JP2007252019A - Armature winding method and armature winding apparatus - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an armature winding method high in productivity and an armature winding apparatus. <P>SOLUTION: The armature winding apparatus 10 is equipped with a supporting machine 11 which supports a work 1, an index machine 70 which shifts each supporting machine 11 between a winding station A and a waiting station B, a work detector 80 which detects the position and form of the work 1 supported by the supporting machine 11, and a winder 30 which applies winding to the work 1. While the winding work is performed in the winding station A, the carrying-in/out process of the work 1 in the waiting station B and the work positioning process are performed in parallel. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an amateur winding method and an amateur winding device for manufacturing an amateur by winding a workpiece.

Conventionally, as an amateur winding device of this type, Patent Document 1 includes a winding machine that winds a wire around a core of a workpiece, and a unit that pushes a coil that is wound around the core into a slot. It is disclosed.
JP 2000-060084

  However, in such a conventional armature winding method and armature winding device, since the workpiece is positioned after the workpiece is set on the winding machine, it takes time to start winding on the core. Therefore, there is a problem that the working tact time for manufacturing the amateur increases.

  In addition, since the workpiece set in the winding machine may be displaced in the insulator mounted in the slot, if the winding is performed while the insulator is displaced from the normal position, a defective product is generated. There was a problem.

  In addition to this, abnormalities such as coil protruding from the slot, coil end height exceeding the specified value, and entanglement of the wire rod to the commutator may occur. There is sex. For this reason, it is necessary to inspect these abnormalities in a separate process after the workpiece is removed from the winding machine, and there is a problem that the working tact time for manufacturing the amateur increases.

  Alternatively, there was a problem that the gap between the commutator and the core was not a regular dimension from the beginning, and the coil was wound around this defective amateur.

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide an amateur winding method and an amateur winding apparatus that reduce the working tact time for manufacturing an amateur and has high productivity.

  The present invention relates to an amateur winding method for manufacturing an amateur by winding a work, and a pair of support machines for supporting a work, an index machine for moving each support machine between a winding station and a standby station, Using a workpiece detector that detects the position and shape of the workpiece supported by the support machine and a winding machine that performs winding on the workpiece, the winding is performed on the workpiece by the winding machine performed at the winding station. A wire unloading process, a work unloading process for unloading a wound work performed at a standby station, a work unloading process for unloading a new work into the support machine, and a position of the work detected by the work detector. The workpiece positioning process for supporting the workpiece at a predetermined position on the support machine, and the index machine is operated every time all the processes at each of these stations are completed. And index step of moving the support device between the winding station and the waiting station, characterized in that it consists.

  The present invention also relates to an armature winding apparatus for manufacturing an armature by winding a work, and a pair of support machines that support the work, and an index machine that moves each support machine between a winding station and a standby station. A workpiece detector for detecting the position and shape of the workpiece supported by the support machine, and a winding machine for winding the workpiece, and winding the workpiece by the winding machine at the winding station. During this time, the work wound in the standby station is unloaded from the support machine, a new work is loaded into the support machine, and the work is placed at a predetermined position on the support machine based on the position of the work detected by the work detector. The index machine is operated each time all the processes at these stations are completed, and each support machine is moved between the winding station and the standby station. It is characterized in.

  According to the present invention, while the winding work is being performed at the winding station, the work loading / unloading process and the work positioning process are performed in parallel at the standby station, so that the work is performed at the winding station. Therefore, the winding operation can be started immediately, and the working tact time of the amateur can be greatly reduced and the productivity can be increased.

  It is also possible to eliminate unnecessary winding work by eliminating the dimensionally defective amateur from the beginning.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.

  FIG. 1 is a perspective view of a workpiece 1 constituting a motor armature (multi-pole armature). The workpiece 1 includes a rotor shaft (output shaft) 5, a core 2 and a commutator (commutator) 7 provided on the rotor shaft 5, and a terminal 6 protruding from the commutator 7.

