JP6252865B2 - Coil manufacturing method and coil manufacturing apparatus - Google Patents

Description

  The present invention relates to a coil manufacturing method and a coil manufacturing apparatus for manufacturing a coil by winding a winding. In particular, the present invention relates to a coil manufacturing method and a coil manufacturing apparatus that can improve productivity.

  Conventionally, a winding (enameled wire) in which an insulating film is formed on the surface of a conductor made of a metal wire is known. The winding is used as a coil of various electric devices. Examples of the electric device using the coil include a reactor, a choke coil, a motor, and a transformer.

  Patent Documents 1 and 2 disclose techniques relating to the manufacture of windings. In general, the winding is manufactured as follows (see Patent Document 1). First, by drawing a wire rod from a drum around which a metal wire (wire rod) as a starting material of a conductor is wound by a feeding device and passing it through a wire drawing machine using a wire drawing die or the like, A metal wire (conductor) having a predetermined cross-sectional shape and wire diameter is produced. Next, after applying an insulating varnish to the surface of the conductor, the insulating varnish is baked by passing it through a baking furnace to form an insulating film on the surface of the conductor. And the coil | winding which formed the insulating film in the surface of a conductor is wound up on a drum with a winding device. As the shape of the winding (conductor), a round wire having a circular cross section and a rectangular wire having a rectangular cross section are typical.

  In the winding, a defective portion (swelling, peeling, pinhole, etc.) may occur in the insulating coating due to manufacturing, and the defective portion is inspected from the viewpoint of quality assurance (see Patent Document 2). In general, the inspection of the defective portion of the insulating coating is performed by various inspection devices while the winding wound around the drum is wound around another drum by a rewinding device. Usually, when a defective part is found in the middle of the winding, the rewinding operation is interrupted and the winding is cut to remove the defective part where the defective part exists. Then, the drum wound up to the middle of the winding is removed from the rewinding device and replaced with a new drum, and the rewinding is started from the middle of the winding to the new drum.

  On the other hand, the coil is manufactured by winding a winding into a predetermined shape. As the shape of the coil, a circular shape (cylindrical shape) or a polygonal shape (square tube shape) is known. The coil is usually formed by bending into a predetermined shape while winding the winding and winding it in a spiral shape. For example, a corner portion is formed by bending while sequentially feeding windings, and a square portion coil having a corner portion and a straight line portion formed by bending is obtained by repeating this process. An apparatus for manufacturing a square cylindrical edgewise coil using a flat wire is disclosed in Patent Document 3. Patent Document 3 includes a winding mechanism having a bender that bends a flat wire, a feed mechanism that sends a flat wire to the winding mechanism, a bending step of bending the flat wire, and a feed step of sending a flat wire. A coil manufacturing apparatus that repeatedly forms an edgewise coil is described.

Japanese Patent Application Laid-Open No. 2011-48956 JP 2003-272457 A JP 2007-74881 A

  From the viewpoint of reducing coil production costs, it is desired to improve productivity.

  In general, the winding is manufactured by a winding manufacturer, and the coil is manufactured by the coil manufacturer. The coil manufacturer purchases the winding from the winding manufacturer and manufactures the coil. The windings are shipped and delivered in the state of being wound on a drum. As described above, the manufactured winding is inspected for a defective portion of the insulating coating, and is cut at a portion where the defective portion exists, and the defective portion is removed. It is difficult to completely prevent the occurrence of defective portions of the insulating coating during the manufacturing process of the winding, and the positions where the defective portions of the insulating coating are generated are also different. Therefore, the winding wound around the drum in the end often has a winding amount smaller than the standard winding amount of the drum, and when individual windings wound around a plurality of drums are compared, There is a large amount of winding variation.

  When manufacturing a coil, a coil is formed by winding a winding while sequentially winding the coil from a drum, and is cut at a position to be the end of the coil, and a plurality of coils are wound from the winding wound on one drum. Is manufactured continuously. Therefore, if the winding amount of the winding wound around one drum is small, not only the number of coils manufactured from the winding is reduced, but also the drum replacement work frequently occurs, which hinders stable production. Bring In addition, since the winding amount of the winding wound around the drum is small and the variation thereof is large, a gap formed between the drums when a plurality of drums are arranged side by side when the winding is transported. May increase and transportation costs may increase.

