having two or more corners on a side surface of the winding shaft, and helically winds the wire rod around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a winding start point and a winding end point in the first region, One pressing member; a movement mechanism that moves the pressing member at least in the axial direction of the reel; a rotation mechanism capable of rotating the pressing member in synchronization with the rotation of the reel; a control unit that controls the movement mechanism and the rotation mechanism so that, for each rotation of the winding shaft, the oblique wrapping is performed with the presser member pressing the wire toward an already wound wire side near a corner on the winding start end side of the first region, the presser member rotates in synchronization with the rotation of the winding shaft while the oblique wrapping is being performed, the presser member is released from the pressure after the wire is wound around the corner on the winding end end side of the first region, and thereafter, the presser member is moved to the vicinity of the corner on the winding start end side of the first region before the oblique wrapping of the next turn begins, the control unit controls the movement mechanism and the rotation mechanism so that, after releasing the pressure from the pressure member, the control unit retracts the pressure member so as not to interfere with the rotating reel, then rotates the pressure member in a direction opposite to the rotation direction of the reel, synchronizes the rotation of the pressure member with the rotation of the reel near a downstream position of the wire rod bridge portion located between the reel and the wire rod supply port in the rotation direction of the reel, and then moves the pressure member to a position where it will press the wire rod during the next revolution of the reel.

8. A winding device that supplies a wire rod from a wire rod supply port while rotating a winding shaft having two or more corners on a side surface of the winding shaft, and helically winds the wire rod around the winding shaft by obliquely winding the wire rod in a first region sandwiched between the two corners on the side surface of the winding shaft such that the axial positions of the wire rod are different at a winding start point and a winding end point in the first region, One pressing member; a movement mechanism that moves the pressing member at least in the axial direction of the reel; a rotation mechanism capable of rotating the pressing member in synchronization with the rotation of the reel; a control unit that controls the movement mechanism and the rotation mechanism so that, for each rotation of the winding shaft, the oblique wrapping is performed with the presser member pressing the wire toward an already wound wire side near a corner on the winding start end side of the first region, the presser member rotates in synchronization with the rotation of the winding shaft while the oblique wrapping is being performed, the presser member is released from the pressure after the wire is wound around the corner on the winding end end side of the first region, and thereafter, the presser member is moved to the vicinity of the corner on the winding start end side of the first region before the oblique wrapping of the next turn begins, the control unit controls the moving mechanism and the rotating mechanism to continue rotating the presser member in the same direction as the winding shaft even after the pressing by the presser member is released, to retract the presser member so as not to interfere with a crossover portion of the wire rod positioned between the winding shaft and the wire rod supply port before the presser member reaches the crossover portion, and to move the presser member to a position where it will press the wire rod in the next revolution of the winding shaft after the presser member has passed the crossover portion; Two main shafts are arranged concentrically opposite each other, and the winding shaft can be held between the two main shafts so as to be sandwiched between them, The presser member is provided corresponding to each of the main shafts, and the moving mechanism and the rotating mechanism are provided corresponding to each of the presser members, the control unit controls the movement mechanism and the rotation mechanism corresponding to each of the pressing members so that, for each layer of wire wound spirally around the winding shaft, the pressing member having the smaller amount of movement for retraction is used to press the wire toward the already-wound side when performing the diagonal winding.

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