Synchronous control device, winding device, and method for manufacturing rotating electric machine

Abstract

A synchronous control device (50) performs control by synchronizing a driven shaft (32) with a main shaft (22). The synchronous control device (50) generates electronic cam data (60) that defines, from the start to the end of driving of the main shaft (22) and the driven shaft (32), a second command value C2 for controlling the position of the driven shaft (32) corresponding to position information of the main shaft (22). A first command value C1 for controlling the main shaft (22) and the second command value C2 for defining the position of the driven shaft (32) corresponding to the position information of the main shaft (22) defined in the first command value are simultaneously commanded to the main shaft and the driven shaft from the start to the end of driving of the main shaft (22) and the driven shaft (32) on the basis of the electronic cam data (60).

Description

Synchronous control device, winding device, and method for manufacturing rotating electric machine

[0001] The present disclosure relates to a synchronous control device, a winding device, and a method for manufacturing a rotating electric machine.

[0002] Conventionally, industrial machinery, such as semiconductor manufacturing equipment and winding machines, has been equipped with a machine tool equipped with multiple slave axes for transporting and machining workpieces. The servo motors driving each slave axis are equipped with a synchronous control device that controls the servo motors so that they operate in synchronization with the position, speed, etc., of the master axis. As a result, the servo motors driving each slave axis operate in a linked manner with a desired operating pattern and timing to execute a series of machining processes. Systems that synchronize and control the slave axes with the master axis in this way are also called synchronous control devices. However, due to delays in the processing and transmission of information for controlling the slave axes in response to the master axis, a phase delay occurs between the operation of the master axis and the slave axis. To suppress this phase delay and accurately synchronize the master axis and the slave axis, for example, the following synchronous control devices have been disclosed.

[0003] That is, in a conventional synchronous control device for a winding machine, a controller is provided with an encoder phase advance unit that advances the phase of an output signal from a synchronous encoder directly connected to a main shaft, which is a rotating shaft on which a winding bobbin is attached, by a set amount. The encoder phase advance unit detects the output signal from the encoder during winding and advances the phase of the output signal from the encoder by the phase delay of the slave shaft. This compensates for the phase delay of the slave shaft that feeds the winding and synchronizes the phases of the main shaft and slave shaft, allowing wire to be wound onto the winding bobbin while accurately aligning the winding (see, for example, Patent Document 1).

[0004] Japanese Patent Application Publication No. 11-334995

[0005] In the control method of Patent Document 1, a phase advance unit is provided within the controller unit, and a phase signal indicating the actual current value of the rotating shaft is detected by an encoder in the winding, and then this phase signal is sent to the phase advance unit within the controller unit.The phase advance unit then sequentially outputs a phase signal of a virtual rotating shaft that is advanced in phase by the aforementioned delay of the traverse shaft based on this phase signal indicating the current value of the rotating shaft.In this way, the traverse shaft is operated based on the phase signal that has been compensated for the aforementioned delay, so the traverse shaft can be accurately moved at the angle of the rotating shaft at which it is desired to operate the traverse shaft.

[0006] However, with this type of control method, a control time is required for the controller to sequentially output a phase signal of the virtual rotary axis after detecting the rotation angle of the rotary axis and before operating the traverse axis. Therefore, if the time it takes for the rotary axis to reach the angle at which the traverse axis is desired to operate becomes shorter than the time it takes for the virtual phase signal of the rotary axis to be sequentially output, the output of the virtual phase signal will not be in time to operate the traverse axis, and the delay cannot be compensated for. This poses a problem in that it is not possible to increase the rotation speed of the rotary axis.

[0007] The present disclosure discloses techniques for solving the above-mentioned problems, and aims to provide a synchronous control device that can speed up synchronous control between a main shaft and a slave shaft, a winding device that can wind wire around an object to be wound at high speed, and a manufacturing method for a rotating electric machine that can manufacture a rotating electric machine at high speed.

[0008] a first command value for controlling the main shaft from the start of driving to the end of driving of the main shaft and the slave shaft, and a second command value for specifying the position of the slave shaft corresponding to the position information of the main shaft specified by the first command value, which is simultaneously issued to the main shaft and the slave shaft based on the electronic cam data; a winding device according to the present disclosure includes the synchronous control device configured as described above, a first drive unit for rotationally driving a real main shaft serving as the main shaft based on the first command value, a nozzle provided on the slave shaft for supplying wire to a winding object provided at the tip of the real main shaft, and a second drive unit for driving the slave shaft based on the second command value to reciprocate the nozzle in the axial direction of the slave shaft. The manufacturing method of a rotating electric machine according to the present disclosure involves using the winding device configured as described above to wind a wire around an iron core that constitutes a stator of the rotating electric machine, which is the object to be wound.

[0009] According to the present disclosure, it is possible to provide a synchronous control device capable of high-speed synchronous control, a winding device capable of winding a wire around an object at high speed, and a manufacturing method for a rotating electric machine capable of manufacturing a rotating electric machine at high speed.

[0010] 8A is a diagram showing a schematic configuration of a winding device according to embodiment 1. FIG. 8B is a block diagram showing a schematic configuration of a synchronous control device provided in the winding device according to embodiment 1. FIG. 8C is a perspective view showing the configuration of the winding device according to embodiment 1. FIG. 8D is a partially enlarged perspective view of the winding device shown in FIG. 3. FIG. 8E is a cross-sectional view including the central axis of the electric motor. FIG. 8F is a top view of the stator of the electric motor as seen from the axial side. FIG. 8G is a top view of a split stator manufactured by the winding device of embodiment 1. FIG. 8A is a top view of the split stator. FIG. 8B is a side view of the split stator. FIG. 8F is a diagram showing an alignment state of wires in slots of the stator. FIG. 8G is a diagram showing an example of winding operation. FIG. 8F is a diagram showing a schematic configuration of a winding device of a comparative example. FIG. 8G is a flow chart showing a control operation of the winding device of the comparative example. FIG. 8H is a flow chart showing an example of a method of generating an electronic cam pattern for the synchronous control device according to embodiment 1. FIG. 8H is a diagram showing an example of an electronic cam pattern. FIG. 8I is a diagram showing a partial section of an electronic cam pattern used by the winding device of embodiment 1. FIG. 8I is a diagram showing an electronic cam pattern used by the winding device of embodiment 1. FIG. 8I is a flow chart showing the control operation of the synchronous control device according to embodiment 1. FIG. 8I is a flow chart showing the control operation of the winding device of the comparative example. FIG. 24A is a flow diagram showing the control operation of a synchronous control device according to embodiment 2. FIG. 25B is a diagram showing an electronic cam pattern used by the winding device of embodiment 2. FIG. 26C is a diagram showing the relationship between the command value of each axis and the current value of each axis in synchronous control in a winding device of a comparative example. FIG. 26D is a diagram showing the relationship between the command value of each axis and the current value of each axis in synchronous control in a winding device of embodiment 3. FIG. 24A and FIG. 24B are diagrams showing electronic cam patterns used by the winding device of the comparative example. FIG. 25A, FIG. 25B, and FIG. 25C are diagrams showing electronic cam patterns used by the winding device of the comparative example. FIG. 26A and FIG. 26B are diagrams showing electronic cam patterns used by the winding device of embodiment 4.

[0011] Embodiment 1. This embodiment relates to a synchronous control device that controls a slave shaft in synchronization with a master shaft, and a winding device that includes this synchronous control device and a winding mechanism and winds a wire around a workpiece. In this embodiment, the workpiece that is the target of the winding device is a segmented core that constitutes an electric motor as a rotating electrical machine. In the drawings, the directions of the annular stator are indicated as the circumferential direction X, the radial direction Y, and the axial direction Z.

[0012] FIG. 1 is a diagram showing a schematic configuration of a winding device 100 according to embodiment 1. FIG. 2 is a block diagram showing a schematic configuration of a synchronous control device 50 provided in the winding device 100 according to embodiment 1. FIG. 3 is a perspective view showing the configuration of the winding device 100 according to embodiment 1. FIG. 4 is a partially enlarged perspective view of the winding device 100 shown in FIG. 3. FIG. 5 is a diagram showing a cross section of an electric motor 5 including the central axis of a rotation shaft, the electric motor 5 being configured using a split stator 3D manufactured by winding a wire using the winding device 100 according to embodiment 1. FIG. 6 is a top view of the stator 3S of the electric motor 5 shown in FIG. 5 as seen from the axial direction Z. FIG. 7 is a top view of the split stator 3D manufactured by the winding device 100 according to embodiment 1 as seen from the axial direction Z.

[0013] First, the configuration of the electric motor 5 will be described with reference to Figures 5 to 7. As shown in Figure 5, the electric motor 5 includes a stator 3S and a rotor 3R rotatably supported by a rotary shaft 4 on the inside of the stator 3S in the radial direction Y. Magnets M that form magnetic poles are embedded on the outside of the rotor 3R in the radial direction Y.

