JP3029744B2 - Coil manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coil manufacturing apparatus for manufacturing a coil having an aligned winding.

[0002]

2. Description of the Related Art In recent transformers and the like, there is a tendency that demand for an arrayed contact type coil having an improved space factor is increased due to the trend toward miniaturization. As shown in FIG. 11, this aligned contact coil is wound so that the upper wire 1 is dropped between the lower adjacent wires 1 so that the thickness L of the coil 10 is reduced. Things.

A configuration of a coil manufacturing apparatus for manufacturing such an aligned contact coil 10 will be described with reference to FIG. The winding shaft 3 on which the former 2 is mounted is driven to rotate by a servomotor 4. A rotation amount detector 5 is provided at one end of the winding shaft 3, and the rotation amount detector 5 detects the rotation amount of the winding shaft 3 (the rotation amount of the former 2).

On the other hand, a feed screw 6 is provided in parallel with the winding shaft 3, and the feed screw 6 is rotated by a servomotor 7 to move the wire guide 8 along the winding form 2.
The movement amount of the wire guide 8 is indirectly detected by detecting the rotation amount of the feed screw 6 by the movement amount detector 9.

[0005] In the case of performing the close contact winding by such a coil manufacturing apparatus, conventionally, the wire guide 8 moves a distance corresponding to the wire diameter of the wire 1 per rotation of the winding shaft 3. The movement of the wire guide 8 is adapted to continuously move at a constant speed in proportion to the rotation amount of the winding shaft 3.

[0006]

When the wire guide 8 is fed at a constant speed as described above, as shown in FIG. 12, the winding angle θ of the wire 1 depends on the feeding direction of the wire 1 ( Although it is inevitable to have a certain angle with respect to the direction perpendicular to the winding form 1), when the wire 1 is wound around the winding form 2 in a plurality of steps, the feed direction of the wire guide 8 is changed at the end of each step. Therefore, the winding angle θ of the wire 1 is alternately reversed in each stage. As a result, the strands 1 intersect each other, so that it is difficult to accurately drop the upper strand 1 between the lower strands 1 as shown in FIG.

[0007] In order to improve this, the strand used in the conventional aligned close winding is made of a polyester-based material having a slippery coating and having a thin wire diameter to bend easily. The wire was wound so as to be slid between the lower wires using the ease and bendability.

[0008] However, this method is a small solution,
It is not a fundamental solution, but only good alignment and close contact winding is possible only when the conditions such as the slipperiness, softness, wire diameter, and reel rotation speed of the strand are matched well by chance. There is almost no effect on a general large coil, a coil using a coating having poor slippage, or a coil having a large wire diameter. However, there is a disadvantage that the size of the image becomes large.

In addition, since the wire guide 8 is continuously moved during the winding operation, the behavior of the wires 1 wound on the winding form 2 is influenced by the frictional resistance and softness of the wires 1. As a result, there is also a disadvantage that it is likely to be unstable and a collapse phenomenon easily occurs. Here, the collapse phenomenon refers to the cross section AA (b) and the cross section BB of the coil 10 as shown in FIG.
When comparing (c), the position of the corresponding element wire 1 will be described with the symbols “a, b, c, d, e”.
In A (b), the e-line located at the fourth stage is a cross section BB
In (c), it means a phenomenon of dropping from the fourth stage to the third stage as shown by the arrow. When such a collapse phenomenon occurs, for example, in a configuration in which the inter-level insulator is removed, a problem occurs that an insulation distance cannot be secured.

[0010] The present invention has been made in view of such circumstances, and the object thereof is to achieve good alignment and close contact winding regardless of the thickness of the wire and the type of coating, and to prevent the collapse phenomenon. An object of the present invention is to provide a coil manufacturing apparatus that does not generate any coil.

[0011]

According to the first aspect of the present invention,
A winding shaft for attaching and rotating a winding form, a wire guide for guiding a wire supplied from a wire supply source to a predetermined position on the winding form, and a rotation amount detector for detecting a rotation angle of the winding form A movement amount detector for detecting a position of the wire guide, and control means for controlling operations of the winding form and the wire guide based on output signals of the rotation amount detector and the movement amount detector. The control means controls the wire guide to change the wire diameter of the wire each time it detects that the winding form makes one rotation and reaches a certain rotation angle based on the output signal of the rotation amount detector. It is controlled to move along the former by every minute to perform aligned winding.

