Winding device and winding method

Abstract

A winding device (100) winds, onto a winding core (30), a wire (1) delivered from a nozzle (24), the winding device comprising: the nozzle (24) that delivers the wire (1) from a tip part (24a); the winding core (30) that has a winding body (31) around which the wire (1) delivered from the nozzle (24) is wound, and that has a first flange (32) provided on one end side of the winding body (31); and a control unit (50) that controls the rotation of one of the nozzle (24) and the winding core (30) which serve as a member to be rotated. The control unit (50) calculates, on the basis of a gap length (L1) between the wire (1) and the first flange (32), a required rotation angle of the member to be rotated, the gap length being measured during the winding of the wire (1) around the winding body (31) toward the first flange (32). The control unit (50) causes the member to be rotated to rotate by the required rotation angle.

Description

Winding device and winding method

[0001] The present invention relates to a winding device and a winding method.

[0002] JP2010-183041A discloses a winding device that winds a wire rod fed from a nozzle onto a winding core.

[0003] In the winding device described in JP2010-183041A, winding is performed so that the overall length of the coil is constant by reducing the effect of shape errors of the wire on the overall length of the coil. However, if there is a large manufacturing error in the winding core around which the wire is wound and there is variation in the distance between the flanges, if winding is performed so that the overall length of the coil is a target length, when winding is performed around a winding core where the distance between the flanges is shorter than the target length, the new wire will run up on the already wound wire near the flanges, and when winding is performed around a winding core where the distance between the flanges is longer than the target length, a gap will be created near the flanges, which could result in a decrease in winding accuracy around the winding core.

[0004] An object of the present invention is to improve the winding accuracy on the winding core.

[0005] According to one aspect of the present invention, a winding device that winds a wire rod unwound from a nozzle onto a winding core includes a nozzle that unwinds the wire rod from its tip, a winding drum around which the wire rod unwound from the nozzle is wound, and a winding core having a flange provided on one end of the winding drum, and a control unit that controls the rotation of either the nozzle or the winding core, which serve as the rotated member, and the control unit calculates the required rotation angle of the rotated member based on the gap length between the wire rod and the flange measured while the wire rod is being wound onto the winding drum toward the flange, and rotates the rotated member by the required rotation angle.

[0006] According to another aspect of the present invention, a winding method for winding a wire rod unwound from a nozzle onto a winding core by rotating either the nozzle or the winding core, which are the rotated members, measures the length of a gap between the wire rod and the flange portion of the winding core as the wire rod is wound onto the winding drum portion of the winding core toward the flange portion of the winding core, calculates the required rotation angle of the rotated member based on the length of the gap, and rotates the rotated member by the required rotation angle.

[0007] Fig. 1 is a side view showing the configuration of a winding device according to an embodiment of the present invention. Fig. 2 is a cross-sectional view showing a cross section taken along line A-A in Fig. 1. Fig. 3 is a diagram showing an example of an image captured by an imaging device. Fig. 4 is a flowchart showing the winding procedure performed by a winding method according to an embodiment of the present invention.

[0008] Hereinafter, a winding device and a winding method according to an embodiment of the present invention will be described with reference to the drawings.

[0009] 1, the winding device 100 is a device for manufacturing an aligned wound coil by winding in order the wire 1 fed from a nozzle 24 around a winding core 30, and is equipped with: a nozzle 24 that feeds out the wire 1 from a tip end 24a; a winding core 30 having a winding drum 31 around which the wire 1 fed from the nozzle 24 is wound; a nozzle moving device 20 that moves the nozzle 24 at a predetermined pitch speed; a rotation device 15 that rotates the winding core 30 as a rotated member about a rotation axis C1; and a control unit 50 that controls the nozzle moving device 20 and the rotation device 15. Note that while FIG. 1 is a side view of the winding device 100, an imaging device 40, which will be described later, is not shown.