[0014] As shown in Fig. 6, the stator 3S is configured by arranging a plurality of stator segments 3D in an annular shape. As shown in Fig. 7, the stator segment 3D has a core segment 1 as an iron core having a yoke portion 1Y extending in the circumferential direction X and teeth portions 1T extending inward in the radial direction Y from the yoke portion 1Y, and is configured by winding wire W around the teeth portions 1T of the core segment 1.

[0015] The winding device 100 of this embodiment uses this segmented core 1 as the workpiece to be wound, and winds wire W around the teeth 1T of this segmented core 1 to produce a segmented stator 3D as shown in FIG. 7. As shown in FIG. 6, in this embodiment, the annular core 2 that makes up the stator 3S is configured by arranging a plurality of segmented cores 1 in an annular shape. However, this configuration is not limited to this, and the core 2 may also be configured without being segmented. Furthermore, the workpiece around which the winding device 100 winds wire W is not limited to the segmented core 1 that makes up the electric motor 5 as described above, but may be other items.

[0016] Next, the configuration of the winding device 100 of this embodiment will be described. As shown in Fig. 1, the winding device 100 includes a winding mechanism 40 and a synchronous control device 50 that controls the winding mechanism 40. The winding mechanism 40 is a mechanism for winding wire W around the teeth 1T of the core segments 1. The synchronous control device 50 can control two or more drive shafts included in the winding mechanism 40.

[0017] The winding mechanism 40 of this embodiment has a two-shaft configuration including a rotating shaft 22 as a main shaft and a traverse shaft 32 as a slave shaft as drive shafts, and has two units: a spindle unit 20 having the rotating shaft 22, and a nozzle unit 30 having the traverse shaft 32. Note that the rotating shaft 22, which is the main shaft that is the basis of synchronous control, physically exists as shown in FIG. 1, and therefore, hereinafter, it may be referred to as the actual main shaft in the following description.

[0018] The spindle unit 20 includes a rotating shaft 22 which is an actual main shaft, a gripping portion 21 which is provided on the end side of the rotating shaft 22 and grips the split core 1, pulleys 23A and 23B for transmitting rotational power, an encoder portion 24A which detects the rotation angle of the rotating shaft 22, a servo motor 24B which rotationally drives the rotating shaft 22, and a servo amplifier 25 which serves as a first drive portion that drives the servo motor 24B. The rotation angle θ1 of the rotating shaft 22 detected by the encoder portion 24A is fed back to the servo amplifier 25, and the servo amplifier 25 controls the position of the servo motor 24B based on this fed back rotation angle θ1.

[0019] The nozzle unit 30 includes a traverse shaft 32 which is a slave shaft, a nozzle 31A which is provided on the traverse shaft 32 and feeds the wire rod W toward the segmented iron core 1, an encoder unit 34A which detects the rotation angle of the traverse shaft, a servo motor 34B which rotationally drives the traverse shaft 32, and a servo amplifier 35 which serves as a second drive unit which drives the servo motor 34B. The rotation angle θ2 of the traverse shaft 32 detected by the encoder unit 34A is fed back to the servo amplifier 35, and the servo amplifier 35 controls the position of the servo motor 34B based on the fed back rotation angle θ2.

[0020] The nozzle 31A has a through hole through which the traverse shaft 32 is inserted, and a female thread of a ball screw (not shown) is formed on the inner peripheral surface of the through hole. Furthermore, a male thread 31B of a ball screw is formed on the outer peripheral surface of the traverse shaft 32, and this male thread 31B is screwed into the female thread on the inner peripheral surface of the through hole of the nozzle 31A. In this way, a ball screw mechanism is formed by the female thread of the nozzle 31A and the male thread 31B of the traverse shaft 32. As a result, when the traverse shaft 32 is rotated around its axis by the servo motor 34B, the nozzle 31A moves forward and backward in accordance with the rotation direction along the axial direction of the traverse shaft 32, i.e., along the radial direction Y which is the extension direction of the teeth portion 1T.

[0021] 4 shows an enlarged view of the winding mechanism 40 with the gripping portion 21 gripping the core segment 1. When the winding operation by the winding mechanism 40 begins, the rotating shaft 22 is rotated. The gripping portion 21, which is provided on the end side of the rotating shaft 22 and grips the core segment 1, rotates in the direction of arrow D1 via the rotating shaft 22, causing the wire W supplied from the nozzle 31A to be wound around the teeth 1T of the core segment 1.

[0022] When the wire W has been wound around the outer periphery of the tooth 1T for one revolution, the servo motor 34B rotates the traverse shaft 32 so that the nozzle 31A moves in the direction of arrow D2, which is the axial direction of the traverse shaft 32, by the diameter of the wire W so that the wire W does not overlap at the same position in the radial direction Y along which the tooth 1T extends. This winding operation is repeated up to the end of the windable area of ​​the tooth 1T, and when the end of the tooth 1T is reached, the next wire W is placed on top of the wire W that has been wound so far. In other words, the nozzle 31A reciprocates between both ends of the tooth 1T in the radial direction Y along which the tooth 1T extends.

[0023] Next, the alignment of the wire W wound around the teeth 1T will be described. Fig. 8A is a top view showing a split stator 3D configured by winding wire W around the teeth 1T of a split core 1. Fig. 8B is a side view showing a split stator 3D configured by winding wire W around the teeth 1T of a split core 1. Fig. 9 is a diagram showing the alignment of the wire W in the slots SO between the teeth 1T of the stator 3S, and is a diagram showing a cross section perpendicular to the axial direction Z of the stator 3S in Fig. 6. Fig. 9 also shows an enlarged partial view of the inside of the slot SO. Fig. 10 is a diagram for explaining an example of winding operation.

[0024] The center of Figure 10 shows a cross section perpendicular to the radial direction Y of the tooth portion 1T around which the wire W is wound, and the nozzle 31A that rotates around this tooth portion 1T. Note that the winding device 100 of this embodiment is not configured so that the nozzle 31A rotates around the tooth portion 1T as shown in Figure 4, but for the sake of convenience of explanation, the state in which the core segments 1 are fixed and the nozzle 31A rotates is shown.

[0025] 10 shows the upper and lower surfaces of the tooth portion 1T wound with the wire W in the axial direction Z and both side surfaces in the circumferential direction X, along with cross-sectional views of the wire W at the upper, lower, and both side surfaces. Each cross-sectional view shows the movement amount of the nozzle 31A at the upper, lower, and both side surfaces when the wire diameter of the wire W is 1.15d.

[0026] As shown in the center of Fig. 10, the top and bottom surfaces of the tooth portion 1T, which have a length L2 in the circumferential direction X, are defined as short sides, and both side surfaces, which have a length L1, are defined as long sides. In order to wind the wire W at a high density, as shown in Figs. 8A and 10, the wire W coil is crossed in upper and lower layers in the axial direction Z on one side of the tooth portion 1T, in this case the upper short side in the axial direction Z of the tooth portion 1T, and the coil is wound in a bale-like pattern on the other three sides, which is called aligned winding.

[0027] To achieve such aligned winding, it is necessary to move the traverse axis 32 provided with the nozzle 31A in a direction perpendicular to the plane of the paper in Fig. 10, i.e., along the radial direction Y in which the teeth 1T extend, within a certain angular range θc within one rotation of the rotating axis 22, as shown in Fig. 10. This causes the wire W to follow a diagonal path on the upper short side of the teeth 1T in the axial direction Z. The wire in the second layer also follows a diagonal path on the upper short side of the teeth 1T in the axial direction Z, so the first and second layers cross at the upper short side of the teeth 1T in the axial direction Z.

[0028] In addition, even in a configuration of the winding device 100 in this embodiment in which the split core 1 side rotates rather than the nozzle 31A side, the concept of movement of the nozzle 31A within the above-mentioned angle range θc, i.e., on the upper short side in the axial direction Z of the tooth portion 1T, is the same.

[0029] Before describing the control operation of the winding device 100 of the present embodiment, the control operation of a winding device of a comparative example will be described. Fig. 11 is a diagram showing a schematic configuration of the winding device 100REF of the comparative example. Fig. 12 is a flowchart showing the control operation of the winding device 100REF of the comparative example. The winding device 100REF of the comparative example is configured such that, when the rotating shaft 22 reaches the above-mentioned angle range θc, the nozzle 31A is moved to achieve highly accurate aligned winding, and the phase signal of the encoder unit 24A, which detects the rotation angle of the rotating shaft 22, is monitored by the synchronous control device 50REF, as described below.

[0030] The winding device 100REF of the comparative example is configured to input the rotation angle θ1 of the rotary shaft 22 and the rotation angle θ2 of the traverse shaft 32 detected by the encoder units 24A and 34A to the synchronous control device 50REF.

[0031] 12, when the winding device 100 starts winding (step SR1), the synchronous control device 50REF outputs a first command value C1 that specifies the phase of the rotating shaft 22 (step SR2). When the rotating shaft 22 starts rotating in response to the first command value C1 (step SR3), the synchronous control device 50REF monitors the rotation angle θ1 indicated by the phase signal from the encoder unit 24A, which indicates the current position of the rotating shaft 22 (steps SR4 and SR5).