In this case, several turns of the winding form at the start of the winding of the wire in each layer and the last one turn of the winding form in each step and each layer are performed at a predetermined low speed. When the winding of the wire is completed, the control means may be configured so that the wire guide is advanced by about half the wire diameter of the wire, and then the winding form is rotated once at a predetermined low speed. (The invention according to claim 2).

[0013] In the case of the first or second aspect of the present invention, data setting means for setting control data for controlling the coil manufacturing operation based on information such as the wire diameter and the number of turns of the element wire, and the control data And control means for operating the winding form and the wire guide based on the control data, and the rotation speed of the winding shaft and the wire guide for each rotation of the winding form. , A one-turn data block representing the moving direction of the wire guide and the feed amount of the wire guide, a one-stage data block composed of the one-turn data block arranged for each stage of the coil, and a layer of the coil. A one-layer data block composed of the one-stage data blocks arranged for each minute; and a one-set data block composed of the one-layer data block arranged for each coil. It may be provided to the control data (the third aspect of the present invention).

[0014]

According to the first aspect of the present invention, during winding of the coil, the winding form makes one rotation by the output signal of the rotation amount detector and reaches a fixed rotation angle without continuously moving the wire guide. Each time the wire winding is detected, the wire guide is moved by the wire diameter of the wire along the winding form to perform the alignment winding. Therefore, until the winding form reaches a certain rotation angle, the wire is wound straight with the wire guide stopped, so the behavior of the wire is stable and the collapse phenomenon occurs. do not do.

Further, by winding the element wire while the element wire guide is stopped, the element wire can be wound perpendicularly to the winding at each stage, so that the overlapping elements on the winding form can be obtained. The wires in the upper stage can be accurately dropped between the wires in the lower stage without the lines intersecting each other.

According to the second aspect of the present invention, several turns of the winding form at the start of the winding of the wire in each layer and the last one turn of the winding form in each stage and each layer are performed at a predetermined low speed. When the winding of the wire is completed at each step, the wire guide is advanced by about half of the wire diameter of the wire, and then the winding form is rotated once at a predetermined low speed. Therefore, the behavior of the wire can be stabilized at both ends of the coil where the behavior of the wire tends to be unstable.

Further, after the winding of the element wire on each layer is completed,
After the wire guide is advanced by about half of the wire diameter, the wire is rotated once at a predetermined low speed, so when the wire is led out to an adjacent next layer, or when the coil end is subjected to processing such as connection, The behavior of the strand is stabilized.

According to the third aspect of the present invention, a one-turn data block representing the rotation speed of the winding shaft, the moving direction of the wire guide, and the feed amount of the wire guide for each rotation of the winding form, Control data including a data block for one stage, a data block for one layer, and a data block for one set, which is an aggregate of the one-turn data blocks, is set by data setting means. It is stored in the storage means. Then, the operating means sequentially reads the control data from the storage means for each rotation of the winding form, and operates the winding form and the wire guide according to the control data.

For this reason, the control means can easily search and retrieve control data, and it is not necessary to perform control data creation and operation control of the winding shaft and the wire guide in parallel. It can be inexpensive with relatively low processing capacity.

[0020]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A first embodiment of the present invention will be described below with reference to FIGS. The mechanical configuration shown in FIG. 1 is the same as that of the above-described conventional example, so that the description thereof will be omitted, and the configuration of the control device 11 as the control means will be mainly described with reference to FIGS.

The control device 11 is mainly composed of a microcomputer, and includes a CPU 12, a memory 13, and a driver 14 for controlling the servomotor 4 for driving the reel 3.
A D / A converter 15 that outputs a speed command signal to the counter, a counter 16 that counts output pulses of a rotation amount detector 5 that detects the rotation amount of the winding form 2 (the winding shaft 3), and a wire guide 8
A D / A converter 18 that outputs a speed command signal to a driver 17 that controls the servomotor 7 for driving the motor, a counter 19 that counts output pulses of a movement amount detector 9 that detects the movement amount of the wire guide 8, A serial input unit 21 connected to a personal computer 20 serving as a host computer via a serial line, and an I / O 22 for inputting operation commands such as operation start / stop from the outside and outputting a state signal such as winding end. It is configured.

The rotation amount detector 5 and the movement amount detector 9 are constituted by, for example, a rotary encoder. Also,
The personal computer 20 is used when creating data such as the amount of movement of the wire guide 8.

