JP2022108998A - Winding device, winding method, and winding body - Google Patents

Abstract

To provide a winding device that can provide a winding body with satisfactory finish.SOLUTION: According to an embodiment, a winding device 1 comprises: a drive mechanism 10 that rotates a bobbin 100 to which one end of a wire W is coupled around the central axis of a drive shaft to draw in the wire W toward the bobbin; a traverser mechanism 20 that has a wire guide 21 for holding the wire W so that the wire W drawn in toward the bobbin is guided along a radial direction with respect to the drive shaft, and adjusts the position of the wire guide 21 to determine a winding position with respect to the bobbin 100 of the wire W; and a molding guide 31 that, when seen in an axial direction, is arranged to overlap the wire W before winding located between the bobbin 100 and the wire guide 21, and is movable in the axial direction. The winding device 1 winds the wire W around the bobbin 100 while restricting the movement of the wire W in the axial direction with the molding guide 31.SELECTED DRAWING: Figure 2

Description

TECHNICAL FIELD Embodiments of the present invention relate to a winding device, a winding method, and a wound body.

A winding operation of a superconducting wire or the like is generally performed using a drive mechanism having a drive shaft that holds and rotates a winding frame, and a traverser mechanism that moves a wire to be wound around the winding frame in the axial direction of the drive shaft. . A winding frame is a member around which a wire is wound, and generally has a cylindrical shape.

When performing a winding operation using the drive mechanism and the traverser mechanism as described above, for example, first, the winding frame is held on the drive shaft, and then pulled out from the bobbin serving as the supply source of the wire via the traverser mechanism. Bond the wire to the bobbin. Next, the winding frame is rotated by the drive shaft, and the wire is wound around the outer peripheral surface of the winding frame. The wire rod is moved in the axial direction by the traverser mechanism before the wire rod makes a full turn around the winding frame, so that the wire rod portion already wound on the winding frame and the wire rod portion to be wound on the winding frame do not interfere with each other. position is changed.

The operation of moving the wire by the traverser mechanism is repeated in conjunction with the rotation of the winding frame, and the wire is sequentially wound between both ends of the winding frame. That is, in this winding operation, the drive mechanism and the traverser mechanism are operated so that the wire rod spirals on the bobbin.

In the winding operation as described above, tension is applied to the wire pulled out to the bobbin side, so that the curl of the wire usually caused by winding on the bobbin is improved. As a result, the wire rod whose straightness is ensured can be wound around the bobbin. However, if the wire is made of a high-hardness material such as a superconducting wire and has a large wire diameter, the straightness of the wire may not be sufficiently improved even if tension is applied to the wire during the winding operation. . If the straightness of the wire is not improved in this way, the wire actually wound on the bobbin has an accumulated error with respect to the theoretical winding position. As a result, it may not be possible to complete the expected number of winding turns within the bobbin.

For example, when a superconducting wire with a wire diameter of 1 mm is wound by a general winding operation, an error of 10 μm may occur for each round of the bobbin. Under this circumstance, if 200 windings are desired on the bobbin, the cumulative error at the time of 198 windings of the wire may be about 2 mm, resulting in a situation where two windings are insufficient. obtain.

Therefore, in consideration of the cumulative error as described above, in general winding work, the worker corrects the position of the wire by hitting the wire during work, or inserts a filler into the end of the winding frame. In some cases, an operation such as restricting the movement of the wire was carried out. For example, in the winding work of a superconducting wire, a wire rod is generally wound several hundred times around a bobbin to form one layer, and several hundred layers are piled up. was performed visually.

However, even if the adjustment work as described above is performed, it is difficult to completely eliminate the integrated error because the wire rod is not straight when viewed microscopically. Also, the finish of the adjustment work varies depending on the skill of the worker. If the worker's skill is insufficient, the wire often jumps over the desired winding position or falls out of the desired winding position during winding.

When the wire is skipped or dropped, the wire is usually partially unwound to correct the arrangement of the wire, and then the winding operation is performed again. However, such correction work is very troublesome.

As described above, the general winding work requires visual monitoring by the operator, and the adjustment work depends on the skill of the operator. In addition, the finish may differ depending on the skill of the operator. Against this background, various techniques have been proposed so far for carrying out the winding work satisfactorily.

JP 2016-100354 A

Therefore, the problem to be solved by the present invention is to provide a winding device, a winding method, and a winding body that can provide a winding body with good finish.

In one embodiment, the winding device holds a winding frame around which a wire is wound on a drive shaft, and rotates the winding frame to which one end of the wire is coupled around the central axis of the drive shaft to rotate the wire. and a wire rod guide that holds the wire rod so that the wire rod pulled into the winding frame side by the rotation of the drive shaft is guided along the radial direction with respect to the drive shaft. a traverser mechanism that determines the winding position of the wire on the winding frame by adjusting the position of the wire rod guide in the axial direction of the drive shaft; and a forming guide arranged so as to overlap with the wire before winding positioned between and and movable in the axial direction. Then, the winding device winds the wire around the bobbin while the movement of the wire in the axial direction is restricted by the forming guide.

In one embodiment, the winding method is such that when the winding frame to which one end of the wire rod is coupled is rotated to draw the wire rod into the winding frame side, the wire rod is pulled along the radial direction with respect to the rotation axis of the winding frame. a step of holding the wire so as to be guided by the wire rod, and a position overlapping the wire rod before winding positioned between the winding frame and the holding position of the wire rod when viewed in the axial direction of the rotation axis. , locating forming guides for restricting the movement of the wire; and rotating the bobbin. In the winding method, the wire is wound around the bobbin while the movement of the wire in the axial direction is restricted by the shaping guide.

Further, in one embodiment, the winding body includes a plurality of wire layers stacked in the radial direction, each wire layer being formed by sequentially winding a wire between both ends of a cylindrical winding frame, and the wire layers adjacent in the radial direction are mutually stacked. It is a winding body formed so as to be positioned at a position offset by the radius of the wire. Each of the plurality of wire rod portions arranged in the axial direction of the winding frame in each wire rod layer has a bent portion that is bent in the axial direction before making one turn around the winding frame. The portions where the bent portions are arranged in each wire layer are arranged in the circumferential direction of the bobbin so as to form a zigzag shape.

ADVANTAGE OF THE INVENTION According to this invention, the winding body with a favorable finish can be provided.

