EP4618118A1 - Winding device and winding method - Google Patents

Winding device and winding method

Info

Publication number
EP4618118A1
EP4618118A1 EP25161610.8A EP25161610A EP4618118A1 EP 4618118 A1 EP4618118 A1 EP 4618118A1 EP 25161610 A EP25161610 A EP 25161610A EP 4618118 A1 EP4618118 A1 EP 4618118A1
Authority
EP
European Patent Office
Prior art keywords
winding
wire
section
length
forming
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
EP25161610.8A
Other languages
German (de)
French (fr)
Inventor
Yusuke Fukushima
Tomoki OHKAWARA
Takahito Ishida
Masayuki Sugiyama
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Mitsuba Corp
Original Assignee
Mitsuba Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Mitsuba Corp filed Critical Mitsuba Corp
Publication of EP4618118A1 publication Critical patent/EP4618118A1/en
Pending legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/077Deforming the cross section or shape of the winding material while winding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01FMAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06Coil winding
    • H01F41/061Winding flat conductive wires or sheets

Definitions

  • the disclosure relates to a winding device and a winding method.
  • the winding When forming a rectangular wire from a round wire using a rectangular wire forming device and winding the formed rectangular wire around the teeth section of a split core, the winding may be damaged when changing the cross-sectional shape of the winding.
  • Patent Literature 1 discloses a winding device that can suppress the quality deterioration of products due to damage to the winding, even in cases where the cross-sectional shape of the winding is deformed midway before being wound around the winding target.
  • the disclosure describes a winding device that supplies a winding from a wire supply source to a winding target side and winds the winding around the winding target.
  • the winding device includes a winding deformation section disposed on the downstream side of the wire supply source, which changes the cross-sectional shape of the winding, and a damage detection section disposed on the downstream side of the winding deformation section, which detects damage to the winding.
  • Patent Literature 1 Japanese Patent Application Laid-Open No. 2023-132628
  • both ends of the coil wire to be wound (also referred to as start and end terminals) become lead parts for connection.
  • start and end terminals of the wire wound on the winding target remain in a round shape, which facilitates the connection work to be performed after winding.
  • the part of the wire corresponding to the start and end terminals is left unformed in a round shape, while the subsequent part to be wound on the winding target is formed into a rectangular shape.
  • a short length part that becomes the initial start terminal is left as a round-shaped wire, followed by forming the rectangular shape to be wound, and the round-shaped wire of the start terminal is not wound on the winding target, while the rectangular-shaped part is wound.
  • the wire is again left unformed in a round shape.
  • the rectangular shape is formed corresponding to the part to be wound, followed by leaving a short length part of the wire unformed for the start and end terminal parts. This process is repeated.
  • the forming process involves repeating a pattern in which there is a short unformed length part, followed by a longer length part formed into a rectangular shape.
  • start and end terminal parts reach the end terminal of the current winding target, the start and end terminal parts are cut to separate the end terminal part and the start terminal part.
  • the part following the start terminal becomes the wire for the next winding target, and the winding operation is continuously performed in this repeating manner.
  • the split stator core which is the winding target, naturally has shape variation within the range of manufacturing tolerances.
  • the outer shape of the winding part can be either smaller or larger, and the variation in the outer shape manifests as a difference in the length of wire required to wind the same number of turns.
  • the wire will be wound longer than the design winding length.
  • start and end terminal parts are formed at the design length position, in reality, because the winding is longer than at the time of design, the start and end terminal parts end up being wound on the winding target. Furthermore, the formed part to be wound on the next winding target ends up being positioned at which the start and end terminal parts should originally be.
  • the disclosure is made in view of such circumstances, and aims to provide a winding device and a winding method that can form the start and end terminals at appropriate positions while being less susceptible to the influence of manufacturing variation in the winding target.
  • the winding device of the disclosure that winds a wire onto a winding target includes: a length correction section which corrects a predetermined reference length; a wire supply section which supplies the wire in a round shape; a forming section which is provided on a downstream side of the wire supply section and forms the wire into a rectangular shape; and a winding section which is provided on a downstream side of the forming section and winds the wire onto the winding target.
  • the forming section performs start and end terminal processing in which forming on a part of the wire corresponding to start and end terminals of the winding target is not performed, and a forming process in which the wire corresponding to a part to be wound on the winding target is formed.
  • the length correction section performs a correction process in which a correction reference length is determined by correcting the reference length based on shape variation of the winding target.
  • the start and end terminal processing is performed when a supply length of the wire supplied from the start of winding reaches the correction reference length.
  • the winding method of the disclosure that winds a wire onto a winding target includes: a start and end terminal step in which does not form a part of the wire corresponding to start and end terminals of the winding target is not formed but is left in a round shape; and a forming step in which the wire corresponding to a part to be wound on the winding target is formed into a rectangular shape.
  • the start and end terminal step is performed when a supply length of the wire supplied from the start of winding reaches a correction reference length, which is obtained by correcting a predetermined reference length based on shape variation of the winding target.
  • a winding device and a winding method may be provided that can form start and end terminals at appropriate positions while being less susceptible to the influence of manufacturing variation in the winding target.
  • FIG. 1 is a perspective view of a brushless motor 1 having a split core 7 that can be suitably applied to a winding device 10 (refer to FIG. 3 ) according to an embodiment of the disclosure.
  • FIG. 2 is a side view of a part corresponding to one split core 7 according to an embodiment of the disclosure.
  • the brushless motor 1 (also simply referred to as a motor) includes a stator 2 press-fitted into a housing (not shown), and a rotor 3 disposed radially inward of the stator 2 and rotatably provided with respect to the stator 2.
  • the stator 2 includes a stator core 4, an insulating insulator 5 mounted on the stator core 4, and a coil 6.
  • the length measuring instrument 15 transmits the measured separation length to the control section PLC as data of the measured length variation of the split core 7 (refer to an arrow DT2 in FIG. 3 ).
  • the control section PLC is a so-called sequencer that includes: a storage section (not shown) that stores a program for performing a control operation, received data, and results of calculations based on the received data; a central processing unit (not shown) that performs calculations; and a touch panel display section (not shown) that inputs settings and other operations.
  • the control section PLC functions as a length correction section that corrects a predetermined reference length.
