Feeding device, conveyance system, and feeding device manufacturing method
Patent Information
- Authority / Receiving Office
- WO · WO
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2026-02-06
- Publication Date
- 2026-08-13
Smart Images
Figure JP2026004318_13082026_PF_FP_ABST
Abstract
Description
Feeding device, conveying system, and method for manufacturing a feeding device
[0001] The present invention relates to a feeding device, a conveying system, and a method for manufacturing a feeding device. The present invention claims the priority of Japanese Patent Application No. 2025-018721 filed on February 6, 2025, and for designated countries where incorporation by reference is permitted, the contents described in that application are incorporated herein by reference.
[0002] In logistics warehouses and manufacturing sites of industrial machines, conveying systems using various feeding devices (conveying devices) are used. As a propulsion means for propelling an object of such a feeding device, for example, a method of rotating a timing belt or a ball screw with a prime mover is common.
[0003] On the other hand, in recent years, feeding devices using linear bodies instead of timing belts have emerged (see, for example, Patent Document 1).
[0004] Japanese Patent Application Laid-Open No. 2007-127138
[0005] The feeding device (forward and reverse winder) using the above linear body is suitable for long-distance conveyance because the linear body has high strength and is easy to manufacture long products. Also, since the linear body generates little dust, it is suitable for use in a clean room.
[0006] On the other hand, the feeding device using the above linear body needs to wind a linear body having a length corresponding to the conveyance distance around the drum of the forward and reverse winder. As the conveyance distance increases, the size of the drum also increases accordingly, resulting in higher costs.
[0007] The present application is for solving at least one of the above problems, and an object thereof is to provide a feeding device, a conveying system, and a method for manufacturing a feeding device that can perform long-distance conveyance while maintaining a compact size regardless of the conveyance distance.
[0008] The present invention includes several means for solving at least part of the above problems, but an example is as follows. In order to solve at least part of the above problems, a feeding device according to one aspect of the present invention is a feeding device for winding and feeding a linear body, comprising a prime mover and a pair of rotating bodies, a first rotating body and a second rotating body, arranged along the winding and feeding direction, wherein the first rotating body is connected to the output shaft of the prime mover and has N grooves on its outer circumference for winding the linear body, and the second rotating body has N-1 or N+1 grooves on its outer circumference for winding the linear body, and the linear body can be wound starting at the groove at one end of the rotating body with a larger number of grooves, winding around both rotating bodies, and ending at the groove at the other end of the rotating body.
[0009] The second rotating body has N-1 grooves on its outer surface, and the first and second rotating bodies are installed such that their axes are twisted relative to each other by an angle θ. The linear body may be capable of being spirally wound around the pair of rotating bodies.
[0010] The first groove of the first rotating body and the second groove of the second rotating body have equivalent groove widths, and the angle θ may be such that, in a forward view, the upper side of the rightmost second groove overlaps with the second first groove from the right and the upper side of the leftmost second groove overlaps with the leftmost first groove, or the upper side of the leftmost second groove overlaps with the second first groove from the left and the upper side of the rightmost second groove overlaps with the rightmost first groove.
[0011] The feeding device comprises a horizontal plate installed parallel to the horizontal plane and a pair of vertical plates installed perpendicular to the horizontal plate, and the rotating shaft to which the second rotating body is fixed may be rotatably mounted on the pair of vertical plates at an angle θ with respect to the horizontal plane.
[0012] The feeding device may include a guide roller having grooves on its outer surface, and the guide roller may be installed between the first rotating body and the second rotating body so as to be in contact with the linear body.
[0013] The second rotating body has N+1 grooves on its outer circumferential surface, the first rotating body and the second rotating body are installed so that their centerlines in the left-right direction coincide, and the linear body may be such that it intersects at the midpoint of the rotation axes of the pair of rotating bodies and can be wrapped around both rotating bodies.
[0014] The feeding device may also include a tension adjustment device for adjusting the tension of the linear body.
[0015] The system may include a power transmission unit for transmitting power between the first rotating body and the second rotating body.
[0016] The rotation axis of the second rotating body may be connected to the transmission unit via a universal joint and an auxiliary rotation axis.
[0017] To solve at least some of the above problems, a transport system according to one aspect of the present invention includes a linear body, a transport trolley connected to the linear body, a guide rail for guiding the transport trolley, a folding pulley for folding the linear body, and the feeding device, wherein the linear body is wrapped around a pair of the rotating bodies on one side of the transport source and the transport destination, and is placed on the folding pulley on the other side.
[0018] To solve at least part of the above problems, a method for manufacturing a feeding device according to one aspect of the present invention is a method for manufacturing a feeding device for winding and feeding a linear body, comprising: a pair of rotating bodies, a first rotating body having N grooves on its outer circumference for winding the linear body and a second rotating body having N-1 or N+1 grooves on its outer circumference for winding the linear body; the pair of rotating bodies being arranged along the winding and feeding direction; and the linear body being set up so that winding begins at the groove at one end of the rotating body with the larger number of grooves, is wound around both rotating bodies, and ends at the groove at the other end of one of the rotating bodies.
[0019] According to the present invention, it is possible to provide a feeding device, a conveying system, and a method for manufacturing a feeding device that can transport over long distances while maintaining compact dimensions, regardless of the transport distance.
[0020] Other issues, configurations, and effects not mentioned above will be clarified by the following description of the embodiments.
[0021] This is a plan view showing an example of a transport system according to Embodiment 1. This is a plan view, a rear view, and a front view showing an example of a feeder according to Embodiment 1. This is a plan view and a side view showing an example of a feeder. This is a diagram for explaining the first groove of an example of a first rotating body. This is a diagram for explaining the second groove of an example of a second rotating body. This is a side view showing an example of a feeder according to Modification 1 of Embodiment 1. This is a side view showing an example of a feeder according to Modification 2 of Embodiment 1. This is a diagram for explaining the groove of a rotating body and a partially enlarged view showing an example of a feeder according to Modification 3 of Embodiment 1. This is a plan view and a front view showing an example of a feeder according to Embodiment 2. This is a rear view showing an example of a feeder according to Embodiment 2. This is a plan view and a side view showing an example of a feeder according to Embodiment 3. This is a plan view and a side view showing an example of a feeder according to Embodiment 4.
