JP2008294430A - Method and apparatus for taking out and shaping of coil - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To achieve high accuracy in size, improve winding alignment, and improve cycle time, in manufacturing a track-shaped or rectangular bobbinless coil. <P>SOLUTION: The method of shaping a coil is as follows: A winding core 13 is slidably arranged at one portion 21 of a winding tool as shown in Fig.1. The winding core 13 is energized toward the other portion 22 of winding tool. Coil receiving pins 47U, 47D are made to face the winding core 13, and the one portion 21 of the winding tool is shifted toward a coil handling member 46 side. The winding core 13 is retreated by being pushed by the coil receiving pins 47U, 47D. The coil 56 is shifted from the winding core 13 to the coil receiving pins 47U, 47D. The coil receiving pins 47U, 47D that bear the coil 56 are mutually separated to elongate the coil 56. A the same time, or before or after the elongation, the coil 56 is pressed by press tools 53L, 53R that are movable in the direction crossing the elongation direction at the same time of the elongation or before or after the elongation. After that, an image of the cross sectional contour of the coil is imaged by a digital camera 59. The acquired contour of the coil is compared with target values, and depending on the differences, the elongation quantity and pressed quantity are corrected. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method or an apparatus related to coil extraction and molding, and more particularly to coil extraction and molding suitable for application to the manufacture of track type (race track type, oval) and rectangular bobbinless coil (coreless coil). It relates to such a method or apparatus.

In the case of winding (winding) a track-shaped or rectangular bobbinless coil, conventionally, a track-shaped or rectangular core having the same shape as the finished shape of the coil is used. A wire rod is wound around this to obtain a bobbinless coil having a target shape (see, for example, Patent Document 1).
JP 2003-168618 A

However, these conventional methods have the following problems.
(1) Alignment In the conventional method, the wire entry position is in the vicinity of the connection portion between the linear portion of the coil and the R portion (deflection portion). This is a position where it is difficult to produce a cross point, and the wire rod is likely to be disturbed.
(2) Deformation of coil In the conventional method, the minor axis (short axis) direction of the coil swells. For this reason, coils often do not fit in the specified dimensions, and post-treatment such as reheating in a furnace was necessary. Further, especially with a high tension wire, the coil was easily warped and twisted.
(3) Tact time a) Because of the problems (1) and (2) above, the conventional method has to reduce the number of rotations to about one fifth when winding a circular coil. B) The bobbin-less coil does not have a bobbin as its name suggests. For this reason, the dimensions are likely to go wrong originally. Therefore, conventionally, even if molding is performed to correct the dimensions, it is once removed from the core and manually remounted on the molding jig or on the winding machine. Forming is performed with a kite wound around. In other words, the operations are alternately performed in series, such as winding and forming, and winding and forming. This further increases the tact time.

  An object of the present invention is to solve the above-described problems and to further improve the dimensional accuracy particularly with respect to a track-shaped and rectangular bobbinless coil winding. At the same time, it is to improve or shorten the coil alignment or tact time.

In order to solve the above-mentioned problem, in the coil forming method according to claim 1, the pressing member is arranged so as to move in the direction crossing the extending direction by separating the supporting member, extending the coil supported by the supporting member, and extending the coil. To the coil, press and shape the coil simultaneously with or before and after the extension, and optically obtain the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference, and one or both of the extension amount and the pressing amount are corrected according to the difference, and after the correction, the next coil is extended or pressed. Execute.

Moreover, in the coil shaping | molding method of Claim 2 which quotes Claim 1, the said coil is formed circularly or elliptically, and the said expansion | extension and press are performed with respect to this coil.
Moreover, in the coil shaping | molding method of Claim 3 which quotes Claim 1 or Claim 2, the width | variety of the said coil is controlled by the width control member in the case of the said expansion | extension and press.
Further, in the coil take-out molding method according to claim 4, a winding core that is slidably disposed on one side of the winding jig and is biased toward the other side of the winding jig, and for supporting the coil from the inside. A support member is directly opposed, and one of the winding jig and the support member is brought close to or close to each other, and the winding core is moved into the winding jig by the approach. Then, the coil wound around the core is transferred to the support member, the coil is supported on the support member from the inside, the support member supporting the coil is separated, and the coil is extended. And forming the coil, optically acquiring the contour data of the coil after the molding, comparing the acquired contour data with a target value, obtaining a difference, and determining the amount of expansion according to the difference After the correction, the next coil is formed.

Further, in the coil take-out and molding method according to claim 5 quoting claim 4, the coil is formed in a circular shape or an elliptical shape, and the extension is performed on the coil.
Further, in the coil take-out molding method according to claim 6 quoting claim 4 or claim 5, a pressing member arranged to be movable in a direction crossing the extension direction is brought close to the coil, and simultaneously with the extension or Before and after pressing the coil to form the coil, optically acquiring the contour data of the coil after molding, obtaining the difference by comparing the acquired contour data with a target value, and according to the difference Then, one or both of the extension amount and the pressing amount is corrected, and after the correction, the next coil is formed.
In the coil take-out and molding method according to claim 7, which cites claim 4, claim 5 or claim 6, the width of the coil is regulated by a width regulating member during the molding.