[0032] When the synchronous control device 50REF detects that the rotation shaft 22 is positioned within the aforementioned angle range θc, it outputs a second command value C2 to rotate the traverse shaft 32 to a corresponding position so that the nozzle 31A moves toward the axial center of the traverse shaft 32 (step SR6), and rotates the traverse shaft 32 (step SR7). By repeating this winding operation, the wire W is moved back and forth between the ends of the teeth 1T, and the wire W is wound around the teeth 1T in an aligned winding manner.

[0033] When the desired number of layers of wire W are wound around the tooth portion 1T, the synchronous control device 50REF terminates the rotation of the rotating shaft 22 (step SR8), terminates the rotation of the traverse shaft 32, and completes the winding operation (step SR9).

[0034] As described above, the synchronous control device 50REF of the comparative example uses a control method in which the encoder unit 24A monitors the current value of the rotating shaft 22 during winding, and after the rotating shaft 22 reaches the angle range θc in which the traverse shaft 32 is desired to move, the second command value C2 for moving the traverse shaft 32 is output, thereby starting the operation of the traverse shaft 32. In other words, this is a control method in which the angle of the rotating shaft 22 is monitored before the traverse shaft 32 moves.

[0035] However, with this control method, a control delay occurs between the detection of the rotation angle of the rotary axis 22 and the movement of the traverse axis 32 due to the synchronous control device 50REF, the servo amplifier 35 of the traverse axis 32, the servo motor 34B, etc. Therefore, when the traverse axis 32 starts to move, the rotary axis 22 is already ahead by this delay, and the traverse axis 32 moves with a delay relative to the angle of the rotary axis at which the traverse axis 32 is actually desired to move. In other words, after the synchronous control device 50REF outputs a first command value C1 for the rotary axis 22, it outputs a second command value C2 for the traverse axis 32 based on the rotation angle θ1 indicating the current value of the rotary axis 22 that moved based on this first command value C1. Therefore, the current value of the traverse axis 32 that moves based on the second command value C2 for the traverse axis 32 necessarily lags behind the position of the rotary axis 22 to be moved.

[0036] Even if the synchronous control device 50REF performs phase adjustment to advance the phase of the rotation angle θ1 detected by the encoder unit 24A by a set amount in order to reduce such delay, if the rotation speed of the rotary shaft 22 increases, a control delay occurs due to the phase adjustment itself, and the output of the second command value C2 to the traverse shaft 32 is not in time. Furthermore, the control delay due to the control calculation for the phase adjustment by the synchronous control device 50 may be difficult to predict and adjust. Therefore, the synchronous control device 50REF of the comparative example may not be able to compensate for the delay.

[0037] The control operation of the winding device 100 of this embodiment will be described below. The synchronous control device 50 of this embodiment uses an electronic cam pattern as described below to suppress phase shift between the rotating shaft 22, which is the actual main shaft, and the traverse shaft 32, which is the slave shaft, and to perform winding operations at high speed and with high precision. First, the electronic cam pattern will be described.

[0038] As mentioned above, many industrial machines use synchronous control devices to coordinate the operation of servo motors provided on each axis according to desired operation patterns and timing. Some of these synchronous control devices are equipped with an electronic cam function. The electronic cam function controls the slave axes using an electronic cam pattern so that the servo motors of the slave axes synchronize with the master axis, instead of using a mechanical cam for the master axis. Such synchronous control devices with an electronic cam function enable precise machining by precisely controlling the servo motors of multiple slave axes corresponding to the master axis according to the operation pattern defined by the electronic cam pattern.

[0039] A synchronous control device with an electronic cam function generally controls a servo motor of a slave axis according to an operation pattern that defines values ​​indicating the position, speed, etc. of the slave axis corresponding to multiple target positions of the master axis, which are defined in a time series. To generate such an operation pattern, multiple sections are defined, with one of two target positions adjacent in time among the multiple target positions of the master axis as the start position and the other as the end position. Then, a curve representing the relationship between the position of the master axis and the position of the slave axis is generated for each section. An electronic cam pattern is then generated by connecting the curves for each section. In other words, an electronic cam pattern is a curve that defines values ​​such as the position, speed, and acceleration of the servo motor of the slave axis according to the position of the master axis in order to realize the above-mentioned electronic cam function.

[0040] The synchronous control device 50 of this embodiment uses an electronic cam pattern that generates an electronic cam pattern to control a slave axis, and is configured, for example, as shown in the block diagram of Fig. 2. As shown in Fig. 2, the hardware configuration of the synchronous control device 50 includes a control unit 51C, which is a processor, and a storage device 51M.

[0041] The control unit 51C includes a pattern generation unit 52 that generates an electronic cam pattern as electronic cam data, and a command generation unit 59 that outputs a first command value C1 and a second command value C2 to the servo amplifiers 25, 35 based on the electronic cam pattern. The pattern generation unit 52 includes a section setting unit 53, a function generation unit 54, a natural waveform generation unit 55, and a linking unit 56. The control operations of these units will be described later.

[0042] The storage device 51M includes a volatile storage device such as a random access memory (not shown) and a non-volatile auxiliary storage device such as a flash memory. Alternatively, a hard disk auxiliary storage device may be provided instead of the flash memory. The control unit 51C as a processor executes a program input from the storage device 51M. In this case, the program is input from the auxiliary storage device to the control unit 51C as a processor via the volatile storage device. Furthermore, the control unit 51C as a processor may output data such as calculation results to the volatile storage device of the storage device 51M, or may store the data in the auxiliary storage device via the volatile storage device.

[0043] First, the generation of an electronic cam pattern as electronic cam data by the pattern generation unit 52 of the synchronous control device 50 will be described. Fig. 13 is a flowchart showing an example of a method for generating an electronic cam pattern by the synchronous control device 50 according to embodiment 1. Fig. 14 is a diagram showing an example of an electronic cam pattern. Note that the curved shape of the electronic cam pattern shown in Fig. 14 is such a shape for the convenience of the following description, and differs from the curved shape of the electronic cam pattern actually generated by the pattern generation unit 52.

[0044] First, the interval setting unit 53 of the pattern generation unit 52 sets an interval according to the position of the rotation axis 22, which is the actual main axis (step S1). In step S1, the interval may be set in any manner. For example, if there is a condition defined regarding the relationship between the main axis and the slave axis, the interval setting unit 53 sets the interval according to this condition. One example of a condition defined regarding the relationship between the main axis and the slave axis is one or more positions that must be passed through. Here, the positions that must be passed through are represented, for example, by coordinate values ​​in a two-dimensional coordinate system formed by the main axis position and the slave axis position. In other words, the positions that must be passed through are represented, for example, by coordinate values ​​in an xy plane where the reference position is the origin, the main axis position is represented by x, and the slave axis position is represented by y.

[0045] Here, when four positions to be passed through on this xy plane are set, the section setting unit 53 sets each section so that these four points become the boundaries of the sections. The section setting unit 53 instructs the connection unit 56 on information indicating the set sections. The information indicating the sections is, for example, information indicating the correspondence between the range of spindle positions with the reference position as the origin and the identification information of the sections. For example, when three sections are set, the information indicating the range of each section is information indicating the range of each section, such as section #1 from spindle position 0 to x1, section #2 from spindle position x1 to x2, and section #3 from spindle position x2 to x3, as shown in FIG. 14 .

[0046] Furthermore, the winding device 100 may have a section in which a unique waveform, i.e., a unique function, is defined. For example, a section may be defined in which the slave shaft position operates so as to be directly proportional to the master shaft position. If a section in which a unique waveform is defined exists, the section setting unit 53 sets the section in which the unique waveform is defined as one section.

[0047] After step S1, the interval setting unit 53 instructs the unique waveform generation unit 55 to generate a unique waveform, along with information indicating the interval for generating the unique waveform, and the unique waveform generation unit 55 generates a unique waveform (step S2). The unique waveform generation unit 55 outputs information indicating the generated unique waveform to the connection unit 56, along with identification information indicating the corresponding interval. The information indicated by the unique waveform may be, for example, a calculation formula, or, if it is determined that the unique waveform is represented by a polynomial, may be the order of the polynomial and the coefficients of each order. The information indicating the unique waveform is not limited to these, and may be any information that enables the unique waveform generation unit 55 to generate a unique waveform.

[0048] Furthermore, the section setting unit 53 sets one of the sections for which pattern generation has not been instructed as the section to be processed, outputs boundary conditions for the section to be processed to the function generating unit 54, and instructs the function generating unit 54 to generate a pattern. As the boundary conditions, for example, the position of the slave axis at the start and end positions of the section and the velocity of the slave axis at the start and end positions of the section are determined. The boundary conditions are the position, velocity, acceleration, etc. of the slave axis at each of the start and end positions of the section. Note that the boundary conditions for each section may be input from outside, or may be predetermined and stored in the storage device 51M.