It is a side view of a winding device concerning one embodiment. 2 is a view of the winding device in the direction of arrow II in FIG. 1; FIG. 2 is a cross-sectional view of a bale-stacked winding body that can be formed with the winding apparatus of FIG. 1; FIG. 1. It is a figure which shows the detection area|region of the shape detection sensor with which the winding apparatus of FIG. 1 is provided, and the example of the image of the shape of the wire rod on the detected bobbin. 2 is a flowchart illustrating an example of the operation of the winding device of FIG. 1; 1. It is a figure which shows a mode that the winding apparatus of FIG. 1 retracts and resets a forming guide. 2 is an exploded view of an example of a winding body formed by the winding device of FIG. 1; FIG. It is a figure explaining the position detection sensor with which the winding device concerning a modification is provided, and its detection information.

An embodiment will now be described in detail with reference to the accompanying drawings.

<Winding device>
FIG. 1 is a side view of a winding device 1 according to one embodiment. FIG. 2 is a view of the winding device 1 in the direction of arrow II in FIG.

The winding device 1 shown in FIGS. 1 and 2 includes a drive mechanism 10 having a drive shaft 12 that rotates a winding frame 100 around which a wire W is wound, and by adjusting the position of the wire W in the axial direction of the drive shaft 12. A traverser mechanism 20 that adjusts the winding position of the wire W on the winding frame 100; and a controller 40 that controls the operation of each part of the line device 1 .

The drive mechanism 10 has a motor 11 , a drive shaft 12 that rotates according to the rotation of the motor 11 , a bobbin holder 13 provided at the tip of the drive shaft 12 , and a tailstock 14 . In FIG. 2, illustration of the tailstock 14 is omitted for convenience of explanation.

The motor 11 has a rotating shaft (not shown), and the rotating shaft is coupled to the drive shaft 12 . The drive shaft 12 is coupled to the rotating shaft of the motor 11 so as to protrude from the motor 11, and rotates around its central axis C as the rotating shaft of the motor 11 rotates. In this example, the rotary shaft of the motor 11 and the drive shaft 12 are separate members, but the rotary shaft of the motor 11 may function as the drive shaft 12 .

In the following description, simply referring to the axial direction means the axial direction of the drive shaft 12 . The axial direction of the drive shaft 12 referred to in the present embodiment means a direction extending along the center axis C or a direction parallel to the center axis C. As shown in FIG.

The bobbin holder 13 has a pedestal 13a provided at the tip of the drive shaft 12 and a chuck 13b provided on the pedestal 13a. The winding frame holding portion 13 holds the winding frame 100 with one end face abutted against the pedestal 13a by means of the chuck 13b. That is, the drive shaft 12 can hold the winding frame 100 via the winding frame holding portion 13 and rotate it.

The tailstock 14 is arranged apart from the bobbin holder 13 in the axial direction and is movable in the axial direction. When the winding frame 100 is held by the winding frame holding portion 13, the winding frame holding portion 13 and the tailstock 14 face each other with the winding frame 100 interposed therebetween. The tailstock 14 has a center 14a inserted into a hole formed in the other end surface of the winding frame 100 opposite to the one end surface that abuts against the pedestal 13a when the winding frame holding portion 13 holds the winding frame 100. have The tailstock 14 is configured to hold the winding frame 100 together with the winding frame holding portion 13 by inserting the center 14 a into the hole of the winding frame 100 .

The winding frame 100 includes a cylindrical shaft portion 101 around which the wire rod W is sequentially wound, a flange-shaped first end plate 102 projecting from one end of the shaft portion 101 , and a flange-shaped first end plate projecting from the other end of the shaft portion 101 . and two end plates 103 . The first end plate 102 and the second end plate 103 are provided to restrict movement of the wire rod W wound around the shaft portion 101 .

In this embodiment, the outer peripheral portion of the first end plate 102 is held by the chuck 13b of the bobbin holder 13, and the second end plate 103 is held by the tailstock . A hole into which the center 14 a of the tailstock 14 is inserted is formed in the center of the second end plate 103 and extends coaxially with the central axis of the shaft portion 101 . Although both the first end plate 102 and the second end plate 103 are disc-shaped, the shape is not particularly limited, and they may not be provided.

When winding the wire W around the winding frame 100 , one end of the wire W is coupled to the shaft portion 101 of the winding frame 100 , and then the drive mechanism 10 rotates the winding frame 100 held via the drive shaft 12 or the like to the drive shaft 12 . rotate around the central axis C of As a result, the wire W can be drawn into the winding frame 100 and wound around the outer peripheral surface of the winding frame 100 .

The traverser mechanism 20 includes a wire rod guide 21 that holds the wire rod W so that the wire rod W drawn into the winding frame 100 side by the rotation of the winding frame 100 by the drive shaft 12 is guided along the radial direction with respect to the drive shaft 12 , and a wire rod guide 21 . and a wire rod guide conveying unit 22 that moves and positions the guide 21 in the axial direction.

The wire guide 21 is arranged on the outer side (upper side) of the winding frame 100 in the radial direction with respect to the drive shaft 12 and supported by the wire guide conveying portion 22 . The position of the wire rod guide 21 in the axial direction is adjusted by the wire rod guide conveying section 22 .

The wire rod guide conveying portion 22 includes a rail portion 23 that extends linearly in parallel with the axial direction of the drive shaft 12, and a slider portion 24 that is held by the rail portion 23 so as to be movable in the direction in which the rail portion 23 extends linearly. and an arm 25 fixed to the slider portion 24 so as to protrude from the slider portion 24 , and the wire rod guide 21 is supported by the arm 25 .

The rail portion 23 has, for example, a ball screw, and the slider portion 24 is fixed to the nut portion of the ball screw. In this case, the wire rod guide 21 can be axially moved via the slider portion 24 and the arm 25 by rotating the screw portion of the ball screw with a motor (not shown). However, the transport structure in the wire rod guide transport section 22 is not particularly limited.

The wire rod guide 21 is arranged between the winding frame 100 and a bobbin (not shown) from which the wire rod W is supplied, and is supported by the arm 25 as described above. In this embodiment, the wire guide 21 is a pulley, and in this case, the wire guide 21 is supported by the arm 25 so as to be rotatable about an axis parallel to the axial direction of the drive shaft 12 . Note that the wire rod guide 21 is not limited to the pulleys, and may be anything that can hold the wire rod W so as to restrict meandering of the wire rod W during transport.