[0010] The nozzle 24 is a cylindrical member having a through-hole (not shown) penetrating in the axial direction. The nozzle 24 is attached to the nozzle moving device 20 so that a tip end 24a where one end of the through-hole opens faces the winding core 30. The nozzle 24 unwinds the wire rod 1 supplied from a wire rod supply source (not shown) from the tip end 24a and guides it to the winding core 30.

[0011] The winding core 30 is a so-called bobbin made of resin, and has a cylindrical winding drum 31 around which the wire 1 is wound, a first flange 32 provided at one end of the winding drum 31, and a second flange 33 provided at the other end of the winding drum 31.

[0012] The nozzle moving device 20 is an electric slider 21 that can reciprocate a movable piece 22 along the direction of the rotation axis C1 of the winding core 30, and the above-mentioned nozzle 24 is attached to the movable piece 22.

[0013] The rotating device 15 is composed of an electric motor 16 and a spindle 17 attached to the rotating shaft of the electric motor 16, and the tip of the spindle 17 is shaped so as to be able to hold the winding core 30 configured as described above.

[0014] The electric motor 16 is provided with a rotary encoder (not shown), which is capable of detecting the instantaneous rotation angle of the rotary shaft of the electric motor 16. Furthermore, the instantaneous rotation angle of the winding core 30, which is rotated by the electric motor 16 via the spindle 17, can also be determined from the detection value of the rotary encoder.

[0015] 1, the nozzle moving device 20 and the rotation device 15 are supported by a support 12 erected on a base 10. Note that the support supporting the nozzle moving device 20 and the support supporting the rotation device 15 may be different supports.

[0016] The control unit 50 controls the operation of the nozzle moving device 20 and the rotation device 15 in accordance with the contents input by an operator via an input device (not shown). The specific control performed by the control unit 50 will be described in detail later in the description of the winding method.

[0017] Specifically, the control unit 50 is composed of a microcomputer equipped with a CPU (Central Processing Unit), a ROM (Read Only Memory), a RAM (Random Access Memory), and an I / O interface (Input / Output Interface). The RAM stores data for CPU processing, the ROM stores the CPU control program and the like in advance, and the I / O interface is used for inputting and outputting information to and from the nozzle moving device 20 and the rotation device 15 connected to the control unit 50, the imaging device 40 described below, an input device (not shown), and a display device (not shown).

[0018] Here, when the winding core 30 is formed particularly from resin as described above, manufacturing errors may cause the positions at which each flange portion 32, 33 is provided relative to the winding drum portion 31 to be slightly shifted, which may result in individual differences in the length of the winding drum portion 31, i.e., the size of the distance between the first flange portion 32 and the second flange portion 33.

[0019] For this reason, for example, when the first layer of wire is wound from the second flange 33 side toward the first flange 32 so that the total length of the coil manufactured by the winding device 100 is a preset target length, if the winding is performed on a winding core 30 whose winding drum 31 is shorter than the target length, the new wire 1 will ride up on the already wound wire 1 near the first flange 32, and if the winding is performed on a winding core 30 whose winding drum 31 is longer than the target length, a gap will be created near the first flange 32, resulting in a decrease in winding accuracy on the winding core 30.

[0020] Therefore, the winding device 100 of this embodiment further includes an imaging device 40 as a distance measurement device in order to improve the winding accuracy for the winding core 30 even when the manufacturing error of the winding core 30 is relatively large.

[0021] The imaging device 40 is a device provided on the base 10 for capturing images of the first flange 32 and the wire 1 while the wire 1 is being wound around the winding drum 31 from the second flange 33 side toward the first flange 32, and as shown in Fig. 2, the imaging device 40 mainly includes a camera 41 and a mirror 43 installed in the imaging direction of the camera 41. In addition to these, the imaging device 40 may also include a lighting device and a white or metallic member that serves as a background screen.