[0049] Here, the "pattern" refers to a function when the slave axis position is expressed as a function with the master axis position as a variable. This function may be, for example, a septenary function or a spline interpolation function. When the function generator 54 receives an instruction to generate a pattern, it calculates the coefficients of the septenary function, spline interpolation, or other function using boundary conditions (step S3). These coefficients are determined so that the acceleration and jerk, or jerk, at the boundaries of the sections are zero. As a result, the electronic cam pattern is interpolated so that the boundaries between the sections are smoothly connected.

[0050] The function generating unit 54 determines a pattern, i.e., a function, using the calculated coefficients (step S4). The function generating unit 54 outputs information indicating the determined pattern to the connecting unit 56 together with identification information indicating the corresponding interval. The information indicating the determined pattern may be, for example, a calculation formula or the coefficients calculated in step S3. The information indicating the determined pattern is not limited to these and may be any information that allows the connecting unit 56 to connect the determined patterns.

[0051] The section setting unit 53 determines whether processing for all sections has been completed, i.e., whether it has instructed the pattern generating unit to generate a pattern or the unique waveform generating unit to generate a unique waveform for all sections (step S5). If processing for all sections has been completed (step S5: YES), the section setting unit 53 terminates the electronic cam pattern generation process. If there is a section for which processing has not been completed (step S5: NO), the section setting unit 53 changes the section to be processed and instructs the function generating unit 54 to generate a pattern, thereby repeating the process from step S3.

[0052] Through the above processing, the connection unit 56 can receive information indicating the pattern of each section and information indicating the inherent waveform. The connection unit 56 generates a series of electronic cam patterns by sequentially connecting the patterns of each section, and outputs the electronic cam patterns to the command generation unit 59. In other words, the pattern of each section is the electronic cam pattern of that section.

[0053] An example of the information indicating the electronic cam pattern is information indicating each section and a calculation formula for the electronic cam pattern for each section. Alternatively, the information indicating the electronic cam pattern may be information indicating each section and an order and coefficient for each section. Note that, although the electronic cam pattern generated by the linking unit 56 is output to the command generating unit 59 here, the electronic cam pattern generated by the linking unit 56 may be stored in the storage device 51M, and the command generating unit 59 may read the electronic cam pattern from the storage device 51M.

[0054] As mentioned above, the electronic cam pattern shown in Fig. 14 is shown as an example to explain the method of generating an electronic cam pattern. Below, an explanation will be given of the electronic cam pattern actually used in the winding device 100 of this embodiment. Fig. 15 is a diagram showing a partial section of the electronic cam pattern 60 used by the winding device 100 of this embodiment. Fig. 16 is a diagram showing the electronic cam pattern 60 used by the winding device 100 of this embodiment.

[0055] The electronic cam pattern shown in FIG. 15 defines a second command value C2 for the traverse shaft 32 corresponding to a first command value C1 as position information for the rotary shaft 22 during one rotation of the rotary shaft 22. The first operating range, which is one rotation cycle of the rotary shaft 22, is defined in degrees from 0° to 360°. Therefore, the first command value C1 as position information for the rotary shaft 22 indicates the angle of the rotary shaft 22 in degrees. However, this is not limited thereto. For example, the first command value C1 as position information may specify an angle in radians or a speed. The second command value C2 for the traverse shaft 32 indicates position information for the traverse shaft 32, and this position information for the traverse shaft 32 corresponds to the winding position in the extension direction of the teeth 1T.

[0056] The electronic cam pattern 60 shown in Fig. 16 is formed by connecting a plurality of electronic cam patterns corresponding to one operation cycle of the rotary shaft 22 shown in Fig. 15. This electronic cam pattern 60 defines a second command value C2 that specifies the position of the traverse axis 32, corresponding to a first command value C1 as position information of the rotary shaft 22, in a synchronous control section from drive start t1 to drive end t3 of the rotary shaft 22 and traverse axis 32. That is, this electronic cam pattern 360 defines a second command value C2 that corresponds to a range exceeding 360° of one operation cycle of the rotary shaft 22.

[0057] In the electronic cam pattern 60, the range of movement of the second command value C2 on the vertical axis corresponds to the winding width between the ends of the teeth portion 1T. The synchronous control device 50 provided in the winding device 100 of this embodiment uses this electronic cam pattern 60 in the winding operation.

[0058] 16 by connecting the electronic cam patterns in the sections of one operation cycle of one rotation of the rotating shaft 22 shown in Fig. 15, the synchronous control device 50 interpolates the boundaries by spline interpolation or the like as described above so that the electronic cam patterns in each section are connected smoothly and continuously at the boundaries of each section. This makes it possible to suppress vibration of the traverse shaft 32 during the winding operation from the drive start t1 of the rotating shaft 22 and the traverse shaft 32 to the drive end t3, thereby enabling highly accurate aligned winding.

[0059] The operation of the synchronous control device 50 of this embodiment, which uses the electronic cam pattern described above, will now be described. Fig. 17 is a flow chart showing the control operation of the synchronous control device 50 according to the first embodiment.

[0060] When control of the synchronous control device 50 is started, the pattern generation unit 52 in the control unit 51C first generates an electronic cam pattern that specifies the position of the traverse axis 32, which is the slave axis, corresponding to the position information of the rotation axis 22, which is the master axis, using the above-mentioned method (step S11).

[0061] When the generation of the electronic cam pattern is completed, the synchronous control device 50 starts the winding operation on the core segments 1 (step S12).

[0062] As described above, the electronic cam pattern of this embodiment defines the second command value C2 for the traverse axis 32, which corresponds to the first command value C1 for the rotation axis 22 from the drive start time t1 to the drive end time t3 of the rotation axis 22 and the traverse axis 32. The command generation unit 59 in the control unit 51C simultaneously outputs the first command value C1 and the second command value C2 based on this electronic cam pattern (step S13).

[0063] The output first command value C1 is input to the servo amplifier 25, and the second command value C2 is input to the servo amplifier 35. The servo amplifier 25, which controls the rotary axis 22, drives the servo motor 24B based on the first command value C1. At the same time, the servo amplifier 35, which controls the traverse axis 32, drives the servo motor 34B based on the second command value C2. In this way, the operations of the rotary axis 22 and the traverse axis 32 start simultaneously (step S14).

[0064] Note that, prior to step S12, before the rotation axis 22 and the traverse axis 32 start to be driven, the synchronization control device 50 may perform adjustment control to position the actual position of the rotation axis 22 at a position corresponding to the position information of the rotation axis 22 defined by the first command value C1 in the electronic cam data, and to position the actual position of the traverse axis 32 at a position of the traverse axis 32 defined by the second command value C2 in the electronic cam data. As a result, for example, if the initial position of the rotation axis 22 defined by the electronic cam data at the start of drive t1 is 0 degrees, the rotation axis 22 is rotated so that the actual position of the rotation axis 22 is 0 degrees. Also, if the initial position of the traverse axis 32 defined by the electronic cam data at the start of drive t1 is defined as "1," for example, the traverse axis 32 is rotated so that the actual position of the traverse axis 32 is positioned at a position corresponding to this "1."

[0065] In this way, when the rotation shaft 22 and the traverse shaft 32 start to be driven, they are already positioned at the initial positions defined by the electronic cam data. Therefore, when the rotation shaft 22 and the traverse shaft 32 are driven, they can follow the positions defined by the electronic cam data without delay, and rotate with high precision without any phase shift between them.

[0066] When the winding operation reaches the drive end time t3, the synchronous control device 50 simultaneously completes the operation of the rotating shaft 22 and the traverse shaft 32 based on the electronic cam pattern, and completes the winding operation of the wire W around the split iron core 1 (steps S15 and S16).

[0067] As described above, the electronic cam pattern used in the winding device 100 of this embodiment is a control method in which all winding operations of the slave axes from the start of drive t1 to the end of drive t3 of the rotating shaft 22 and the traverse shaft 32 are determined before winding begins. Based on this electronic cam pattern in which the second command values ​​for controlling the slave axes are defined in correspondence with the first command values ​​for the main shaft from the start of drive t1 to the end of drive t3 of the rotating shaft 22 and the traverse shaft 32, the first command values ​​for controlling the main shaft and the second command values ​​for controlling the slave axes can be simultaneously output from the start of drive to the end of drive of the main shaft and the slave axes. This ensures that the phases of the command values ​​for the rotating shaft 22 and the traverse shaft 32 are aligned from the start of drive of the rotating shaft 22 and the traverse shaft 32. Thus, even when the rotation speed of the rotating shaft 22 is increased, the command values ​​for the rotating shaft 22 and the traverse shaft 32 can be accurately synchronized, and the current values ​​of the rotating shaft 22 and the traverse shaft 32 can be made to correspond to each other. This makes it possible to achieve high-speed winding even when performing aligned winding, which requires accurate position control of the traverse shaft 32 according to the current position of the rotating shaft 22, and is expected to improve productivity.