  In the coil forming apparatus according to claim 8, a support member for supporting the coil from the inside, a pressing member arranged so as to be movable in a direction crossing the extending direction of the coil, optical means, and control Means for separating the support member, extending the coil supported by the support member, causing the pressing member to approach the coil, and simultaneously with or before and after the extension, The coil is pressed and molded, the contour data of the coil after molding is optically obtained, the obtained contour data is compared with a target value, a difference is obtained, and the amount of expansion according to the difference And one or both of the pressing amounts are corrected, and after the correction, the next coil is formed.

Further, in the coil forming apparatus according to claim 9 quoting claim 8, the coil is formed in a circular shape or an oval shape, and the control means executes the extension and the pressing on the coil.
Further, in the coil forming apparatus according to claim 10 quoting claim 8 or claim 9, further comprising a width regulating member, wherein the control means reduces the width of the coil by the width regulating member during the pressing and molding. regulate.

  According to another aspect of the coil take-out and forming apparatus of the present invention, the winding jig disposed opposite to the winding jig is slidably disposed on one of the winding jigs and biased toward the other of the winding jigs. A winding core, a support member for supporting the coil from the inside, an optical means, and a control means. The control means makes the winding core and the support member face each other, and One of the tools and the supporting member, either one of them approaching the other or approaching each other, and the coil is wound around the winding core by moving the winding core into the winding jig by the approach. To the support member, the coil is supported by the support member from the inside thereof, the support member supporting the coil is separated, the coil is extended to form the coil, and the coil after forming The contour data is optically acquired, and the acquired contour data is compared with the target value. And it obtains the differences, to modify the amount of the extension in response to said difference, to perform the molding of the next coil after the corrected.

Moreover, in the coil take-out and molding apparatus according to claim 12 quoting claim 11, the cross section of the core is circular or elliptical.
Moreover, in the coil take-out and molding apparatus according to claim 13 quoting claim 11 or claim 12, the coil take-out molding apparatus further comprises a pressing member movably arranged in a direction crossing the extension direction, and the control means includes the pressing means. A member is brought close to the coil, and the coil is formed by pressing the coil simultaneously with or before and after the extension.
In addition, in the coil take-out and molding apparatus according to claim 14, which is cited in claim 11, claim 12 or claim 13, the apparatus further comprises a width regulating member, and the control means uses the width regulating member during the molding. Regulate the width of.

  Each method or apparatus of the present invention is a combination of the following components. That is, a wire is wound around a winding core having a circular or elliptical cross section that is slidably disposed on one of the winding jigs and is biased toward the other side of the winding jig. This winding core and a supporting member for supporting the coil from the inside are directly opposed, and one of the winding jig and the supporting member is brought close to each other or close to each other. Transfer the coil to the member. The coil support member is separated to extend the coil, and the coil is formed into a track shape or the like. Alternatively, the coil is formed into a track shape or the like by extending and pressing with a forming member. And the contour data of the coil after shaping | molding are acquired with an optical means, the difference with target value is acquired, and one or both of the expansion | extension amount and the pressing amount are corrected according to the value. The following effects are exhibited by these combinations.

(1) Higher dimensional accuracy can be obtained.
In the conventional method, maintenance of dimensional accuracy relies on human hands. For example, before starting production, confirm the shape, repeat the process of making a prototype several times, and adjust each specification of the winding machine so that the dimensions of the completed coil match the target value. After that, during production, measures were taken to check the dimensions of the product at appropriate intervals, and if they were not within the target values, the specifications were changed accordingly.

In the present invention, the difference from the target value is automatically detected. Accordingly, one or both of the extension amount and the pressing amount of the coil are corrected. Accordingly, the dimensional accuracy is always maintained at the target value, and a higher dimensional accuracy than before can be obtained.
In this case, the dimension of the coil after molding is detected without contact. Accordingly, the measurement probe or the like does not touch the coil during measurement and the coil is not deformed, and a high dimensional accuracy can be obtained even with a bobbinless coil whose shape tends to be distorted.
Further, in the present invention, a coil that is aligned and wound in a circle or an ellipse is formed. This also contributes to high dimensional accuracy.

(2) Alignment is improved.
In the conventional method, since the lengths of the sides of the winding core are different, the drawing of the wire becomes pulsating. For this reason, disorder of the wire was easy to occur. However, in the present invention, the wire winding itself is performed with a circular or elliptical core. If this is the case, the wire will not be disturbed. Moreover, high speed rotation is possible. Nevertheless, alignment is maintained. Therefore, a stable fully aligned winding is possible.

(3) No deformation of the coil occurs.
In the conventional method, the short axis direction of the coil swelled. In particular, with a high tension wire, the coil is likely to warp and twist. However, in the present invention, winding is performed with a circular or elliptical core. For this reason, warping and twisting hardly occur.
Furthermore, the coil receiving method itself of the present invention smoothly shifts the coil, and the coil to be transferred has high alignment. This also contributes to prevention of deformation of the coil.