[0022] The camera 41 is a digital camera having a pixel count and a field of view large enough to sufficiently identify the shapes of the first flange 32, the winding drum 31, and the wire 1 from the captured image data, and is supported by a support 13 erected on the base 10 so that the height of the imaging center C2 is approximately the same as the height of the vicinity of the upper end of the winding drum 31 of the winding core 30. In other words, the height of the imaging center C2 of the camera 41 is set so that at least the wire 1 extending from the nozzle 24 to the winding drum 31 and the first flange 32 of the winding core 30 are within the field of view.

[0023] The camera 41 is also connected to the control unit 50 , and the timing of capturing an image is controlled by the control unit 50 , and the captured image data is sent to the control unit 50 .

[0024] The mirror 43 is a rectangular prism mirror having a reflective surface that changes the direction in which the imaging surface 41a of the camera 41 faces (towards the imaging center C2) toward the winding core 30, and is supported by a support 14 erected on the base 10 so that the height of its center position is approximately the same as the height of the imaging center C2.

[0025] Specifically, the direction in which the imaging surface 41a of the camera 41 faces (towards the imaging center C2) and the angle and position of the mirror 43 are set so that the analysis image P, which will be described later, captured by the camera 41 includes the portion of the wire 1 unwound from the nozzle 24 just before it is wound around the winding drum 31, i.e., the wire 1 that appears to extend radially outward from the winding drum 31, and the winding drum 31 and first flange 32 of the winding core 30.

[0026] The camera 41 may be arranged so that the imaging surface 41a directly faces the vicinity of the upper end of the winding drum 31 of the winding core 30, without the mirror 43 in between. In this case, the mirror 43 is unnecessary, but the main body of the camera 41 including the lens is arranged in a direction perpendicular to the rotation axis C1, which may increase the size of the entire winding device 100. Therefore, in order to make the entire winding device 100 compact, it is preferable to use the mirror 43 as appropriate.

[0027] The analysis image P captured by the imaging device 40 having such a configuration will be described with reference to Fig. 3. Fig. 3 shows an example of the analysis image P captured by the imaging device 40.

[0028] As described below, the camera 41 takes an image at a timing instructed by the control unit 50 so that the first flange 32 and the wire 1 are included in the analysis image P while the wire 1 is being wound around the winding drum 31 from the second flange 33 side toward the first flange 32.

[0029] The control unit 50 processes the digital data of the analysis image P to extract the end line on the first flange portion 32 side of the wire 1 and the end face 32a of the first flange portion 32, and calculates the gap length L1 between them.

[0030] Specifically, as shown in FIG. 3, after a first line segment R1 along the end face 32a of the first flange portion 32, a second line segment R2 along the upper end of the winding drum portion 31, and a third line segment R3 along the first flange portion 32 side of the wire rod 1 are recognized, the distance between the first line segment R1 and the third line segment R3 at a point parallel to and spaced apart from the second line segment R2 by a predetermined specified distance D1 is calculated as the gap length L1.

[0031] The method for calculating the gap length L1 is not limited to this, and the gap length L1 may be calculated from two line segments: a first line segment R1 along the end face 32a of the first flange 32 and a third line segment R3 along the first flange 32 side of the wire rod 1. The gap length L1 may also be calculated within the area in which the winding drum 31 is visible. However, since the color and gloss of the winding drum 31 are similar to those of its surrounding areas, it may be difficult to accurately recognize, for example, the end face 32a of the first flange 32 or the end line of the wire rod 1 on the first flange 32 side. For this reason, it is preferable to calculate the gap length L1 based on the above-mentioned line segments R1, R2, and R3, which are relatively easy to recognize when the background is white, for example.

[0032] The calculation of the gap length L1 may be performed by a calculation unit provided within the imaging device 40 instead of the control unit 50, in which case the size of the gap length L1 is transmitted from the imaging device 40 to the control unit 50.