In the traverser mechanism 20 as described above, the position of the wire rod guide 21 in the axial direction corresponds to the winding position of the wire rod W on the winding frame 100 . Thus, by adjusting the position of the wire rod guide 21 in the axial direction by the wire rod guide conveying unit 22, the winding position of the wire rod W on the winding frame 100 can be determined. By rotating the winding frame 100 with the drive shaft 12 in a state where the position of the wire W in the axial direction is determined in this way, the wire W can be wound around the winding frame 100 at a predetermined position.

Further, the traverser mechanism 20 in the present embodiment also bends the wire rod W when moving the wire rod guide 21 to adjust the position of the wire rod guide 21 in the axial direction during winding. Specifically, the traverser mechanism 20 moves the wire rod guide 21 to one or the other side in the axial direction before (more specifically, immediately before) the wire rod W makes one turn around the winding frame 100 due to the rotation of the winding frame 100. The wire rod W is thereby bent. By repeating such a bending operation of the wire W in conjunction with the winding of the wire W, the wire W can be sequentially wound toward one side or the other side of the winding frame 100 in the axial direction.

For example, in the winding device 1 according to the present embodiment, a so-called bale-stacked winding body 200 as shown in FIG. 3 can be formed. In the winding body 200, a plurality of wire rod layers Lw1 to Lw6 formed by sequentially winding the wire rod W between both ends of the winding frame 100 are piled up in the radial direction of the winding frame 100 (six layers in this example) and are adjacent in the radial direction. The wire rod layers Lw are in a state of being shifted by the radius of the wire rod W from each other.

The portion indicated by the white circle in FIG. 3 shows the cross section of the wire rod W wound around the bobbin 100. , a gap S is formed. The gaps S formed corresponding to the wire layers Lw1 to Lw6 are alternately formed on one end side and the other end side in the axial direction. The axial dimension of the gap S is the radius of the wire W. As shown in FIG.

When positioning the wire W while bending the wire W with the wire guide 21 at the time of forming one wire layer Lw of the winding body 200 as shown in FIG. Sequentially move by the diameter. As a result, the wire layer Lw can be formed by laying the wire rods W on the winding frame 100 in the axial direction. On the other hand, when stacking a new wire layer Lw after forming one wire layer Lw, the wire W wound first to form the new wire layer Lw is moved by the radius of the wire W. While the wire rod guide 21 is moved to one side or the other side in the axial direction, the wire rod W is wound around the wire rod layer Lw corresponding to the lower layer so as to climb over the gap S. The details of such operation will be described later.

Returning to FIGS. 1 and 2, the shaping guide transport mechanism 30 has a shaping guide 31 and a shaping guide transport section 32 that moves and positions the shaping guide 31 in the axial direction.

The forming guide 31 is a member that can be arranged so as to overlap the wire W before being wound, which is positioned between the winding frame 100 and the wire rod guide 21 when viewed in the axial direction, and extends from the wire rod guide 21 to the winding frame 100 side. It is provided to limit the axial movement of the wire rod W drawn into. The shaping guide 31 has a first restricting surface 31a formed at one end in the axial direction and a second restricting surface 31b formed at the other end in the axial direction. The first restricting surface 31 a and the second restricting surface 31 b are parallel to the radial direction of the drive shaft 12 .

The first restricting surface 31a and the second restricting surface 31b are arranged so as to be in contact with the wire rod W or away from the wire rod guide 21 when the wire rod W drawn from the wire rod guide 21 toward the winding frame 100 is about to move in the axial direction. It can be positioned by the forming guide conveying part 32 so as to be in constant contact with the wire rod W drawn into the bobbin 100 side. In this state, movement of the wire rod W in the axial direction can be restricted. Thus, in the present embodiment, the wire W can be wound around the winding frame 100 while the axial movement of the wire W is restricted by the shaping guide 31 .

The shaping guide conveying portion 32 has a mechanism similar to that of the wire guide conveying portion 22. The rail portion 33 extends linearly in parallel with the axial direction of the drive shaft 12, and the rail portion 33 moves in the direction in which the rail portion 33 extends linearly. and an arm 35 fixed to the slider portion 34 so as to protrude from the slider portion 34 . It supports forming guides 31 .

Referring to FIG. 2, the advance/retreat mechanism 36 has an advanced state in which the tip of the forming guide 31 is positioned at position P1 shown in FIG. 2, and a retracted state in which the tip of the forming guide 31 is positioned at position P2 shown in FIG. In between, the shaping guide 31 can be moved. When the forming guide 31 is in the retracted state, it is retracted to a position where the forming guide 31 does not overlap the winding frame 100 and the wire rod W when viewed in the axial direction.

As described above, the traverser mechanism 20 bends the wire rod W by moving the wire rod guide 21 before the wire rod W makes one turn around the winding frame 100 due to the rotation of the winding frame 100 . By repeating such a bending operation, the wire rod W is sequentially wound toward one side or the other side in the axial direction. Here, the shaping guide 31 in the present embodiment is arranged on one side of the wire W in the axial direction when the wire W is sequentially wound toward one side in the axial direction. On the other hand, when the wire W is sequentially wound toward the other side in the axial direction, the shaping guide 31 is arranged on the other side of the wire W in the axial direction.

That is, when the wire W is successively wound toward one side in the axial direction, the forming guide 31 restricts the movement of the wire W to one side in the axial direction, so that the wire W is directed toward the other side in the axial direction. When the wire rod W is sequentially wound on the other side, the movement of the wire rod W to the other side in the axial direction is restricted.

More specifically, assuming that the left side in FIG. is spaced from the center of the wire W on the wire guide 21 by a distance equal to or less than the radius of the wire W to one side in the axial direction. On the other hand, when the wire W is successively wound toward the other side in the axial direction (the right side in FIG. 1), the first restricting surface 31a of the forming guide 31 is positioned so that the wire W is wound from the center of the wire W on the wire guide 21. They are spaced apart in the other axial direction by a distance equal to or less than the radius of W.

When the first restricting surface 31a or the second restricting surface 31b is separated from the center of the wire W on the wire rod guide 21 by the distance corresponding to the radius of the wire W, the axis of the wire W drawn from the wire rod guide 21 toward the winding frame 100 side Movement in the direction is restricted by the first restriction surface 31a or the second restriction surface 31b. Further, when the first restricting surface 31a or the second restricting surface 31b is separated from the center of the wire rod W on the wire rod guide 21 by a distance less than the radius of the wire rod W, the wire rod W drawn from the wire rod guide 21 toward the winding frame 100 side is always in contact with the first restricting surface 31a or the second restricting surface 31b. As a result, the movement of the wire W is restricted, and the winding is performed while pushing the wire W in the axial direction opposite to the winding side.