[0022] Hereinafter, examples of embodiments of the present invention will be described with reference to the drawings. Note that common components in the following embodiments may be denoted by the same reference numerals as those mentioned above, and their descriptions may be omitted. Furthermore, when referring to the shape, positional relationship, etc., of components, unless otherwise explicitly stated or it is clearly considered otherwise in principle, this shall include those that are substantially similar or analogous to their shape, etc.
[0023] In the figures of this application, X represents the front-to-back direction (-X is backward, +X is forward), Y represents the up-and-down direction (vertical direction) (-Y is downward, +Y is upward), and Z represents the left-to-right direction (lateral direction) (-Z is left, +Z is right). In this application, the XZ plane is defined as the horizontal plane, and the XY plane is defined as the vertical plane.
[0024] <Embodiment 1> Figure 1 is a diagram showing an example of a conveying system 100 according to Embodiment 1, and is a plan view observed from above. The conveying system 100 includes a linear body 1, a conveying trolley 2 connected to the linear body 1, a guide rail 3 for guiding the conveying trolley 2, a folding pulley 4 for folding the linear body 1, and a feeding device 5 equipped with a pair of rotating bodies (first rotating body 70 and second rotating body 80) for winding and feeding the linear body 1. In the illustrated example, the linear body 1 is wound onto the feeding device 5 along the front-rear direction (X direction) and fed out (hereinafter also referred to as the "winding and feeding direction"). The conveying system 100 may also include a pulley for guiding the linear body 1 between the feeding device 5 and the folding pulley 4.
[0025] The linear body 1 is a long member used to transport (propel) an object, and is typically a metal wire. The linear body 1 only needs to have a predetermined strength, and its composition is not particularly limited. Materials such as iron, stainless steel, copper, and high-strength fibers can be used for the linear body 1. The linear body 1 may be coated with special nylon on its surface to increase its durability. As an example, the linear body 1 may be made by bundling and twisting thin strands together, and the outer diameter is determined according to the diameter of the strands from the viewpoint of ensuring durability against bending deformation. The linear body 1 may have an outer diameter of φ1.0 mm to φ6.0 mm. The linear body 1 has high strength (for example, the breaking load of one with an outer diameter of φ2.5 mm exceeds 300 kg) and is easy to manufacture in long lengths, making it suitable for long-distance transport. The linear body 1 generates little dust, making it suitable for transport in a clean room.
[0026] The linear body 1 is installed by being wound around the rotating body of the feeder 5 on one of the transport source and destination sides, and by being placed on the folding pulley 4 on the other side. In other words, the linear body 1 includes a wound portion that is wound around the feeder 5 and an extended portion whose intermediate part is placed on the folding pulley 4 and extends between the feeder 5 and the folding pulley 4. The extended portion includes a first extended portion 11 and a second extended portion 12 that extend parallel to each other. When in operation, one is wound around the feeder 5, the other is fed out by the same amount as the wound portion, folded back by the folding pulley 4, and returned to the other side. In the transport system 100, as described later, the linear body 1 is made into an endless track, and the wound portion and the extended portion are relative to each other.
[0027] The transport trolley 2 is a mobile trolley for carrying an object and transporting it to its destination. The transport trolley 2 is connected to one of the first extension section 11 and the second extension section 12 of the linear body 1, and when in operation, it is pulled by the linear body 1 and travels along the guide rail 3, transporting the loaded object to its destination. The transport trolley 2 only needs to be capable of carrying an object and traveling along the guide rail 3, and its configuration is not particularly limited.
[0028] The guide rail 3 has one end installed near the transport source area (including the transport source area and its vicinity) and the other end installed near the transport destination area (including the transport destination area and its vicinity). The guide rail 3 only needs to be capable of guiding the transport trolley 2, and its configuration is not particularly limited.
[0029] The return pulley 4 is installed, for example, near the end of the guide rail 3. The return pulley 4 only needs to be capable of guiding and returning the linear body 1, and its configuration is not particularly limited.
[0030] A distinctive feature of this transport system 100 is that the linear body 1 is not fixed to the rotating body of the feeder 5, but is instead made into an endless track (continuous track).
[0031] As mentioned above, in recent years, transport systems suitable for long-distance transport (e.g., transport distance of 10m to 30m) and high-speed transport (e.g., transport speed of 5m / s to 10m / s) have been put into practical use by taking advantage of the characteristics of the linear body 1. In this conventional transport system, the feeder (also called a wire feeder) needs to fix the linear body to the drum in at least one place so that it does not slip against the drum, and wind a length of wire corresponding to the transport distance onto the drum. For this reason, the dimensions of the drum tend to be large in the case of long-distance transport. In other words, in conventional wire feeders, the length of the drum depends on the transport distance.
[0032] To explain in more detail, the outer diameter of the drum is mainly required to be 600 to 700 times the diameter of the wire strands. For example, in the case of a φ2.5 mm wire strand, the wire strand diameter is φ0.13 mm, so the outer diameter (circumferential diameter) of the drum will be approximately φ80 mm or more. The length of one turn of wire strands wound around the outer circumference of a drum with an outer diameter of φ80 mm is approximately φ80 mm × π = 250 mm, and if the transport distance is 10 m, the number of turns will be 10 m / 250 mm = approximately 40 turns. In the case of a φ2.5 mm wire strand, the pitch (distance between the centers of adjacent windings of wire strands) required to wind them on the drum without overlapping is approximately 3.0 mm, so if the transport distance is 10 m, the length of the drum required to wind 40 turns of wire strands will be 3.0 mm × 40 turns = 120 mm. While increasing the drum's outer diameter can lengthen a single roll and reduce the number of rolls, even with a drum outer diameter of φ160 mm, a drum length of 600 mm is still required to wind 100 m of linear material. In any case, with a system that winds the linear material for the entire transport distance onto a single drum, an increase in drum length due to increased transport distance is unavoidable.
[0033] Furthermore, conventional wire-type feeders have a double-tube structure consisting of an outer drum and an inner moving cylinder. Because the drum rotates integrally with the drive shaft and moves parallel to the drive shaft, the components used are expensive and the number of parts is large.