  Thus, one of the objects of the present invention is to provide a coil manufacturing method and a coil manufacturing apparatus that can improve productivity.

  A coil manufacturing method according to an aspect of the present invention includes the following feeding process, winding process, and inspection process. The unwinding step unwinds the winding from a drum that has wound a winding having a conductor, an insulating film covering the conductor, and a mark indicating a defective portion of the insulating film. In the winding step, a coil is formed by winding the wound winding. The inspection step inspects the defective portion of the winding. The inspection step includes a mark detection step for detecting the mark, and the defective portion cutting step for cutting the winding at a position corresponding to the defective portion based on the mark detected in the mark detection step. .

  A coil manufacturing apparatus according to an aspect of the present invention includes the following feeding device, a winding device, and an inspection device. The feeding device feeds the winding from a drum on which a winding having a conductor, an insulating coating covering the conductor, and a mark indicating a defective portion of the insulating coating is wound. The winding device winds the wound winding to form a coil. The inspection device inspects the defective portion of the winding. The inspection apparatus includes: a mark detector that detects the mark; a cutter that cuts the winding; and the cutter that detects the mark based on the mark detected by the mark detector at a position corresponding to the defective portion. A cutting control unit for cutting the winding.

  The coil manufacturing method and the coil manufacturing apparatus can improve coil productivity.

It is a schematic block diagram which shows an example of a coil | winding manufacturing apparatus. 1 is a schematic configuration diagram of a coil manufacturing apparatus according to Embodiment 1. FIG. FIG. 3 is a schematic process diagram of the coil manufacturing method according to the first embodiment. It is a schematic flowchart of the test process in the coil manufacturing method which concerns on Embodiment 1. FIG. It is a schematic block diagram of the coil manufacturing apparatus which concerns on Embodiment 2. FIG. 6 is a schematic flow diagram of an inspection process in a coil manufacturing method according to Embodiment 2. It is a schematic block diagram of the coil manufacturing apparatus which concerns on Embodiment 3. It is a schematic diagram which shows the structural example of the surplus length path | route in the coil manufacturing apparatus which concerns on Embodiment 3. FIG.

  The present inventor studied to improve the productivity of the coil by reducing the number of times of changing the drum when manufacturing the coil. First, the inventor considered increasing the winding amount of the winding wound around the drum. However, it is practically difficult to completely eliminate defective portions of the insulation coating in the winding manufacturing process. Conventionally, the defective portion where the defective portion exists is cut and removed, so that it is wound around the drum with a predetermined winding amount. If an attempt is made to produce only the windings that have been taken, windings that do not meet that requirement must be discarded, which in turn increases production costs. Then, this inventor considered using the coil | winding which gave the mark which shows that the defective part of an insulating film exists in the defective location around a drum. Unlike the conventional winding, this winding does not have a defective portion removed, and only has a mark on the defective portion. Therefore, the winding can be wound around the drum with a predetermined winding amount. Then, the present inventors have found that the coil productivity can be improved by preparing the winding in a state wound on a drum and inspecting the defective portion based on the mark in the coil manufacturing process.

[Description of Embodiment of the Present Invention]
First, embodiments of the present invention will be listed and described.

  (1) A coil manufacturing method according to one aspect of the present invention includes the following feeding process, winding process, and inspection process. In the feeding step, the winding is fed out from a drum that has wound a winding having a conductor, an insulating coating covering the conductor, and a mark indicating a defective portion of the insulating coating. In the winding step, the wound winding is wound to form a coil. In the inspection process, a defective portion of the winding is inspected. This inspection process includes a mark detection process for detecting a mark, and a defective part cutting process for cutting the winding at a position corresponding to the defective part based on the mark detected in the mark detection process.