In any of the above cases (by the radius or less than the radius), it is possible to prevent the wire rod W wound around the bobbin 100 from bulging in the winding direction. As a result, in the present embodiment, the wire rod W can be wound accurately at a desired winding position.

Further, as described above, when the traverser mechanism 20 moves the wire guide 21 to bend the wire W in forming one wire layer Lw, the forming guide 31 basically interlocks with the movement of the wire guide 21. is moved. The distance that the forming guide 31 is moved at this time is the same distance as the moving distance of the wire rod guide 21 .

However, when the shaping guide 31 moves as described above, the shaping guide 31 gradually approaches the first end plate 102 or the second end plate 103 of the bobbin 100 . As the movement continues, the forming guide 31 collides with the first end plate 102 or the second end plate 103 . In the present embodiment, such a collision is avoided by the advancing/retreating mechanism section 36 described above. That is, the advancing/retreating mechanism 36 is moved from the advanced state to the retracted state by the controller 40 when the controller 40 detects that the molding guide 31 and the first end plate 102 or the second end plate 103 approach each other.

The controller 40 will be described below. The controller 40 winds the wire rod W around the winding frame 100 by controlling the drive mechanism 10 , the traverser mechanism 20 and the forming guide transport mechanism 30 . The controller 40 stores the dimensions of the winding frame 100, the wire diameter of the wire W, the number of windings in the axial direction of the winding body to be produced, the number of layers of the winding body (the number of wire layers stacked in the radial direction), and the like. information is recorded. Further, the controller 40 can recognize the rotation angle of the winding frame 100 from the winding start position, for example, based on detection information from an encoder provided in the motor 11 .

As a result, the controller 40 controls the operations of the traverser mechanism 20 and the forming guide 31 at predetermined timings, thereby bending the wire rod W appropriately and winding it sequentially to form a wound body having a desired number of layers. The winding start position is a position where one end of the wire W is connected to the winding frame 100 .

In addition, since the controller 40 can recognize the rotation angle of the winding frame 100 from the winding start position as described above, the axial direction of the forming guide 31 that is basically moved each time the winding frame 100 makes one rotation is detected. Know your location in This makes it possible to detect the approach between the forming guide 31 and the first end plate 102 or the second end plate 103 .

By controlling the traverser mechanism 20, the forming guide 31, and the like, the controller 40 can form, for example, the bales-stacked winding body 200 shown in FIG. Street.

That is, in this case, the controller 40 first controls the drive mechanism 10 to rotate the winding frame 100 in order to form the first wire layer Lw1. After that, the controller 40 controls the traverser mechanism 20 and the forming guide so that the wire rod guide 21 and the forming guide 31 move by the diameter of the wire W before the wire W makes one turn around the winding frame 100 due to the rotation of the winding frame 100 . 31 operation. The controller 40 then repeats this operation. As a result, first, a wire layer Lw1 is formed in which the wire rods W are wound in a state that they are laid out in the axial direction.

When the wire layer Lw1 is covered with the wires W as described above, the gap S is formed between the wire portion of the wire W wound last in the wire layer L1 and the first end plate 102. can be controlled to the radius of the wire rod W with high accuracy. Further, in the present embodiment, the controller 40 retracts the forming guide 31 at least when the wire rod W is finally wound during the formation of the wire layer Lw1. Such retraction of the forming guide 31 is also performed when the second and subsequent wire layers Lw2 to Lw6 are formed.

Then, when stacking the next wire layer Lw2 on the wire layer Lw1, the controller 40 moves the wire guide 21 so that the wire W is wound on the gap S. The moving distance at this time is the radius of the wire W. As shown in FIG.

After that, the controller 40 controls the traverser mechanism 20 and the forming guide 31 so that the wire rod guide 21 and the forming guide 31 move by the diameter of the wire W before the wire W makes one turn around the winding frame 100, as described above. controls the behavior of By repeating this operation, the wire layer Lw2 is formed. The third and subsequent wire layers Lw3 to Lw6 are also formed in the same procedure as for the second wire layer Lw2.

It should be noted that the direction in which the wire rod W is sequentially wound after the wire rod W is wound in the state of riding on the gap S as described above is the direction in which the wire rod W was wound when the wire rod layer corresponding to the lower layer was formed. can be switched in the opposite direction. When the winding direction is switched in this manner, the shaping guide 31 is returned to the position where the movement of the wire rod W is restricted in this embodiment.

By the controller 40 controlling each part of the winding device 1 as described above, the winding bodies 200 stacked in bales can be formed. However, the processing of the controller 40 is not limited to the above mode, and each part of the winding device 1 may be controlled so as to form a winding body different from the bales.

Reference numeral 51 in FIG. 1 indicates a wire diameter detection sensor, and reference numeral 52 indicates a shape detection sensor. These wire diameter detection sensor 51 and shape detection sensor 52 are electrically connected to the controller 40 .

The wire diameter detection sensor 51 detects the wire diameter of the wire W by detecting between the winding frame 100 and the wire rod guide 21 the shape of the wire W drawn into the winding frame 100 side by the rotation of the winding frame 100 . The wire diameter detection sensor 51 may be, for example, a sensor using a light cutting method that detects the wire diameter by irradiating the wire W with a belt-shaped laser. In this example, the wire diameter detection sensor 51 detects the wire diameter of the wire W projected in the axial direction, and the wire diameter of the wire W projected at the viewpoint shown in FIG. 2 is detected.

The shape detection sensor 52 also detects the position and shape of the wire rod W wound around the winding frame 100 projected in a direction parallel to the radial direction of the drive shaft 12 . FIG. 4A shows the detection area Ar of the shape detection sensor 52, and FIG. 4B shows an image of the position and shape of the wire W wound around the winding frame 100 detected by the shape detection sensor 52. It is shown. The shape detection sensor 52 may also be a sensor using the light section method.