(4) Tact time In the conventional method, because of the problems (2) and (3), the core rotation speed has to be reduced to about one fifth of that of a circular coil. However, if it is this invention, it can wind by the same rotation speed as a normal circular coil.
Furthermore, in the conventional method, the work must be performed alternately, such as winding → molding → winding → molding, which further increases the tact time. However, if the winding method and the coil receiving method of the present invention are combined, the winding operation and the forming operation can be separated, and both can be performed in parallel. In this respect, the tact time is further shortened.

  The details of the present invention will be described below based on the embodiments shown in the drawings. FIG. 1 shows the front of a winding forming apparatus 50 according to an embodiment. Regarding the structure of the winding machine portion of the device 50, for example, Japanese Patent Application Laid-Open No. 2005-116657, Japanese Patent Application Laid-Open No. 2001-358029, Japanese Patent Application Laid-Open No. 10-304628, etc., which are filed by the present applicant. Are described in detail. Therefore, only the part understood as necessary for the description of the embodiment is shown here.

  FIG. 1 shows the front of an embodiment 50. Reference numeral 1 denotes a spindle block, which is installed on the cabinet 5, with a block left 2 (fixed side) on the left side and a block right 3 (movable side) on the right side. A spline shaft 4 having a square cross section is rotatably supported at the lower portion of the spindle block 1. A shaft left pulley 10 is attached to the shaft 4. A main motor (not shown) is also arranged on the spindle block 1, and a motor pulley 11 having two grooves is attached to the shaft. An inter-motor spline belt 8 is stretched between the motor pulley 11 and the shaft left pulley 10, and the spline shaft 4 is rotated by the main motor. The drive control of each component and member, including the drive control of the main motor, is executed by a control device (not shown) composed of a microcomputer.

A fixed spindle is rotatably supported on the block left 2 and a fixed pulley 9 is attached to the left side of the block. A fixed-side motor belt 12 is stretched between the fixed-side pulley 9 and the motor pulley 11, and the fixed-side spindle is also rotated by the main motor.
A trabass base 14 extending to the left side is attached to the block left 2. A sliding frame 16 is disposed on the trabus base 14. The sliding frame 16 is driven by a left traverse motor 17 to traverse the line guide 18.

A tail plate support shaft 19 is attached to the middle of the block right 3. The tail plate support shaft 19 extends rightward and is inserted through the center of the tail plate 23 to support the tail plate 23 slidably.
An upper slide shaft 27 is slidably supported above the block right 3. A lower slide shaft 26 is slidably held below the block right 3. The right ends of the sliding shafts 26 and 27 are attached to the tail plate 23.
A tail plate air cylinder 24 is connected to the right end of the tail plate support shaft 19. With the air supply / exhaust to the air cylinder 24, the tail plate 23 and the upper and lower sliding shafts 26 and 27 move to the left and right by the required amount.

A driven pulley 28 is rotatably attached to the lower portion of the tail plate 23. A female spline (not shown) is formed in the center of the driven pulley 28. The spline shaft 4 meshes with the female spline, and the driven pulley 28 rotates together with the spline shaft 4.
The spline shaft 4 is rotatably supported on the tail plate 23. The driven pulley 28 is also rotatably supported by the tail plate 23 and moves to the left and right together with the tail plate 23.

A movable spindle (not shown) is rotatably supported on the upper sliding shaft 27. A movable pulley 31 is attached to the right side of the movable spindle, and a spline movable side belt 32 is stretched between the movable pulley 31 and the driven pulley 28. Thereby, the rotation of the spline shaft 4 is transmitted to the movable spindle.
A movable winding jig (jig cap) 21 is attached to the left end of the movable spindle. The core 13 is slidably held at the center. A core advance / retreat air cylinder 29 is attached to the right end of the upper sliding shaft 27. A connecting rod (not shown) inserted through the movable side spindle connects the core 13 and the air cylinder 29, and the air core 29 is supplied with air to the air cylinder 29 to fix the core 13 to the fixed side winding jig 22. It is biased in the (positioning jig) direction. The fixed-side winding jig 22 is attached to the right end of the fixed-side spindle and faces the movable-side winding jig 21.

A horizontal guide 33 is disposed above the spindle block 1. The horizontal guide 33 is supported by a bracket (not shown) standing on the cabinet 5. Here, the bracket is not shown in order to make the drawing easy to see.
A horizontal moving body 34 is supported on the horizontal guide 33 so as to be slidable in the horizontal direction. A horizontal moving bolt 36 is screwed to the horizontal moving body 34. Both ends of the horizontal movement bolt 36 are rotatably supported by the horizontal guide 33.
A horizontal movement motor 37 is attached to the right end of the horizontal guide 33. A horizontal movement bolt 36 is connected to the horizontal movement body 34 to move it.

  A vertical bracket 38 is attached to the horizontal moving body 34. A vertical guide 39 is attached to this. A vertical moving body 41 is supported on the vertical guide 39 so as to be vertically movable. A vertical moving bolt 42 is screwed to the vertical moving body 41. A bearing body 43 is attached to the vertical bracket 38, and an upper portion of the vertical movement bolt 42 is rotatably supported by the bearing body 43. A vertical movement motor 44 is attached to the upper end of the vertical bracket 38, and a vertical movement bolt 42 is connected to the vertical bracket 38 to move the vertical movement body 41 up and down.