  • the coil wire 8 is wound 32 times around the split core 7 to complete the winding.
  • an operator inputs, through touch operation on the display section, the length L of the long side of the split core 7 used as a reference, and the reference length that serves as the standard for determining at what length of the coil wire 8 supplied from the start of winding should be considered as the start and end terminal part.
  • the input of the reference supply length is performed for the start and end terminal processing in which the forming section 12 does not perform forming.
  • the split core 7 used as a reference refers to a split core 7 that is close to the design center in terms of design. Using the split core 7 that is close to the design center, actual winding is performed, and data collection is conducted to measure the supply length required to execute the start and end terminal processing from the start of winding, based on which the reference length is determined.
  • the number of windings indicating how many times the coil wire 8 is to be wound around the split core 7, is input.
  • the input (the length L of the long side of the split core 7 used as a reference, the reference length, and the number of windings) is an operation that needs to be performed merely once at the beginning when repeatedly conducting the work of winding the coil wire 8 around split cores 7 of the same design.
  • the operator sets the split core 7 on which the coil wire 8 is about to be wound into the length measuring instrument 15, and has the length measuring instrument 15 measure the length variation in the shape of the split core 7.
  • the length measuring instrument 15 transmits the measured length variation data, that is, the data of the long side length of the set split core 7, to the control section PLC (refer to the arrow DT2 in FIG. 3 ).
  • control section PLC issues a command to start rotation to the servo motor (not shown) of the winding section 14, and a command to start measuring the supply length of the coil wire 8 to the encoder ENC.
  • control section PLC functions as a length correction section and corrects the reference length described earlier, which is set in advance.
  • FIG. 7 is a diagram describing the content of the correction performed by the length correction section according to an embodiment of the disclosure.
  • FIG. 7 shows the body part of the split core 7 measured by the length measuring instrument 15 with a solid line, aligns the left short side position of the split core 7 used as a reference, and indicates the right end side position with a dotted line.
  • the split core 7 on which the coil wire 8 is about to be wound has a larger outer shape within the range of manufacturing tolerances than the split core 7 used as a reference.
  • the long side of the split core 7 is longer, and the length thereof is denoted as L'.
  • the discrepancy occurs 32 times.
  • control section PLC functioning as the length correction section, conducts a correction process in which the overall length discrepancy is calculated based on the measured length variation of the shape of the split core 7, and determines a correction reference length in which the reference length is corrected by adding the discrepancy to a predetermined reference length.
  • the control section PLC monitors the number of rotations of the split core 7, that is, the number of windings of the split core 7, based on the output signal (refer to the arrow DT1 in FIG. 3 ) related to the rotational speed sequentially transmitted from the servo motor (not shown). Simultaneously, the control section PLC monitors the measurement results of the measured supply length sequentially transmitted (refer to an arrow DT3 in FIG. 3 ) from the encoder ENC.
  • the control section PLC issues a command (refer to a dotted arrow CM in FIG. 3 ) to execute the start and end terminal processing in which forming is not performed in the forming section 12.
  • the forming section 12 drives an undepicted drive mechanism to widen the separation distance between the upper roller and the lower roller, and the separation distance between the left roller and the right roller, so that the round-shaped coil wire 8 passes through without being formed.
  • the forming section 12 performs the start and end terminal processing in which forming on the part of the coil wire 8 corresponding to the start and end terminals of the split core 7 is not performed.
  • control section PLC continues to monitor the supply length even after issuing the command to execute the start and end terminal processing. After issuing the command for the start and end terminal processing and when the coil wire 8 has been supplied for the length of the start and end terminal part, the control section PLC issues a command (refer to the dotted arrow CM in FIG. 3 ) to execute the forming process in which forming is performed in the forming section 12.
  • the forming section 12 drives an undepicted drive mechanism to narrow the separation distance between the upper roller and the lower roller, and the separation distance between the left roller and the right roller, so that the round-shaped coil wire 8 is formed into a rectangular shape.
  • the forming section 12 performs the forming process in which forming on the coil wire 8 corresponding to the part to be wound on the split core 7 is conducted.
  • the device when stopping upon reaching 32 windings, the device typically stops in a state where the forming process is being performed. Therefore, at the start of the next winding operation, it begins from the state where the forming process is being conducted.
  • the control section PLC sends a command to end winding to the winding section 14.
  • the winding section 14 ends the rotation and activates the cutting section (not shown) to perform a cutting process to cut the start and end terminal parts so as to separate the start and end terminal parts into a start terminal part and an end terminal part.
  • the influence of such variation is mitigated.
  • the correction of the reference length for the switching timing of the start and end terminals is performed for split cores 7 close to the design center, and the switching timing of the start and end terminals is controlled based on the correction reference length after the correction.
  • the start and end terminal parts can be formed at appropriate positions.
  • the winding method using the winding device 10 of the embodiment includes a start and end terminal step in which the part of the coil wire 8 corresponding to the start and end terminals of the split core 7 is left in a round shape without forming, and a forming step in which the coil wire 8 corresponding to the part to be wound around the split core 7 is formed into a rectangular shape.
  • the start and end terminal step is performed when the supply length of the coil wire 8 supplied from the start of winding reaches a correction reference length, which is obtained by correcting a predetermined reference length based on the shape variation of the split core 7.
  • the method can reduce the susceptibility to the influence of manufacturing tolerance variation in the split core 7, and consequently, the formation positions of the start and end terminal parts can be set at appropriate locations.
  • the length of the long side is measured and used for correction because the length of the long side can be easily measured.
  • the circumference can also be measured and used for correction.
  • tension adjustment section 13 is shown with two tension rollers, the tension adjustment section 13 may be provided with three or more tension rollers.
  • all tension rollers are drive rollers that are synchronously driven.
  • 1... brushless motor 2... stator, 3... rotor, 4... stator core, 5... insulator, 6... coil, 7... split core, 8... coil wire, 8A, 8B... part, 10... winding device, 11... wire supply section, 12... forming section, 12A... first forming section, 12B... second forming section, 13... tension adjustment section, 13A... first tension roller, 13B... second tension roller, 14... winding section, 15... length measuring instrument, 15A... base, 15B... drive unit, E1... turntable, E2... light sensor, ENC... encoder, L, L'... length, NZ... nozzle, PLC... control section, R... roller, S... slit