The shape detection sensor 52 may detect the position and shape of the wire W at the timing when the winding frame 100 reaches a predetermined rotation angle, for example, based on detection information from an encoder provided in the motor 11, or may detect the position and shape at all times. may

The controller 40 determines that an abnormality has occurred when the wire diameter of the wire rod W detected by the wire diameter detection sensor 51 deviates from a predetermined standard. Then, when an abnormality is determined, the operation of the winding device 1 is stopped. Since the wire rod W is generally manufactured by draw molding, the diameter of the wire tends to vary due to wear of the mold. Therefore, the controller 40 monitors the wire diameter via the wire diameter detection sensor 51 .

Further, the controller 40 determines that an abnormality has occurred when the position and/or shape of the wire rod W detected by the shape detection sensor 52 deviates from a predetermined standard. Then, when an abnormality is determined, the operation of the winding device 1 is stopped. Whether or not the position and/or shape of the wire rod W deviates from a predetermined standard is determined by, for example, whether or not the position of the wire rod W is at a predetermined position, or whether the roundness of the wire rod W on the winding frame 100 is appropriate. and whether the diameter of the winding body formed by the wire rod W on the winding frame 100 is appropriate.

Based on the information detected by the shape detection sensor 52, the controller 40 recognizes the latest winding position of the wire W that is sequentially wound as indicated by DP in FIG. 4(B). The controller 40 compares the position of the wire W recognized as the latest winding position with a pre-stored reference range, and determines whether or not the position of the wire W is at the expected position. Then, when it is determined that the reference range is exceeded, it is determined that an abnormality has occurred. Such comparison between the latest winding position of the wire W and the reference range may be performed, for example, by pattern matching using an image.

Based on the information detected by the shape detection sensor 52, the controller 40 recognizes the shape and position of the wound wire rod portion in a variable detection range extending in the axial direction indicated by symbol DR in FIG. 4(B). there is The controller 40 identifies the difference between the positions of the radial end points of the plurality of wire rod portions included in the range DR and the reference positions with respect to these. Then, the controller 40 determines whether the roundness of the wire rod W on the winding frame 100 is appropriate by determining whether the difference between the specified maximum value and minimum value of the difference exceeds the threshold value. . Then, when it is determined that the threshold is exceeded, it is determined that the roundness of the wire rod W is abnormal.

When determining whether or not the diameter of the winding body is appropriate, the controller 40 uses the information detected by the shape detection sensor 52 to determine the position of the end point in the radial direction of the wound wire portion and the reference point therefor. Identify the difference with the position. Then, the controller 40 determines that the diameter of the winding body is abnormal when the identified difference exceeds the upper limit threshold or falls below the lower limit threshold.

Further, the controller 40 can detect the position of the end surface of the winding frame 100 in the axial direction based on the information detected by the shape detection sensor 52, specifically the position of the end surface 101E of the shaft portion 101 shown in FIG. Then, the controller 40 moves the wire rod guide 21 and the forming guide 31 based on the detected position of the end face 101E of the winding frame 100 . The winding frame 100 has manufacturing errors and the like, and variations in dimensions may occur. However, if the controller 40 detects the end face 101E of the winding frame 100 as described above and specifies the origin for each winding frame 100 that is attached, the wire rod W can be wound accurately at a desired position. Moreover, contact between the shaping guide 31 and the winding frame 100 can be reliably prevented.

Note that the controller 40 is, for example, a PLC (Programmable Logic Controller) including a processor, and implements various functions by reading necessary programs from a storage unit and executing them. The storage section is implemented by, for example, a RAM (Random Access Memory), a semiconductor memory device such as a flash memory, a hard disk, an optical disk, or the like. In addition, the term processor includes, for example, CPU (Central Processing Unit), Application Specific Integrated Circuit (ASIC), Programmable Logic Device (SPLD, CPLD), Field Programmable Gate Array (FPGA). ) means a circuit such as

<Action>
Next, an example of the operation of the winding device 1 will be described with reference to the flowchart of FIG.

The operation to be described below is the operation of forming the winding body 200 stacked in bales by the winding device 1 . In this operation, one end of the wire W is coupled to the shaft portion 101 of the winding frame 100 held by the winding frame holding portion 13 and the tailstock 14, and the wire W is guided radially toward the winding frame 100 side. After the wire rod W is held by the wire rod guide 21 as shown in FIG.

When a start instruction is issued, in step S101, the controller 40 first controls the traverser mechanism 20 and the forming guide transport mechanism 30 to position the wire rod guide 21 and forming guide 31 at the initial positions. The forming guide 31 overlaps the wire W before winding positioned between the winding frame 100 and the holding position (wire guide 21) of the wire W when viewed in the axial direction (the axial direction of the rotation axis of the winding frame 100). placed in position.

The initial position of the wire guide 21 is, for example, the position where the wire W drawn from the wire guide 21 side to the bobbin 100 side is wound around the shaft portion 101 in contact with or close to the second end plate 103 . On the other hand, the initial position of the shaping guide 31 is a position axially away from the center of the wire rod W on the wire rod guide 21 at the initial position by the radius of the wire rod W or less than the radius.

Next, in step S<b>102 , the controller 40 rotates the winding frame 100 via the drive shaft 12 . As a result, winding of the wire rod W around the bobbin 100 is started.

Next, in step S103, the controller 40 specifies the wire diameter of the wire W detected by the wire diameter detection sensor 51, and then in step S104, compares the specified wire diameter of the wire W with a predetermined reference. Judge wire diameter abnormality.

If it is determined in step S104 that the wire diameter is abnormal, the operation is stopped in step S116, and the process ends (END). On the other hand, if no wire diameter abnormality is determined in step S104, the process proceeds to step S105.

Then, in step S<b>105 , the controller 40 determines whether or not the rotational position of the winding frame 100 has reached the position measured by the shape detection sensor 52 . When it is determined that the measurement position has been reached, the shape detection sensor 52 performs detection in step S106. Note that the measurement position may be changed as appropriate according to the progress of the winding.

Next, in step S107, the controller 40 determines whether the position and/or shape of the wire rod W detected by the shape detection sensor 52 is abnormal.

If it is determined in step S107 that the position and/or shape of the wire rod W is abnormal, the operation is stopped in step S116, and the process ends (end). On the other hand, if no abnormality in the position and/or shape of the wire W is determined in step S107, the process proceeds to step S108. Step S108 is performed when it is determined in step S107 that there is no abnormality in the position and/or shape of the wire W, or when it is determined in step S105 that the rotational position of the winding frame 100 is not the position measured by the shape detection sensor 52 .