  In the annular core 2, a plurality of teeth 3 project radially outward in the radial direction, and slots 4 are opened between the teeth 3. The wire wound around each terminal 6 is wound around each tooth 3 to form an amateur coil.

  In a commutator motor (not shown), a current supplied from the commutator 7 flows to the armature coil via the terminal 6, so that a magnetic force acts between the magnet (permanent magnet) and the armature coil to drive the rotor shaft 5 to rotate.

  FIG. 2 is a perspective view showing the armature winding apparatus 10 according to the embodiment of the present invention. This amateur winding device 10 is for automatically winding a wire 8 around a core 2 of a work 1 to manufacture an amateur.

  Here, three axes X, Y, and Z orthogonal to each other are set, the X axis extends in a substantially horizontal lateral direction, the Y axis extends in a substantially horizontal front-rear direction, and the Z axis extends in a substantially vertical direction. The configuration of will be described. In FIG. 2, arrows indicate the operation directions of the respective parts.

  The winding station A includes a pair of winding machines 30 that wind the wire 8 around the core 2 of the workpiece 1. Each winding machine 30 is provided side by side in the Y-axis direction so as to sandwich the core 2, and each winding machine 30 performs winding simultaneously on each tooth 3 of the core 2.

  A nozzle 33 is attached to a flyer 31 of the winding machine 30 via a rotating cylinder 32. A wire W supplied from a wire supply source (not shown) is guided to the nozzle 33 through a head 41 and a guide hole (not shown) of the rotary cylinder 32.

  As a mechanism for rotating the flyer 31, the flyer 31 is supported so as to be rotatable about the Y axis with respect to the head 41, and includes a flyer drive motor 39 that rotationally drives the flyer 31 via a belt 36 and pulleys 34 and 35. .

  A center former mechanism 60 that guides the wire 8 to the teeth 3 is provided between the flyer 31 and the core 2. The center former mechanism 60 includes a center former 61 that guides the wire 8 wound by the flyer 31 to the teeth 3, a center former support shaft 62 that supports the center former 61, and the center former support shaft 62. A bearing (not shown) that is rotatably supported on the center axis of the center former and a center former rotation stopping mechanism (not shown) that stops the rotation of the center former 61 are provided.

  The center former rotation stopping mechanism stops rotation of the center former 61 using a permanent magnet (not shown), and presses and fixes the center former 61 against the outer peripheral surface of the core 2 during winding work. The center former rotation stop mechanism is not limited to this, and a mechanism that rotates opposite to the flyer 31 via a belt and a pulley, a planetary gear mechanism, or the like is provided so that the center former 61 is stationary, The center former 61 may be slightly separated from the core 2 during work.

  A moving mechanism 40 for moving each winding machine 30 in a three-dimensional direction is provided. The moving mechanism 40 includes a head 41 on which the winding machine 30 is mounted, a Y guide 44 that supports the head 41 so as to be movable in the Y-axis direction, and a motor 43 that drives the Y guide 44 via a ball screw 42. . As a result, the winding machine 30 is moved back and forth in the Y-axis direction with respect to the core 2.

  Similarly, the moving mechanism 40 of the winding machine 30 includes an X guide 45 that supports the Y guide frame 97 so as to be movable in the X-axis direction, and a motor 47 that drives the X guide 45 via a ball screw 46. Thereby, the winding machine 30 is moved in the X-axis direction with respect to the core 2.

  Similarly, the moving mechanism 40 of the winding machine 30 includes a Z guide 48 that supports the X guide frame 38 so as to be movable in the Z-axis direction, and a lifting motor 50 that drives the Z guide 48 via a ball screw 49. Thereby, the winding machine 30 is moved up and down with respect to the core 2 in the Z-axis direction. A pair of springs 51 are stretched between the column 103 and the Z guide 48 so as to reduce the load on the lifting motor 50.

  A commutator cover 20 that covers the terminal 6 and a commutator cover moving mechanism 22 that moves the commutator cover 20 are provided between the winding machines 30.

  In a state where the cylindrical commutator cover 20 covers the commutator 7, each terminal 6 protrudes from the pair of cutout portions 21.