  According to the above coil manufacturing method, by using a drum in which a winding having a mark indicating a defective portion of an insulating coating (hereinafter sometimes simply referred to as “coating defective portion”) is wound with a predetermined winding amount. The number of drum replacements can be reduced. As a result, the productivity of the coil can be improved. In addition, an inspection process for inspecting the defective film portion of the winding is provided. In this inspection process, a mark attached to the winding is detected, and the winding is cut at a position corresponding to the defective film portion based on the mark. By doing so, it is possible to remove a defective portion of the winding that becomes a film defect when the coil is formed. Further, by making the winding amount of each winding wound around the plurality of drums constant, it is easy to make the timing for replacing the drums constant and easy to predict.

  By cutting the winding at a position corresponding to the coating failure portion, the amount of windings discarded can be reduced as compared with the case where the coil including the coating failure portion is sorted and removed after the coil is manufactured. In addition, it is possible to reduce the transportation cost by winding the winding around the drum with a predetermined winding amount. When cutting the winding, the position corresponding to the defective film portion may be a position where the defective portion is included on the side to be cut and removed.

  (2) As an example of the coil manufacturing method, the inspection process includes the following mark position measurement process and formation position determination process. In the mark position measurement step, the distance from the position that is the starting end of the coil in the winding to the detection position of the mark is measured. The formation position determination step determines whether or not the defective portion is located at a predetermined position when the coil is formed based on the detection position of the mark. And the aspect which cut | disconnects a coil | winding is mentioned when the said defective part cutting process determines with a formation position determination process that a defective part is located in a predetermined position.

  Since the shape and size of the coil to be formed are determined in advance, when the coil is formed by winding the coil, the position of the coil corresponding to the specific position of the coil is determined by the start of the coil. It can be determined if the distance from the position becomes known. Therefore, by measuring the distance from the starting position of the coil in the winding to the detection position of the mark, when the coil is formed based on the detection position of the mark, the defective coating portion of the winding becomes the predetermined coil position. It can be determined whether or not it is located at the position. Here, the predetermined position is a place where a problem of coating failure is likely to occur due to the presence of a coating failure portion when the coil is used, and is set in advance. Examples of the predetermined position include a bent portion (corner portion) to be bent and both end portions of the coil. In addition, as the predetermined position, for example, if the coil is formed of a series of windings and has a plurality of winding parts around which the windings are wound, a connecting part (crossing part) that connects the winding parts. Etc. According to the above aspect, when the coating failure portion is located at a predetermined position of the coil where the coating failure problem due to the coating failure portion is likely to be manifested, the winding is cut to solve the problem of the coil coating failure. The amount of windings discarded can be reduced while avoiding this.

  (3) As an example of the coil manufacturing method, in the aspect including the mark position measurement step and the formation position determination step, the winding step includes a corner portion that forms a corner portion by bending a winding. A mode in which the predetermined position in the formation position determining step is a corner is included.

  As described above, the corner of the coil is given as the predetermined position where the problem of coating failure is likely to occur. When the corner is formed by bending the winding, the insulating film is pulled outside the corner by the bending, and therefore, if there is a defective film part (especially a bulging defect) at that position, it is caused by this. As a result, the insulating coating is easily cracked outside the corners, and the problem of defective coating tends to occur. In particular, in the case of an edgewise coil, this problem appears remarkably. On the other hand, in the straight part of the coil that is not bent, for example, it is difficult for the film cracking due to the defective film part to occur, so that the problem of the defective film is less likely to occur than the corner part. That is, it can be said that it is one of the cases in which the problem of the coating failure is easily manifested when the defective coating portion is located at the corner of the coil when the coil is formed. According to the above aspect, by cutting the winding when the defective coating portion is located at the corner of the coil, the winding amount is reduced while avoiding the problem of defective coating at the coil corner. it can.

  (4) As an example of the coil manufacturing method, an aspect in which the winding is a rectangular wire having a rectangular cross section can be cited.

  By using a flat wire, the space factor of a coil can be raised compared with a round wire.

  (5) As an example of the coil manufacturing method, in the above aspect in which the winding is a flat wire, the winding step includes forming the edgewise coil by winding the winding edgewise.

  An edgewise coil in which a rectangular wire is wound edgewise has a high space factor and can be miniaturized.