[0068] 15, in a control system in which a plurality of electronic cam patterns are provided for each rotation of the rotary shaft 22 and the electronic cam patterns are switched for each 360° rotation of the rotary shaft 22, electronic cam patterns must be generated in units of the total number of turns of the wire W, which makes the program complicated and the number of electronic cam patterns enormous. Therefore, it is not easy to change the model of each device constituting the winding mechanism 40.

[0069] The synchronous control device of this embodiment generates an electronic cam pattern that defines a second command for controlling the slave axis, corresponding to the position information of the main axis from the start to the end of driving of the main axis and the slave axis. Therefore, the synchronous control device does not need to replace the electronic cam pattern with another electronic cam pattern during winding operation, which simplifies the program and also makes it easier to change models because the number of electronic cam patterns to be handled does not become enormous.

[0070] The above description concerns a control method in which the synchronous control device 50 simultaneously outputs a first command value and a second command value from the start of driving the main and slave axes to the end of driving. This control method for simultaneously outputting the first command value and the second command value may, for example, simultaneously output the first command value for each phase of the synchronous control section from the start of driving the main and slave axes to the end of driving, and the second command value that defines the slave axis position corresponding to the main axis position information defined by the first command value for each phase, for each phase, or may simultaneously output the first command value and the second command value for each set period. Alternatively, for example, a control method may be used in which, at the start of driving, the first command value and the second command value for the period from the start of driving to the end of driving are output all at once. That is, it is sufficient that the first command value indicating the position information of the main shaft at each phase from the start to the end of driving of the main shaft and the slave shaft, and the second command value specifying the position of the slave shaft corresponding to the position information of the main shaft specified by this first command value, are simultaneously issued to the main shaft and the slave shaft without any phase delay until the end of driving, and the command values ​​are simultaneously updated.

[0071] Furthermore, the electronic cam pattern generated by the synchronous control device 50 of this embodiment defines the second command value C2 of the traverse axis 32 corresponding to the first command value C1 as position information of the rotary axis 22, but does not define the second command value C2 of the traverse axis 32 corresponding to the time elapsed since the rotary axis 22 started to rotate. In other words, the horizontal axis of the electronic cam pattern 60 is the first command value C1, not the time axis since the rotary axis 22 started to rotate. With this configuration, it becomes possible to accommodate changes in the rotational speed of the spindle, as will be described below.

[0072] Below, we will explain an example of changing the rotation speed of the spindle when the spindle reaches a rotation angle of 180°. More specifically, we will explain the case where the spindle speed is set to 1 from 0 to 180° and to 1 / 2 from 180 to 360°.

[0073] In this case, the first command value C1 of the rotating shaft 22 increases proportionally with a slope such that the rotation angle of the rotating shaft 22 is 0° to 180° during a period from 0 ms to 100 ms on the time axis. Furthermore, the first command value C1 of the rotating shaft 22 increases proportionally with a slope such that the rotation angle of the rotating shaft 22 is 180° to 270° during a period from 100 ms to 200 ms on the time axis. Furthermore, the first command value C1 of the rotating shaft 22 increases proportionally with a slope such that the rotation angle of the rotating shaft 22 is 270° to 360° during a period from 200 ms to 300 ms on the time axis.

[0074] In this way, the slope indicating the amount of change in the first command value C1 for the rotating shaft 22 changes by approximately 180°. Therefore, when the second command value C2 for the traverse axis 32 is defined with respect to the time axis, it is necessary to take into account the change in the slope of the first command value C1 for the rotating shaft 22. Therefore, when it is desired to change the rotation speed of the rotating shaft 22, it becomes necessary to change the electronic cam pattern for the traverse axis 32 as well.

[0075] In this way, the electronic cam pattern 60 of this embodiment defines the second command value C2 of the traverse shaft 32 with respect to the first command value C1 of the rotating shaft 22. Therefore, even when the first command value C1 of the rotating shaft 22 is changed, the second command value C2 of the traverse shaft 32 is defined with respect to the first command value C1 of the rotating shaft 22 whose speed has been changed, so there is no need to change the electronic cam pattern. In this way, even when the speed of the rotating shaft 22 is changed, the control calculation required for the synchronous control device 50 to re-define the position information of the traverse shaft 32 is not required. In this way, regardless of the conditions for changing the speed of the rotating shaft 22, the winding operation can be increased in speed and accurate synchronous control is possible.

[0076] 3 and 4, the winding device does not use a mechanical cam. Therefore, when it is desired to change the operation of the traverse shaft 32, this can be achieved simply by rewriting the electronic cam pattern in the synchronous control device. As such, there is no need to change the machine setup, which also has the effect of making it easy to change the model of the traverse shaft 32.

[0077] Although the above description shows a configuration in which the slave shaft synchronized with the rotating shaft (main shaft) is a single traverse shaft, the present invention is not limited to this, and the winding device may be configured with multiple slave shafts. In this case, the synchronization control device generates an electronic cam pattern as shown in Figure 16 for each slave shaft, and simultaneously outputs a first command value for the main shaft and second command values ​​for the multiple slave shafts based on this electronic cam pattern.

[0078] The winding method to which the control of this embodiment is applied is not limited to the spindle winding method shown in FIG. 4 , but can also be applied to flyer winding, nozzle winding, and other methods. In flyer winding and nozzle winding, the nozzle unit moves in the traverse axis direction while rotating with the spindle unit, winding the coil on the fixed core. In flyer winding, the nozzle axis is wound perpendicular to the spindle axis, as in spindle winding, but in nozzle winding, the nozzle axis is wound parallel to the spindle axis, unlike spindle winding. Thus, by using the synchronous control device of this embodiment, a manufacturing method can be obtained in which wire is wound with high precision around the teeth of the iron core that constitutes the stator of a rotating electric machine, which is the object to be wound. In this way, high-precision rotating electric machines with precisely wound coils can be manufactured at high speed.

[0079] According to the synchronous control device of this embodiment configured as described above, the synchronous control device includes a control unit that controls a slave axis in synchronization with a main axis, wherein the control unit generates electronic cam data that defines a second command value for controlling the position of the slave axis, corresponding to position information of the main axis from the start to the end of driving of the main axis and the slave axis, and based on the electronic cam data, simultaneously commands the main axis and the slave axis to control a first command value for controlling the main axis from the start to the end of driving of the main axis and the slave axis, and the second command value that defines the position of the slave axis corresponding to the position information of the main axis defined by the first command value. This makes it possible to increase the speed of synchronous control, and in a winding device using this synchronous control, high-speed winding can be achieved and model changes can be easily made.

[0080] Furthermore, according to the synchronous control device of this embodiment configured as described above, the control unit performs adjustment control before starting to drive the main axis and the slave axis, such that the actual position of the real main axis is positioned at a position corresponding to the position information of the real main axis defined by the first command value B in the electronic cam data, and the actual position of the slave axis is positioned at the position of the slave axis defined by the second command value in the electronic cam data. This allows the main axis and the slave axis to follow the positions defined in the electronic cam data without delay, and enables precise operation without phase deviation between them.

[0081] Furthermore, according to the synchronous control device of this embodiment configured as described above, the control unit continuously defines the second command value for controlling the slave axis in accordance with a range of the electronic cam data that exceeds a first operating range, which is one operating cycle of the master axis, thereby enabling high-speed synchronous control.

[0082] Furthermore, according to the synchronous control device of this embodiment configured as described above, the control unit divides the electronic cam data into a plurality of synchronous control sections from the start to the end of drive of the master axis and the slave axis, and interpolates the boundaries between the sections so that the electronic cam patterns in the electronic cam data are smoothly connected at the boundaries between the sections. This makes it possible to suppress fluctuations in the command value during synchronous control and achieve highly accurate synchronous control.

[0083] Embodiment 2. Hereinafter, Embodiment 2 of the present invention will be described, focusing on the differences from Embodiment 1 described above, and will also be described in comparison with a winding machine of a comparative example. Portions similar to those of Embodiment 1 described above will be assigned the same reference numerals and description thereof will be omitted. Figure 18 is a flow diagram showing the control operation of the winding device 100REF of the comparative example. Figure 19 is a diagram showing an electronic cam pattern 261 used by the winding device 100 of this embodiment 2. Figure 20 is a flow diagram showing the control operation of the synchronous control device 50 according to Embodiment 2.

[0084] First, the change in the rotational speed of the rotating shaft 22 in the winding device 100REF of the comparative example will be described with reference to Fig. 18. In the winding device 100REF of the comparative example, when changing the speed of the rotating shaft 22, the phase signal indicating the current value of the rotating shaft 22 is monitored (step SR5), the angle at which the speed of the rotating shaft 22 is to be changed is detected, and then a command to change the speed is issued to the rotating shaft 22 (steps SR6A and SR7A).

[0085] Therefore, a control delay occurs due to the synchronous control device 50REF, the servo amplifier 25 of the rotating shaft 22, the servo motor 24B, etc., from the time the angle of the rotating shaft 22 is detected until the speed of the rotating shaft 22 is changed. Therefore, when the speed of the rotating shaft 22 actually changes, the phase of the rotating shaft 22 is already ahead of the angle at which the speed change is to be made by the aforementioned delay period. Thus, in the winding device 100REF of the comparative example, the speed change of the rotating shaft 22 is delayed relative to the angle of the rotating shaft 22 at which the speed change is actually desired.