Then, in step S<b>108 , the controller 40 determines whether or not the rotational position of the winding frame 100 has reached the movement position of the wire rod guide 21 . That is, here, it is determined whether or not the wire rod W is to be bent by moving the wire rod guide 21 to one side or the other side in the axial direction before the wire rod W makes one turn around the winding frame 100 .

When it is determined in step S108 that the wire rod guide 21 has reached the movement position, the process proceeds to step S109. Returning to S103, determination of abnormality and the like are made.

Then, when the process proceeds to step S<b>109 , the controller 40 determines whether or not the rotational position of the winding frame 100 has reached the retracted position of the forming guide 31 . If reaching the retracted position is not determined in step S109, the process proceeds to step S110. If it is determined in step S109 that the vehicle has reached the retracted position, the process proceeds to step S113.

Then, in step S110, the controller 40 determines whether or not the wire rod W to be bent by the movement of the wire rod guide 21 corresponds to the last winding portion in the wire rod layer Lw. If it is determined in step S110 that the wire W to be bent is not the last winding portion in the wire layer Lw, the process proceeds to step S111. Further, when it is determined in step S110 that the wire W to be bent is the last winding portion in the wire layer Lw, the process proceeds to step S115.

On the other hand, in step S113, which is performed when reaching the retracted position is determined in step S109, the controller 40 retracts the forming guide 31 from the position where the movement of the wire W is restricted. After this, the process proceeds to step S111. That is, in step S109, it is determined that the shaping guide 31 has approached the end of the bobbin 100 . Then, in step S<b>113 , the forming guide 31 is retracted in order to avoid the forming guide 31 colliding with the first end plate 102 or the second end plate 103 of the bobbin 100 .

Then, in step S111, the controller 40 performs a process of moving the wire rod guide 21 and the forming guide 31 from their current positions by the standard distance. Here, the standard distance is a distance corresponding to the diameter of the wire rod W in this embodiment. That is, in step S111, a process of bending and winding the wire W so as not to interfere with the portion where the wire W is already wound is performed.

On the other hand, in step S115, the controller 40 performs a process of moving the wire rod guide 21 by a distance corresponding to 1/2 of the standard distance. That is, in step S115, the process of winding the wire W so that the wire W rides over the gap S shown in FIG. 3 is performed. Then, in step S115, after the wire rod guide 21 is moved, processing for positioning the forming guide 31, in other words, processing for returning is performed.

The shaping guide 31 returned in step S115 is arranged at a position axially separated from the center of the wire rod W on the wire rod guide 21 by the radius of the wire rod W or less than the radius. More specifically, the forming guide 31 is arranged at a position away from the center of the wire W on the wire guide 21 in the axial direction toward the side on which the wire W is wound. That is, in step S115, after the forming guide 31 is retracted, it is determined that the direction in which the wire rod W was axially wound before the forming guide 31 was retracted is switched to the opposite direction. A process of returning the shaping guide 31 to the position where the movement of the wire rod W is restricted is performed.

Then, when the processes of steps S111 and S115 are completed, the controller 40 determines whether or not the winding is completed in step S112. If it is determined that the winding is completed, the process ends (END). If the winding completion is not determined, the process returns to step S103.

6A and 6B are diagrams showing how the winding device 1 retracts and returns the forming guide 31. FIG. FIG. 6A shows a state in which the wire W is wound while the axial movement of the wire W is restricted by the shaping guide 31 . FIG. 6B shows how the rotational position of the winding frame 100 reaches the retracted position of the shaping guide 31 (YES in step S109) and the shaping guide 31 retracts (step S113). In the illustrated example, even after the forming guide 31 is retracted, the process of winding the wire W up to the end of the winding frame 100 is continued, but the forming guide 31 is not used.

FIG. 6(C) shows how the forming guide 31 is restored. That is, in FIG. 6C, in step S115, the controller 40 moves the wire rod guide 21 by a distance corresponding to 1/2 of the standard distance so that the wire rod W rides over the gap S shown in FIG. It shows how the forming guide 31 is returned after the wire W is wound. After the shaping guide 31 is thus restored, normal winding is performed as shown in FIG. 6(D).

In the present embodiment, the shaping guide 31 is retracted at a predetermined timing as described above, but when the shaping guide 31 is retracted, the wire rod W tends to swell in the axial direction. Therefore, the winding position of the wire rod W may be adjusted to the negative side in consideration of such swelling. Adjusting to the negative side means adjusting the position of the wire rod guide 21 to a position where the wire rod W to be wound from now on is wound so as to partially overlap the already wound wire rod portion.

In the winding device 1 , most of the wire W forming the wire layer is wound while being restrained from bulging by the forming guide 31 . Therefore, even if the wire rod W swells in the axial direction due to the withdrawal of the forming guide 31, the swell amount can be reduced. After the forming guide 31 is retracted, the wire W is wound so as to ride on the gap S, and at this time, the wire W can be wound accurately at a desired winding position in the gap S. Therefore, the bulge of the wire layer corresponding to the lower layer can be corrected by the wire W wound so as to climb over the gap S. Therefore, a desired winding body 200 can be obtained by suppressing an accumulated error in the winding body 200 stacked in bales.

Further, in the present embodiment, the movement position of the wire rod guide 21 determined in step S108 is changed by a predetermined angle each time the wire rod W is wound one round. That is, when forming a plurality of wire layers Lw in the winding body 200 stacked in bales, each of the positions where the wire rod guide 21 is moved to one side or the other side in the axial direction to bend the wire W is bent once. It means that the traverser mechanism 20 controls the movement of the wire rod guide 21 so as to deviate by a predetermined angle in the direction opposite to the bending position of the previously wound wire rod portion. Although the predetermined angle is not particularly limited, it may be 3°, for example.

FIG. 7 is a developed view of the winding body 200 shown in FIG. 3, and is a winding body formed when the traverser mechanism 20 is controlled such that the bending position of the wire rod W is shifted by a predetermined angle in the opposite direction of the rotation direction. 200 is an exploded view.