On the other hand, as shown in FIG. 4, the schematic configuration of software used for the control device 11 is roughly divided into an I / O processing unit 23 for transmitting and receiving signals to and from the outside,
2 includes a timer interrupt unit 24 activated every 10 ms by the timer in 2, and a reception processing unit 25 activated every time 1-byte data is received. Among them, the timer interrupt unit 24 plays the most important role, and controls all of the winding shaft 3 and the wire guide 8 according to the control program shown in FIG.

As shown in FIG. 5, the configuration of the timer interrupt unit 24 controls the operation of the count value capturing unit 26 for capturing the respective values of the counters 16 and 19, and the operations of the wire guide 8 and the winding shaft 3. It comprises a guide / winding shaft control unit 27 for issuing a command, and a D / A output unit 28 for actually generating and outputting a speed command based on the command.

On the other hand, the control data is, as shown in FIG.
For each turn, the moving direction of the wire guide 8, the winding speed,
It has a block of one-turn data representing the feed amount of the wire guide 8, and is composed of one turn data collected for the total number of turns and data representing the total number of turns.

Next, the operation of the above configuration will be described.
When the personal computer 20 starts transmitting control data, the reception processing unit 25 starts taking in control data. The fetched data is stored in a predetermined location of the memory 13, and when all the data is received, the control device 11 is ready for the winding operation.

Thereafter, an external operation start instruction is sent to the I / O2
2, the I / O processing unit 23 of the software notifies the guide / spindle control unit 27 and starts the winding operation. During this winding operation, the guide / spindle control unit 2
7 first calculates the amount of rotation of the winding shaft 3 from the "total number of windings" in the control data of FIG.
/ A output unit 28 is notified. In response to this, the D / A output unit 28 starts the servomotor 4 and starts the operation of the reel 3. The D / A output unit 28 also has a function of changing the rotation speed of the winding shaft 3 when instructed at any time.

On the other hand, the guide / winding shaft control section 27 initializes a winding number counter and feed target data as internal variables. Here, the winding number counter is incremented by one each time the winding shaft 3 makes one rotation, and the count value is used as an index amount for extracting the currently executed one-turn data from the control data. In addition, in order to determine whether or not the winding is completed, a comparison is made with the “total number of windings” in the control data.

The above-mentioned feed target data is for measuring the timing of moving the wire guide 8 by one pitch, and this feed target data counts the amount of rotation of the winding shaft 3 (winding form 2). The value is compared with the count value of the counter 16. Here, the rotation amount of the winding shaft 3 is obtained from the count value of the pulse output from the rotation amount detector 5, and if the number of pulses per rotation of the rotation amount detector 5 is, for example, 1000, the feed target data Is 1000. Thereafter, if the count value of the counter 16 exceeds 1000 and the wire guide 8 moves by one pitch, 1000 is newly added, and the next feed target data becomes 2000. Each time it moves by one pitch, the feed target data is sequentially added by 1000.

Next, 10 m is measured by a timer in the CPU 12.
The operation of the timer interrupt unit 24 started every second will be described with reference to the flowchart of FIG. First, reel 3
In order to know the amount of rotation of the (winding form 2) and the current position of the wire guide 8, the count value capturing section 26
Then, the respective count values are taken out and stored in a predetermined location in the memory 13 (step S1). Thereafter, it is determined whether or not the rotation amount of the winding shaft 3 (winding form 2) does not exceed the above-described feed target data (step S2). If not, "NO" is determined in step S2 and step S2 is performed. S7
The D / A output unit 28 (D / A converter 15)
To give an operation command to the servo motor 4 to continue the operation of the reel 3.

On the other hand, if the rotation amount of the winding shaft 3 (winding form 2) exceeds the feed target data, it means that the winding shaft 3 (winding form 2) makes one rotation and reaches a certain rotation angle. . In this case, “YES” is determined in the step S2, and the process shifts to the step S3 to take out one turn data corresponding to the value of the winding number counter from the control data, and to move the wire guide 8 in the one turn data. And D /
The wire guide 8 is connected to the A output unit 28 (D / A converter 18).
Notify the move instruction. Thereby, the wire guide 8 is moved by one pitch (the wire diameter of the wire 1) along the winding form 2.