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Coil Winding Methods And Apparatuses (AREA)

Abstract

A winding device (10) includes: a length correction section which corrects a predetermined reference length; a wire supply section (11) which supplies a round-shaped wire; a forming section (12) which forms the wire into a rectangular shape; a winding section (14) which winds the wire onto a winding target. The forming section (12) performs start and end terminal processing in which forming on a part of the wire corresponding to start and end terminals of the winding target is not performed, and a forming process in which the wire corresponding to a part to be wound on the winding target is formed. The length correction section performs a correction process to determine a correction reference length, and the start and end terminal processing is performed when a supply length of the wire supplied from the start of winding reaches the correction reference length.

Description

    BACKGROUND Technical Field
  • The disclosure relates to a winding device and a winding method.
  • Description of Related Art
  • When forming a rectangular wire from a round wire using a rectangular wire forming device and winding the formed rectangular wire around the teeth section of a split core, the winding may be damaged when changing the cross-sectional shape of the winding.
  • Therefore, Patent Literature 1 discloses a winding device that can suppress the quality deterioration of products due to damage to the winding, even in cases where the cross-sectional shape of the winding is deformed midway before being wound around the winding target.
  • Specifically, the disclosure describes a winding device that supplies a winding from a wire supply source to a winding target side and winds the winding around the winding target. The winding device includes a winding deformation section disposed on the downstream side of the wire supply source, which changes the cross-sectional shape of the winding, and a damage detection section disposed on the downstream side of the winding deformation section, which detects damage to the winding.
  • Related Art Patent Literature
  • [Patent Literature 1] Japanese Patent Application Laid-Open No. 2023-132628
  • SUMMARY Technical Problem
  • Incidentally, in winding targets such as split cores, both ends of the coil wire to be wound (also referred to as start and end terminals) become lead parts for connection.
  • For this reason, it is preferable that the start and end terminals of the wire wound on the winding target remain in a round shape, which facilitates the connection work to be performed after winding.
  • Therefore, in order to form such start and end terminals that remain in a round shape, the part of the wire corresponding to the start and end terminals is left unformed in a round shape, while the subsequent part to be wound on the winding target is formed into a rectangular shape.
  • Specifically, a short length part that becomes the initial start terminal is left as a round-shaped wire, followed by forming the rectangular shape to be wound, and the round-shaped wire of the start terminal is not wound on the winding target, while the rectangular-shaped part is wound.
  • Then, for a short length of the wire corresponding to the end terminal part of the current winding target and the start terminal part of the next winding target (also referred to as start and end terminal parts), the wire is again left unformed in a round shape. Subsequently, the rectangular shape is formed corresponding to the part to be wound, followed by leaving a short length part of the wire unformed for the start and end terminal parts. This process is repeated.
  • In other words, regarding the forming of the wire, the forming process involves repeating a pattern in which there is a short unformed length part, followed by a longer length part formed into a rectangular shape.
  • When the start and end terminal parts reach the end terminal of the current winding target, the start and end terminal parts are cut to separate the end terminal part and the start terminal part. The part following the start terminal becomes the wire for the next winding target, and the winding operation is continuously performed in this repeating manner.
  • Incidentally, the split stator core, which is the winding target, naturally has shape variation within the range of manufacturing tolerances.
  • In other words, the outer shape of the winding part can be either smaller or larger, and the variation in the outer shape manifests as a difference in the length of wire required to wind the same number of turns.
  • Therefore, even if the number of windings on the winding target is the same, variation occurs in the required length of the wire to be wound. When controlling the position to form the start and end terminals based on the supply length of a wire fed from the start of winding, there were cases where the start and end terminals could not be formed at an appropriate position due to the influence of variation in the actual required length of wire to be wound.
  • Specifically, in the case where the winding target to be wound is larger than the design outer shape of the winding target, the wire will be wound longer than the design winding length.
  • If the start and end terminal parts are formed at the design length position, in reality, because the winding is longer than at the time of design, the start and end terminal parts end up being wound on the winding target. Furthermore, the formed part to be wound on the next winding target ends up being positioned at which the start and end terminal parts should originally be.
  • When this occurs, not only does the positioning of the round-shaped wire within the winding part cause the winding to collapse, but also the rectangular-shaped part that should be formed as the end terminal ends up being positioned at which the rectangular-shaped part should not be. This leads to the problem of a higher defect rate in the subsequent connection process.
  • The disclosure is made in view of such circumstances, and aims to provide a winding device and a winding method that can form the start and end terminals at appropriate positions while being less susceptible to the influence of manufacturing variation in the winding target. Solution to the Problem
  • To achieve the above-mentioned objective, the disclosure is understood by the following configuration.
  • The winding device of the disclosure that winds a wire onto a winding target includes: a length correction section which corrects a predetermined reference length; a wire supply section which supplies the wire in a round shape; a forming section which is provided on a downstream side of the wire supply section and forms the wire into a rectangular shape; and a winding section which is provided on a downstream side of the forming section and winds the wire onto the winding target. The forming section performs start and end terminal processing in which forming on a part of the wire corresponding to start and end terminals of the winding target is not performed, and a forming process in which the wire corresponding to a part to be wound on the winding target is formed. The length correction section performs a correction process in which a correction reference length is determined by correcting the reference length based on shape variation of the winding target. The start and end terminal processing is performed when a supply length of the wire supplied from the start of winding reaches the correction reference length.
