JP3094054B2 - Basket type heater 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 cage type heater manufacturing apparatus, and more particularly to a cage type heater manufacturing apparatus for manufacturing a cage type heater buried in the vicinity of an inner peripheral surface of a receiving port of an electric fusion joint.

[0002]

2. Description of the Related Art An example of this type of cage type heater is disclosed in FIG. 1 of International Publication WO92 / 15182, and a method of manufacturing the same is disclosed in FIG. 3 and FIG. This conventional cage-type heater is formed by welding or fixing a plurality of cross wires to a wound body formed of a winding including a magnetic alloy body. For example, a winding is formed by winding a winding around a mandrel. And a cross wire is welded to the wound body by a spot welder or the like.

[0003]

Since the conventional cage type heater is formed manually, there has been a problem that it takes a long time to manufacture the heater, the cost is high, and the quality varies. . Therefore, a main object of the present invention is to provide a cage heater manufacturing apparatus capable of manufacturing a high quality cage heater at low cost in a short time.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a rotating cylinder made of a conductive material, winding sending means for sending a winding to the rotating cylinder, and winding the winding on the rotating cylinder a predetermined number of times. Winding means to be formed, cross line sending means for sequentially feeding a cross line of a predetermined length to the rotating cylindrical body, cross line positioning means for sequentially positioning the cross line at a predetermined position in the circumferential direction of the outer surface of the winding body, and And a welding device for sequentially welding the crossed wires to the wound body using the rotating cylindrical body as an electrode.

[0005]

The winding sent out from the winding sending-out means is wound around the rotating cylindrical body by the winding means to form a wound body.
Then, the cross line of a predetermined length sent from the cross line sending unit is positioned at a predetermined position by the cross line positioning unit, and the winding body and the cross line are welded by the welding unit using the rotating cylindrical body as an electrode. Then, the next cross line is positioned by rotating the motor by a predetermined angle, and welding is performed by welding means. This operation is repeated by the number of cross lines.

[0006]

According to the present invention, a cage type heater can be manufactured automatically, so that a high quality cage type heater can be manufactured at low cost and in a short time. The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description of embodiments with reference to the drawings.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A squirrel-cage heater manufacturing apparatus 10 according to this embodiment shown in FIGS. 1 and 2 has a spirally wound winding 12 as shown in FIG. For manufacturing the cage type heater 16 including the cross wires 14 of the first frame 18 and the second frame 2.
Contains 0. The first frame 18 is provided with a heater manufacturing section 22, a winding feeding means 24 (FIG. 2), a welding means 26, and the like.
The heater 16 (FIG. 3) is manufactured by sequentially operating these components.

The heater manufacturing section 22 includes a winding jig mounting section 30, a servomotor 32, a ground electrode 34, and the like, as can be clearly seen from FIG. Pulleys 36 and 38 are provided on the respective rotating shafts of the winding jig mounting portion 30 and the motor 32.
Is attached, and the pulley 36 and the pulley 38
0. Therefore, the rotation of the motor 32 is transmitted to the winding jig mounting section 30 via the belt 40. The heater 16 to be manufactured is provided on the winding jig mounting portion 30.
The winding jig 42 according to the size of FIG. 3 is attached. The winding jig 42 is made of a conductive material such as copper, is divided into three by a radially extending split surface 44 (FIG. 2), and is configured so that the diameter can be increased or reduced by an air cylinder 46. The ground electrode 34 is for grounding the winding jig 42 during welding by the welding means 26, and is configured to be vertically movable by an air cylinder 48.

As shown in FIG. 2, the winding feeding means 24 includes a first plate 52 and a second plate 54 supported on side surfaces of the first frame 18 via guide rails 50.
including. A plate 58 is supported on the first plate 52 via a guide rail 56, and a winding feed chuck 60 and the like are attached to the plate 58. Chuck 6
4 includes a chuck main body 62, holes 64 and 66 are formed in the chuck main body 62, and a bent plate 68 and a push rod 70 are inserted through the holes 64 and 66. An air cylinder 72 for opening and closing the chuck main body 62 and an air cylinder 74 for moving the bending plate 68 and the push rod 70 in the vertical direction are disposed behind the chuck main body 62 at predetermined positions. An air cylinder 76 for moving the plate 58 in the lateral direction is attached to a side end (the right end in FIG. 1) of the first plate 52.
At the lower end of the plate 52, a return roller 78 for returning the twist of the winding 12 (FIG. 3) supplied to the winding jig 42.
Is attached.