[0086] Next, the control operation of the synchronous control device 50 of this embodiment will be described. In this embodiment, the synchronous control device 50 sets, as the spindle, a virtual spindle that is virtually controlled and an actual spindle that actually exists. The actual spindle corresponds to the rotation axis 22 that actually exists, as shown in embodiment 1, and the virtual spindle is a virtual axis that the synchronous control device 50 sets in software.

[0087] In the following description, the first command value for controlling the command generation axis, which is the virtual main axis, will be referred to as a first A command value C1V, and the first command value for controlling the rotation axis 22, which is the real main axis, will be referred to as a first B command value C1R.

[0088] 19 , the synchronous control device 50 generates an electronic cam pattern 261 that defines a first B command value C1R, which is position information of the command generating axis relative to the passage of time from the start of drive of the command generating axis and the rotating axis 22 to the end of drive of the command generating axis and the rotating axis 22. At the same time, as in the first embodiment, the synchronous control device 50 generates an electronic cam pattern 60 that defines position information of the traverse axis 32, which is the slave axis, corresponding to the position information of the rotating axis 22, which is the actual master axis (step S211). Note that, although the passage of time (sec) is used here as the position information of the command generating axis, the position information of the command generating axis is not limited to the passage of time as long as the position of the command generating axis can be specified in a program.

[0089] When the winding operation on the segmented core 1 is started (step S12), the command generating unit 59 in the control unit 51C outputs, in phase, i.e., simultaneously, a first A command value C1V for controlling the command generation axis, a first B command value C1R for controlling the rotation axis 22, and a second command value C2 for controlling the traverse axis 32, based on the electronic cam pattern 60 and the electronic cam pattern 261 (step S213).

[0090] The command generating axis starts constant speed operation based on the firstA command value C1V, the rotating axis 22 starts rotation based on the firstB command value C1R, and the traverse axis 32 starts operation based on the second command value C2. In this way, the command generating axis, rotating axis 22, and traverse axis 32 start operating simultaneously (step S214).

[0091] When the winding operation reaches the end of drive, the synchronous control device 50 simultaneously completes the operation of the command generation axis, the rotation axis 22, and the traverse axis 32 based on the electronic cam patterns 60, 261, and completes the winding operation of the wire W around the split iron core 1 (steps S215, S16).

[0092] As described above, the synchronous control device 50 of the second embodiment generates the electronic cam pattern 261 of the first B command value C1R of the rotating shaft 22 for the command generating axis set on software within the synchronous control device 50. By determining the position of the rotating shaft 22 corresponding to the passage of time of the command generating axis before winding in this way, the first B command value C1R of the rotating shaft 22 can be changed at high speed even when the command generating axis is operated at high speed.

[0093] In this way, even when changing the speed of the rotating shaft 22, the angle at which the speed of the rotating shaft 22 should be changed is not detected during the winding, and no operation change command for the rotating shaft 22 is issued during the winding. When the winding operation is started, signals for the respective command values ​​of the first A command value C1V of the command generating axis, the first B command value C1R of the rotating shaft 22, and the second command value C2 of the traverse axis 32 are output simultaneously.

[0094] As described above, the rotating axis 22 is synchronously controlled with respect to the command generating axis, and the traverse axis 32 is synchronously controlled with respect to this synchronously controlled rotating axis 22. This aligns the phases of the command values ​​of the command generating axis and the rotating axis 22 from the start of winding, reducing control delays and enabling accurate synchronization of the command values ​​of the command generating axis and the rotating axis 22. In this way, the second command value C2 of the traverse axis 32 can also operate in accurate synchronization with the first B command value C1R of the rotating axis 22, regardless of the conditions for changing the speed of the first B command value C1R of the rotating axis 22.

[0095] Furthermore, when generating the electronic cam pattern 261, the synchronous control device 50 interpolates the boundaries by spline interpolation or the like as described above so that the electronic cam patterns in each section are smoothly connected at the boundaries of each section. This makes it possible to suppress vibration of the rotating shaft 22 during the winding operation from the start to the end of driving of the rotating shaft 22 and the traverse shaft 32, thereby enabling highly accurate aligned winding.

[0096] Next, a control operation of the synchronous control device 50 of this embodiment, which is different from the above, will be described. Fig. 21 is a diagram showing an electronic cam pattern 260 used by the winding device 100 of this embodiment. The synchronous control device 50 generates electronic cam data that defines a second command value C2 for the traverse axis 32, which corresponds to the passage of time as position information of the command generating axis from the start of driving of the traverse axis 32, which is the command generating axis and the slave axis, to the end of driving of the traverse axis 32.

[0097] That is, this is a synchronization control method in which the horizontal axis of the electronic cam pattern for the rotating axis 22 represents the passage of time as position information of the command generating axis shown in Figure 19 above, and the horizontal axis of the electronic cam pattern for the traverse axis 32 also represents the passage of time as position information of the command generating axis. In this way, the operation of the rotating axis 22 during winding of the first B command value C1R relative to the command generating axis, and the operation of the traverse axis 32 during winding of the second command value C2 relative to the command generating axis are defined in advance in electronic cam patterns 261 and 260, respectively. Then, the rotating axis 22 is synchronously controlled with respect to the command generating axis, and the traverse axis 32 is synchronously controlled with respect to the command generating axis.

[0098] This allows accurate speed changes to be made to the first B command value C1R of the rotating axis 22. Furthermore, by defining the second command value C2 of the traverse axis 32 with respect to the passage of time of the command generating axis, the command values ​​of the rotating axis 22 and the traverse axis 32 can be accurately synchronized with the command generating axis, regardless of the speed change conditions of the command generating axis.

[0099] Embodiment 3. Hereinafter, embodiment 3 of the present application will be described with reference to the drawings, focusing on the differences from embodiment 1 above. Portions similar to embodiment 1 above will be assigned the same reference numerals and description thereof will be omitted. Fig. 22 is a diagram showing the relationship between the command value of each axis and each actual current value under synchronous control in winding device 100REF of the comparative example. Fig. 23 is a diagram showing the relationship between the command value of each axis and each actual current value under synchronous control in winding device 100 of this embodiment.

[0100] The first B command value C1R for the rotating axis 22 and the second command value C2 for the traverse axis 32 are output simultaneously by the aforementioned synchronization control. However, the relationship between the first B command value C1R for the rotating axis 22 and the current value of the rotating axis 22, and the relationship between the second command value C2 for the traverse axis 32 and the current value of the traverse axis 32, is subject to a control delay due to dead time and response time constants of the servo amplifiers 25, 35 and the synchronization control device 50. Therefore, when the rotation speed of the rotating axis 22 increases, as shown in Figure 22, a time lag occurs between the position P2 of the rotating axis 22 relative to the first B command value C1R and the position P3 of the traverse axis 32 relative to the second command value C2, and the loci of the phase signals for the respective current values ​​do not overlap.

[0101] In this embodiment, the synchronous control device 50 adjusts at least one of the first servo gain, which adjusts the control parameters for driving the servo motor 24B, and the second servo gain, which adjusts the control parameters for driving the servo motor 34B, so as to reduce the difference between the first delay period T1, which indicates the delay period until the operational response of the rotating axis 22 to the firstB command value C1R, and the second delay period T2, which indicates the delay period until the operational response of the traverse axis 32 to the second command value C2.

[0102] In this way, by adjusting the servo gain, the difference between the command value and the current value of the traverse axis 32 or the rotating axis 22 can be adjusted to correspond to the difference between the command value and the current value of the rotating axis 22 or the traverse axis 32. In this way, the trajectories of the current values ​​of the rotating axis 22 and the traverse axis 32 overlap, making it possible to achieve accurate aligned winding even at high speeds. In this way, as shown in FIG. 23 , the difference T1 between the firstB command value C1R and the current value of the rotating axis 22, and the difference T2 between the second command value C2 and the current value of the traverse axis 32 are adjusted. This allows the current value of the traverse axis 32 to accurately operate the traverse axis 32 at the angle at which you want to operate the traverse axis 32 at the current value of the rotating axis 22. In other words, aligned winding can be achieved at high speed and with high precision.

[0103] Fourth Embodiment Hereinafter, the fourth embodiment will be described with reference to the drawings, focusing on the differences from the second embodiment. First, the electronic cam pattern used by the winding device of the comparative example will be described. Figures 24A and 24B are diagrams showing the electronic cam pattern used by the winding device of the comparative example. Figures 25A, 25B, and 25C are diagrams showing the electronic cam pattern used by the winding device of the comparative example.