  • The winding method of the disclosure that winds a wire onto a winding target includes: a start and end terminal step in which does not form a part of the wire corresponding to start and end terminals of the winding target is not formed but is left in a round shape; and a forming step in which the wire corresponding to a part to be wound on the winding target is formed into a rectangular shape. The start and end terminal step is performed when a supply length of the wire supplied from the start of winding reaches a correction reference length, which is obtained by correcting a predetermined reference length based on shape variation of the winding target.
  • Effects
  • According to the disclosure, a winding device and a winding method may be provided that can form start and end terminals at appropriate positions while being less susceptible to the influence of manufacturing variation in the winding target.
  • BRIEF DESCRIPTION OF THE DRAWINGS
    • FIG. 1 is a perspective view of a brushless motor having split cores to which the winding device according to an embodiment of the disclosure can be suitably applied.
    • FIG. 2 is a side view of a part corresponding to one split core according to an embodiment of the disclosure.
    • FIG. 3 is a top view for describing the winding device according to an embodiment of the disclosure.
    • FIG. 4 is a diagram for describing the forming operation in the forming section according to an embodiment of the disclosure.
    • FIG. 5 is a side view showing a part of the encoder according to an embodiment of the disclosure as viewed from the side.
    • FIG. 6 is a diagram for describing the essential parts of the length measuring instrument according to an embodiment of the disclosure.
    • FIG. 7 is a diagram describing the content of the correction performed by the length correction section according to an embodiment of the disclosure.
    DESCRIPTION OF THE EMBODIMENTS
  • The following describes in detail an aspect for implementing the disclosure (hereinafter referred to as "embodiment") with reference to the attached drawings.
  • It should be noted that throughout the description of the embodiment, the same elements are assigned the same numbers or symbols.
  • FIG. 1 is a perspective view of a brushless motor 1 having a split core 7 that can be suitably applied to a winding device 10 (refer to FIG. 3) according to an embodiment of the disclosure.
  • FIG. 2 is a side view of a part corresponding to one split core 7 according to an embodiment of the disclosure.
  • As shown in FIG. 1, for example, the brushless motor 1 (also simply referred to as a motor) includes a stator 2 press-fitted into a housing (not shown), and a rotor 3 disposed radially inward of the stator 2 and rotatably provided with respect to the stator 2.
  • The stator 2 includes a stator core 4, an insulating insulator 5 mounted on the stator core 4, and a coil 6.
  • The stator core 4 is a split core type stator core 4 formed by annularly connecting multiple split cores 7 (an example of a winding target of the disclosure) divided in the circumferential direction.
  • As shown in FIG. 2, a coil wire 8 (an example of a wire of the disclosure) is wound on the split core 7 to form the coil 6. A part 8A of the coil wire 8 wound on the split core 7 has a rectangular shape in order to be wound with as little gap as possible, increase density, and improve motor performance.
  • On the other hand, a part 8B of the coil wire 8 drawn out from the split core 7 (hereinafter referred to as the start terminal, end terminal, or collectively as start and end terminals) is made into a round-shaped coil wire 8 to reduce the occurrence of defects during connection work such as welding to a bus bar.
  • It should be noted that FIG. 2 is a side view, therefore merely the end terminal of the start and end terminals is depicted, and the start terminal overlapping in the direction into the page is not visible.
  • The winding device 10 of the embodiment is suitable for winding on the split core 7 while forming the part to be wound into a rectangular shape, while maintaining the start and end terminals in a round shape. This will be described below with reference to FIG. 3 to FIG. 7.
  • FIG. 3 is a top view for describing the winding device 10 according to an embodiment of the disclosure.
  • As shown in FIG. 3, the winding device 10 of the embodiment includes a wire supply section 11 that supplies the round-shaped coil wire 8, a forming section 12 that is provided on the downstream side of the wire supply section 11 and forms the shape of the coil wire 8 into a rectangular shape, a tension adjustment section 13 that is provided on the downstream side of the forming section 12 and controls the tension during winding, and a winding section 14 that is provided on the downstream side of the forming section 12 (more specifically, the tension adjustment section 13) and winds the coil wire 8 on the split core 7.
  • It should be noted that the upstream side (upstream) refers to the wire supply section 11 side where the supply of the coil wire 8 begins, the downstream side (downstream) refers to the opposite side thereof, which is the winding section 14 side, and the same applies hereinafter.
  • Furthermore, the winding device 10 of the embodiment includes an encoder ENC (an example of a supply length measuring section of the disclosure) that is provided between the forming section 12 and the winding section 14 (more specifically, between the forming section 12 and the tension adjustment section 13) and measures the supplied length of the coil wire 8, a length measuring instrument 15 that is provided next to the winding section 14 and measures the length variation of the shape of the split core 7, a control section PLC that controls the overall operation of the winding device 10, and a nozzle NZ that is provided between the tension adjustment section 13 and the winding section 14 and supplies the coil wire 8 to the winding section 14.
  • The wire supply section 11 is a reel on which round-shaped magnet wire, serving as the coil wire 8, is wound.
  • The forming section 12 includes a first forming section 12A having a pair of forming rollers that form the coil wire 8 by sandwiching the coil wire 8 from a first direction (up-down direction) perpendicular to the coil wire 8 (note that in the figure, merely the forming roller positioned on the upper side is visible), and a second forming section 12B having a pair of forming rollers that form the coil wire 8 by sandwiching the coil wire 8 from a second direction (left-right direction) perpendicular to both the coil wire 8 and the first direction.