Further, if the reel speed of the one-turn data is different from the current reel speed, the change is also added to the D / A output unit 2.
8 (D / A converter 18) (step S
4). Thereby, the rotation speed of the winding shaft 3 is made to match the winding speed of the one-turn data.

Thereafter, the winding number counter is incremented and the feed amount data is updated (step S).
6). When this is completed, the process moves to step S7, where D
The winding shaft 3 and the wire guide 8 are controlled by the / A output unit 28 (D / A converters 15 and 18). Here, the D / A output unit 28 implements a pulse distribution function and a deviation counter function used for position / speed control of the servomotors 4 and 7 by software.

The end of the rotation of the winding shaft 3 is determined by the D / A output unit 28.
When it is transmitted to the I / O processing unit 23, the I / O processing unit 2
No. 3 judges that the winding is completed, stops the winding operation, and outputs a state signal indicating the end of the winding.

When the close contact winding is performed in the above-described manner, during the winding operation, the winding wire 2 is rotated once by the output signal of the rotation amount detector 5 without continuously moving the wire guide 8. Every time it is detected that the rotation angle has reached a certain rotation angle, the wire guide 8 is moved along the winding form 2 by the wire diameter of the wire 1 to perform the alignment winding. Therefore, the wire 1 can be wound straight with the wire guide 8 stopped until the winding form 2 reaches a certain rotation angle, so that the behavior of the wire 1 is stabilized, and No collapse phenomenon occurs.

Further, by winding the wire 1 with the wire guide 8 stopped, the wire 1 can be wound perpendicularly to the winding form 2 at each stage. The wires 1 overlapping on the upper wire 2 do not cross each other, the upper wire 1 can be accurately dropped between the lower wires 1, regardless of the thickness of the wires 1 and the type of coating. And good alignment and close contact winding.

In this case, as shown in FIG.
If the wire guide 8 is moved by one pitch (the wire diameter of the wire 1) on the A side of the four sides of the wire, the wire 1 is moved by the wire diameter of the wire 1 during the moving operation. Although the wire 1 is wound diagonally, the range in which the wire 1 is wound diagonally is only the side A, and the wire 1 is wound straight on the other three sides, which is favorable. Aligned close winding is performed. However, the side A is thicker than the other three sides, but since it is a value that can be accurately predicted, the winding dimension of the entire coil 30 can be completely grasped, and variations in the manufacturing dimensions can be reduced.

Next, a second embodiment of the present invention will be described with reference to FIGS. First, in FIG.
9 has a plurality of body portions 32 and 33, and a face plate 34 is provided with a wire 1 of the body portion 32 as shown in FIG.
A notch 34a is formed for leading out to the above. The trunks 32, 33 have grooves 32a, 3 except for both ends.
3a is engraved, and as described later, the first-stage element wire 1 is wound so as to be dropped into the grooves 32a and 33a.

On the other hand, in this case, the control means includes data setting means for setting control data for controlling the coil manufacturing operation based on information such as the wire diameter of the strand 1 and the number of turns.
It comprises storage means for storing the control data, and driving means for driving the former 31 and the wire guide 8 based on the control data. In FIG. 2, the personal computer 20 corresponds to the data setting means. , Memory 13
Corresponds to the storage means, and the control device 11 corresponds to the driving means.

As shown in FIG. 10, the control data indicates the rotation speed of the winding shaft 3, the moving direction of the wire guide 8, and the feed amount of the wire guide 8 for each rotation of the former 31. It has a block of one-turn data. Hereinafter, specific contents of each block of one-turn data will be described with reference to FIGS. 9 and 10.

One-turn data Da is stored in each layer (body 32,
33), the first turn at the start of the wire winding (FIG. 9)
A), the moving direction and the feed amount of the wire guide 8 are “0”, and the rotation speed of the winding shaft is low (hereinafter, referred to as “L”). One turn data D
b is the second or third turn from the start of the wire winding (B,
B), the moving direction of the wire guide 8 is the direction of arrow A (hereinafter, referred to as “A”), and the wire guide 8
Is the wire diameter r of the strand 1 (hereinafter, referred to as “r”), and the rotation speed of the winding shaft is “L”.