  The commutator cover moving mechanism 22 includes a support member 23 that supports the commutator cover 20 and an elevating cylinder 24 that drives the support member 23 up and down in the Z-axis direction.

  The winding machine 30 is movably provided with a clamp (not shown) that grips the wire 8 and a cutter (not shown) that cuts the wire 8.

  As shown in FIG. 3, the armature winding apparatus 10 is provided with a pair of support machines 11 that support the workpiece 1, and an index machine 70 that moves each support machine 11 between the winding station A and the standby station B. .

  The support machine 11 includes a work support 12 that is rotatably supported around the Z axis with respect to the gantry 9, an index motor 13 that rotationally drives the work support 12 via gears 53 and 54, and a work support 12 is provided with a chuck 15 that supports the rotor shaft 5 so as to grip the rotor shaft 5 and a chuck cylinder 14 that drives the chuck 15 to open and close.

  The support machine 11 includes a chuck moving mechanism 16 that moves the chuck 15 in the Z-axis direction. The chuck moving mechanism 16 includes a lift 18 on which the support machine 11 is provided, a guide frame 17 that supports the lift 18 so that it can be lifted in the Z-axis direction with respect to the gantry 9, and a ball screw (not shown). And an elevating motor 19 that is driven to elevate via the like. A pair of springs 52 are stretched between the support member 55 of the guide frame 17 and the lifting platform 18 so as to reduce the load on the lifting motor 19.

  The index machine 70 includes an index arm 71 on which each support machine 11 is mounted. The index arm 71 is rotated by 180 ° around the Z axis to move each support machine 11 between the winding station A and the standby station B. .

  Each support machine 11 is mounted so as to be suspended from the index arm 71. The guide frame 17 is connected to the lower surface of the index arm 71 via a support member 55.

  A pair of openings 72 are formed at both ends of the index arm 71. Each opening 72 opens coaxially with the rotation axis of each support machine 11. The chuck 15 of each support machine 11 and the workpiece 1 supported by each chuck 15 are inserted through the openings 72 and moved up and down.

  An index shaft 73 is connected to the central portion of the index arm 71, and the index shaft 73 is supported by the gantry 9 so as to be rotatable around the Z axis. The index shaft 73 is rotationally driven by an index motor 74.

  The standby station B is provided with a work detector 80. The workpiece detector 80 detects the mounting position of the workpiece 1 supported by the support machine 11 and the shape of the workpiece 1.

  The workpiece detector 80 moves up and down while the laser detection unit 81 irradiates the workpiece 1 with the laser beam, and the measurement unit 82 detects the edge of the laser beam irradiation state to detect the edge of the core 2 or a commutator. By detecting the edge 7, the dimension in the height direction or the circumferential rotation direction is measured, and it is detected whether the insulator is inserted in the correct position.

  In addition, a CCD camera can be mounted on the laser detection unit 81 and an image processing apparatus can be incorporated in the measurement unit 82 to detect a winding state or the like based on a difference from the master shape.

  A moving mechanism 83 for moving the work detector 80 in the X axis and the Y axis is provided. As the moving mechanism 83, a pedestal 84 on which the work detector 80 is mounted, an X guide 85 that supports the pedestal 84 so as to be movable in the X-axis direction, and a motor 87 that drives the X guide 85 via a ball screw 86. Prepare. Thereby, the work detector 80 is moved in the X-axis direction.

  Similarly, a moving mechanism 83 of the workpiece detector 80 includes a Y guide 99 that supports the X guide frame 100 so as to be movable in the Y-axis direction, and a motor 89 that drives the Y guide 99 via a ball screw 88. As a result, the workpiece detector 80 is moved back and forth in the Y-axis direction.

  The measurement unit 82 has a height a of the lower end portion of the core 2 or the armature coil, a height b of the upper end portion of the core 2 or the armature coil, a height c of the lower end portion of the commutator 7 and a height d of the upper end portion of the commutator 7. taking measurement.