  • FIG. 4 is a diagram for describing the forming operation in the forming section 12 according to an embodiment of the disclosure, illustrated from left to right to show the direction from upstream to downstream.
  • As shown in FIG. 4, the coil wire 8 supplied from the wire supply section 11 (refer to FIG. 3) is a round-shaped coil wire 8.
  • Then, as the coil wire 8 passes through the first forming section 12A, the width of which is regulated by an upper roller and a lower roller, and the coil wire 8 is formed to have a width X in the up-down direction. Furthermore, as the coil wire 8 passes through the second forming section 12B, the width of which is regulated by a left roller and a right roller, and the coil wire 8 is formed to have a width Y in the left-right direction. As a result of passing through the forming section 12, the coil wire 8 is formed into a rectangular shape with the width X in the up-down direction and the width Y in the left-right direction, as shown on the right side.
  • It should be noted that the upper roller and the lower roller can be moved in directions to approach and separate from each other by a drive mechanism (not shown), allowing the separation distance between the upper roller and the lower roller to be changed.
  • Similarly, the left roller and the right roller can also be moved in directions to approach and separate from each other by a drive mechanism (not shown), allowing the separation distance between the left roller and the right roller to be changed.
  • Therefore, to avoid forming the part of the coil wire 8 corresponding to the start and end terminals, the drive mechanism (not shown) drives to widen the separation distance between the upper roller and the lower roller, and the separation distance between the left roller and the right roller. As a result, the round-shaped coil wire 8 supplied from the wire supply section 11 passes through without being formed, and the round-shaped coil wire 8 is left as start and end terminal parts.
  • The tension adjustment section 13 includes, as shown in FIG. 3, tension rollers (first tension roller 13A, second tension roller 13B) and a motor (not shown) that rotates the tension rollers.
  • In the embodiment, the tension rollers (first tension roller 13A, second tension roller 13B) are designed to have a high gripping force to pull out the coil wire 8 from the forming section 12 without causing slippage between the rollers and the coil wire 8.
  • Specifically, the diameter of the tension rollers (first tension roller 13A, second tension roller 13B) is set to 150 mm φ to increase the contact area with the coil wire 8. Additionally, at least the part that contacts the coil wire 8 is made of a natural rubber material with a high friction resistance, equivalent to Shore hardness A90.
  • Regarding the diameter, if the diameter is too large, space is required. Therefore, it is preferable to set the diameter, for example, to be 140 mm φ or more and 200 mm φ or less.
  • Although not shown in the figures, the first tension roller 13A and the second tension roller 13B are connected by a belt, and by driving the belt with a motor, the first tension roller 13A and the second tension roller 13B are made to rotate in synchronization.
  • In this configuration, both the first tension roller 13A and the second tension roller 13B become drive rollers. Therefore, unlike when one is a follower roller that simply rotates according to the movement of the coil wire 8, the follower roller does not act as a load against the drive roller. This contributes to the suppression of slippage between the rollers and the coil wire 8.
  • FIG. 5 is a side view showing a part of the encoder ENC according to an embodiment of the disclosure from the side.
  • The figure in the callout box in FIG. 5 is a plan view showing merely a turntable E1.
  • In addition, FIG. 5 omits the illustration of a unit that calculates the supply length of the supplied coil wire 8 based on the detection results detected by a detection section of the encoder ENC, which will be described later.
  • However, it is not necessarily limited to providing a unit for calculation. The control section PLC, which will be described later, may be configured to perform the calculation to determine the supply length of the coil wire 8 that has been supplied based on the detection results detected by the detection section.
  • The encoder ENC has a detection section (described later) provided between the forming section 12 and the winding section 14 (more specifically, the tension adjustment section 13), and is a measuring section that measures the supply length of the supplied coil wire 8 that has been supplied. As will be described later, it is important to be able to perform accurate measurements to determine the timing for the start and end terminals.
  • Depending on the structure of the encoder, the load on the detection mechanism may be large, making it difficult for the roller R to rotate due to the load, causing slippage between the roller R and the coil wire 8, resulting in unstable detection.
  • As a result, the accuracy of the supply length of the supplied coil wire 8, which is determined based on the detection results, deteriorates.
  • Therefore, as shown in FIG. 5, the encoder ENC of the embodiment includes, as a detection section, a pair of rollers R that rotate in contact with the coil wire 8, a turntable E1 that has slits S at equal intervals in the circumferential direction and is provided on the rotation axis of one of the rollers R, and a light sensor E2 (an example of the passage sensor of the disclosure) that detects the passage of the slits S of the turntable E1 without contact. The detection mechanism (refer to the dotted line enclosure in FIG. 5) is configured with the turntable E1 and the light sensor E2 in a non-contact manner, significantly reducing friction resistance.
  • As a result, the roller R on which the turntable E1 is provided can rotate more easily, and consequently, slippage between the roller R and the coil wire 8 is suppressed, enabling stable measurement of the supply length.
  • It should be noted that the structure detects the rotation state (rotational speed) of the roller R by the passage of the slits S, and determines the length of the coil wire 8 that has passed through based on the rotational speed of the roller R and the circumferential length of the contact part between the roller R and the coil wire 8, thereby measuring the length of the supplied coil wire 8.
  • The winding section 14 includes a rotation mechanism (not shown) that winds the coil wire 8 supplied to the split core 7 by rotating while holding the split core 7 and the start terminal of the coil wire 8. As a result, the start terminal held by the rotation mechanism is not wound on the split core 7, and subsequently, the rectangular-shaped coil wire 8 supplied in accordance with the rotation is wound on the split core 7.
  • In addition, the winding section 14 includes a servo motor (not shown) for rotating the rotation mechanism, and a cutting section (not shown) that cuts the start and end terminal parts to separate the start and end terminal parts into a start terminal part and an end terminal part.