  (6) As an example of the coil manufacturing method, the above inspection process is performed on a winding having a length corresponding to a series of coils to be formed. After securing, the aspect which implements the said winding process is mentioned.

  As for the timing of starting winding of the winding, while inspecting the winding, start winding from the side of the starting end of the winding that passed the inspection, or the winding of a predetermined length passes the inspection And then starting winding. In the former case, the winding inspection and winding winding are partially overlapped, and in the latter case, the winding winding is performed after the inspection of the predetermined length winding is completed. (Hereinafter, the former may be referred to as “simultaneous implementation method” and the latter as “individual implementation method”).

  According to the above aspect, before starting the winding in the winding process, the inspection process is performed on the winding having the length of the series of coils to be formed, and the winding of the length of the coil that has passed the inspection process is performed. By securing the wire, it is possible to wind the winding for the coil length that has passed the inspection of the defective film portion in the winding process. Therefore, when the winding is wound in the winding process, the winding is not cut in the middle of the winding, and the coil can be formed. In the above simultaneous implementation method, the winding may be cut off during the winding process by the inspection process, and the winding wound halfway is treated as a defective product. Therefore, when winding a winding around a bobbin (winding core) or winding a winding directly around a core (magnetic core), in the above simultaneous implementation method, it is necessary to recycle the winding wound halfway. Considering this, it is necessary to separate the winding from the bobbin and core, which is inferior in terms of recyclability. On the other hand, the above-described aspect corresponds to the above-described individual implementation method, and before starting winding, the defective part of the winding can be cut and removed in the inspection process in advance, and the winding is cut in the middle of winding. Therefore, there is no need for separation work when recycling the winding including the removed defective film portion, which is excellent in recyclability.

  (7) A coil manufacturing apparatus according to an aspect of the present invention includes the following feeding device, a winding device, and an inspection device. The feeding device feeds the winding from a drum around which a winding having a conductor, an insulating coating covering the conductor, and a mark indicating a defective portion of the insulating coating is wound. The winding device forms a coil by winding the wound winding. The inspection device inspects a defective portion of the winding. This inspection device includes a mark detector that detects a mark, a cutter that cuts the winding, and a cutting control that cuts the winding with the cutter at a position corresponding to the defective portion based on the mark detected by the mark detector. Part.

  According to the above coil manufacturing apparatus, by using a drum in which a winding having a mark indicating a defective film portion is wound with a predetermined winding amount, the number of times of replacing the drum can be reduced, and the productivity of the coil can be reduced. Can improve. In addition, an inspection device that inspects the defective coating portion of the winding is provided. With this inspection device, a mark attached to the winding is detected, and the winding is cut at a position corresponding to the defective coating portion based on the mark. By doing so, it is possible to remove a defective portion of the winding that becomes a film defect when the coil is formed.

  (8) As an example of the coil manufacturing apparatus, the inspection apparatus includes the following mark position measurement unit and formation position determination unit. The mark position measurement unit measures the distance from the position that is the starting end of the coil in the winding to the mark detection position. The formation position determination unit determines whether or not the defective portion is located at a predetermined position when the coil is formed based on the detection position of the mark. And the said cutting | disconnection control part cut | disconnects a coil | winding, when the formation position determination part determines with a defective part being located in a predetermined position.

  According to the above aspect, by cutting the winding when the defective coating portion is located at a predetermined position of the coil, it is possible to reduce the amount of discarded winding while avoiding the problem of defective coating of the coil. .

  (9) As an example of the coil manufacturing apparatus, in the aspect including the mark position measurement unit and the formation position determination unit, the winding device is configured to form a corner by bending a winding. There is a mode in which a formation mechanism is provided and the predetermined position in the formation position determination unit is the corner.

  According to the above aspect, by cutting the winding when the defective coating portion is located at the corner of the coil, the winding amount is reduced while avoiding the problem of defective coating at the coil corner. it can.

  (10) As an example of the coil manufacturing apparatus, an aspect in which the winding is a rectangular wire having a rectangular cross section may be mentioned.

  By using a flat wire, the space factor of a coil can be raised compared with a round wire.

  (11) As an example of the coil manufacturing apparatus, in the above aspect in which the winding is a rectangular wire, the winding apparatus may form an edgewise coil by winding the winding edgewise.