[0034] In order to solve the above-mentioned problems, the conveying system 100 of this embodiment focuses on the frictional force between the linear body and the rotating body and provides a feeding device 5 that replaces the method of fixing and winding the material onto the drum (fixed winding method).
[0035] In this configuration, the feeder 5 utilizes the frictional force between the linear body and the rotating body to prevent the linear body from slipping, and realizes an endless track system where the linear body 1 is not fixed to the rotating body. This enables long-distance transport while maintaining a compact size, regardless of the transport distance.
[0036] Figure 2 shows an example of the feed device 5 according to Embodiment 1, and is (a) a top view, (b) a rear view (viewed from the rear), and (c) a front view (viewed from the front). In Figure 2(b), the first rotating body 70 is shown as the center, and other components are omitted as appropriate. In Figure 2(c), the second rotating body 80 is shown as the center, and other components are omitted as appropriate. As described above, the feed device 5 is a device for winding up and feeding out the linear body 1, and is used to move an object that is directly or indirectly connected to the linear body 1.
[0037] The feeding device 5 includes, as a support for each of the functional parts described later, a horizontal plate 50 installed parallel to the horizontal plane, and a pair of vertical plates, a first vertical plate 51 and a second vertical plate 52, installed perpendicular to the horizontal plate 50. The pair of vertical plates are installed facing each other at a predetermined interval.
[0038] The feeding device 5, as a functional unit, includes, for example, a prime mover 6 that provides rotational power, and a pair of rotating bodies, a first rotating body 70 and a second rotating body 80, arranged along the winding and feeding direction. The first rotating body 70 is directly or indirectly connected to the output shaft 61 of the prime mover 6. The first rotating body 70 has N first grooves on its outer circumference for winding the linear body 1. The second rotating body 80 has N-1 second grooves on its outer circumference for winding the linear body 1. The first and second grooves are circumferential grooves that are continuous in the circumferential direction.
[0039] The feeding device 5 can wind the linear body 1 starting at the first groove 701 at one end of the first rotating body 70 which has a large number of grooves, winding it around both the first rotating body 70 and the second rotating body 80, and ending the winding at the first groove 706 at the other end of the first rotating body 70. The starting portion of the linear body 1 is connected to the first extended portion 11, and the ending portion is connected to the second extended portion 12. Note that the starting and ending points are relative, and the winding may start at the first groove 706 at the other end and end at the first groove 706 at one end.
[0040] The feed device 5 in this embodiment can spirally wind a linear body 1 onto a pair of rotating bodies. The wound linear body 1 includes a first groove winding a wound in contact with the first groove of the first rotating body 70, a second groove winding b wound in contact with the second groove of the second rotating body 80, and a connecting portion c that spans between the first rotating body 70 and the second rotating body 80. The connecting portion c is the part between the first groove winding a and the second groove winding b, and each connecting portion c extends parallel to each other.
[0041] The first rotating body 70 is positioned with its axis E1 parallel to the XZ and YZ planes. The first groove winding a, which is wound in contact with each first groove of the first rotating body 70, is parallel to the vertical plane when viewed from the rear.
[0042] The second rotating body 80 is positioned such that its axis E2 is oblique to the XZ plane at an angle θ and parallel to the YZ plane. The second groove winding b, which is wound in contact with each second groove of the second rotating body 80, forms an angle θ with respect to the plane perpendicular to the front view. In other words, although the axes of the first rotating body 70 and the second rotating body 80 are not on the same plane in a plan view, they are positioned such that they form an angle θ when observed in the front-to-back direction; in other words, their axes are twisted relative to each other by an angle θ, and the first groove winding a on the first rotating body 70 and the second groove winding b on the second rotating body 80 are wound in a relationship that is twisted by an angle θ.
[0043] Thus, the feeding device 5 of this embodiment arranges a pair of rotating bodies along the winding and feeding direction, and installs them such that their axes are twisted by an angle θ, and winds the linear body 1 integrally around both rotating bodies in an oval spiral shape (refer to FIG. 3(b) described later). By doing so, it acquires a frictional force that can overcome the slippage of the linear body 1, and realizes an infinite orbit without fixing the linear body 1.
[0044] The feeding device 5 of this embodiment that utilizes frictional force can thus be configured with a pair of rotating bodies regardless of the conveying distance. Therefore, it can perform long-distance conveyance while maintaining a compact size, reduce the cost due to the enlargement of the drum, and reduce the installation space. Further, since the rotating bodies of the feeding device 5 do not depend on the conveying distance, they can be made common, and the processing of the circumferential grooves is relatively easy, so the manufacturing cost can be further reduced. In addition, as in the conventional case, since there is little sliding in the mechanism part and the dust generation is low, it can also be used in a clean room, and since there is almost no noise during operation, it is also excellent in terms of the environment.
[0045] FIG. 3 is a diagram showing an example of the feeding device 5, (a) is a plan view, and (b) is a side view (viewed from the left). For convenience of explanation, some configurations are shown in perspective or in cross-section (the same applies to each figure below). Hereinafter, a more specific configuration of the feeding device 5 will be described.
[0046] The prime mover 6 may be any device that gives rotational power to the entire device, and its configuration is not particularly limited. The prime mover 6 includes, for example, a motor. The prime mover 6 may include a speed reducer in addition to the motor. The output shaft 61 of the prime mover 6 is, for example, the output shaft of the motor or the output shaft of the speed reducer. <00The pair of rotors are generally cylindrical or disc-shaped members, each having an inner peripheral hole penetrating axially through the center. The pair of rotors are typically pulleys, and the material is not particularly limited. For example, they can be made of aluminum, stainless steel, steel, resin, rubber, etc. As an example, the pair of rotors are made of metal and have a non-slip surface treatment on the surface. As an example, they can be made of metal and resin or rubber can be attached to the surface. The first rotor 70 may be composed of a single member having N grooves on the outer peripheral surface, or may be an integrated structure formed by stacking and joining N members each having one groove on the outer peripheral surface at the end face. The second rotor 80 may be composed of a single member having N - 1 grooves on the outer peripheral surface, or may be an integrated structure formed by stacking and joining N - 1 members each having one groove on the outer peripheral surface at the end face.