  The measurement unit 82 performs image processing to recognize the shape of the work 1 on which the winding has been performed, and determines, for example, whether the amateur coil protrudes from the slot 4 of the core 2.

  The standby station B is provided with a coil forming machine 90, and the coil forming machine 90 automatically corrects the shape of the amateur coil of the workpiece 1.

  The coil molding machine 90 includes a molding plate 91 that is pressed against the armature coil of the workpiece 1 from the radial direction, a Z guide 92 that supports the molding plate 91 so as to be movable in the Z-axis direction, and a ball screw ( A motor 93 that is driven through a ball screw 95, and a Y guide 94 that supports the Z guide frame 102 so as to be movable in the Y-axis direction. When the motor 96 operates, the forming plate 91 advances and retreats in the Y-axis direction and is pressed against the work 1. When the motor 93 operates, the coil forming machine 90 is moved up and down in the Z-axis direction.

  The tip of the forming plate 91 of the coil forming machine 90 extends in the Z-axis direction and is inserted into the slot 4 of the core 2 of the workpiece 1. The armature coil that protrudes from the slot 4 of the core 2 is molded so as to be accommodated in the slot 4 by being pushed by the tip of the molding plate 91.

  Next, the winding operation of the amateur winding device 10 will be described.

(1) Work carrying-in process The work 1 is carried into the support machine 11 in the standby station B by the following procedure.
-Open the chuck 15 of the support machine 11.
-The rotor shaft 5 of the workpiece 1 is automatically inserted into the chuck 15 by a transfer machine (not shown).
Close the chuck 15 and support it so as to grip the rotor shaft 5.
The work of inserting the rotor shaft 5 of the work 1 into the chuck 15 may be performed manually.

(2) Workpiece positioning step The height of the work 1 supported by the support machine 11 is adjusted by the following procedure.
The elevator motor 19 of the chuck moving mechanism 16 is operated to lower the elevator table 18 to a predetermined measurement position.
The height b of the upper end portion of the core 2 is measured by the work detector 80.
The elevator 1 of the chuck moving mechanism 16 is operated so that the workpiece 1 is at a predetermined height with respect to the gantry 9, and the elevator 18 is moved up and down and stopped.

(3) Pre-winding work inspection process Whether the shape of the set work 1 is normal is inspected by the following procedure.
The workpiece detector 80 measures the height a of the lower end portion of the core 2, the height b of the upper end portion of the core 2, the height c of the lower end portion of the commutator 7, and the height d of the upper end portion of the commutator 7. The presence / absence of an insulator interposed in the slot 4 of the core 2 is confirmed in advance.
Based on the measured data a, b, c, d, it is determined whether the shape of the workpiece 1 is normal and the insulator is mounted.
If it is determined that there is an abnormality in the shape of the work 1 or the mounting state of the insulator, an alarm is issued, the chuck 15 is opened, and the abnormal work 1 is transported to a predetermined collection pallet via a transporter (not shown). To do. Subsequently, the steps (1), (2) and (3) are repeated to set a new workpiece 1. The work for replacing the work 1 may be manually performed by an operator.
On the other hand, if it is determined that the shape of the workpiece 1 is normal, the process proceeds to the next workpiece positioning step.

(4) Workpiece positioning process The work 1 is held at a predetermined rotational position by the following procedure.
The indexing motor 13 of the support machine 11 is rotated and the end of the slot 4 of the core 2 is detected by the work detector 80.
The indexing motor 13 is rotated and stopped so that the end of the detected slot 4 is at a predetermined rotational position.

(5) Indexing process The index motor 74 is operated to rotate the index arm 71 by 180 ° and stop. The support machine 11 that supports the workpiece 1 before winding is moved from the standby station B to the winding station A.