The second plate 54 is provided with a plate 80, a chuck 82, an air cylinder 84 for moving the chuck 82 in the horizontal direction, a nipper 86, and an air cylinder 88 for moving the nipper 86 in the vertical direction. The air cylinder 8 is located below the air cylinder 88.
A moving unit 90 for moving the nipper 86, the chuck 82, and the like in the axial direction of the winding jig 42 is provided.

An air cylinder 92 is mounted on the upper portion of the first frame 18, and the air cylinder 92 is provided with the winding delivery means 24 (the first plate 52 and the second plate 5).
4) is connected via the connecting member 94 and the plate 96. The welding means 26 includes a winding wire 12 (FIG. 3) wound on the outer peripheral surface of the winding jig 42 and a cross wire 14 (see FIG. 3) fed onto the outer peripheral surface of the winding jig 42 by the cross wire feeding means 28. 3), and a frame 102 supported on the side surface of the first frame 18 via an air cylinder 98 and a guide rail 100 attached to a plate 96 and connected to the air cylinder 98. including. A welding electrode 104, a welding electrode 104
An air cylinder 106 for moving the welding electrode 104 in the vertical direction, an air cylinder 108 for moving the welding electrode 104 in the horizontal direction, and the like are attached.

As shown in FIG. 1, the cross line delivery means 28 is supported on the side surface of the second frame 20 via an air cylinder 112 and a guide rail 114 formed on the upper portion of the second frame 20. A plate 116 is connected to 112. A plate 120, which is moved in a lateral direction by an air cylinder 118, is supported on a top of the plate 116 via a guide rail 122, and a cross-line feeding chuck 124 is attached to a bottom of the plate 120. On the other hand, plate 116
A plate 128 which is moved in the lateral direction by an air cylinder 126 is supported via a guide rail 130 at a lower portion, and a cross line feeding chuck 132 is attached to an upper portion of the plate 128. Further, the return roller 13 is provided at the center of the plate 116 from the upstream side (the right side in FIG. 1) in the supply direction of the cross line 14 (FIG. 3).
4, guide member 136, guide member 138, chuck 1
40 and the nipper 142 are sequentially arranged.

Such a cage type heater manufacturing apparatus 10 includes:
It is controlled by a control unit 144 as shown in FIG. The control unit 144 includes a microcomputer 146 that performs various controls.
M148 and ROM 150 are connected. RAM14
8 temporarily stores data necessary for various controls performed by the microcomputer 146.
Is stored with a formula for calculating the rotation angle pitch of the winding jig 42 according to the number of cross lines. The input port 152 of the microcomputer 146 is connected to input means 154 for inputting various conditions (diameter, number of turns, pitch, number of cross wires, etc.) of the heater 16.
6 includes a cylinder valve 158 for operating the air cylinder 48 of the ground electrode 34, a cylinder valve 160 for operating the air cylinder of each chuck, and a cylinder valve 1 for operating the air cylinder of each nipper.
62, a motor 32 for rotating the winding jig 42 and the like are connected.

FIGS. 6 to 10 are flow charts showing the operation of this embodiment. In this embodiment, as a preparatory operation before the automatic operation shown in FIGS. 8 to 10 is started, a return-to-origin operation shown in FIG. 6 and a test run of the winding shown in FIG. 7 are executed. In the home return operation shown in FIG. 6, first, a home return switch (not shown) of the operation board is turned on in step S1, and servo home return of the motor 32 (FIG. 1) is started in step S3. And
In step S5, it is determined whether or not the cylinders are at the origin according to the set data. If it is determined that the cylinder is at the origin, the process proceeds to step S7. If it is determined that the cylinder is not at the origin, the process proceeds to step S9. After the origin return of the cylinders is started, the process proceeds to step S7. In step S7, it is determined whether or not the servo origin return has been completed, and if it is determined that "completed", it is determined in step S11 whether or not the cylinders have returned to the home position. Step S1
If it is determined in step S1 that "return", step S1
At 3, the original position lamp is turned on, and the origin return operation is completed.