[0048] The first rotor 70 is located at a remote position by means of the reversing pulley 4. The first rotor 70 is fixed to the output shaft 61 that passes through the inner peripheral hole along the axis E1 and rotates integrally therewith. That is, in this embodiment, the output shaft 61 is the rotation axis of the first rotor 70. The method of fixing the first rotor 70 to the output shaft 61 may be to provide key grooves on one inner peripheral surface and the other outer peripheral surface and fix them with a key. However, from the perspective of more effectively suppressing the axial movement of the first rotor 70, it is preferably fixed via a shaft coupling 72. The shaft coupling 72 utilizes the wedge principle. When the bolt is tightened, the outer sleeve moves, and friction occurs between the outer sleeve and the inner sleeve, enabling the output shaft 61 and the first rotor 70 to be fastened more firmly.
[0049] The second rotor 80 is fixed to the second rotating shaft 81 that passes through the inner peripheral hole along the axis E2 and rotates integrally with the second rotating shaft 81. Similar to the first rotor 70, the method of fixing the second rotor 80 to the second rotating shaft 81 is preferably fixed via a wedge-type shaft coupling 82.
[0050] As shown in Figure 3(b), when the first rotating body 70 is driven to rotate counterclockwise by the prime mover 6, the second rotating body 80, around which the linear body 1 is wound integrally with the first rotating body 70, follows and rotates freely, and the pair of rotating bodies together wind up the linear body 1. As a result, the first extension section 11 is wound up and moves backward (-X direction), and the second extension section 12 is fed out and moves forward (+X direction), thereby moving the transport trolley 2 connected to the first extension section 11 or the second extension section 12. Conversely, when the first rotating body 70 is driven to rotate clockwise by the prime mover 6, the second extension section 12 is wound up and moves backward (-X direction), and the first extension section 11 is fed out and moves forward (+X direction), thereby moving the transport trolley 2 connected to the first extension section 11 or the second extension section 12 in the opposite direction.
[0051] The spacing between the first rotating body 70 and the second rotating body 80 is, for example, greater than 0 mm so that they do not touch, and less than or equal to the outer diameter of the pair of rotating bodies. The first rotating body 70 and the second rotating body 80 have outer diameters that match the outer diameter of the linear body 1, and as an example, they have the same outer diameter D. The winding angle of the linear body 1 around the first rotating body 70 and the second rotating body 80 is approximately 180° in both cases, and the linear body 1 is wound around each rotating body by half a turn. That is, in this embodiment, the portion wound in contact with the rotating body is the rear half turn of the first rotating body 70 and the front half turn of the second rotating body 80 combined to make up one turn in the conventional configuration.
[0052] Figure 4 is a diagram illustrating the first groove of an example of the first rotating body, showing the first rotating body 70 and its surrounding configuration viewed from the front. As an example, the first rotating body 70 has six first grooves on its outer circumferential surface, numbered 701, 702, 703, 704, 705, and 706, in order from the right end (towards the prime mover 6). Each first groove is a circumferential groove that is continuous in the circumferential direction, with equal groove widths and extending parallel to each other. Each first groove extends parallel to the vertical plane because the output shaft 61 is installed parallel to the horizontal plane (it is a horizontal axis). The linear body 1 is wrapped around the rear half of each first groove, forming six first groove windings a, a1, a2, a3, a4, a5, and a6, as shown in the cross-section.
[0053] Figure 5 is a diagram illustrating the second groove of an example of a second rotating body, showing the second rotating body 80 and its surrounding configuration viewed from the front. As an example, the second rotating body 80 has five second grooves on its outer circumferential surface, numbered 801, 802, 803, 804, and 805, in order from the right end (towards the prime mover 6). Each second groove is a circumferential groove that is continuous in the circumferential direction, with equal groove widths and extending parallel to each other. Each second groove extends diagonally to the vertical plane because the second rotating shaft 81 is installed diagonally to the horizontal plane (it is an inclined shaft). As an example, the second rotating shaft 81 is diagonally mounted via a pair of bearings 83 to a pair of diagonal through holes (receiving holes) provided in the first vertical plate 51 and the second vertical plate 52, corresponding to each other, and is rotatably supported by the pair of vertical plates in an inclined state. The linear body 1 is wrapped around the front half of each second groove, forming five second groove windings b, b1, b2, b3, b4, and b5, as shown in the cross-section.
[0054] The second rotating body 80 has a second pitch P2 that is approximately the same as the first pitch P1 of the first rotating body 70. In other words, the grooves of the first rotating body 70 and the second rotating body 80 have approximately the same groove width. The second rotating body 80 is formed to be shorter in length (shorter distance between end faces) than the first rotating body 70 because it has one less groove.
[0055] The inclination angle θ is the angle at which, when viewed from the front, the second groove of the second rotating body 80 overlaps with the first groove of the first rotating body 70 by N-1 positions from the second groove at one end on one side (upper and lower), and overlaps with the first groove of the first rotating body 70 by N-1 positions from the second groove at the other end on the other side. In other words, as shown in the illustrated example, the upper part of the rightmost second groove 801 overlaps with the second first groove 702 from the right and the upper part of the leftmost second groove 805 overlaps with the leftmost first groove 706, or, conversely to the illustrated example, the upper part of the leftmost second groove 805 overlaps with the second first groove 705 from the left and the upper part of the rightmost second groove 801 overlaps with the rightmost first groove 701. That is, the second rotating body 80 may be installed at an angle θ on the opposite side from the illustrated example, and the linear body 1 may be wrapped around it. Furthermore, the inclination angle θ is also the angle at which the first groove windings a1 and a6 at both ends of the first rotating body 70 do not interfere with (contact with) the second rotating body 80. In the illustrated example, the origin of angle θ is set to the center of the left bearing 83, but it is not limited to this, and for example, it could be the center of the second rotating body 80. In this example, since the outer diameters D of the pair of rotating bodies are the same and the pitches P1 and P2 are approximately the same, the angle θ only needs to be an angle at which the ends of the first rotating body 70 and the ends of the second rotating body 80 are separated by a pitch of P2 or more. For example, the appropriate value can be found using tanθ = P2 / D (Equation 1). As an example, if the outer diameter D of the second rotating body 80 is 60 mm and the pitch P2 is 4 mm, the calculated value of angle θ is 3.81°.