[0033] Next, the winding method performed by the winding device 100 having the above configuration will be described with reference to the flowchart of FIG.

[0034] When an operator operates a coil production start button or the like, the control unit 50 starts winding the wire rod 1 around the winding core 30 in step S11. Note that the following description will be given of a case where the tip end of the wire rod 1 is held on the second flange 33 side, and the wire rod 1 is wound around the winding drum 31 from the second flange 33 side toward the first flange 32.

[0035] Specifically, the control unit 50 causes the electric slider 21 to move the movable piece 22 at a pitch speed input in advance, thereby moving the nozzle 24 toward the first flange 32, and also causes the electric motor 16 to rotate, thereby rotating the winding core 30. As a result, the wire 1 is gradually wound around the winding drum 31 toward the first flange 32.

[0036] The control unit 50 controls the driving of the electric motor 16 and the electric slider 21, and when winding begins, in the subsequent step S12, the control unit 50 determines whether the length of the coil formed on the winding core 30 has reached a predetermined length at which the gap length L1 should be measured.

[0037] Specifically, when the distance traveled by the nozzle 24 along the direction of the rotation axis C1 since the start of winding reaches two-thirds or more, preferably three-quarters or more, of the planned total length of the coil, the control unit 50 determines that the state has been reached where gap length L1 should be measured, and proceeds to step S13. On the other hand, if it is determined that the state has not yet been reached where gap length L1 should be measured, the winding continues. Note that whether the state has been reached where gap length L1 should be measured may also be determined by whether the total number of rotations of the winding core 30 or the total number of rotations of the electric motor 16 since winding started has reached a predetermined number of rotations.

[0038] In the following step S13, the control unit 50 instructs the imaging device 40 to capture an image P for analysis.

[0039] When instructed to take an image, the imaging device 40 captures an analysis image P in which the first flange 32 and the wire 1 are included in a single image while the wire 1 is being wound around the winding drum 31 toward the first flange 32, and transmits the image to the control unit 50.

[0040] Also, in step S13, the control unit 50 determines the rotation angle of the winding core 30 at the time when the analysis image P was captured from the detection value of the rotary encoder, and stores the determined rotation angle as the starting position for starting counting the required rotation angle RA described below.

[0041] If the rotation speed of the winding core 30 is high, the analysis image P may become blurred, making it difficult to extract the end line of the wire 1 on the first flange 32 side or the end face 32a of the first flange 32. For this reason, when capturing the analysis image P in step S13, the rotation speed of the winding core 30 may be reduced or the rotation of the winding core 30 may be temporarily stopped.

[0042] The control unit 50 receives the analysis image P and calculates the gap length L1 by image processing as described above (see FIG. 3).

[0043] In the subsequent step S14, the control unit 50 calculates, based on the calculated gap length L1, a required rotation angle RA, which is the rotation angle of the winding core 30 (rotated member) required until the wire 1 wound around the winding drum 31 comes into contact with the end face 32a of the first flange 32.

[0044] The required rotation angle RA is a rotation angle that indicates how much further the winding core 30 needs to be rotated from the rotation angle of the winding core 30 at the time when the gap length L1 is measured, i.e., at the time when the analysis image P is captured, so that the wire 1 being unwound from the nozzle 24 comes into contact with the end face 32 a of the first flange portion 32, and is the rotation angle of the winding core 30 that is required to wind the wire 1 just enough relative to the measured gap length L.

[0045] Specifically, the required rotation angle RA is calculated from the gap length L1 and the movement distance X1 (pitch speed) that the nozzle 24 moves along the rotation axis C1 during one rotation of the winding core 30, using the following formula (1):

[0046] RA=(L1 / X1)・360...(1)

[0047] The integer part of the value obtained by dividing the gap length L1 by the movement distance X1 is set as the required number of rotations RA1, and the decimal part is multiplied by 360 to set the required angle RA2. The required angle RA2 may be calculated by dividing the required number of rotations of the winding core 30 (the rotated member) and the required angle RA2. In this case, the sum of the required number of rotations RA1 and the required angle RA2 essentially corresponds to the required rotation angle RA described above.