A coil handling member 46 is attached to the vertical moving body 41. The coil handling member 46 has two upper and lower coil receiving pins 47U and 47D protruding in the right side surface direction. A solenoid (not shown) is arranged inside the coil handling member 46, and when energized, the coil receiving pins 47U and 47D are retracted (stored) in the coil handling member 46 (FIG. 9 (15)). In the figure, it is expressed by a circled number. The same applies to other figures.) Above the coil handling member 46, a receiving pin up / down air cylinder 48 is arranged. The air cylinder 48 is attached to the vertical moving body 41 with a bracket (not shown). The air cylinder 48 is connected to the upper coil receiving pin 47U, and the upper coil receiving pin 47U is moved up and down by supplying and exhausting air. Instead of the air cylinder 48, a pulse motor may be used.
A shutter 49 is also supported on the vertical moving body 41. The vertical moving body 41 has a shutter up / down air cylinder 51 and a shutter lateral movement air cylinder (not shown) attached thereto. The shutter 49 is connected to these, and moves up and down and left and right.

Reference numeral 52 denotes a press mechanism. This press mechanism 52 is also supported by a bracket (not shown). This bracket (not shown) is erected on the cabinet 5. The press mechanism 52 includes a pair of press jigs 53L and 53R. The press jigs 53L and 53R are arranged in a direction perpendicular to the paper surface so as to face each other. Its shape is shown in FIG. FIG. 6 shows the shapes of the press jigs 53L and 53R when the press jigs 53L and 53R are viewed from the right side surface of the winding forming apparatus 50. FIG. As shown in the figure, these centers bulge in a bowl shape toward the other party. A press motor 54 is disposed in the press mechanism 52, and the press jigs 53 </ b> L and 53 </ b> R are moved toward and away from the press mechanism 52.
Reference numeral 59 denotes a digital camera. This digital camera 59 is also supported by a bracket (not shown) and images the coil after molding. This bracket (not shown) is also erected on the cabinet 5.

  A procedure for manufacturing the oval coil 57 according to the embodiment 50 will be described. Here, the wire rod is wound around the core 13 having an elliptical cross section. At this time, the inner circumferential length of the forming object coil 56 is set to be the same as the inner circumferential length of the desired oval coil 57, for example. As an example, if the inner short diameter of the oval coil 57 is 3 mm and the inner long diameter is 13 mm, the inner circumferential length of the elliptical coil 56 is 29.42 mm. If the core cross section is circular, the diameter is 9.37 mm.

First, pre-imaging will be described. In the embodiment, the digital camera 59 is used to obtain contour data of the oval coil 57 after molding. In order to extract the contour data from the captured image, for example, chroma key technology or luminance key technology is used.
Here, chroma key technology is used. At least two specific methods can be assumed. One is to use the difference in color. That is, the color of the oval coil 57 itself and the color of the mechanical structure such as the coil receiving pin are usually different. Therefore, if the same pixel as the color of the oval coil 57 is extracted from the image captured by the digital camera 59, this becomes the contour data of the oval coil 57.

Another possible method is to subtract two images. That is, after the molding, an image in which no oval coil 57 is present is subtracted from an image in which the oval coil 57 is held by the coil receiving pins 47U and 47D.
Specifically, after the shaping, each pixel of the image in which the oval coil 57 is held by the receiving pins 47U and 47D is collated with each pixel of the image without the oval coil 57. to erase. As a result, contour data (a pixel group representing the contour) of the oval coil 57 after molding is obtained. This is understood to be reliable detection. Here, this method is used. Details will be described with reference to FIG.

That is, FIG. 10A shows an example of a camera image without the oval coil 57. FIG. 10B shows an example of a camera image in which an oval coil 57 is held by a support pin after molding.
In this case, the wire rod of the coil is fully stretched at the heel obtained by extending the elliptical coil 57 up and down. In this case, when removed from the receiving pins 47U and 47D, there is a possibility that the wire rod contracts or swells in the horizontal direction so that an image is captured in a shape different from the contour of the oval coil 57 after molding.

Therefore, here, imaging is performed by lowering the upper coil receiving pin 47U by a predetermined value. In this way, since an up-down direction tension is not applied to the oval coil 57, an original contour image after molding can be acquired.
Subtraction is performed from this image. To this end, the position of the coil receiving pin 47U must be the same even in a camera image without the base oval coil 57. Therefore, as shown in FIG. 10A, the coil receiving pin 47U is lowered by the same predetermined amount, and imaging is performed in this state. The above-mentioned pre-imaging means obtaining this camera image.

The operation of the embodiment 50 will be described. When the winding of the wire ends, the movable side winding jig 21 is retracted (state shown in FIG. 1). Next, the horizontal moving body 34, that is, the coil handling member 46 is advanced toward the fixed-side winding jig 22 (FIG. 1 (1)).
Next, the coil handling member 46 is lowered, and the upper and lower coil receiving pins 47U and 47D are opposed to the core 13 (FIG. 2 (2)). At this time, the difference between the outer sides of the upper and lower coil receiving pins 47 </ b> U and 47, i.e., the major axis of the ellipse that circulates them, is made slightly smaller than the major axis of the core 13. Thus, the two coil receiving pins 47U and 47D are located slightly inside the inner periphery of the wound coil 56.