[0056] In other words, when the feed device 5 tilts the second rotation shaft 81 at the angle θ, the second rotating body 80 tilts at the angle θ, and for example, in the illustrated example, when viewed from the front, the second grooves overlap N-1 times with the first groove of the first rotating body 70 from the rightmost second groove 801 on the lower side (the second grooves 801 to 805 overlap with the first grooves 701 to 705 in order), and when viewed from the upper side, the second grooves overlap N-1 times with the first groove of the first rotating body 70 from the leftmost second groove 805 (the second grooves 805 to 801 overlap with the first grooves 706 to 702 in order). In other words, when viewed from above, the second grooves 801 to 805 are in a position that coincides with the first grooves 702 to 706 in the left-right direction, and when viewed from below, the second grooves 805 to 801 are in a position that coincides with the first grooves 705 to 701 in the left-right direction. Furthermore, as shown in the figure, the first groove winding a1 is offset by one pitch from the second groove winding b1, so that it does not come into contact with one end of the second rotating body 80. Similarly, the first groove winding a6 is also offset by one pitch from the second groove winding b5, so that it does not come into contact with the other end of the second rotating body 80. As a result, the linear body 1 can be wound spirally around the pair of rotating bodies, and regardless of the direction in which the first rotating body 70 is driven, the pair of rotating bodies can work together to smoothly wind and feed out the linear body 1.
[0057] The number of grooves N is the number that allows the linear body 1 to be wound and fed out without slipping during operation. This number depends on the application of the feeding device 5, but is, for example, between 2 and 18. In this example, even when the number of grooves N is 6 and the second rotating body 80 is free-rotating, the linear body 1 is in contact with both rotating bodies for a total of 5.5 turns, obtaining a suitable frictional force and sufficient friction to drive the linear body 1 to rotate without slippage. Depending on the application of the feeding device 5, the number of grooves N may be 5 or less if sufficient frictional force is obtained. Within the limitations of the installation space, the number of grooves N may be increased to 7 or more to increase the frictional force.
[0058] The manufacturing method of the feed device 5 in this embodiment includes, for example, the following steps. That is, a pair of rotating bodies is prepared: a first rotating body 70 having N grooves on its outer circumference for winding a linear body 1, and a second rotating body 80 having N-1 grooves on its outer circumference for winding a linear body 1. The pair of rotating bodies are then arranged along the winding and feeding direction, and the linear body 1 is set up so that it can be wound starting at the first groove at one end of the first rotating body 70 which has more grooves, wound around both rotating bodies, and ending at the first groove at the other end of the first rotating body 70. In this embodiment, in the setup step, the two rotating bodies are set up so that their axes are twisted relative to each other by an angle θ. This can be done, for example, by rotatably mounting one rotation axis to a vertical plate so that it becomes a horizontal axis, and rotatably mounting the other rotation axis to a vertical plate so that it becomes an inclined axis, as described above.
[0059] As described above, in this embodiment, the length of the rotating body is short and there is no need to provide a helical groove, so manufacturing costs can be significantly reduced. In addition, since the double cylindrical structure of the outer drum and inner moving cylinder that is used in the conventional form is not required, the unit price of the parts used can be reduced, the number of parts can be reduced, and costs can be significantly reduced.
[0060] <Embodiment 1 Modification 1> Figure 6 is a side view showing an example of a feeding device 5 according to Modification 1 of Embodiment 1. The feeding device 5 in this example differs from the above embodiment mainly in that it includes a guide roller 911. Hereafter, common components will be omitted from explanation as appropriate, and the differences will be described in detail (the same applies to each embodiment and modification below).
[0061] The guide roller 911 is installed between a pair of rotating bodies so as to be in contact with the linear body 1. The guide roller 911 is installed in a predetermined position via a shaft member 912 that penetrates the first vertical plate 51 and the second vertical plate 52 and is supported by them (see also the dashed line portion in Figure 3(a)). As an example, the guide roller 911 has the same number of circumferential grooves as the crossing portion c on its outer surface.
[0062] As an example, the guide roller 911 is installed at the top as shown in the figure, with its lower end surface below the upper end surfaces of the pair of rotating bodies and in contact with each of the upper connecting parts c of the linear body 1. As an example, the guide roller 911 is installed at the bottom, with its upper end surface above the lower end surfaces of the pair of rotating bodies and in contact with each of the lower connecting parts c of the linear body 1. The guide roller 911 may be installed at both the top and bottom. By installing the guide roller 911, the feeding device 5 acquires a gripping angle, and the portion in contact with both rotating bodies becomes longer.
[0063] The feed device 5 in this example, by providing guide rollers 911, can not only prevent slack in the linear body 1 but also increase the frictional force between the linear body 1 and the pair of rotating bodies by lengthening the contact area. For this reason, the feed device 5 in this example can be configured to have multiple guide rollers 911 between the pair of rotating bodies, allowing the pair of rotating bodies to be positioned at a greater distance than in the previously described example. The feed device 5 in this example may also be configured to have a tension adjustment function by further pressing the guide rollers 911 against the linear body 1 using springs or the like.
[0064] <Modification 2 of Embodiment 1> Figure 7 is a side view showing an example of a feeding device 5 according to Modification 2 of Embodiment 1. The feeding device 5 in this example differs from Modification 1 of Embodiment 1 in that it includes a tension adjustment device 92 for adjusting the tension of the linear body 1.
[0065] The tension adjustment device 92 includes, as an example, a pulley 921 and a pulling means (not shown) for pulling the pulley 921 in the direction of the arrow shown (the direction in which tension increases). The pulley 921 may be provided on the side of the first rotating body 70 as shown, or, although not shown, on the side of the second rotating body 80. As an example, the pulley 921 has the same number of circumferential grooves on its outer surface as the first rotating body 70, and the intermediate portion of the first groove winding a is wound on the back side of the grooves of the pulley 921.