When the test run of the winding shown in FIG. 7 is started,
First, in step S15, it is determined whether the mode is the manual mode. If it is determined that the operation mode is the "manual mode", it is determined in step S17 whether or not the home return operation has been completed. If it is determined that the operation has been completed, the test run switch of the operation board (not shown) is turned on in step S19. Thereafter, the process proceeds to step S21. In step S21, arithmetic processing of the input various data is executed, and the motor 32
The servo of FIG. 1 is initialized, and the test run lamp blinks. Then, in step S23, the test run lamp is turned on, and the idle winding is started. In step S25,
It is determined whether or not an overrun has occurred. If it is determined that "an overrun has occurred", it means that the input data was not appropriate. Therefore, the test run was interrupted in step S27, and the data was determined in step S29. It is reset. If it is determined in step S25 that "overrun has not occurred", the flow advances to step S31 to determine whether the set number of turns has been completed. Step S
If it is determined in step S31 that "the set number of windings has been completed", the winding test operation is terminated in step S33, and step S33 is performed.
At 35, the trial run complete lamp flashes. And
After visual confirmation of the machine operation status is performed in step S37, the process proceeds to step S39, and it is determined whether the operation status is good. When it is determined in step S39 that the operation status is good, the test operation confirmation switch is turned on in step S41, the test operation completion lamp is turned on in step S43, and the setting data is determined in step S45. If it is determined in step S39 that “the operation situation is not good”, then step S39
Proceeding to S29, the data is reset.

After the return-to-origin operation and the trial run of the winding are completed, an automatic operation operation as shown in FIGS. 8 to 10 is executed. When the automatic operation is started, first, in step S4
7, it is determined whether or not the mode is the automatic mode. If it is determined that the mode is the automatic mode, the origin return operation (FIG. 6) and the test run of the winding (FIG. 7) are performed in steps S49 to S59.
It is determined whether or not the preparation operation such as is completed. If it is determined that “preparation operation has not been completed”, step S
It is necessary to execute the preparation operation in 59, and when it is determined that "the preparation operation has been completed", the automatic lamp is turned on in step S61. When the automatic operation start switch of the operation board (not shown) is turned on in step S63, the automatic operation lamp is turned on in step S65, the motor 32 is driven in step S67, and the diameter of the winding jig 42 is expanded in step S69. .

Then, in step S71, the winding 12
Is wound, and the winding insertion chuck 60 is advanced in step S73. In step S75, the leading end of the winding 12 is fixed to the locking groove 164 formed in the winding jig 42.
Is locked. That is, first, the winding 12 cut by the nipper 86 (FIG. 1) is gripped by the chuck 82, and is pulled back by the air cylinder 84 to a position where the tip slightly protrudes from the plate 80. Then, as shown in FIG. 11, the bending plate 68 is lowered by the air cylinder 74, and the tip of the winding 12 is bent at a right angle by the plate 80 and the bending plate 68. Then, as shown in FIG. 12, the chuck 82 holding the winding 12 is moved forward by the air cylinder 84, and the tip of the winding 12 is positioned at the center of the hole 66. After the chuck 60 has been closed in this state, as shown in FIG.
6, the leading end of the winding 12 is positioned above the locking groove 164 of the winding jig 42. afterwards,
The push rod 70 is lowered by the air cylinder 74,
The bent portion of the winding 12 is pushed into the locking groove 164 at the tip of the pushing rod 70.