[0104] When winding wire around the teeth of the segmented core, which is the object to be wound, the nozzle is turned back when the winding of the wire reaches the end of the tooth, and at the "layer change point" where the next layer of wire begins to be wound on top of the wound wire, the driving direction of the traverse shaft is reversed before and after the turn point. It is known that the nozzle movement distance becomes large at this layer change point. This is because the wire is smaller than the nozzle hole diameter.

[0105] When the traverse shaft is driven in a fixed direction, i.e., when the nozzle is moving in a fixed direction, the wire is shifted in the opposite direction to the nozzle movement. Therefore, when the driving direction of the traverse shaft is reversed at the layer change point and the nozzle is moved in the opposite direction, the wire is not moved by the amount equal to the difference between the nozzle hole diameter and the diameter of the wire. Therefore, in order to move the wire in the direction of the nozzle turn back at the layer change point, the nozzle movement amount must be greater than the nozzle movement amount at other than the layer change point.

[0106] However, when the rotating axis is operated at a constant speed, the required acceleration of the traverse axis increases at layer-changing points where the amount of movement of the traverse axis increases, which may exceed the limit torque of the motor that drives the traverse axis. Therefore, in order to achieve synchronous control of the rotating axis and the traverse axis, it is necessary to reduce the speed of the rotating axis and reduce the required torque of the traverse axis.

[0107] The fourth embodiment is intended to solve the above-mentioned problems and is realized using the synchronous control device 50 shown in the second embodiment. FIG. 19 of the second embodiment shows an example of an electronic cam pattern configured so that the first-B command value C1R operates in proportion to the command generation axis. In the fourth embodiment, control is also performed based on electronic cam data such as the comparative example in FIG. 24A , in which the first-B command value C1R operates in proportion to such a command generation axis. Consider a case in which the second command C2, which is a command for the traverse axis 32, is operated using electronic cam data with the command generation axis as the horizontal axis, as shown in FIG. 24B . As shown in FIG. 24B , section S is a layer-switching operation period, during which the amount of operation is large.

[0108] If an attempt is made to synchronize the rotating axis and the traverse axis in section S, the torque required by the traverse axis motor will increase. For this reason, it is considered to decelerate the rotating axis in section S and operate it at high speed outside of section S. FIG. 25A shows an example in which the command generating axis is decelerated in section S in a winding device of a comparative example. In this comparative example, the command generating axis is decelerated, and the rotating axis and the traverse axis are operated using electronic cam data that takes this command generating axis as the horizontal axis. In this case, if the horizontal axis is taken as time, as shown in FIGS. 25B and 25C, the rotating axis and the traverse axis will take operating trajectories that are as if section S were elongated, and the torque required by the traverse axis will be reduced.

[0109] Next, the control of the winding device of this embodiment will be described. In this embodiment, a method of expressing deceleration based on the electronic cam data shown in Fig. 24A described above is used. Fig. 26A is a diagram showing an electronic cam pattern used by the winding device of this embodiment 4, with the horizontal axis showing position information of the command generation axis and the vertical axis showing the 1B command value C1R that controls the rotation axis 22, which is the actual spindle.

[0110] The winding device of this embodiment reduces the tilt only in the first position range (section S') set in the position information of the command generating axis, which is the section where deceleration is desired, and decelerates the rotating shaft 22 in this section S'. In this case, the command generating axis may be controlled so that it has a constant tilt with respect to time.

[0111] In this case, it is easier to consider controlling the traverse axis 32 using electronic cam data in which the horizontal axis, as shown in Fig. 26B, is the first B command value C1R, as was also used in the first embodiment. This is because the traverse axis 32 needs to be synchronized with the angle of the rotation axis 22, and if the horizontal axis is used as the command generation axis, the electronic cam data needs to take into account the acceleration and deceleration of the electronic cam data for the rotation axis 22. However, this is not a necessary limitation, and control is also possible even if the horizontal axis is used as the position information for the command generation axis.

[0112] At this time, the section S' shown in Fig. 26A where the rotation axis 22 decelerates is the "layer change point" as shown in Fig. 26B. That is, the section S' in the position information of the command generation axis is set to correspond to the position where the drive direction of the traverse axis 32 is reversed in the first B command value C1R that controls the rotation axis 22.

[0113] 10, in winding the wire W, it is necessary to move the traverse shaft 32 provided with the nozzle 31A in a direction perpendicular to the paper surface of Fig. 10, i.e., along the radial direction Y in which the teeth portion 1T extends, within a certain angle range θc within one rotation of the rotary shaft 22. Therefore, in the section S', an initial value I1 indicating the start point of the section S and a target value I2 indicating the end point are given for the firstB command value C1R and the second command value C2, and control is performed based on electronic cam data interpolated between the initial value I1 and the target value I2.

[0114] In the winding device of this embodiment, as shown in FIG. 26A, electronic cam data is used in which the slope indicating the amount of change in the position information of the 1B command value C1R, which corresponds to the amount of change in the position information of the virtual main shaft, is set smaller within section S' than the slope outside this section S'.

[0115] For ease of understanding, this embodiment shows an example in which linear interpolation is performed between the initial value and the target value in the section S' as shown in Figures 26A and 26B, resulting in discontinuous spatial differentiation of the second command value C2 with respect to the position of the command generation axis. However, in this case, the torque input to the servo motor becomes discontinuous and a step input, which is likely to cause vibration. Therefore, instead of linear interpolation, the initial value and the target value in the section S' may be interpolated using a modified sine curve or modified trapezoidal curve used in mechanical cams, or an interpolation function such as a spline function. In other words, the electronic cam pattern is interpolated into a continuous curve that is differentiable at the boundary between the section S' and the range outside of this section S'. This makes the torque input to the servo motor continuous, thereby suppressing vibration.

[0116] In the above example, the section S' in which the slope is reduced is provided in only one location between the start and end of drive of the virtual spindle and the real spindle, but it may be provided in multiple locations. Also in this embodiment, the elapsed time (sec) is used as the position information of the command generating axis, but the position information of the command generating axis is not limited to the elapsed time as long as the position of the command generating axis can be specified on the program.

[0117] In the synchronous control device of this embodiment configured as described above, in the electronic cam data, a gradient indicating the amount of change in the position information of the first B command value, corresponding to the amount of change in the position information of the virtual spindle, is set to be smaller within a first position range set in the position information of the virtual spindle than the gradient in a range outside the first range. In this way, by providing a first position range in which the gradient indicating the amount of change in the position information of the real spindle, corresponding to the amount of change in the position information of the virtual spindle, i.e., the speed of the real spindle, is decelerated from the start to the end of driving of the virtual spindle and the real spindle, the required torque can be reduced and the wire can be made to follow the moving direction of the nozzle with high accuracy, thereby improving winding accuracy.

[0118] In the synchronous control device of this embodiment configured as described above, the first position range of the virtual master axis is set to correspond to a position where the drive direction of the slave axis is reversed in accordance with the first command value B. This reduces the required torque and improves winding accuracy by allowing the wire to accurately follow the nozzle movement direction at a nozzle turning point where positional deviation is particularly likely to occur.

[0119] Although various exemplary embodiments and examples are described in this disclosure, the various features, aspects, and functions described in one or more embodiments are not limited to the application of a particular embodiment, but may be applied to the embodiments alone or in various combinations. Therefore, countless variations not illustrated are anticipated within the scope of the technology disclosed in this specification. For example, this includes cases where at least one component is modified, added, or omitted, or where at least one component is extracted and combined with components of another embodiment.

[0120] Various aspects of the present disclosure are summarized below as appendices.