In this state, the movable-side winding jig 21 is advanced toward the coil receiving pins 47U and 47D (FIG. 2 (3)). The winding core 13 is urged by the air pressure of the air cylinder, but is pushed by the coil receiving pins 47U and 47D by the advance of the movable side winding jig 21 and retracts into the movable side winding jig 21.
As a result, the coil receiving pins 47U and 47D enter the inside of the forming object coil 56 wound around the winding core 13, and the forming object coil 56 moves to the coil receiving pins 47U and 47D and is externally fitted thereto. (Fig. 2 (3)).

Next, the movable-side winding jig 21 is retracted (FIG. 3 (4)). As a result, the core 13 comes out of the forming object coil 56.
Next, the coil handling member 46 is raised (FIG. 3 (5)). After that, it is moved backward (FIG. 4 (6)). Thus, the forming object coil 56 is positioned between the two pressing jigs 53L and 53R (FIG. 6 (9)).
Next, the shutter 49 is lowered and positioned on the side surface of the molding object coil 56 (FIG. 5 (7)).
At this time, the movable-side winding jig 21 is advanced to prepare for the next wire winding. This shortens the tact time.

  Next, the shutter 49 is advanced. The distance from the coil handling member 46 is made equal to the finished width of the oval coil 57 (FIG. 5 (8)). The winding jigs 21 and 22 start winding the next wire 58 (same as above). Next, the upper coil receiving pin 47U is raised until the inner diameter on the major axis side of the coil 56 to be formed coincides with a desired finished dimension (FIG. 6 (9) → (10)). The forming object coil 56 is extended in the long axis direction. At the same time, the pressing jigs 53L and 53R are advanced from both sides. Thus, the short axis direction of the molding object coil 56 is pressed and molded (FIG. 5 (11)). Thus, the elliptical coil becomes an oval coil 57.

In FIG. 5, (10) and (11) are shown separately. However, it is preferable that the stretching in the major axis direction and the pressing in the minor axis direction are performed simultaneously. This is because if the minor axis direction is pressed while stretching in the major axis direction, the ellipse is smoothly deformed into an ellipse.
At this time, the width of the forming object coil 56 (direction perpendicular to the paper surface of FIG. 6) is regulated by the shutter 49 and the coil handling member 46 (FIG. 5 (8)). Therefore, this pressing does not increase the width of the forming object coil 56.

When the molding is finished, the pressing jigs 53L and 53R are retracted (FIG. 6 (12)). The shutter 49 is raised (FIG. 7 (13)). Next, the upper coil receiving pin 47U is lowered by a predetermined value (FIG. 10B). Then, the molded coil 57 and coil receiving pins 47U, 47D and the like are imaged by the digital camera 59 (FIG. 10B, FIG. 8 (14)).
Thereafter, the image is subtracted as described above. That is, the image without the coil as shown in FIG. 10A is subtracted from the image of the coil 57 after being formed as shown in FIG. Thus, the contour data of the coil 57 after molding is obtained (FIG. 11C). 11 and 13, the image is rough (the number of pixels is small). Needless to say, the real thing is much denser.

Based on this extracted image, the quality of the coil after molding is determined. A feedback process is also performed to accurately match the dimensions with the target values. Therefore, first, the coil center CP1 (FIG. 11 (d)) is detected. This is for overlapping with the center of the determination area (CP2 (FIG. 5E)) to determine the quality of the coil 57 after molding.Here, the coil center CP1 is obtained by the following procedure. Therefore, it is described with a number in brackets.
[1] First, the image ID representing the molded coil 57 is scanned in the horizontal direction sequentially from the top.
[2] The leftmost pixel and the rightmost pixel in this horizontal scanning are extracted and stored.
[3] If these pixels are located to the left or right of the leftmost pixel or the rightmost pixel stored before, the extracted pixel is used as a new leftmost pixel or rightmost pixel. Store as a pixel. If this process is repeated, the leftmost pixel and the rightmost pixel can be extracted from among the pixels showing the coil 57 after molding.

[4] For the X coordinates of these two pixels, the X coordinate (average value) corresponding to the intermediate value is obtained. This X coordinate is the X coordinate of the center point CP1 being obtained. To facilitate understanding, a set of pixels having the X coordinate is the vertical line VL in FIG. 11, and the center point CP1 to be found exists on the vertical line VL.
[5] This time, the image is scanned in the vertical direction sequentially from the left. Similar to [1] to [4], the Y coordinate of the center point CP1 to be obtained is obtained. Explaining with reference to the figure, the set of pixels having the obtained Y coordinate is the horizontal line HL in FIG. 11, and the obtained center point CP1 is on the horizontal line HL. From these two conditions, the center point CP1 is obtained as the intersection of the horizontal line HL and the previously obtained vertical line VL, that is, CP1 in FIG.

The pass / fail judgment area JA is shown in FIG. The inner line IL and the outer line OL are obtained by adding a tolerance to the design value of the coil. The center point CP2 of this area JA is obtained from the design data.
[6] The center point CP1 of the image of the coil 57 after molding is superimposed on the center point CP2 of the pass / fail judgment area JA.
From here, reference is made to FIG. FIG. 12 shows a subroutine for determining whether the formed coil 57 is good or defective, and correcting the amount of extension and the amount of pressing during molding. The operation of the entire apparatus from coil winding to coil discharge, which has been described so far, is executed in a main routine (not shown).