FIG. 7A is a developed view of the first wire layer Lw1. Symbol In1 in FIG. 7A indicates the winding start position of the wire layer Lw1. This winding start position In1 corresponds to one end of the wire rod W coupled to the winding frame 100 . A region surrounded by a dashed line indicated by symbol B1 indicates a continuous bending portion in which the bent portions of the wound wire portions forming the wire layer Lw1 are arranged. The bent portion of each wound wire portion constituting the wire layer Lw1 shifts by a predetermined angle to the opposite side in the rotational direction as the winding progresses, so the continuous bending portion B1 extends obliquely with respect to the circumferential direction. In addition, the symbol In2 in FIG. 7A indicates the winding start position of the second wire layer Lw2.

FIG. 7B is a developed view of the second wire layer Lw2. A region surrounded by a dashed line indicated by symbol B2 indicates a continuous bending portion in which the bent portions of the wound wire portions forming the wire layer Lw2 are lined up. The bent portions of the wound wire portions constituting the wire layer Lw2 are also displaced by a predetermined angle in the opposite direction of rotation as the winding progresses, so the continuous bend portion B2 also extends obliquely with respect to the circumferential direction. The continuous bending portion B1 of the first layer and the continuous bending portion B2 of the second layer are displaced in the circumferential direction so as not to overlap in the radial direction. Further, reference symbol In3 in FIG. 7B indicates the winding start position of the third wire layer Lw3.

FIG. 7C is a developed view of the third wire layer Lw3. A region surrounded by a dashed line indicated by reference numeral B3 indicates a continuous bending portion in which the bent portions of the wound wire portions forming the wire layer Lw3 are arranged. The bent portions of the wound wire portions forming the wire layer Lw3 are also displaced by a predetermined angle in the opposite direction of rotation as the winding progresses, so the continuous bend portion B3 also extends obliquely with respect to the circumferential direction. The continuous bending portion B2 of the second layer and the continuous bending portion B3 of the third layer are displaced in the circumferential direction so as not to overlap in the radial direction.

As described above, when the continuous bending portions B1 to B3 are formed so as to be sequentially shifted in the circumferential direction, the continuous bending portions B1 to B3 are arranged in the circumferential direction of the winding frame 100 so as to form a zigzag shape ( offset), the winding body 200 is formed. In such a winding body 200, good roundness can be ensured by not overlapping each of the continuous bending portions B1 to B3 in the radial direction.

That is, the wire rod W wound on the second and subsequent layers is bent so as to jump over the wire rod portion of the wire rod layer corresponding to the lower layer, and overlaps the wire rod portion of the lower layer in the radial direction. This overlapped portion (bent portion) extends radially beyond the portion wound between two adjacent wire rod portions in the wire rod layer corresponding to the lower layer. And if this overlap part overlaps with a radial direction, roundness will be impaired. On the other hand, in the winding body 200, since the continuous bending portions B1 to B3 do not overlap in the radial direction, no accumulation of portions protruding in the radial direction occurs. Thereby, good roundness can be ensured.

As described above, in the winding device 1 according to the present embodiment, the winding frame 100 around which the wire W is wound is held on the drive shaft 12 , and the winding frame 100 to which one end of the wire W is coupled is attached to the drive shaft 12 . A drive mechanism 10 that draws the wire W to the winding frame 100 side by rotating around the central axis C of the drive shaft 12, and a wire W that is drawn to the winding frame 100 side by the rotation of the drive shaft 12 is guided along the radial direction with respect to the drive shaft 12. a traverser mechanism 20 which has a wire rod guide 21 for holding the wire rod W so as to hold the wire rod W in such a manner that the wire rod W is held in such a manner that the wire rod W is wound on the winding frame 100 by adjusting the position of the wire rod guide 21 in the axial direction of the drive shaft 12; A forming guide 31 is disposed so as to overlap the wire W before winding positioned between the winding frame 100 and the wire rod guide 21 when viewed in the direction, and is movable in the axial direction. Then, the wire W is wound around the winding frame 100 in a state in which the movement of the wire W in the axial direction is restricted by the shaping guide 31 .

With such a winding device 1 , it is possible to wind the wire W around the winding frame 100 while correcting the curl of the wire W by the shaping guide 31 . In addition, the forming guide 31 can suppress the bulging of the wire rod W in the axial direction before or after being wound around the winding frame 100 . As a result, the wire rod W can be wound at a desired winding position with high accuracy, and as a result, a well-finished winding body can be provided.

Further, in the traverser mechanism 20 of the present embodiment, a plurality of wire layers Lw1 to Lw6 are piled up in the radial direction, and the wire layers adjacent to each other in the radial direction are shifted from each other by the radius of the wire W. is formed, the movement of the wire rod guide 21 is controlled in conjunction with the winding of the wire rod W by the rotation of the winding frame 100 . When forming the plurality of wire layers Lw1 to Lw6, the traverser mechanism 20 moves the wire rod guide 21 to one side or the other side in the axial direction so that each of the positions where the wire rod W is bent is bent one time before. The movement of the wire rod guide 21 is controlled so as to deviate from the bending position of the wound wire rod portion by a predetermined angle in the direction opposite to the rotation direction. As a result, a wound body with good roundness can be produced.

Although the embodiment has been described above, the embodiment is presented as an example and is not intended to limit the scope of the invention. This novel embodiment can be embodied in various other forms, and various omissions, replacements, and modifications can be made without departing from the scope of the invention. Such embodiments and their modifications are included in the scope and gist of the invention, and are included in the scope of the invention described in the claims and equivalents thereof.

For example, FIG. 8 is a diagram illustrating the position detection sensor 54 provided in the winding device according to the modification and its detection information. The position detection sensor 54 detects the radial and axial positions of the wire rod W wound around the winding frame 100 based on the distance measurement information in the radial direction. In the present embodiment, it is determined that an abnormality has occurred when the position of the wire W detected by the position detection sensor 54 deviates from a predetermined reference.

As shown in FIG. 8A, the position detection sensor 54 detects the diameter between the wound wire W and the position detection sensor 54 by receiving the reflected light of the light emitted from the light emitting element with the light receiving element, for example. Get ranging information in a direction. Then, the position detection sensor 54 expresses the ranging information as two-dimensional information as shown in FIG. 8(B).