[0048] For example, when the movement distance X1 is 0.2 mm and the gap length L1 is 0.75 mm, the required rotation angle RA is 1350°. In this case, the required number of rotations RA1 is 3 rotations, and the required angle RA2 is 270°.

[0049] Furthermore, the control unit 50 compares the number of turns that would be obtained by rotating the winding core 30 by the required rotation angle RA from the rotation angle of the winding core 30 at the time the analysis image P was captured to the number of turns of the first layer that was planned in advance, and stores the difference as the number of turns that is either excessive or insufficient. Note that the number of turns may be converted into the winding length of the wire 1, and the number of turns that is either excessive or insufficient may be stored as the wire length that is either excessive or insufficient.

[0050] When the required rotation angle RA is calculated in step S14, the control unit 50 further rotates the winding core 30 by the required rotation angle RA in the following step S15.

[0051] Specifically, by rotating the electric motor 16, the rotation angle of the winding core 30, which starts counting from the rotation angle of the winding core 30 at the time the analysis image P is captured, is rotated until it reaches the required rotation angle RA, and the electric slider 21 moves the movable piece 22 at a pitch speed that has been input in advance.

[0052] As a result, the wire 1 unwound from the nozzle 24 is wound exactly around the winding drum 31 until it is almost in contact with the end face 32a of the first flange 32 without riding on the already wound wire 1 near the first flange 32.

[0053] Note that, if winding is performed until the rotation angle of the winding core 30, counting of which is started from the rotation angle of the winding core 30 at the time when the analysis image P is captured, finally reaches the required rotation angle RA, then winding after the analysis image P is captured in step S13 may be resumed without waiting for the measurement of the gap length L and the calculation of the required rotation angle RA to be completed, or may be resumed after these calculations, etc. are completed.

[0054] In this way, the wire 1 is wound around the end face 32a of the first flange portion 32 with almost no gap between them, and when the winding of the first layer is completed, the process proceeds to step S16, where the winding of the second and subsequent layers is started.

[0055] The second and subsequent winding layers are wound in the same manner as the first layer, with the same number of turns as the first layer, without calculating the required rotation angle RA. The number of turns of the outermost layer is set to be increased or decreased by the excess or deficiency of turns stored in step S14 relative to the previously planned number of turns.

[0056] When winding the second and subsequent layers, the gaps between the wire rods 1 may expand or contract slightly during winding depending on the error in the wire diameter of the wire rod 1, the shape of the wire rod 1, and the accuracy of the feed speed of the nozzle 24, resulting in a winding width that differs from that of the first layer. In such cases, even if the same number of turns as in the first layer are wound, the new wire rod 1 may ride up on the already wound wire rod 1 near the flanges 32 and 33, or gaps may occur near the flanges 32 and 33.

[0057] Therefore, measurement of the gap length L and calculation of the required rotation angle RA may be performed not only for the first winding layer, but also for the second and subsequent winding layers. For example, they may be performed when winding layers in a predetermined order, such as the third or seventh layer, or they may be performed when winding all layers.

[0058] When measuring the gap length L and calculating the required rotation angle RA in the second or fourth winding layer in which the wire 1 unwound from the nozzle 24 is wound around the winding drum 31 toward the second flange 33 instead of the first flange 32, the imaging device 40 captures an analysis image P in which the second flange 33 and the wire 1 are included in one image while the wire 1 is being wound around the winding drum 31 toward the second flange 33. In this case, the second flange 33 corresponds to the flange, and the gap length L1 is the distance between the end line of the wire 1 on the second flange 33 side and the end face of the second flange 33. Furthermore, the imaging device 40 that images the area near the second flange 33 may be, for example, an imaging device that can image both the area near the first flange 32 and the area near the second flange 33 by switching the position of the mirror 43, or it may be an imaging device that is provided separately from the imaging device 40 that images the area near the first flange 32.