[7] In the non-defective product / defective product determination in step S1, the protrusion of the pixel is inspected. If the pixel of the coil 57 after molding does not protrude from the pass / fail judgment area JA, the coil 57 at this time is a non-defective product (S1 “none”).
[8] In this case, the value of the unillustrated discharge position buffer is set as a non-defective product discharge position Pg (“good product position” in FIG. 12). Here, the position where the molding is performed, that is, the position shown in FIG. 4 is defined as a non-defective product discharge position Pg. This is to prevent excessive movement. The value of the discharge position buffer is reflected when the discharging operation of the molded coil 57 is performed in the main routine after the completion of this subroutine (FIG. 9 (15), which will be described later).

[9] Next, the non-illustrated good product number counter is incremented by one. The number of good products held here is displayed on a display (not shown) and used for production management. It can also be used to automatically stop the device when the desired number of good products has been produced.
[10] Thereafter, the extension amount and the push-in amount are corrected. This is because even if it is within the allowable range, the shape may not be as designed.

[11] First, the midpoint of each side is determined (S4, FIG. 13G, white dots D1 to D4). From these, distances Wp and Hp between the horizontal and vertical midpoints are calculated (S5, FIG. 13 (h)).
The difference between the horizontal direction and the vertical direction (difference from the target value (design value)) Eh, Ev is obtained by the following equation (S6). In this equation, the target values of the distance between the center points in the horizontal direction and the vertical direction are expressed as Wt and Ht.
Eh = Wp-Wt
Ev = Hp-Ht

[12] One or both of the extension amount and the pressing amount are corrected according to the magnitudes of the differences Eh and Ev (S7). Specifically, the extension amount is corrected as correction of the rising amount of the coil receiving pin 47U in FIG. The correction of the pressing amount is executed as a correction of the advance amount of the pressing jigs 53L and 53R in FIG.
These corrections are reflected in the molding process for the next coil executed after the subroutine of FIG. 12 is returned to the main routine.

The function that gives the correction amount Rh of the rising amount of the receiving pin 47U with respect to the difference Eh in the horizontal direction and the function that gives the correction amount Rw of the pressing amount with respect to the vertical difference Ev refer to the results of the prototype and past manufacturing data. Determine. This is because it is understood that these functions differ depending on the diameter of the wire, the rigidity of the wire, the size of the coil, the number of turns, and the like.
The function type may simply be a linear function. For example,
Rh = kh × Eh + Ch (However, if Eh = 0, Ch = 0)
Rv = kv × Ev + Cv (However, if Ev = 0, Cv = 0)
And In this equation, kh, kv, Ch, and Cv are constants, which are determined based on prototype data and past manufacturing data as described above.

kh and kv are constants that give corrections proportional to the difference. Ch and Cv are constants added to prevent the difference from remaining. However, when the difference becomes 0, that is, when Eh = 0 or Ev = 0, it is not necessary. In this case, Ch = 0 or Cv = 0.
[13] If the extension amount or the pressing amount is too large, the extension or the pressing may disturb the alignment. In order to prevent this, after the above correction is made, it is inspected whether the extension amount or the pressing amount exceeds the respective limit values (S8).
If it does not exceed the limit value (S8 “No”), there is no problem. Exit this subroutine and return to the main routine (not shown).
If the limit value is exceeded (S8 “Yes”), a correction amount limit flag (not shown) is set. When exiting this subroutine and returning to the main routine (not shown), a warning to that effect is issued (buzzer sound, lamp blinking, flashing of characters and figures on the display, etc.), and the apparatus is stopped.

[14] Return to the determination of S1 in FIG. When the pixel of the coil 57 after molding protrudes from the pass / fail judgment area, the coil 57 molded at this time is a defective product (S1 “present”).
[15] The discharge position is set to the defective product discharge position Png (“defective product position” in FIG. 12). Here, it is set to an intermediate position between the coil extraction position and the molding position (FIG. 4). This setting is also reflected when the molded coil 57 is ejected in the main routine executed after the end of this subroutine (FIG. 9 (15), which will be described later).

[16] Next, the defective product counter is incremented by one (S11). Then, it is inspected whether the number of defective products after the increment does not exceed a predetermined value N. If it exceeds, there is a problem with the specification settings or device functions. An unillustrated defective product number excess flag is set (S13), and the process returns to the unillustrated main routine. This flag is referred to in the main routine, the alarm as described above is issued, and the apparatus is stopped.
If the number of defective products after the increment does not exceed the predetermined value N, there is no problem. Proceeding to S4 and subsequent steps, the above-described correction of the extension amount and the pressing amount is executed.