[0066] The tension adjustment device 92 only needs to be capable of maintaining the tension of the linear body 1, and its configuration is not particularly limited. For example, the main body of the feeding device 5 described above may be configured on a slider, and the tension adjustment device 92, which includes a spring, cylinder, screw, or other pulling means, may pull this slider to maintain the tension of the linear body 1.
[0067] Figure 8 shows an example of a feed device 5 according to modification 3 of Embodiment 1, where (a) is a diagram illustrating the groove of the rotating body, and (b) is a partially enlarged view of (a). Here, the first rotating body 70 is the central focus of the illustration, and a modification of the first groove is described, but the second groove of the second rotating body 80 may be configured similarly, except that it is installed at an inclination. In the following description, the bottom surface of the linear body 1 refers to the lower approximately 1 / 4 of the outer circumferential surface, and the side surface of the linear body 1 refers to the approximately 1 / 4 of the outer circumferential surface on each side.
[0068] As an example, in the first rotating body 70, at least one of the N first grooves is formed as a contact surface increasing groove, which increases the contact surface with the linear body 1. In this first groove, the linear body 1 contacts not only its bottom surface but also a part of its side surface, increasing the frictional force during operation. For example, in the illustrated example, the first grooves 702, 703 and 704 are formed as contact surface increasing grooves. The contact surface increasing grooves will be explained below, using the first groove 702 as an example and comparing it with the first groove 701.
[0069] The first groove 701 has an arcuate surface s1 and inclined surfaces s2 that are connected to the arcuate surface s1 on both sides. In the winding state, the first groove winding a1 in the first groove 701 has part or all of its bottom surface in contact with the arcuate surface s1. For example, in the illustrated example, the portion of the linear body 1 corresponding to the contact width Ga1 in cross-sectional view is in contact. As an example, this configuration can be achieved by making the radius of the arcuate surface s1 of the first groove 701 larger than the radius of the linear body 1.
[0070] On the other hand, the first groove 702, which is a contact surface increasing groove, has an arcuate surface s1, inclined surfaces s2 that are continuous with the arcuate surface s1 on both sides, and a substantially vertical extended surface s3 between the two. In the winding state, the first groove winding a2 in the first groove 702 is in contact with the arcuate surface s1 not only on the bottom surface but also on a part of the side surface. For example, in the illustrated example, the portion of the linear body 1 corresponding to the contact width Ga2 in cross-sectional view is in contact. As an example, this configuration can be achieved by making the radius of the arcuate surface s1 of the first groove 702 equal to or slightly smaller than the radius of the linear body 1. In addition, the first groove 702 has an extended surface s3, which increases the depth to which contact is possible. Note that the contact surface increasing groove may also be configured without an extended surface s3.
[0071] In this example, the feed device 5 may have at least one of the N-1 second grooves of the second rotating body 80 formed as a contact surface increasing groove, either instead of the first rotating body 70 or together with the first rotating body 70. In this example, since at least one of the grooves on one or both of the pair of rotating bodies is a contact surface increasing groove, the contact area between the linear body 1 and the rotating body is increased, the frictional force is increased, and the linear body 1 becomes less likely to slip.
[0072] <Embodiment 2> Figures 9 and 10 show an example of a feeder 5 according to Embodiment 2, where Figure 9(a) is a plan view, Figure 9(b) is a front view, and Figure 10 is a rear view. In Figure 9(b), the second rotating body 80 is shown as the center, and other components are omitted as appropriate. In Figure 10, the first rotating body 70 is shown as the center, and other components are omitted as appropriate. The conveying system 100 of this embodiment is the same as Embodiment 1 and its modified versions, except for the feeder 5 and the prime mover 6. This example differs from Embodiment 1 and its modified versions mainly in that rotational power is also supplied to the second rotating body 80. The feeder 5 of this embodiment has the same effects as the above embodiment and its modified versions, and further effects can be obtained with the following configuration.
[0073] The feed device 5 in this embodiment further includes a third vertical plate 53 installed perpendicular to the horizontal plate 50 and facing the second vertical plate 52, a first rotating shaft 71, and a transmission unit 93. The feed device 5 may further include a universal joint 94 and an auxiliary rotating shaft 95.
[0074] The transmission unit 93 transmits power between the first rotating body 70 and the second rotating body 80, and as an example, includes a first pulley (e.g., a timing pulley) 931, a second pulley (e.g., a timing pulley) 932, and a belt (e.g., a timing belt) 933 stretched between them.
[0075] The first rotating body 70 is fixed to the first rotating shaft 71. In this embodiment, the prime mover 6 is equipped with a coupling 62, and one end of the first rotating shaft 71 is connected to the output shaft 61 via the coupling 62, and the other end is connected to the first pulley 931. The portion of the first rotating shaft 71 between both ends is rotatably mounted and supported in the through holes (receiving holes) of the first vertical plate 51, the second vertical plate 52, and the third vertical plate 53, respectively, via a pair of bearings 73 and 74. In other words, in this embodiment, the first rotating shaft 71 is the rotating shaft of the first rotating body 70.
[0076] Although not shown in the diagram, if the feed device 5 does not have a universal joint 94 and an auxiliary rotating shaft 95, one end of the second rotating shaft 81 of the second rotating body 80 is rotatably attached and supported to the first upright plate 51 via a bearing 83, and the other end is inserted through the third upright plate 53 and connected to the second pulley 932. The portion between the two ends of the second rotating shaft 81 is rotatably attached and supported to the receiving holes of the second upright plate 52 and the third upright plate 53, respectively, via bearings 83 and 84. In this case, the receiving holes of the third upright plate are also provided at an angle, and the second pulley 932 is attached to the second rotating shaft 81 at an angle. Depending on the inclination angle of the second rotating shaft 81, if the inclination angle is small, the second pulley may be rotated while tilted.
[0077] In this configuration, the feed device 5 also provides rotational power to the second rotating body 80, which increases the frictional force and makes the linear body 1 less likely to slip.
[0078] As shown in the figure, when the feed device 5 is equipped with a universal joint 94 and an auxiliary rotating shaft 95, the other end of the second rotating shaft 81, which passes through the second vertical plate 52, is connected to one end of the auxiliary rotating shaft 95 via the universal joint 94. The other end of the auxiliary rotating shaft 95 passes through the third vertical plate 53 and is connected to the second pulley 932. The portion between the two ends of the auxiliary rotating shaft 95 is rotatably mounted and supported on the third vertical plate 53 via a bearing 84.