  • In the embodiment, the control section PLC, which will be described later, receives (refer to an arrow DT1 in FIG. 3) an output signal related to the rotational speed from the servo motor (not shown), and is configured to enable the control section PLC to grasp the number of rotations of the split core 7 (i.e., the number of windings of the coil wire 8).
  • However, an encoder which detects the number of rotations of the rotation mechanism (not shown) may be separately provided, and the control section PLC may acquire the detection results of the encoder, enabling the control section PLC to grasp the number of rotations of the split core 7.
  • The length measuring instrument 15 (refer to FIG. 3) is a measuring instrument called a digital micrometer or digital caliper that measures the length variation in the shape of the split core 7.
  • FIG. 6 is a diagram for describing the essential parts of the length measuring instrument 15 according to an embodiment of the disclosure.
  • It should be noted that the split core 7 shown in FIG. 6 is a plan view showing the shape of the body part around which the coil wire 8 is wound.
  • As shown in FIG. 6, although curved surfaces are formed at the four corners of the split core 7, the split core 7 basically has a shape close to a rectangle, with the length of the long side indicated as L.
  • And the part that corresponds to the long side is the part that is wound longer when winding the coil wire 8.
  • Therefore, in the embodiment, the length variation of the long side is measured as the length variation of the shape of the split core 7.
  • Specifically, the length measuring instrument 15 includes a base 15A that contacts one end side of the split core 7, a drive section 15B that can move towards and away from the base 15A, and a length calculation section (not shown) that calculates the separation length between the base 15A and the tip of the drive section 15B based on the moving distance of the drive section 15B from a reference position before the drive section 15B is driven to the point of contact with the split core 7. The separation length becomes the length of the long side of the body part of the split core 7 around which the coil wire 8 is wound.
  • Then, as shown in FIG. 3, the length measuring instrument 15 transmits the measured separation length to the control section PLC as data of the measured length variation of the split core 7 (refer to an arrow DT2 in FIG. 3).
  • The control section PLC is a so-called sequencer that includes: a storage section (not shown) that stores a program for performing a control operation, received data, and results of calculations based on the received data; a central processing unit (not shown) that performs calculations; and a touch panel display section (not shown) that inputs settings and other operations.
  • However, it is not necessarily limited to a sequencer, and may be a PC or the like.
  • The control section PLC functions as a length correction section that corrects a predetermined reference length.
  • To make it easier to understand specifically, an example will be described below.
  • However, please note that the following example is merely an example to make the description easier to understand.
  • For example, it is assumed that the coil wire 8 is wound 32 times around the split core 7 to complete the winding.
  • Before starting the winding on the winding device 10, an operator inputs, through touch operation on the display section, the length L of the long side of the split core 7 used as a reference, and the reference length that serves as the standard for determining at what length of the coil wire 8 supplied from the start of winding should be considered as the start and end terminal part.
  • In other words, the input of the reference supply length is performed for the start and end terminal processing in which the forming section 12 does not perform forming.
  • The split core 7 used as a reference refers to a split core 7 that is close to the design center in terms of design. Using the split core 7 that is close to the design center, actual winding is performed, and data collection is conducted to measure the supply length required to execute the start and end terminal processing from the start of winding, based on which the reference length is determined.
  • Additionally, through touch operation on the display section by the operator, the number of windings, indicating how many times the coil wire 8 is to be wound around the split core 7, is input.
  • It should be noted that the input (the length L of the long side of the split core 7 used as a reference, the reference length, and the number of windings) is an operation that needs to be performed merely once at the beginning when repeatedly conducting the work of winding the coil wire 8 around split cores 7 of the same design.
  • Then, the operator sets the split core 7 on which the coil wire 8 is about to be wound into the length measuring instrument 15, and has the length measuring instrument 15 measure the length variation in the shape of the split core 7.
  • In response to this, the length measuring instrument 15 transmits the measured length variation data, that is, the data of the long side length of the set split core 7, to the control section PLC (refer to the arrow DT2 in FIG. 3).
  • Then, when the operator sets the split core 7 on the rotation mechanism (not shown) of the winding section 14 and performs the start of winding operation on the winding device 10, the control section PLC issues a command to start rotation to the servo motor (not shown) of the winding section 14, and a command to start measuring the supply length of the coil wire 8 to the encoder ENC.
  • In addition, the control section PLC functions as a length correction section and corrects the reference length described earlier, which is set in advance.
  • FIG. 7 is a diagram describing the content of the correction performed by the length correction section according to an embodiment of the disclosure.
  • FIG. 7 shows the body part of the split core 7 measured by the length measuring instrument 15 with a solid line, aligns the left short side position of the split core 7 used as a reference, and indicates the right end side position with a dotted line.
  • In the example, the split core 7 on which the coil wire 8 is about to be wound has a larger outer shape within the range of manufacturing tolerances than the split core 7 used as a reference. In other words, the long side of the split core 7 is longer, and the length thereof is denoted as L'.
  • The control section PLC, functioning as the length correction section, calculates a value δL (=L'-L) by subtracting the long side length L of the split core 7 used as a reference from the measured length L'.
  • Considering the value δL, since the split core 7 has two long sides, a length discrepancy of 2×δL occurs in one winding operation.
  • In the example, as the number of windings is 32, the discrepancy occurs 32 times.
  • Therefore, when considering the overall process, a length discrepancy of 32×2×δL occurs.