[17] Thus, when the subroutine of FIG. 12 is exited, the process returns to the main routine (not shown) and the discharge process of the molded coil 57 is executed. That is, the set discharge position is read, and the vertical bracket 38 is moved there (in the case of a non-defective product, there is no movement because it is the position of the bag that has been molded).
At that position, the coil receiving pins 47U and 47D are retracted (stored) in the coil handling member 46 (FIG. 9 (15)). The coil 57 thus molded is discharged to a non-illustrated non-defective product tray (chute) or defective product tray (chute).
[18] Thereafter, the vertical bracket 38 is returned to the state shown in FIG. When the next coil winding is finished, the coil 56 is immediately taken out and molded (FIG. 2 (2)). If not finished, the molding work is started after the end of winding.
The poorly formed coil 57 is not re-formed on the spot. This is because the coil winding is performed at a predetermined interval, and if the winding is not performed immediately after the winding, the work is delayed and the function of the folding angle is not sufficiently exhibited. If the number of windings is large and there is time until the next winding, re-molding may be performed during that time.

A modification will be described. Coil transition from the core 13 to the coil receiving pins 47U and 47D (FIG. 2 (3)) may be performed by moving the coil handling member 46 toward the movable winding jig 21 side. However, the moving method as in the embodiment can use the fixed-side winding jig 22 as a backup of the coil handling member 46, and the coil can be moved smoothly (FIGS. 2 (2) and 3 (4). )). The coil handling member 46 and the movable side winding jig 21 may be brought close to each other.
The pressing of the molding object coil 56 in the minor axis direction may be performed before and after the stretching.

  The cross section of the winding core 13 may be oval. That way, the amount of deformation is reduced during subsequent molding, and the dimensional accuracy is improved. However, if the ratio of the short axis to the long axis is too small, the winding is likely to be disturbed. How small it can be made depends on the function of the tension device, the rigidity of the wire, etc. In this case, there is a hand that lowers the rotation speed to some extent. The extent to which the ratio is reduced and the extent to which the rotational speed is reduced are determined by trial several times using actual devices and wire rods. Specifically, the ratio and the rotation speed reduction range are determined within a range in which the alignment property, tact time, etc. are not inferior to those when a circular core is used. The ratio of the molding object coil 56 in FIG. 6 (9) is obtained in this way.

The coil receiving pins 47U and 47D are not limited to a cylindrical shape and a circular cross section as in the embodiment. These are appropriately changed depending on the shape of the coil to be formed, which part of the coil is to be deformed, and the like. For example, in the case where the curved portion after molding is a saddle shape, the cross section is also a saddle shape like the coil receiving pins 47-1 and 47-2 in FIG. The number of coil receiving pins is not limited to two. FIG. 14B shows an example constituted by four coil receiving pins 47-3 to 47-6. These are used, for example, when forming a coil having a quadrangular shape and rounded corners. Here, the coil extends in the left-right direction as necessary, and is also pressed from above and below as needed (press jigs 53U, 53D).
The winding core 13 may be disposed toward the fixed-side winding jig 22. In this case, the core advance / retreat air cylinder 29 and the like are also arranged on the left side of the block. The direction of the coil handling member 46 is also reversed, and the coil receiving pins 47U and 47D are also directed toward the fixed-side winding jig 22.

The front view which shows the winding shaping | molding apparatus 50 of the embodiment of this invention (coil handling member 46 advance). The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (the coil handling member 46 descends, the movable side winding jig 21 advances). Since the structure is the same, the reference numeral is attached only to the left figure (2). The same applies below. The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (the movable side winding jig 21 retreats, the coil handling member 46 rises). The front view which shows the winding shaping | molding apparatus 50 of the embodiment of this invention (coil handling member 46 retreat). For the reference numerals, see FIG. 1 having the same structure. The enlarged front view which takes out and shows the winding jigs 21 and 22, the coil handling member 46, etc. (shutter 49 descending, movable winding jig 21 advance, shutter 49 advance, and next winding start). The enlarged right view which takes out and shows the press jig | tool 53L, 53R part. Each process (9)-(12) of coil shaping | molding is shown. Enlarged front view showing coil receiving pins 47U, 47D, coil 57, etc. ((13) shutter 49 raised) The front view (imaging state) which takes out and shows the coil 57, digital camera 59, etc. after shaping | molding. The enlarged front view which takes out the coil handling member 46 grade | etc., (Coil receiving pin 47U and 47D accommodation, coil 57 discharge | emission). FIG. 6 is an explanatory diagram illustrating an example of a captured image. (A) shows a state without a prior coil, and (b) shows a state with a coil after molding. Explanatory drawing which shows a pixel group (image) etc. FIG. (C) shows a pixel group (image) representing a coil. (D) shows the center point of this pixel group. (E) shows the determination area. (F) shows a state in which a pixel group representing a coil is overlaid on the determination region. Explanatory drawing which shows the subroutine for determination and correction. Explanatory drawing for demonstrating determination. (G) shows the middle point (white dot) of the center of each side of the pixel group representing the coil. (H) represents the distance between these midpoints. The modification of a coil receiving pin is shown, (A) shows the coil receiving pins 47-1 and 47-2 etc. of cross-sectional saddle type, (B) shows the coil receiving pins 43-3 to 47-6 etc. of 4 composition. The enlarged right view shown.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Spindle block 2 ... Block left 3 ... Block right 4 ... Spline shaft 5 ... Cabinet 8 ... Motor spline belt 9 ... Fixed side pulley 10 ... Shaft left pulley 11 ... Motor pulley 12 ... Fixed side motor belt 13 ... Core 14 ... Trabus base 16 ... Sliding frame 17 ... Trabus motor 18 ... Line guide 19 ... Tail plate support shaft 21 ... Moving side winding jig 22 ... Fixing side winding jig 23 ... Tail plate 24 ... Tail plate air cylinder 26 ... Lower part Slide shaft 27 ... Upper slide shaft 28 ... Follow pulley 29 ... Core cylinder advancing / retreating air cylinder 31 ... Movable pulley 32 ... Spline movable side belt 33 ... Horizontal guide 34 ... Horizontal moving body 36 ... Horizontal moving bolt 37 ... Horizontal movement motor 38 ... vertical bracket 39 ... vertical guide 41 ... vertical moving body 42 ... vertical Moving bolt 43 ... bearing body 44 ... vertical moving motor 46 ... coil handling member 47U, 47D ... coil receiving pin 47-1～47-6 ... coil receiving pin (Modification)
48 ... Air cylinder for receiving pin up / down 49 ... Shutter 50 ... Winding forming device 51 ... Air cylinder for up / down shutter ... Press mechanism 53L, 53R ... Press jig 53U, 53D ... Press jig (modified example)
54 ... Pressing motor 56 ... Molding target coil 57 ... Oval coil 58 ... Wire 59 ... Digital camera