[0059] In this way, by measuring the gap length L and calculating the required rotation angle RA when winding the second and subsequent layers, it is possible to wind the wire 1 around the winding core 30 without excess or deficiency when winding each layer.

[0060] Since the performance of a coil generally varies depending on the number of turns and the length of the winding, when winding of the second layer or subsequent layers begins, in step S17, the control unit 50 determines whether the number of turns of the coil has reached a predetermined design number of turns or whether the length of the wire 1 used to wind the coil has reached a predetermined design length in order to achieve the required performance.

[0061] When it is determined that the number of turns of the coil has reached the predetermined design number of turns, or when it is determined that the length of the wire 1 used to wind the coil has reached the predetermined design length, the control unit 50 stops the electric motor 16 and the electric slider 21 and ends the winding.

[0062] Through the above steps, the winding of the wire 1 around the winding core 30 is completed, and an aligned wound coil of predetermined dimensions is formed on the winding core 30.

[0063] The above embodiment provides the following advantages.

[0064] In the winding device 100 having the above-described configuration, the control unit 50 calculates the required rotation angle RA of the winding core 30, which serves as the rotated member, based on the gap length L between the wire 1 unwound from the nozzle 24 and the first flange 32, which is measured while the wire 1 is being wound around the winding drum 31 toward the first flange 32, and rotates the winding core 30 by the required rotation angle RA.

[0065] In this way, the required rotation angle RA of the winding core 30 required to wind the wire rod 1 without excess or deficiency with respect to the gap length L between the wire rod 1 and the first flange 32 measured while the wire rod 1 is being wound around the winding drum 31 toward the first flange 32 is determined, and the winding core 30 is rotated by this required rotation angle RA. Even if there are individual differences in the length of the winding drum 31 due to manufacturing errors of the winding core 30 or the like, it is possible to prevent new wire rod 1 from riding up on the already wound wire rod 1 near the first flange 32 and to prevent a gap from occurring near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0066] Furthermore, with the winding device 100 having the above configuration, even if the manufacturing error of the winding core 30 is relatively large or if the winding drum 31 is not formed with a guide groove or the like that defines the position of the first layer of wire rod 1, it is possible to wind the wire rod 1 just enough around the winding core 30. Therefore, the manufacturing cost of the winding core 30 can be reduced, and the manufacturing cost of the coil formed on the winding core 30 can also be reduced.

[0067] The following modified examples are also within the scope of the present invention, and it is possible to combine the configuration shown in the modified example with the configuration described in the above embodiment, or to combine the configurations described in the different modified examples below.

[0068] In the above embodiment, the winding device 100 is described as an alignment winding machine in which the winding core 30 is the rotated member. Alternatively, the winding device may be a flyer-type alignment winding machine in which the nozzle 24 is the rotated member. In this case, the control unit 50 controls the rotation of the nozzle 24 that rotates around the winding core 30 while unwinding the wire 1.

[0069] Furthermore, in the above embodiment, the measurement of the gap length L and the calculation of the required rotation angle RA are performed when the first layer of wire is wound around the winding core 30. In addition to this, the measurement of the gap length L and the calculation of the required rotation angle RA may be performed not only when the first layer of wire is wound around the winding core 30, but also when the second and subsequent layers of wire are wound around the winding core 30. Alternatively, if a guide groove that defines the position of the wire 1 for the first layer is formed in the winding drum 31, the measurement of the gap length L and the calculation of the required rotation angle RA may not be performed when the first layer of wire is wound around the winding core 30, but may be performed when the second and subsequent layers of wire are wound around the winding core 30.