  An edgewise coil in which a rectangular wire is wound edgewise has a high space factor and can be miniaturized.

  (12) As an example of the coil manufacturing apparatus, a margin for securing a length of a series of coils to be formed on a path through which a winding between the mark detector of the inspection apparatus and the winding apparatus passes. There is a mode in which the winding is sent to the winding device after having a long path, passing through the inspection device, and securing the winding of the length of the coil.

  According to the above aspect, by having an extra length path between the inspection device (mark detector) and the winding device, the length of a series of coils to be formed before the winding is sent to the winding device. It is possible to secure a winding having a length equivalent to the coil that has passed through the inspection device. Therefore, since the winding for the length of the coil that has passed the inspection of the defective coating portion is sent to the winding device, the winding can be formed without being cut during the winding. The above aspect corresponds to the above-described individual implementation method, and before the winding is sent to the winding device, the defective portion of the winding is cut and removed in advance by the inspection device, and the winding is cut in the middle of winding. Since it is never used, it is excellent in recyclability.

[Details of the embodiment of the present invention]
Specific examples of a coil manufacturing method and a coil manufacturing apparatus according to an embodiment of the present invention will be described below with reference to the drawings. The same reference numerals in the figure indicate the same names. First, windings used in the coil manufacturing method and the coil manufacturing apparatus according to the embodiment will be described, and then the coil manufacturing method and the coil manufacturing apparatus according to the embodiment will be described. In addition, this invention is not limited to these illustrations, is shown by the claim, and is intended that all the changes within the meaning and range equivalent to the claim are included.

<Winding>
The winding has a conductor, an insulating coating covering the conductor, and a mark indicating a defective coating portion, and is prepared in a state wound on a drum. In this winding, only a defective portion where a defective coating portion is present is marked, and the defective portion remains without being removed, and is wound around the drum with a predetermined winding amount. For example, the winding amount of the winding wound around the drum may be a standard winding amount of the drum.

  Examples of the material for forming the conductor include copper or a copper alloy, aluminum or an aluminum alloy, and the like. Examples of the insulating film forming material include polyimide resin, polyamideimide resin, and polyesterimide resin. As the shape of the winding, for example, various shapes such as a circular shape, an elliptical shape, a race track shape, a polygonal shape such as a triangular shape or a quadrangular shape can be adopted as a cross-sectional shape. Typically, a round wire having a circular cross section and a rectangular wire having a rectangular cross section can be given.

<Winding production equipment>
A manufacturing process of the winding having a mark indicating a defective film portion will be described with reference to FIG. The winding manufacturing apparatus 100 shown in FIG. 1 includes a feeding apparatus 110, a wire drawing machine 120, a softening furnace 130, a varnish coating apparatus 140, a baking furnace 150, a defective portion inspection apparatus 160, a marking apparatus 170, A winding device 180. In this winding manufacturing apparatus 100, the drawn wire rod R is drawn and softened to form a conductor E, an insulating film is formed on the surface of the conductor E to form a winding W, and inspection / marking of a defective film portion is then performed. Then, a series of steps of winding the winding W around the drum is performed. The winding manufacturing apparatus 100 includes a feeding apparatus 110, a wire drawing machine 120, a softening furnace 130, a varnish coating apparatus 140, a baking furnace 150, and a winding apparatus 180. As for each of these configurations, a known configuration can be adopted. Hereinafter, each structure of the coil | winding manufacturing apparatus 100 is demonstrated in detail.

(Feeding device)
The feeding device 100 is a device that feeds the wire rod R from the drum A around which the wire rod R serving as a conductor starting material is wound. The feeding device 100 includes a tension adjusting mechanism (dancer) (not shown) that adjusts the tension applied to the fed wire rod R.

(Wire drawing machine)
The wire drawing machine 120 is a device that draws the wire rod R to a predetermined cross-sectional shape and wire diameter. The wire drawing machine 120 has a plurality of wire drawing dies 121, and by gradually inserting the wire rod R through the wire drawing dies 121, the wire drawing machine 120 gradually approaches a predetermined cross-sectional shape and wire diameter. As the wire drawing die 121, a wire drawing die or a roller die can be used. The conductor E is obtained by this wire drawing process.