  • In this manner, the control section PLC, functioning as the length correction section, conducts a correction process in which the overall length discrepancy is calculated based on the measured length variation of the shape of the split core 7, and determines a correction reference length in which the reference length is corrected by adding the discrepancy to a predetermined reference length.
  • In the example, in the case where L' > L, the discrepancy occurs in the direction where the required length of the coil wire 8 for winding becomes longer. Therefore, correction can be made by adding to the predetermined length as described above.
  • Conversely, in the case where L' < L, the required length of the coil wire 8 for winding becomes shorter. In this case, the calculation result of the value δL is a negative value, so correction can still be made by adding to the predetermined length as described above.
  • When winding starts, the control section PLC monitors the number of rotations of the split core 7, that is, the number of windings of the split core 7, based on the output signal (refer to the arrow DT1 in FIG. 3) related to the rotational speed sequentially transmitted from the servo motor (not shown). Simultaneously, the control section PLC monitors the measurement results of the measured supply length sequentially transmitted (refer to an arrow DT3 in FIG. 3) from the encoder ENC.
  • Then, when the supply length of the coil wire 8 supplied from the start of winding reaches the correction reference length, the control section PLC issues a command (refer to a dotted arrow CM in FIG. 3) to execute the start and end terminal processing in which forming is not performed in the forming section 12.
  • In response to receiving the command to execute the start and end terminal processing, the forming section 12 drives an undepicted drive mechanism to widen the separation distance between the upper roller and the lower roller, and the separation distance between the left roller and the right roller, so that the round-shaped coil wire 8 passes through without being formed.
  • In this manner, the forming section 12 performs the start and end terminal processing in which forming on the part of the coil wire 8 corresponding to the start and end terminals of the split core 7 is not performed.
  • In addition, the control section PLC continues to monitor the supply length even after issuing the command to execute the start and end terminal processing. After issuing the command for the start and end terminal processing and when the coil wire 8 has been supplied for the length of the start and end terminal part, the control section PLC issues a command (refer to the dotted arrow CM in FIG. 3) to execute the forming process in which forming is performed in the forming section 12.
  • In response to receiving the command to execute the forming process, the forming section 12 drives an undepicted drive mechanism to narrow the separation distance between the upper roller and the lower roller, and the separation distance between the left roller and the right roller, so that the round-shaped coil wire 8 is formed into a rectangular shape.
  • In this manner, the forming section 12 performs the forming process in which forming on the coil wire 8 corresponding to the part to be wound on the split core 7 is conducted.
  • It should be noted that when stopping upon reaching 32 windings, the device typically stops in a state where the forming process is being performed. Therefore, at the start of the next winding operation, it begins from the state where the forming process is being conducted.
  • Then, when the number of rotations (number of windings) of the split core 7 reaches 32, the control section PLC sends a command to end winding to the winding section 14. In response to receiving the command, the winding section 14 ends the rotation and activates the cutting section (not shown) to perform a cutting process to cut the start and end terminal parts so as to separate the start and end terminal parts into a start terminal part and an end terminal part.
  • In this manner, even for split cores 7 that deviate from the ideal shape close to the design center due to manufacturing tolerances, as in the embodiment, the influence of such variation is mitigated. The correction of the reference length for the switching timing of the start and end terminals is performed for split cores 7 close to the design center, and the switching timing of the start and end terminals is controlled based on the correction reference length after the correction. As a result, the start and end terminal parts can be formed at appropriate positions.
  • Therefore, the winding method using the winding device 10 of the embodiment includes a start and end terminal step in which the part of the coil wire 8 corresponding to the start and end terminals of the split core 7 is left in a round shape without forming, and a forming step in which the coil wire 8 corresponding to the part to be wound around the split core 7 is formed into a rectangular shape. In the winding method, the start and end terminal step is performed when the supply length of the coil wire 8 supplied from the start of winding reaches a correction reference length, which is obtained by correcting a predetermined reference length based on the shape variation of the split core 7. As a result, the method can reduce the susceptibility to the influence of manufacturing tolerance variation in the split core 7, and consequently, the formation positions of the start and end terminal parts can be set at appropriate locations.
  • It should be noted that in the embodiment, the length of the long side is measured and used for correction because the length of the long side can be easily measured. However, it goes without saying that the circumference can also be measured and used for correction.
  • The disclosure has been described based on specific embodiments, but the disclosure is not limited to the above-described embodiments.
  • For example, while the tension adjustment section 13 is shown with two tension rollers, the tension adjustment section 13 may be provided with three or more tension rollers.
  • In this case, it is preferable that all tension rollers are drive rollers that are synchronously driven.
  • As such, the content that can be understood from the embodiments, as well as modifications and improvements made to the embodiments, are included in the technical scope of the disclosure, which is clear to those skilled in the art from the description in the claims. Description of Reference Numerals
  • 1... brushless motor, 2... stator, 3... rotor, 4... stator core, 5... insulator, 6... coil, 7... split core, 8... coil wire, 8A, 8B... part, 10... winding device, 11... wire supply section, 12... forming section, 12A... first forming section, 12B... second forming section, 13... tension adjustment section, 13A... first tension roller, 13B... second tension roller, 14... winding section, 15... length measuring instrument, 15A... base, 15B... drive unit, E1... turntable, E2... light sensor, ENC... encoder, L, L'... length, NZ... nozzle, PLC... control section, R... roller, S... slit