The first turn data Dc is the m-th stage (m ≧ 1)
, The feed amount is “r”, the reel speed is “L”, and in the one-turn data Dc, m is an odd number. The movement direction is "A", and the movement direction of the even-numbered movement is in the direction opposite to the arrow A (hereinafter referred to as "anti-A"). The one-turn data Dd corresponds to the first turn (D in FIG. 9) of the n-th stage (n ≧ 2), the feed amount is half the wire diameter “r / 2”, and the reel speed is "L" and Dd
Among them, when n is an odd number, the moving direction is "A", and when n is an even number, the moving direction is "Anti".

The one-turn data De corresponds to the last one turn (E in FIG. 9) in each layer. The feed amount is "r", the winding speed is "L", and the moving direction is "A". "It has become. The one-turn data Df corresponds to F in FIG. 9, and the movement direction is “A”, the feed amount is “r / 2”, and the reel speed is “0”.

The one-turn data Dg corresponds to one turn (G in FIG. 9) other than the data Da to Df. The feed amount is "r" and the reel speed is a predetermined medium speed. , The one-turn data Dg at the odd-numbered stage has a moving direction of “A”, and the one-turn data Dg at the even-numbered stage has
The moving direction is “anti-a”. D is the torso 32
Is the layer-crossing data for deriving the strand 1 from the body 33 to the trunk 33. The layer-crossing data D indicates that the moving direction of the guide 8 is "A" and the feed amount of the strand guide 8 is the thickness of the face plate. At “t”, the reel speed is “0”.

The blocks of the one-turn data Da to Dg and the layer transition data D are combined for each stage to form one stage of data blocks (α) to (γ 2). Data block (α) to (γ2)
Are combined for each layer to form one layer of data blocks (α) and (β), and these one layer of data blocks (α) and (β) are combined for one coil set to form one block. It constitutes a data block for the expression. The one-stage data block (γ2) constituting the one-layer data block (β) is equivalent to the one-stage data block (γ1) from which the layer-crossing data D is deleted.

Next, the operation of the above configuration will be described.
When information such as the wire diameter r of the element wire, the number of turns for one coil, the total number of layers for one coil, and the total number of layers for one coil is input to the personal computer 20, the personal computer 20 Based on these information and a predetermined rule stored in the memory 13 in advance, the control data is created and the total number of turns for one coil is calculated. When the personal computer 20 starts transmitting control data, the control data is received by the reception processing unit 25 and stored in the memory 13 as in the first embodiment.

In this state, an operation start instruction from the outside
When input to O22, the control device 11 first takes out the one-turn data Da from the memory 13, rotates the winding shaft 3 at a predetermined low speed in accordance with the one-turn data Da, and places the wire 1 on the winding form 31. Wind relatively slowly. Next, when the control device 11 detects that the rotation amount of the winding shaft 3 has reached the feed target data, the control device 11 takes out the one-turn data Db using the value of the winding number counter as an index.
Is advanced in the direction of arrow A by the wire diameter r, and the wire 1 is wound again at a predetermined low speed.

Thereafter, the control device 11 advances the wire guide 8 in the direction of the arrow A by the wire diameter r in accordance with the one-turn data Dg, and then winds the wire 1 around the winding form 31 at a medium speed. Thereby, the element wire 1 is aligned and wound so as to be dropped into the grooves 32a and 33a (G in FIG. 9). Further, the control device 11 winds the wire 1 around the former 31 at a low speed according to the one-turn data Dc (the last one turn C of the first stage),
In accordance with the one-turn data Dd, the wire guide 8 is advanced in the direction of arrow A by r / 2, and the wire 1 is wound around the former 31 at a low speed (the first turn D of the second stage).

Further, in accordance with the one-turn data Dg, the control device 11 winds the strand 1 so as to drop it between the first-stage strands, and then performs the one-turn data Dc, Dd, Dg.
The wire 1 is wound in accordance with.

When the control device 11 receives the one-turn data De, the control device 11 advances the wire guide 8 in the direction of the arrow A by the wire diameter r in accordance with the one-turn data De, and moves the wire 1 at a predetermined low speed. Winding is performed (last one turn E of the first layer), and then the wire guide 8 according to one turn data Df.
Is advanced in the direction of arrow a by r / 2, and the wire 1 is wound around the winding form 31 at a low speed (F in FIG. 10).

Next, the control device 11 moves the wire guide in the direction of arrow A by t in accordance with the layer transition data D to derive the wire 1 from the notch 34a of the face plate 34 to the body 33,
Thereafter, by repeating the above series of operations, the trunk 33
The wire 1 is also wound. When detecting that the value of the winding number counter has reached the total number of winding times, the I / O processing unit 23
Determines that the winding is completed, stops the winding operation, and outputs a status signal indicating the end of the winding.