When the leading end of the winding 12 is locked in the locking groove 164, in step S77, the winding jig 42
After the rotation, the winding insertion chuck 60 is retracted in step S79. Then, at step S81, the winding jig 42 is continuously rotated at a high speed, and at step S83, the welding means 26 is lowered by the air cylinder 98. At this time, in order to spirally wind the winding 12, the moving unit 90 is synchronized with the rotation of the winding jig 42.
(FIG. 2) is driven, and the chuck 82 and the nipper 86 are moved in the axial direction of the winding jig 42. Step S85
Then, it is determined whether or not the winding 12 has been wound by the set number of turns. If it is determined that the winding has been wound by the set number of turns, the high-speed continuous winding operation is terminated in step S87, and the process proceeds to step S89. Then, after the winding jig 42 is rotated by a predetermined angle in step S89, the cross line supplying step and the welding step are executed in step S91.

In the cross line supplying step, as shown in FIG. 14, while the cross line 14 is held by the chuck 132, the air chuck 132 is moved forward by the air cylinder 126 as shown in FIG. The chucks 124 and 140 are withdrawn a predetermined length forward.
The cross wire 14 is gripped by the
2 cut. Then, as shown in FIG.
The chuck 124 is moved forward by the air cylinder 118, and the cross wire 14 is positioned on the winding jig 42. At this time, the chuck 132 opens and returns backward.

In the welding step, as shown in FIG. 16, the ground electrode 34 is connected to the winding jig 42, and the welding electrode 104 is lowered by the air cylinder 106 (FIG. 2). The winding 12 wound on the outer peripheral surface and the cross wire 14 supplied thereon are spot-welded using the winding jig 42 as a counter electrode. The cross line 14
If the length of the welding electrode 104 is longer than the length of the welding electrode 104, the plurality of welding electrodes 104 are displaced in the axial direction of the winding jig 42 and arranged in parallel with each other, and these welding electrodes 104 are sequentially operated. As a result, the entire cross wire 14 is welded. At this time, switching of the welding electrodes 104 is performed by sequentially moving the welding electrodes 104 in the lateral direction with the air cylinder 108.

When one cross wire 14 is thus welded, the welding electrode 104 is raised by the air cylinder 106 (FIG. 2), the ground electrode 34 is lowered by the air cylinder 48, and the motor 32 winds. The wire jig 42 is rotated by a predetermined angle. Then, the next cross wire 14 is positioned on the winding jig 42 by the cross wire supply means 28, and the cross wire 14 and the winding 12 are welded by the welding means 26. Such a cross line supply step and a welding step are repeated by the number of cross lines 14.

If it is determined in step S93 that all welding steps have been completed, the welding means 26 is raised by the air cylinder 98 in step S95, and the servo origin is returned in step S97. Then, in step S99, the winding 12 is cut by the nipper 86, and in step S101, the diameter of the winding jig 42 is reduced, and each device is returned to the origin. Subsequently, in step S103, the motor 32 is turned off, and
At 105, the automatic operation lamp is turned off and the cycle end lamp is turned on. Then, step S1
At 07, the heater 16 is removed from the winding jig 42. In step S109, it is determined whether or not to restart the heater manufacturing operation. If "restart" is determined, the process returns to step S63 (FIG. 8). If "no restart" is determined, automatic operation is started. Will be terminated.

According to this embodiment, since the heater 16 can be manufactured automatically, a high quality heater can be manufactured at low cost and in a short time. In the above-described embodiment, an arbitrary heater can be manufactured by individually setting data such as the diameter, the number of turns, the pitch, and the number of cross wires. However, one heater 16 is associated with each diameter. An optimum heater may be manufactured only by setting the aperture. In this case, the ROM 150 of the control unit 144 (FIG. 5) includes
An aperture-cross line number-angle table, an aperture-turns table, and the like are stored, and only the aperture is input from the input unit 154. In this way, if one heater 16 is made to correspond to each diameter, the occurrence of overrun can be prevented beforehand, so that the trial run of the winding (FIG. 7) can be omitted.