[0070] In the above embodiment, the cross-sectional shape of the wire rod 1 is circular. Alternatively, the cross-sectional shape of the wire rod 1 may be rectangular or polygonal. In the above embodiment, the cross-sectional shape of the outer peripheral surface of the winding drum 31 around which the wire rod 1 is wound is circular. Alternatively, the cross-sectional shape of the winding drum 31 may be rectangular or polygonal.

[0071] In the above embodiment, the winding core 30 is made of resin. Alternatively, the winding core 30 may be a bobbin made of metal.

[0072] In the above embodiment, the winding core 30 is formed integrally with the winding drum 31 and both flanges 32, 33. Alternatively, the winding core 30 may be formed such that the winding drum 31 and both flanges 32, 33 are separate members. The winding core 30 may be formed of the winding drum 31 and either one of the flanges 32, 33, or a portion of the spindle 17 may be used as the winding drum 31 of the winding core 30.

[0073] In the above embodiment, the travel distance X1 used in calculating the required rotation angle RA is a preset value. Alternatively, the travel distance X1 may be determined from the analysis image P, similar to the gap length L1. Specifically, the width of the wire rod 1 in the direction along the rotation axis C1 when the wire rod 1 is wound around the winding drum 31 may be measured from the analysis image P, and the required rotation angle RA may be calculated by regarding the measured width as the travel distance X1 that the nozzle 24 moves along the rotation axis C1 during one rotation of the winding core 30.

[0074] Furthermore, in the above embodiment, the gap length L1 is measured using the analysis image P captured by the camera 41. Alternatively, the gap length L1 may be measured using a laser distance measuring device such as a 2D-LiDAR (Light Detection and Ranging) sensor. For example, the gap length L1 may be measured from the shape of the winding core 30 including the wire rod 1, which is determined by irradiating a laser onto the first flange 32 and a portion of the wire rod 1 just before it is wound around the winding drum 31, or by irradiating a laser from the first flange 32 toward the second flange 33 along the rotation axis C1.

[0075] The configuration, operation, and effects of the embodiment of the present invention will be described below.

[0076] The winding device 100 includes a nozzle 24 that pays out the wire rod 1 from a tip end 24a, a winding drum 31 around which the wire rod 1 paid out from the nozzle 24 is wound, a winding core 30 having a first flange 32 provided on one end side of the winding drum 31, and a control unit 50 that controls the rotation of either the nozzle 24 or the winding core 30, which serve as the rotated member. The control unit 50 calculates a required rotation angle RA of the rotated member based on a gap length L1 between the wire rod 1 and the first flange 32 measured while the wire rod 1 is being wound around the winding drum 31 toward the first flange 32, and rotates the rotated member by the required rotation angle RA.

[0077] In this configuration, a required rotation angle RA of the rotated member required to wind the wire rod 1 without excess or deficiency relative to the gap length L between the wire rod 1 and the first flange 32 measured while the wire rod 1 is being wound around the winding drum 31 toward the first flange 32 is determined, and the rotated member is rotated by this required rotation angle RA. Even if there are individual differences in the length of the winding drum 31 due to manufacturing errors of the winding core 30, it is possible to prevent new wire rod 1 from riding up on the already wound wire rod 1 near the first flange 32 or to prevent a gap from occurring near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0078] In addition, the required rotation angle RA is the rotation angle of the rotated member from the time when the gap length L1 is measured, and is set to the rotation angle of the rotated member required until the wire 1 wound around the winding drum portion 31 comes into contact with the first flange portion 32.

[0079] In this configuration, the required rotation angle RA is set to the rotation angle of the rotated member required until the wire rod 1 wound around the winding drum 31 comes into contact with the first flange 32. By rotating the rotated member by the required rotation angle RA set in this manner, it becomes possible to wind the wire rod 1 without excess or deficiency relative to the gap length L. As a result, even if there are individual differences in the length of the winding drum 31 due to manufacturing errors of the winding core 30 or the like, it is possible to prevent new wire rod 1 from riding up on the already wound wire rod 1 near the first flange 32 or to prevent a gap from being generated near the first flange 32.