According to the second embodiment, the following effects can be obtained. That is, when aligning and winding the wires 1 on the former 31, the first-stage wires 1 constituting the coil are dropped into the grooves 32 a and 33 a of the former 31, and
The wires 1 after the first stage are guided by being dropped between the lower wires 1. However, the former 31
As shown in FIG. 9, there is no gap between the grooves 32a, 33a and the lower strand 1 at both ends of
If the winding work is performed at a middle speed or higher at both ends of the wire 1, the behavior of the wire 1 becomes unstable, and there is a situation that the winding collapse phenomenon easily occurs.

In this respect, in the second embodiment, each layer (the trunk 3
By performing the first rotation at the start of the winding of the wire and the first rotation at each stage and the last rotation at each stage and each layer at a predetermined low speed in (2, 33), the winding form 31 is formed.
The winding was performed relatively slowly at both ends. Therefore, the behavior of the wire 1 is also stabilized at both ends of the coil, and as a result, the aligned winding is favorably performed over the entire area of the former 31.

Further, at the start of winding the wire in each layer, the winding form 31 is rotated several times at a predetermined low speed, so that the operator can easily recognize the winding state of the wire 1. Therefore, when the winding of each layer is started, when the behavior of the wire 1 becomes unstable, abnormal processing such as immediately stopping the operation of the device can be performed. It is possible to prevent the behavior of the strand from becoming unstable.

On the other hand, after the winding of the wire 1 in each stage is completed,
If the wire guide 8 is immediately retracted, a gap is formed between the end face of the coil and the face plate 34, and a winding collapse phenomenon occurs. Conversely, after the winding of the wire 1 is completed in each stage, the wire guide 8 is further advanced by the wire diameter r of the wire 1,
The strand 1 is pressed against the former 31 and is damaged. In this regard, in the second embodiment, the wire guide 8 is advanced by r / 2 after the winding of the wire 1 on each stage is completed, so that these troubles do not occur and the wire guide 8 can be satisfactorily obtained. An alignment winding can be performed.

Further, after the winding of the wire 1 on each layer is completed, the wire guide 8 is advanced by r / 2, and the wire 1 is wound at a predetermined low speed. When the wire 1 is led out to the second layer from the eye or when a process such as connection is performed on the coil end, the behavior of the wire 1 is stabilized, and the winding collapse phenomenon is less likely to occur.

Incidentally, the conditions such as the wire diameter r and the number of turns of the strand 1 cannot be uniquely specified, and there are many combinations thereof. Moreover, as described above, in order to stabilize the behavior of the wire 1 over the entire area of the coil, the rotation speed of the winding shaft 3, the moving direction of the wire guide 8, and the moving amount of the wire guide 8 must be changed for each rotation of the winding form. Need to be controlled. In this case, the control means controls the operation in accordance with all combinations of the various wires and the various numbers of windings.
1, if the operation control of the wire guide 8 is performed in parallel, a control means having a high processing capacity is required, and the control means becomes expensive, and the production cost of the coil becomes high. is there.

In this respect, in the second embodiment, the control means
It comprises data setting means, storage means and operating means,
In addition, the control data includes a one-turn data block representing the rotation speed of the winding shaft 3, the moving direction of the wire guide 8 and the feed amount of the wire guide 8 for each rotation of the former 31, and the one-turn data. , A data block for one stage, a data block for one layer, and a data block for one set.

Therefore, the control means sequentially reads out the control data from the storage means, and in accordance with the control data, forms 3
1 and the wire guide 8 may be operated. As a result, the control means can easily search and retrieve the control data, and it is not necessary to perform the control data creation and the operation control of the wire guide 8 in parallel. It can be inexpensive, which can reduce the manufacturing cost of the coil.

In the above embodiment, the rotation amount detector 5 and the movement amount detector 9 are constituted by rotary encoders, but may be constituted by using other sensors such as a resolver, a magnetic sensor and an optical sensor. .

[0061]

As apparent from the above description, the coil manufacturing apparatus of the present invention has the following excellent effects.