[0121] (Supplementary Note 1) A synchronous control device including a control unit that controls a slave axis in synchronization with a main axis, wherein the control unit generates electronic cam data that defines second command values ​​for controlling the position of the slave axis, corresponding to position information of the main axis from the start to the end of driving of the main axis and the slave axis, and based on the electronic cam data, simultaneously commands the main axis and the slave axis to a first command value for controlling the main axis from the start to the end of driving of the main axis and the slave axis, and the second command value that defines the position of the slave axis corresponding to the position information of the main axis defined by the first command value. (Supplementary Note 2) The synchronous control device according to Supplementary Note 1, wherein the control unit continuously defines the second command values ​​for controlling the slave axis in the electronic cam data, corresponding to a range that exceeds a first operating range that is one operating cycle of the main axis. (Supplementary Note 3) The synchronization control device according to Supplementary Note 2, wherein the control unit sets a virtually controlled virtual spindle and an actual spindle as the spindles, defines in the electronic cam data a first B command value for controlling the actual spindle as the first command value corresponding to the passage of time of the virtual spindle as the position information of the spindles from the start of driving of the virtual spindle and the actual spindle to the end of driving, and simultaneously issues a first A command value for controlling the virtual spindle as the first command value and the first B command value for controlling the actual spindle based on the electronic cam data. (Supplementary Note 4) The synchronization control device according to Supplementary Note 3, wherein the control unit positions the actual position of the real spindle at a position corresponding to the position information of the real spindle specified by the first B command value in the electronic cam data, and performs adjustment control to position the actual position of the slave axis at the position of the slave axis specified by the second command value in the electronic cam data before driving of the main spindle and the slave axis starts. (Supplementary Note 5) The synchronization control device according to Supplementary Note 4, wherein the control unit defines, in the electronic cam data, the second command value of the slave axis corresponding to the first B command value controlling the real main axis as the position information of the main axis. (Supplementary Note 6) The synchronization control device according to Supplementary Note 4, wherein the control unit defines, in the electronic cam data, the second command value of the slave axis corresponding to the elapsed time of the virtual main axis as the position information of the main axis.(Supplementary Note 7) The synchronization control device according to any one of Supplementary Notes 3 to 6, wherein the control unit divides the electronic cam data into a synchronization control section from the start to the end of driving of the main axis and the slave axes into a plurality of sections, and interpolates the boundaries of the electronic cam data so that the boundaries between the sections are smoothly connected. (Supplementary Note 8) The synchronization control device according to any one of Supplementary Notes 3 to 7, comprising a plurality of slave axes, and wherein the control unit defines, for each of the slave axes, in the electronic cam data the second command value for controlling the plurality of slave axes, which corresponds to the position information of the main axis from the start to the end of driving of the main axis and the plurality of slave axes. (Supplementary Note 9) The synchronous control device according to any one of Supplementary Notes 3 to 8, wherein the control unit adjusts at least one of a first servo gain for adjusting a control parameter for driving the actual main spindle and a second servo gain for adjusting a control parameter for driving the slave axis so as to reduce a difference between a first delay period indicating a delay period until the operational response of the real main spindle to the first command value B and a second delay period indicating a delay period until the operational response of the slave axis to the second command value B. (Supplementary Note 10) The synchronous control device according to any one of Supplementary Notes 2 to 9, wherein the control unit defines the first operating range as an angle range from 0 to 360 degrees, and defines the second command value for controlling the slave axis in the electronic cam data continuously in an angle range exceeding 360 degrees of the first operating range of the main spindle. (Supplementary Note 11) The synchronous control device according to any one of Supplementary Note 3 to Supplementary Note 10, wherein the control unit simultaneously outputs, based on the electronic cam data, a first command value for controlling the main spindle and the second command value for defining the position of the slave spindle corresponding to the position information of the main spindle defined by the first command value at every set period in a synchronous control section from the start of driving of the main spindle and the slave spindle to the end of driving, or outputs, at the start of driving of the main spindle and the slave spindle, the first command value and the second command value in the synchronous control section from the end of driving at once.(Supplementary Note 12) A winding device comprising: a synchronous control device according to any one of Supplementary Note 3 to Supplementary Note 9; a first drive unit that rotationally drives the actual main shaft based on the first command value B; a nozzle that is provided on the slave shaft and supplies wire to a workpiece that is provided at the tip of the actual main shaft; and a second drive unit that drives the slave shaft based on the second command value to reciprocate the nozzle in an axial direction of the slave shaft.

[0122] 22 Rotating axis (main shaft, actual main shaft), 25 Servo amplifier (first drive unit), 31A Nozzle, 32 Traverse axis (slave shaft), 35 Servo amplifier (second drive unit), 50 Synchronous control device, 51C Control unit, 60, 260, 261 Electronic cam pattern (electronic cam data), 100 Winding device.

Claims

1. A synchronous control device equipped with a control unit that synchronizes and controls a driven shaft with a main shaft, The control unit generates electronic cam data that defines a second command value for controlling the position of the follower shaft, corresponding to preset position information of the main shaft from the start to the end of the drive of the main shaft and the follower shaft. Based on the electronic cam data, a first command value for controlling the spindle and a second command value for defining the position of the drive shaft corresponding to the position information of the spindle defined in the first command value are simultaneously commanded to the spindle and the drive shaft from the start to the end of the drive of the spindle and the drive shaft. Synchronization control device.

2. The control unit, In the electronic cam data, the second command value for controlling the driven axis is continuously defined to correspond to a range exceeding the first operating range, which is one cycle of the operation of the main axis. The synchronous control device according to claim 1.

3. The control unit, As the aforementioned spindles, a virtual spindle that is virtually controlled and an actual spindle are set, In the electronic cam data, a first B command value is defined as the first command value that controls the actual spindle, corresponding to the position information of the virtual spindle from the start to the end of the drive of the virtual spindle and the actual spindle. Based on the electronic cam data, a first command value, a first A command value for controlling the virtual spindle and a first B command value for controlling the actual spindle are simultaneously commanded. The synchronous control device according to claim 2.

4. In the aforementioned electronic cam data, The slope indicating the change in position information of the 1B command value, which corresponds to the change in position information of the virtual principal axis, is set to be smaller within the set first position range of the virtual principal axis position information than the slope outside the first range. The synchronous control device according to claim 3.

5. The control unit, In the aforementioned electronic cam data, The electronic cam pattern, which represents the change in the position information of the 1B command value corresponding to the change in the position information of the virtual principal axis, is interpolated into a continuous curve that is differentiable at the boundary between the first position range and the range outside the first position range. The synchronous control device according to claim 4.

6. The control unit positions the actual position of the actual spindle at a position corresponding to the position information of the actual spindle defined in the 1B command value in the electronic cam data, Before the start of driving of the main shaft and the subordinate shaft, adjustment control is performed to position the subordinate shaft at the position specified in the second command value in the electronic cam data. The synchronous control device according to claim 3.

7. The control unit, In the aforementioned electronic cam data, The second command value of the slave axis is defined, which corresponds to the first command value of the actual principal axis, which is the position information of the principal axis. The synchronous control device according to claim 3.

8. The control unit, In the aforementioned electronic cam data, The second command value of the subordinate axis is defined, which corresponds to the time progression of the virtual principal axis as position information of the principal axis. The synchronous control device according to claim 3.

9. The control unit, The electronic cam data is divided into multiple sections, from the start to the end of the drive of the main spindle and the drive shaft, and the boundaries are interpolated so that the electronic cam patterns in the electronic cam data are smoothly connected at the boundaries of each section. The synchronous control device according to claim 3.

10. Equipped with multiple aforementioned follower shafts, The control unit defines a second command value in the electronic cam data for each of the multiple follower shafts, corresponding to the position information of the main shaft from the start to the end of the drive of the main shaft and the multiple follower shafts. The synchronous control device according to claim 3.

11. The control unit, A first delay period indicating the delay period from the command value of the 1B to the actual spindle's operational response, The first servo gain adjusts the control parameters for driving the actual spindle, and the second servo gain adjusts the control parameters for driving the drive shaft, such that the difference between the second delay period, which indicates the delay period from the second command value to the operation response of the drive shaft, becomes small. The synchronous control device according to claim 3.

12. The control unit, The first operating range is defined as an angular range from 0 degrees to 360 degrees, In the electronic cam data, the second command value for controlling the subordinate axis is defined continuously over an angular range exceeding 360 degrees of the first operating range of the main axis. The synchronous control device according to claim 2.

13. The control unit, Based on the electronic cam data, a first command value for controlling the spindle and a second command value for defining the position of the drive shaft corresponding to the position information of the spindle defined in the first command value are output simultaneously at set intervals during the synchronous control section from the start to the end of the drive of the spindle and the drive shaft, or At the start of driving the main shaft and the drive shaft, the first command value and the second command value for the synchronous control section until the end of driving are output simultaneously. The synchronous control device according to claim 1.

14. The first position range of the virtual principal axis is set to correspond to the position in which the driving direction of the subordinate axis is reversed in the first B command value. The synchronous control device according to claim 4.

15. A synchronous control device according to any one of claims 1 to 14, A first drive unit that rotates the actual spindle, which is the spindle, based on the first command value, A nozzle provided on the trailing shaft and located at the tip of the main shaft for supplying wire material to the winding object, The system includes a second drive unit that drives the drive shaft based on the second command value to cause the nozzle to reciprocate in the axial direction of the drive shaft. Winding device.

16. A method for manufacturing a rotating electric machine, comprising winding a wire around an iron core constituting the stator of the rotating electric machine, which is the object to be wound, using the winding device described in claim 15.

17. A synchronous control device comprising a control unit for synchronizing and controlling a driven shaft with a main shaft, The control unit generates electronic cam data that defines a second command value for controlling the position of the follower shaft, corresponding to the position information of the main shaft, from the start to the end of the drive of the main shaft and the follower shaft. Based on the electronic cam data, a first command value for controlling the spindle and a second command value for defining the position of the drive shaft corresponding to the position information of the spindle defined in the first command value are simultaneously commanded to the spindle and the drive shaft from the start to the end of the drive of the spindle and the drive shaft. The control unit further, As the aforementioned spindles, a virtual spindle that is virtually controlled and an actual spindle are set, In the electronic cam data, a first B command value is defined as the first command value that controls the actual spindle, corresponding to the position information of the virtual spindle from the start to the end of the drive of the virtual spindle and the actual spindle. Based on the electronic cam data, a first command value, a first A command value for controlling the virtual spindle and a first B command value for controlling the actual spindle are simultaneously commanded. Synchronization control device.