Claims (4)

  1. A winding device (10) which winds a wire onto a winding target,
    the winding device (10) comprising:
    a length correction section, correcting a predetermined reference length;
    a wire supply section (11), supplying the wire in a round shape;
    a forming section (12), provided on a downstream side of the wire supply section (11), and forming a shape of the wire into a rectangular shape; and
    a winding section (14), provided on a downstream side of the forming section (12), and winding the wire onto the winding target, and
    the forming section (12) performing:
    start and end terminal processing of not performing forming on a part of the wire corresponding to start and end terminals of the winding target; and
    a forming process of forming the wire corresponding to a part to be wound on the winding target,
    the length correction section performing a correction process to determine a correction reference length, which is obtained by correcting the reference length based on shape variation of the winding target, and
    the start and end terminal processing being performed when a supply length of the wire supplied from a start of winding reaches the correction reference length.
  2. The winding device (10) according to claim 1, wherein
    the winding device (10) comprises a length measuring instrument (15) which measures length variation of a shape of the winding target, and
    the correction process corrects the reference length based on the length variation measured.
  3. The winding device (10) according to claim 1 or 2, wherein
    the winding device (10) comprises a supply length measuring section which comprises a detection section provided between the forming section (12) and the winding section (14), and measures the supply length of the wire that has been supplied, and
    the detection section comprises
    a roller (R) which rotates in contact with the wire,
    a turntable (E) which comprises slits (S) at equal intervals in a circumferential direction and is provided on a rotation axis of the roller (R), and
    a passage sensor which detects passage of the slits (S) of the turntable (E) without contact.
  4. A winding method which winds a wire onto a winding target,
    the winding method comprising:
    a start and end terminal step of not performing forming on a part of the wire corresponding to start and end terminals of the winding target and leaving the part in a round shape; and
    a forming step of forming the wire corresponding to a part to be wound on the winding target into a rectangular shape, and
    the start and end terminal step being performed when a supply length of the wire supplied from a start of winding reaches a correction reference length, which is obtained by correcting a predetermined reference length based on shape variation of the winding target.
EP25161610.8A 2024-03-12 2025-03-04 Winding device and winding method Pending EP4618118A1 (en)

Applications Claiming Priority (1)

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JP2024037779A JP2025139056A (en) 2024-03-12 2024-03-12 Winding device and winding method

Publications (1)

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EP4618118A1 true EP4618118A1 (en) 2025-09-17

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EP (1) EP4618118A1 (en)
JP (1) JP2025139056A (en)
CN (1) CN120637088A (en)

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2022039605A (en) * 2020-08-28 2022-03-10 株式会社ミツバ Winding supply device
EP4243257A1 (en) * 2022-03-11 2023-09-13 Mitsuba Corporation Winding device

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2022039605A (en) * 2020-08-28 2022-03-10 株式会社ミツバ Winding supply device
EP4243257A1 (en) * 2022-03-11 2023-09-13 Mitsuba Corporation Winding device
JP2023132628A (en) 2022-03-11 2023-09-22 株式会社ミツバ winding device

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CN120637088A (en) 2025-09-12

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