According to the first aspect of the present invention, the wire is wound straight without stopping the wire guide without continuously moving the wire guide until the winding form reaches a predetermined rotation angle. Since the wire can be turned, the behavior of the wire is stable, and the winding collapse phenomenon does not occur. In addition, by winding the element wire while the element wire guide is stopped, the element wire can be wound perpendicularly to the winding form at each stage, so that the upper element element is located between the lower element elements. The wire can be accurately dropped, and good alignment and close contact winding can be performed regardless of the thickness of the wire and the type of coating.

According to the second aspect, the first several rotations at the start of the wire winding in each layer, the first rotation in each stage, and the last rotation in each stage and each layer are performed relatively slowly. Since the winding can be performed, the behavior of the wire can be stabilized even at both ends of the winding form where the behavior of the wire tends to be unstable. In addition, the contact state between the end face of the coil and the winding form, the state of drawing out the wires to the adjacent next layer, and the like can be improved, so that the aligned winding can be generally performed satisfactorily.

According to the third aspect, the control means sequentially reads the control data set by the data setting means from the storage means, and operates the winding form and the wire guide according to the control data by the operating means. Just do it. As a result, the control means can easily search and retrieve control data, and it is not necessary to perform control data creation and operation control of the wire guide in parallel. And the cost of manufacturing the coil can be reduced.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a mechanical configuration showing a first embodiment of the present invention.

FIG. 2 is a block diagram showing an electrical configuration.

FIGS. 3A and 3B are a top view and a front view showing a winding state of a coil. FIGS.

FIG. 4 is a diagram illustrating a schematic configuration of software.

FIG. 5 is a diagram illustrating a schematic configuration of a timer interrupt unit.

FIG. 6 is a diagram conceptually illustrating the contents of control data.

FIG. 7 is a flowchart for explaining the operation of a timer interrupt unit;

FIG. 8 is a view corresponding to FIG. 1 showing a second embodiment of the present invention.

FIG. 9 is a sectional view of a coil showing a winding state;

FIG. 10 is a diagram specifically illustrating the contents of control data.

FIGS. 11A and 11B are a front view and a cross-sectional view taken along the line AA of FIG.

FIG. 12 is a diagram illustrating a conventional winding method.

FIGS. 13A and 13B are a front view of a coil and a cross-sectional view taken along line AA of FIG.
And BB sectional view (c)

[Explanation of symbols]

1 is a strand, 2 is a winding form, 3 is a winding axis, 4 is a servomotor, 5
Is a rotation amount detector, 7 is a servo motor, 8 is a strand guide,
9 is a movement amount detector, 11 is a control device (control means), 30
Denotes a coil, and 31 denotes a winding form.

Claims (3)

(57) [Claims] 1. A coil manufacturing apparatus for manufacturing a coil by winding a wire around a winding form, wherein a winding shaft for attaching and rotating the winding form and a wire supplied from a wire supply source are placed on the winding form. A wire guide for guiding the wire guide to a predetermined position, a rotation amount detector for detecting a rotation amount of the winding form, a movement amount detector for detecting a movement amount of the wire guide, the rotation amount detector and the movement Control means for controlling the operation of the winding form and the wire guide based on an output signal of an amount detector, wherein the control means controls the operation of the winding form by the output signal of the rotation amount detector.
Each time the rotation is detected to reach a certain rotation angle, the wire guide is controlled to be moved along the winding form by the wire diameter of the wire to perform the alignment winding. Characteristic coil manufacturing equipment. 2. The control means performs a number of turns of the winding form at the start of winding of the wire in each layer and the last one turn of the winding form in each step and each layer at a predetermined low speed. When detecting that the winding of the wire has been completed on each layer, the wire guide is advanced by about half the wire diameter of the wire, and then the winding form is controlled to make one rotation at a predetermined low speed. The coil manufacturing apparatus according to claim 1, wherein: 3. A data setting means for setting control data for controlling a coil manufacturing operation based on information such as a wire diameter and the number of turns of a wire, and a storage for storing the control data. Means, and operating means for operating the winding form and the wire guide based on the control data,
The control data includes a block of one-turn data indicating a rotation speed of a winding shaft, a moving direction of the wire guide, and a feed amount of the wire guide for each rotation of the winding form, and a block of each turn of the coil. A one-stage data block composed of the one-turn data blocks combined, a one-layer data block composed of the one-stage data blocks combined for each layer of the coil, and one coil set The coil manufacturing apparatus according to claim 1, further comprising: one set of data blocks including the one layer of data blocks arranged for each layer.