[0079] In this embodiment of the feed device 5, if it is equipped with a universal joint 94 and an auxiliary rotating shaft 95, the universal joint 94 is provided at the other end of the second rotating shaft 81, which is an inclined shaft, and connected to the auxiliary rotating shaft 95, which is a horizontal shaft, and the second pulley 932 is installed using the auxiliary rotating shaft 95. This eliminates the inclination of the second rotating shaft, and the belt 933 can be placed on the second pulley 932 in an inclined state and connected to the first rotating shaft 71, making connection easier and rotation more stable.
[0080] The feed device 5 may also be configured without the third vertical plate 53, by connecting the first pulley 931 to the first rotating shaft 71 and the second pulley 932 to the second rotating shaft 81, and by stretching the belt 933 between them to shorten the length in the left-right direction. In this case, the first pulley 931 and the second pulley 932 may be connected to the part of these rotating shafts on the prime mover 6 side before the second vertical plate 52 is inserted (to the right of the second vertical plate 52 in the illustrated example), or to the part on the opposite side after the second vertical plate 52 is inserted (to the left of the second vertical plate 52 in the illustrated example). The transmission section 93 may also use a chain or gears instead of pulleys and a belt.
[0081] <Embodiment 3> Figure 11 shows an example of a feeder 5 according to Embodiment 3, (a) a plan view and (b) a side view. Here, the diagram focuses on a pair of rotating bodies, and components other than the rotating bodies are omitted as appropriate. The transport system 100 of this embodiment is the same as the above embodiment and its modified form, except for the feeder 5. The feeder 5 of this embodiment differs from the above embodiment and its modified form mainly in the pair of rotating bodies. The feeder 5 of this embodiment provides the same effects as the above embodiment and its modified form, and further effects can be obtained from the following configuration.
[0082] In this embodiment, the first rotating body 70 and the second rotating body 80 are arranged along the winding and unwinding direction, with the first rotating body 70 located at a distance from the return pulley 4. In this embodiment, the first rotating body 70 and the second rotating body 80 are installed so that their centerlines F1 and F2 coincide in the left-right direction in a plan view. The first rotating body 70 has N first grooves on its outer circumference, and the second rotating body 80 has N+1 second grooves on its outer circumference. Each first groove is a circumferential groove that is continuous in the circumferential direction and extends parallel to each other. Similarly, each second groove is a circumferential groove that is continuous in the circumferential direction and extends parallel to each other. The first rotating body 70 and the second rotating body 80 have approximately the same outer diameter and approximately the same groove width.
[0083] In this embodiment, the first rotating body 70 and the second rotating body 80 are preferably both installed with their axes parallel to the XZ plane and the YZ plane, and are installed parallel to each other. The first rotating body 70 is fixed to the output shaft 61 of the prime mover 6, for example. The first rotating body 70 may also be fixed to a first rotating shaft 71 connected to the output shaft 61. In other words, the axis of rotation of the first rotating body 70 is the output shaft 61 or the first rotating shaft 71. The second rotating body 80 is fixed to a second rotating shaft 81, and the second rotating shaft 81 is its axis of rotation. In this embodiment, the first rotating body 70 and the second rotating body 80 are installed such that, when viewed from the front, their grooves are offset by 0.5 grooves at one end (the right end in the illustrated example) and by 0.5 grooves at the other end (the left end in the illustrated example).
[0084] The linear body 1 can be wound starting at the second groove 801 at one end of the second rotating body 80, which has a large number of grooves, and wound around both the second rotating body 80 and the first rotating body 70, ending at the second groove 804 at the other end of the second rotating body 80. In this embodiment, the linear body 1 can intersect at the midpoint of the rotation axes of the pair of rotating bodies and be wound around both rotating bodies.
[0085] The linear body 1 begins winding from above at the second groove 801 at one end of the second rotating body 80 (b1), then wraps around the first rotating body 70, starting from below and going backward through the first groove 701 at one end and winding towards the front (a1), then wraps around the next second groove at the second rotating body 80, starting from below and winding towards the rear (b2). Next, it wraps around the first rotating body 70 again, starting from below and going backward through the next first groove and winding towards the front (a2). In this way, the linear body 1 is wrapped around each groove sequentially, spanning the second rotating body 80 and the first rotating body 70, and ends at the second groove 804 at the other end of the second rotating body 80 (b4). The beginning portion of the linear body 1 is connected to the first extended portion 11, and the end portion is connected to the second extended portion 12. Note that the starting and ending points of the winding are relative, and you can wind it in the opposite direction as well.
[0086] In this embodiment, the first groove windings a1, a2, a3 and the second groove windings b2, b3 are all greater than half-circle windings. That is, the winding angle α1 of the linear body 1 on the first rotating body 70 is greater than 180°, resulting in a longer winding length and increased frictional force. Also, excluding the grooves at both ends, the winding angle α2 of the linear body 1 on the second rotating body 80 is greater than 180°, resulting in a longer winding length and increased frictional force.
[0087] The number of grooves N is the number required to wind and feed the linear body 1 without slipping during operation. This number depends on the application of the feeding device 5, but is, for example, between 1 and 10. As in this example, if the number of grooves N is 3, sufficient frictional force can be obtained to wind and feed the linear body 1 without slipping in normal applications. Depending on the application of the feeding device 5, the number of grooves N may be 2 or less if sufficient frictional force can be obtained. Within the limitations of the installation space, the number of grooves N may be increased to 4 or more to increase the frictional force.
[0088] The manufacturing method of the feed device 5 in this embodiment includes, for example, the following steps. That is, a pair of rotating bodies is prepared: a first rotating body 70 having N grooves on its outer circumference for winding a linear body 1, and a second rotating body 80 having N+1 grooves on its outer circumference for winding a linear body 1. The pair of rotating bodies are then arranged along the winding and feeding direction, and the linear body 1 is set up so that it can be wound starting at the second groove at one end of the second rotating body 80, which has more grooves, and wound around both rotating bodies, ending at the second groove at the other end of the second rotating body. The pair of rotating bodies can be set up by fixing them to their respective rotating shafts and rotatably mounting these rotating shafts to corresponding vertical plates, as in the above embodiments and their modified examples.