[0080] At least one of the winding drum 31 and the first flange 32 is made of resin.

[0081] In this configuration, because at least one of the winding drum 31 and the first flange 32 is made of resin, there is a risk that individual differences will occur in the length of the winding drum 31 and the size of the gap between the first flange 32 and the second flange 33 due to manufacturing errors, etc. However, because the wire 1 is wound just enough with respect to the gap length L1 measured for each winding core 30, it is possible to improve the winding accuracy around the winding core 30 regardless of manufacturing errors.

[0082] The winding device 100 also includes an imaging device 40 capable of capturing images of the first flange 32 and the wire 1 while the wire 1 is being wound around the winding drum 31 toward the first flange 32, and the control unit 50 calculates the gap length L1 from the image captured by the imaging device 40.

[0083] In this configuration, the gap length L1 is calculated from the image captured by the imaging device 40. In this way, by measuring the gap length L1 using a relatively simple system, it is possible to suppress an increase in the manufacturing cost of the winding device 100.

[0084] In addition, the winding method for winding the wire 1 unwound from the nozzle 24 onto the winding core 30 by rotating either the nozzle 24 or the winding core 30, which are the rotated members, measures the gap length L1 between the wire 1 and the first flange 32 while the wire 1 is being wound onto the winding drum 31 of the winding core 30 toward the first flange 32 of the winding core 30, calculates the required rotation angle RA of the rotated member based on the gap length L1, and rotates the rotated member by the required rotation angle RA.

[0085] In this configuration, a required rotation angle RA of the rotated member required to wind the wire rod 1 without excess or deficiency relative to the gap length L between the wire rod 1 and the first flange 32 measured while the wire rod 1 is being wound around the winding drum 31 toward the first flange 32 is determined, and the rotated member is rotated by this required rotation angle RA. Even if there are individual differences in the length of the winding drum 31 due to manufacturing errors of the winding core 30, it is possible to prevent new wire rod 1 from riding up on the already wound wire rod 1 near the first flange 32 or to prevent a gap from occurring near the first flange 32. As a result, the winding accuracy around the winding core 30 can be improved.

[0086] Although the embodiments of the present invention have been described above, the above embodiments merely illustrate some of the application examples of the present invention, and it is not intended that the technical scope of the present invention be limited to the specific configurations of the above embodiments.

Claims

1. A winding device which winds a wire rod unwound from a nozzle around a winding core, comprising: the nozzle which unwinds the wire rod from a tip thereof; the winding core having a winding drum around which the wire rod unwound from the nozzle is wound and a flange provided on one end of the winding drum; and a control unit which controls the rotation of either the nozzle or the winding core, which serve as rotated members, wherein the control unit calculates a required rotation angle of the rotated member based on a gap length between the wire rod and the flange measured while the wire rod is being wound around the winding drum toward the flange, and rotates the rotated member by the required rotation angle.

2. A winding device as claimed in claim 1, wherein the required rotation angle is the rotation angle of the rotated member from the time when the gap length is measured, and is set to the rotation angle of the rotated member required until the wire wound around the winding drum comes into contact with the flange.

3. A winding device according to claim 1, wherein at least one of the winding body and the flange is made of resin.

4. A winding device as claimed in claim 1, further comprising an imaging device capable of capturing images of the flange and the wire as the wire is being wound around the winding drum towards the flange, and the control unit calculates the gap length from the images.

5. A winding method for winding a wire fed from a nozzle onto a winding core by rotating one of the nozzle and a winding core, the method comprising: measuring a gap length between the wire and a flange portion of the winding core while the wire is being wound onto the winding body of the winding core toward the flange portion of the winding core; calculating a required rotation angle of the rotated member based on the gap length; and rotating the rotated member by the required rotation angle.

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