(6) Winding process Each winding machine 30 is operated in the following procedure to wind the core 2 of the workpiece 1.
The commutator cover 20 is lowered to cover the terminals 6 and the terminals 6 project from the notches 21 of the commutator cover 20.
At this time, the predetermined terminal 6 faces the flyer 31 of each winding machine 30 at the start of winding, and there is no need to adjust the rotational position of the work 1 again, and this winding work is started immediately.
The nozzle 33 of each winding machine 30 is moved around each terminal 6, and the work of tying the wire 8 fed from each nozzle to each terminal 6 of the work 1 is performed.
-The elevating motor 19 is operated to raise the workpiece 1 to a predetermined winding position.
The commutator cover 20 is raised and the center former 61 of each winding machine 30 is pressed against each tooth 3. As a result, the core 2 of the work 1 is sandwiched between the center formers 61.
-The flyer 31 of each winding machine 30 is rotated, and the wire 8 drawn out from each nozzle is wound around each tooth 3 of the workpiece 1.
-The raising / lowering motor 19 is operated, the workpiece | work 1 is raised to a predetermined bend position, and the wire 8 is bound to the said terminal 6. FIG.
-The wire 8 is gripped by a clamp (not shown), and the wire 8 extending from the terminal 6 to the clamp is cut by a cutter (not shown).
The index motor 13 is rotated and the teeth 3 to be wound next are opposed to the center formers 61.

  The above operation is repeated to repeat the operation of winding the wire 8 around the terminal 6 and the operation of winding the wire 8 around each of the teeth 3 to form an armature coil on the work 1 and finish the winding operation.

  Note that the winding method is not limited to concentrated winding in which the wire 8 is wound for each single tooth 3, and distributed winding in which the wire 8 is wound over a plurality of teeth 3 may be performed.

(7) Indexing process The index motor 74 is operated to rotate the index arm 71 by 180 ° and stop. The supporting machine 11 supporting the work 1 after winding is moved from the winding station A to the standby station B.

(8) Winding forming process Using the work detector 80 and the coil forming machine 90, the amateur coil of the work 1 is formed by the following procedure.
The part where the irradiation state of the laser beam is changed by the work detector 80 is detected and the protruding part of the coil protruding from the slot 4 of the amateur coil core 2 is detected.
-The detected coil protrusion is pushed into the slot 4 by the coil molding machine 90.

(9) Post-winding work inspection process Whether the shape or the like of the work 1 is normal is inspected by the following procedure.
The work detector 80 measures the height a of the coil end lower end and the height b of the coil end upper end, respectively, captures the location where the laser light irradiation state has changed, and processes the shape of the amateur coil, It is determined whether there is an abnormality in the size and shape of the workpiece 1 after winding.

(10) Workpiece unloading process The workpiece 1 is unloaded from the support machine 11 in the standby station B according to the following procedure.
-Open the chuck 15 of the support machine 11.
-When it is determined in the post-winding work inspection process that the size and shape of the work 1 are abnormal, an alarm is issued and the abnormal work 1 is transported to a predetermined recovery pallet via a not-shown transporter. . The work 1 may be carried out manually by the operator.
On the other hand, when it is determined in the post-winding workpiece inspection step that there is no abnormality in the size and shape of the workpiece 1, the chuck 15 is opened, and the workpiece 1 is conveyed to a predetermined pallet via a conveying machine (not shown).

  Returning to the above-described (1) workpiece loading step, the following steps (2) to (10) are repeatedly performed, and winding is sequentially performed on the new workpiece 1.

  Next, the operation and effect will be described.

  In an amateur winding apparatus 10 that manufactures an amateur by winding a work 1, a pair of support machines 11 that support the work 1, and an index that moves each support machine 11 between a winding station A and a standby station B Machine 70, a work detector 80 for detecting the position and shape of the work 1 supported by the support machine 11, and a winding machine 30 for winding the work 1. 30, while the work 1 is wound on the work 1, the work 1 wound at the standby station B is unloaded from the support machine 11, and a new work 1 is loaded onto the support machine 11 and detected by the work detector 80. The work 1 is supported at a predetermined position of the support machine 11 based on the position of the work 1 to be operated, and the index machine 70 is operated each time all the processes at these stations A and B are completed. 1 is moved between the winding station A and the standby station B. Therefore, while the winding work is being performed at the winding station A, the loading and unloading steps of the workpiece 1 and the workpiece are performed at the standby station B. Since the positioning process is performed in parallel, it is not necessary to position the workpiece 1 at the winding station A, and the winding operation can be started immediately, greatly reducing the working tact time of the amateur. And increase productivity.