[0089] The feeding device 5 may, for example, be configured to increase the tension by installing the tension adjustment device 92 on the second rotating body 80 side to pull the linear body 1.
[0090] <Embodiment 4> Figure 12 shows an example of a feeding device 5 according to Embodiment 4, where (a) is a plan view and (b) is a side view. In this embodiment, the feeding device 5 links multiple rotating bodies with a timing belt and feeds the linear body 1 by the frictional force between the multiple rotating bodies and the linear body.
[0091] The feed device 5 in this embodiment includes, as an example, three rotating bodies: a first rotating body 96, a second rotating body 97, and a third rotating body 98. Each rotating body is typically a pulley, having grooves (961, 971, 981) on its outer circumference for grabbing a single linear body 1, and timing pulleys (963, 973, 983) connected to its rotating shafts (962, 972, 982). A timing belt 991 is placed over the timing pulleys of each rotating body, and rotational power is transmitted to cause each rotating body to move in conjunction. In one example, the feed device 5 is driven by connecting the rotating shaft 962 of the first rotating body 96 to the output shaft of a prime mover 6 (not shown).
[0092] As shown in the figure, when the first rotating body 96 is driven counterclockwise, power is transmitted by the timing belt 991, causing the second rotating body 97 and the third rotating body 98 to also rotate counterclockwise. As a result, the linear body 1 that is wrapped around these rotating bodies (one turn) is wound up on the first extension portion 11 side and fed out on the second extension portion 13 side. The feeding device 5 may use a chain or gears instead of the timing pulley and timing belt described above. The feeding device 5 may also include an idler 992 and a direction changing pulley 993.
[0093] In this configuration, the feed device 5 has the advantage of having a large planar area because multiple rotating bodies are installed in a planar manner, but it can be configured with a small vertical width.
[0094] Although embodiments and variations of the present invention have been described above, these are merely examples of the present invention and are not limited thereto. The present invention includes combinations of the above embodiments and their variations, as well as various further variations. Various additions, modifications, and partial deletions are possible without departing from the conceptual idea and spirit of the present invention derived from the claims and their equivalents.
[0095] 100...Conveying system, 1...Linear body, 2...Conveying trolley, 3...Guide rail, 4...Folding pulley, 5...Feeding device, 50...Horizontal plate, 51...First vertical plate, 52...Second vertical plate, 6...Prime motor, 61...Output shaft, 70...First rotating body, 71...First rotating shaft, 701...First groove (at one end), 706...First groove (at the other end), 80...Second rotating body, 81...Second rotating shaft, 911...Guide roller, 92...Tension adjustment device, 93...Transmission unit, 94...Universal joint, 95...Auxiliary rotating shaft.
Claims
1. A feeding device for winding and feeding a linear body, comprising: a prime mover; and a pair of rotating bodies, a first rotating body and a second rotating body, arranged along the winding and feeding direction, wherein the first rotating body is connected to the output shaft of the prime mover and has N grooves on its outer circumference for winding the linear body; and the second rotating body has N-1 or N+1 grooves on its outer circumference for winding the linear body; and the feeding device is capable of winding the linear body by starting to wind it at the groove at one end of the rotating body with the larger number of grooves, winding it around both rotating bodies, and ending the winding at the groove at the other end of the rotating body.
2. The feed device according to claim 1, wherein the second rotating body has N-1 grooves on its outer circumferential surface, the first rotating body and the second rotating body are installed such that their axes are twisted relative to each other by an angle θ, and the linear body can be spirally wound around the pair of rotating bodies.
3. The feeding device according to claim 2, wherein the first groove of the first rotating body and the second groove of the second rotating body have equivalent groove widths, and the angle θ is such that, in a forward view, the upper side of the rightmost second groove overlaps with the second first groove from the right and the upper side of the leftmost second groove overlaps with the leftmost first groove, or the upper side of the leftmost second groove overlaps with the second first groove from the left and the upper side of the rightmost second groove overlaps with the rightmost first groove.
4. The feeding device according to claim 2, comprising a horizontal plate installed parallel to a horizontal plane and a pair of vertical plates installed perpendicular to the horizontal plate, wherein the rotating shaft to which the second rotating body is fixed is rotatably mounted on the pair of vertical plates at an angle θ with respect to the horizontal plane.
5. The feeding device according to claim 2, wherein the feeding device comprises a guide roller having a groove on its outer surface, and the guide roller is installed between the first rotating body and the second rotating body so as to be in contact with the linear body.
6. The feeding device according to claim 1, wherein the second rotating body has N+1 grooves on its outer circumferential surface, the first rotating body and the second rotating body are installed so that their centerlines in the left-right direction coincide, and the linear body can intersect at the midpoint of the rotation axes of the pair of rotating bodies and wrap around both rotating bodies.
7. The feeding device according to claim 1, further comprising a tension adjustment device for adjusting the tension of the linear body.
8. The feeder according to claim 1, further comprising a transmission unit for transmitting power between the first rotating body and the second rotating body.
9. The feeder according to claim 8, wherein the rotation axis of the second rotating body is connected to the transmission unit via a universal joint and an auxiliary rotation axis.
10. A conveying system comprising: a linear body; a transport trolley connected to the linear body; a guide rail for guiding the transport trolley; a folding pulley for folding the linear body; and a feeding device according to any one of claims 1 to 9, wherein the linear body is wrapped around a pair of the rotating bodies on one side of the transport source and the transport destination, and is hung on the folding pulley on the other side.
11. A method for manufacturing a feeding device for winding and feeding a linear material, comprising: preparing a pair of rotating bodies: a first rotating body having N grooves on its outer circumference for winding the linear material and a second rotating body having N-1 or N+1 grooves on its outer circumference for winding the linear material; arranging the pair of rotating bodies along the winding and feeding direction; and setting up the device so that the linear material can be wound starting at the groove at one end of the rotating body with the larger number of grooves, wound around both rotating bodies, and ending at the groove at the other end of the rotating body.