Claims (14)

Separating the support member and extending the coil supported by the support member;
A pressing member arranged so as to be movable in a direction crossing the extension direction is brought close to the coil;
Press and shape the coil simultaneously with or before and after the extension,
Optically acquiring the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference,
Correct one or both of the amount of extension and the amount of pressing according to the difference,
A coil forming method, wherein the next coil is extended and pressed after the correction. The coil forming method according to claim 1, wherein the coil is formed in a circular shape or an elliptical shape, and the extension and the pressing are performed on the coil. The coil forming method according to claim 1 or 2, wherein the width of the coil is regulated by a width regulating member during the extension and pressing. A winding core that is slidably arranged on one side of the winding jig and is biased toward the other side of the winding jig, and a support member for supporting the coil from the inside, face each other,
For one of the winding jigs and the support member, either one of them is brought close to the other or close to each other,
The winding is moved into the winding jig by the approach, whereby the coil wound around the winding core is transferred to the support member, and the coil is supported by the support member from the inside thereof.
Separating the support member that supported the coil, extending the coil, and forming the coil;
Optically acquiring the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference,
Modify the amount of expansion according to the difference,
A coil take-out and molding method, wherein the next coil is shaped after the correction. The coil extraction and molding method according to claim 4, wherein the coil is formed in a circular shape or an elliptic shape, and the extension is performed on the coil. A pressing member arranged to be movable in a direction crossing the extension direction is brought close to the coil, and the coil is formed by pressing the coil simultaneously with or before and after the extension,
Optically acquiring the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference,
Correct one or both of the amount of extension and the amount of pressing according to the difference,
6. The coil take-out forming method according to claim 4, wherein the next coil is formed after the correction. The coil extraction and molding method according to claim 4, wherein the width of the coil is regulated by a width regulating member during the molding. A support member for supporting the coil from the inside;
A pressing member arranged so as to be movable in a direction crossing a direction in which the coil extends;
Optical means;
Control means, the control means comprising:
Separating the support member, elongating a coil supported by the support member;
The pressing member is brought close to the coil, and the coil is pressed simultaneously with or before and after the extension, and molded,
Optically acquiring the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference,
Correct one or both of the amount of extension and the amount of pressing according to the difference,
A coil forming apparatus, wherein the next coil is formed after the correction. The coil is formed in a circular or elliptical shape;
The coil forming apparatus according to claim 8, wherein the control unit performs the extension and the pressing on the coil. Furthermore, a width regulating member is provided,
The coil forming apparatus according to claim 8 or 9, wherein the control means restricts the width of the coil by the width restricting member during the pressing and forming. Winding jigs arranged opposite to each other;
A winding core slidably disposed on one of the winding jigs and biased toward the other side of the winding jig;
A support member for supporting the coil from the inside;
Optical means;
Control means, the control means comprising:
Make the core and the support member face each other,
For one of the winding jigs and the support member, either one of them is brought close to the other or close to each other,
The winding is moved into the winding jig by the approach, the coil wound around the winding core is transferred to the support member, and the coil is supported from the inside to the support member,
Separating the support member that supported the coil, extending the coil, and forming the coil;
Optically acquiring the contour data of the coil after the molding,
The acquired contour data is compared with a target value to obtain a difference,
Modify the amount of expansion according to the difference,
A coil take-out and forming apparatus, wherein the next coil is formed after the correction.   12. The coil take-out and molding apparatus according to claim 11, wherein the winding core has a circular or elliptical cross section. A pressing member arranged to be movable in a direction crossing the extension direction;
The coil according to claim 11 or 12, wherein the control means makes the pressing member approach the coil, presses the coil simultaneously with or before and after the extension, and forms the coil. Take-out molding equipment. Furthermore, a width regulating member is provided,
14. The coil take-out and molding apparatus according to claim 11, wherein the control means regulates the width of the coil by the width regulating member during the molding.

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