DESCRIPTION OF SYMBOLS 1... Winding device, 10... Drive mechanism, 11... Motor, 12... Drive shaft, 13... Winding frame holder, 13a... Pedestal, 13b... Chuck, 14... Tailstock, 14a... Center, 20... Traverser mechanism, DESCRIPTION OF SYMBOLS 21... Wire guide, 22... Wire guide conveying part, 23... Rail part, 24... Slider part, 25... Arm, 30... Forming guide conveying mechanism, 31... Forming guide, 32... Forming guide conveying part, 33... Rail part, DESCRIPTION OF SYMBOLS 34... Slider part 35... Arm 36... Retraction mechanism part 40... Controller 51... Wire diameter detection sensor 52... Shape detection sensor 54... Position detection sensor 100... Winding frame 101... Shaft part 102... First end plate 103 Second end plate 200 Winding body Ar Detection area C Central axis B1, B2, B3 Bending continuous portion W Wire rod Lw1 to 6 Wire layer

Claims (14)

a drive mechanism that holds a winding frame around which a wire is wound on a drive shaft and rotates the winding frame to which one end of the wire is coupled around the central axis of the drive shaft to pull the wire toward the winding frame;
a wire rod guide that holds the wire rod so that the wire rod pulled into the winding frame side by the rotation of the drive shaft is guided along a radial direction with respect to the drive shaft, and the wire rod in the axial direction of the drive shaft; a traverser mechanism that determines the winding position of the wire on the bobbin by adjusting the position of the guide;
a shaping guide arranged so as to overlap with the wire before winding positioned between the winding frame and the wire rod guide when viewed in the axial direction, and is movable in the axial direction;
A winding device that winds the wire around the winding frame while the movement of the wire in the axial direction is restricted by the shaping guide. 2. The winding device of claim 1, wherein the forming guide is spaced apart in the axial direction from the center of the wire on the wire guide by a distance equal to or less than the radius of the wire. The traverser mechanism bends the wire rod by moving the wire rod guide to one side or the other side in the axial direction before the wire rod makes one turn around the winding frame due to the rotation of the winding frame, By repeating the operation, the wire rod is sequentially wound toward one side or the other side in the axial direction,
The forming guide is disposed on one side of the wire in the axial direction when the wire is wound sequentially toward the one side in the axial direction, and the forming guide is arranged on the other side in the axial direction. 3. The winding device according to claim 1, wherein the winding device is disposed on the other side in the axial direction with respect to the wire when the wire is sequentially wound on the wire rod. The traverser mechanism bends the wire rod by moving the wire rod guide to one side or the other side in the axial direction when forming one wire rod layer by sequentially winding the wire rod between both ends of the bobbin, sequentially moving the wire rod guide by the diameter of the wire rod;
4. The winding device according to claim 3, wherein the forming guide is moved by the diameter of the wire in conjunction with the movement of the wire guide by the diameter of the wire. The traverser mechanism forms a wound body in which a plurality of wire layers are stacked in the radial direction, and the wire layers adjacent in the radial direction are shifted from each other by the radius of the wire, The movement of the wire rod guide is controlled in conjunction with the winding of the wire rod by the rotation of the winding frame,
When forming the plurality of wire layers, the traverser mechanism moves the wire rod guide to one side or the other side in the axial direction to bend the wire at each of the previously wound winding positions. 5. The winding device according to claim 4, wherein the movement of said wire rod guide is controlled so as to deviate by a predetermined angle in the direction opposite to the bending position of said wire rod portion. Each of a plurality of wire rod portions arranged in the axial direction of the winding frame in each of the wire rod layers has a bent portion that is bent in the axial direction before making one turn around the winding frame,
6. The winding device according to claim 5, forming a winding body in which the portions of the wire rod layers where the bent portions are arranged are arranged in the circumferential direction of the winding frame so as to form a zigzag shape. 4. The winding device according to claim 3, wherein when it is detected that said shaping guide approaches the end of said winding frame, said shaping guide is retracted to a position where it does not overlap with said wire rod in said axial direction. 8. The method according to claim 7, wherein after the forming guide is retracted, when the direction in which the wire is wound in the axial direction before the retraction is switched, the forming guide is returned to a position restricting movement of the wire. Winding device as described. The winding according to any one of claims 1 to 8, wherein the end face of the winding frame in the axial direction is detected, and the wire rod guide and the shaping guide are moved based on the position of the detected end face of the winding frame. Device. A shape detection sensor that detects the position and shape of the wire wound around the winding frame projected in a direction parallel to the radial direction,
10. The winding device according to any one of claims 1 to 9, wherein it is determined that an abnormality has occurred when the position and/or shape of the wire rod detected by the shape detection sensor deviates from a predetermined standard. A position detection sensor that detects the position of the wire wound around the winding frame in the radial direction and the axial direction based on distance measurement information in the radial direction,
10. The winding device according to claim 1, wherein it is determined that an abnormality has occurred when the position of the wire rod detected by the position detection sensor deviates from a predetermined reference. The wire rod is held so that the wire rod is guided along the radial direction with respect to the rotation axis of the winding frame when the winding frame to which one end of the wire rod is coupled is rotated to draw the wire rod into the winding frame side. process and
A forming guide for restricting the movement of the wire is arranged at a position overlapping the wire before being wound between the bobbin and the holding position of the wire when viewed in the axial direction of the rotation axis. and
and rotating the winding frame,
A winding method, wherein the wire is wound around the bobbin while movement of the wire in the axial direction is restricted by the forming guide. In the step of rotating the winding frame, by rotating the winding frame, the holding position of the wire rod is moved to one side or the other side in the axial direction before the wire rod makes one turn around the winding frame. is performed, and by repeating the operation, the wire rod is sequentially wound toward one side or the other side in the axial direction,
Each of the positions at which the wire rod is bent by moving the holding position of the wire rod to one side or the other side in the axial direction is on the reverse side in the rotational direction with respect to the bending position of the previously wound wire rod portion that was bent once before. is adjusted to be shifted by a predetermined angle to
A winding body in which a plurality of wire layers formed by sequentially winding the wire between both ends of the winding frame are piled up in the radial direction, and the wire layers adjacent in the radial direction are shifted from each other by the radius of the wire. 13. The winding method of claim 12, forming. A plurality of wire layers formed by sequentially winding a wire between both ends of a cylindrical winding frame are piled up in the radial direction, and the wire layers adjacent in the radial direction are formed so as to be shifted from each other by the radius of the wire. A winding body that
Each of a plurality of wire rod portions arranged in the axial direction of the winding frame in each of the wire rod layers has a bent portion that is bent in the axial direction before making one turn around the winding frame,
A winding body, wherein the portions of the wire rod layers where the bent portions are arranged are arranged in the circumferential direction of the winding frame so as to form a zigzag shape.

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