  Also, while winding the workpiece 1 at the winding station A, the workpiece 1 is normal based on the shape of the workpiece 1 before being wound detected by the workpiece detector 80 at the standby station B. Since the pre-winding work inspection process is performed to check whether the work is abnormal or not, it is possible to eliminate the abnormal work 1 at the standby station B and wind only the normal work 1 at the winding station A. Thus, the generation of defective products can be prevented and the production yield can be increased.

  Furthermore, whether the workpiece 1 is normal based on the shape of the workpiece 1 on which the winding is detected by the workpiece detector 80 at the standby station B while the workpiece 1 is being wound at the winding station A. Since a post-winding work inspection process for inspecting whether or not there is an abnormality is performed, the post-winding work inspection process is provided separately, and the quality of the product can be improved without increasing the working tact time of the amateur.

  Since the standby station B is provided with the coil forming machine 90 for pushing the protruding portion of the workpiece 1 into the slot 4, the workpiece detector is detected at the standby station B while the workpiece 1 is being wound at the winding station A. 80, the coil protruding portion of the workpiece 1 is detected, and the coil forming process of pushing the detected coil protruding portion into the slot 4 by the coil molding machine 90 is performed, without increasing the working tact time of the amateur, The production yield can be increased.

  The present invention is not limited to the above-described embodiment, and it is obvious that various modifications can be made within the scope of the technical idea.

  The armature winding method and the armature winding apparatus of the present invention can be used for, for example, etc.

The perspective view of the workpiece | work which shows embodiment of this invention. The perspective view of a winding position similarly. Sectional drawing of a winding position similarly.

Explanation of symbols

1 Work 2 Core 3 Teeth 4 Slot 5 Rotor Shaft 10 Winding Position 11 Supporting Machine 31 Winding Machine 70 Indexing Machine 80 Work Detector 90 Coil Forming Machine

Claims (5)

  In an amateur winding method for manufacturing an amateur by winding a work, a pair of support machines that support the work, an index machine that moves each support machine between a winding station and a standby station, and a support machine. A winding process for winding the workpiece by the winding machine performed at the winding station, using a workpiece detector for detecting the position and shape of the workpiece and a winding machine for winding the workpiece; Support is based on the workpiece unloading process for unwinding the wound workpiece at the standby station from the support machine, the workpiece unloading process for loading a new workpiece into the support machine, and the position of the workpiece detected by the workpiece detector. The workpiece positioning process for supporting the workpiece at a predetermined position of the machine, and the index machine is activated each time all the processes at each of these stations are completed to Amateur winding wherein the index step, that consists of moving between line station and standby station.   2. The amateur according to claim 1, wherein a pre-winding work inspection step of inspecting a work based on a shape of the work before being wound detected by the work detector at the standby station is performed. Winding method.   The post-winding work inspection step of inspecting the work based on the shape of the work subjected to the winding detected by the work detector at the standby station is performed. Amateur winding method.   In an amateur winding device that manufactures amateurs by winding a work, a pair of support machines that support the work, an index machine that moves each support machine between the winding station and the standby station, and a support machine. A workpiece detector for detecting the position and shape of the workpiece and a winding machine for winding the workpiece, and winding the workpiece by the winding machine at the winding station, while the standby station Unwind the workpiece that has been wound from the support machine, load the new work into the support machine, and support the work at a predetermined position of the support machine based on the position of the work detected by the work detector. The index machine is operated every time the entire process at the station is completed, and each support machine is moved between the winding station and the standby station. Amateur-winding device.   5. The amateur winding apparatus according to claim 4, further comprising a coil molding machine that pushes a coil in which a workpiece is wound at the standby station into a slot.

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