Further, in the above-described embodiment, the winding jig 42 divided by the radially extending split surface 44 is used. Alternatively, for example, the winding jig shown in FIGS. 17 and 18 may be used. A jig 42 'may be used. This winding jig 4
Reference numeral 2 'denotes a structure in which the first slide piece 168 and the second slide piece 170 are drawn inward or pushed out by operating the core pin 166. When the second slide piece 170 is pushed out, the outer diameter becomes maximum as shown in FIG. 17, and when the second slide piece 170 is pulled inward, as shown in FIG.
As shown in FIG. When this winding jig 42 'is used, no crack is generated on the surface of the winding jig 42' at the time of diameter expansion, so that control for avoiding the cross wire 14 from being arranged on the crack becomes unnecessary. The control operation can be simplified.

In the above-described embodiment, the heater 16 must be manually removed from the winding jig 42. For example, a push pin operated by an air cylinder or the like is provided inside the winding jig mounting portion 30. Alternatively, the heater 16 may be automatically removed by pressing the heater 16 with the push pin.

[Brief description of the drawings]

FIG. 1 is an illustrative view showing one embodiment of the present invention;

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is an illustrative view showing a cage heater manufactured in the embodiment of FIG. 1;

FIG. 4 is an illustrative view showing a winding feed chuck;

FIG. 5 is a block diagram showing a control unit of the embodiment in FIG. 1;

FIG. 6 is a flowchart showing an origin return operation.

FIG. 7 is a flowchart showing a test operation of a winding.

FIG. 8 is a flowchart showing an automatic driving operation.

FIG. 9 is a flowchart showing an automatic driving operation.

FIG. 10 is a flowchart showing an automatic driving operation.

FIG. 11 is an illustrative view showing a state where a leading end portion of a winding is bent;

FIG. 12 is an illustrative view showing a state in which a distal end portion of a winding is gripped by a chuck;

FIG. 13 is an illustrative view showing a state where a leading end portion of a winding is positioned on a winding jig;

FIG. 14 is an illustrative view showing a state where a cross line is cut;

FIG. 15 is an illustrative view showing a state where a cross line is extended by a predetermined length and gripped by a chuck;

FIG. 16 is an illustrative view showing a state where a cross wire cut to a predetermined length is positioned on a winding jig;

FIG. 17 is an illustrative view showing a state where another winding jig is expanded in diameter;

FIG. 18 is an illustrative view showing a state where the diameter of another winding jig is reduced;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 ... Cage type heater manufacturing apparatus 12 ... Winding 14 ... Cross wire 16 ... Cage type heater 22 ... Heater manufacturing part 24 ... Winding sending out means 26 ... Welding means 28 ... Cross line sending out means 32 ... Motor 34 ... Earth electrode 42 ... Winding jigs 60, 82, 124, 132, 140 ... chucks 86, 142 ... nipper 104 ... welding electrodes

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Taku Taku 64 Ishizukita-cho, Sakai City, Osaka Inside Kubota Co., Ltd. Vinyl pipe factory (72) Inventor Shigeru Nagamatsu 64 Ishizukita-cho, Sakai City, Osaka Prefecture Kubota Co., Ltd. In the vinyl pipe plant (56) References Table 6-509437 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) H05B 3/06 H05B 3/00 330 H05B 3/40

Claims (2)

(57) [Claims] 1. A rotating cylinder made of a conductive material, winding sending means for sending a winding to the rotating cylinder, winding means forming the winding by winding the winding on the rotating cylinder a predetermined number of times. A cross line sending means for sequentially sending a cross line of a predetermined length to the rotating cylindrical body; a cross line positioning means for sequentially positioning the cross line at a predetermined position in a circumferential direction of an outer surface of the winding body; A cage type heater manufacturing apparatus, comprising: welding means for sequentially welding a cross wire onto the winding body using the rotating cylindrical body as an electrode. 2. The cross line positioning means according to claim 1, wherein said cross line positioning means includes a motor for rotating said rotary cylindrical body, and means for intermittently controlling said motor at every angular pitch determined by the number of cross lines. Basket type heater manufacturing equipment.