(Softening furnace)
The softening furnace 130 is an apparatus that heats and softens the drawn conductor E. By heating the conductor E in the softening furnace 130, the processing strain introduced by wire drawing is removed, and the conductor E is softened.

(Varnish coating device)
The varnish applying device 140 is a device that applies an insulating varnish to the surface of the conductor E. The varnish coating apparatus 140 includes an insulating varnish tank 141 that stores the insulating varnish, and a coating die 142 through which the conductor E that has passed through the insulating varnish tank 141 is inserted. The conductor E passes through the insulating varnish tank 141 so that the surface is coated with the insulating varnish. By passing through the coating die 142, the thickness of the coated insulating varnish is adjusted.

(Baking furnace)
The baking furnace 150 is an apparatus for heating the conductor E coated with an insulating varnish to form an insulating film. By heating the conductor E in the baking furnace 150, the insulating varnish is baked on the surface of the conductor E and an insulating film is formed on the surface of the conductor E. In this example, by winding and winding the winding W between the varnish coating apparatus 140 and the baking furnace 150, the insulating coating with a predetermined thickness is formed by repeatedly applying and baking the insulating varnish. The winding W is obtained by this baking process.

(Defect inspection equipment)
The defective part inspection device 160 is an apparatus for inspecting a defective part of the insulating coating. Examples of defective portions of the insulating coating include swelling and peeling of the coating, pinholes, and the like. Depending on these detection targets, the defective portion inspection device 160 may be a combination of a plurality of inspection devices. As a method for inspecting a defective portion of the insulating film, for example, if it is swollen or peeled off, for example, the surface of the winding is imaged with a CCD camera or the like, and the captured image is detected by processing with an image processing device. For example, the thickness of the insulating coating formed on the surface of the wire may be detected by measuring with a laser displacement meter. For example, pinholes can be detected by measuring insulation resistance using a withstand voltage tester (spark tester).

(Marking device)
The marking device 170 is a device that attaches to the winding W a mark indicating that there is a defective portion of the insulating coating detected by the defective portion inspection device 160. Specifically, when a defective film portion is detected by the defective portion inspection device 160, a defective portion detection signal is sent from the defective portion inspection device 160 to the marking device 170, and the marking device 170 marks the winding W based on the signal. Add. Since the moving distance of the winding W between the defective portion inspection device 160 and the marking device 170 is determined, if the moving speed of the winding W is known, there is a coating defect portion detected by the defective portion inspection device 160. It is possible to calculate the time until the part to be reached reaches the marking device 170. In this example, a speed sensor (not shown) for measuring the moving speed of the winding W is attached, and a timer for measuring the elapsed time since the marking device 170 received the defective portion detection signal is provided. From the moving speed and the elapsed time, it is determined that the defective portion has reached the marking device 170. The moving speed of the winding W can be detected using, for example, an encoder. By this inspection process, the defective film portion is inspected, and a mark indicating the defective film portion is applied to the winding W.

  Any mark can be used as long as it can be automatically detected later. For example, coloring the surface of the winding W can be mentioned. In this example, an ink jet printer is employed for the marking device 170, and a defective portion where a defective coating portion exists is colored. The position and range for marking can be selected as appropriate. The position to be marked may be, for example, the entire circumference of the surface of the winding W or a part of the surface of the winding W. Moreover, the range to which the mark is applied is, for example, within a range of ± 1.0 cm centering on the position where the defective film portion exists.

  The winding device 180 is a device that winds the winding W that has been inspected / marked on the defective film portion around the drum D. The winding amount of the winding W can be set to the standard winding amount of the drum D.

  In the winding W manufactured by the above-described winding manufacturing apparatus 100, only a defective portion is marked in the inspection process, and the defective portion is not cut and removed as in the prior art. Can be wound on D. Therefore, transportation costs can be reduced. In addition, since the winding manufacturing apparatus 100 inspects and marks defective film portions in-line, it does not require a rewinding operation as in the prior art, so that the winding production cost can be reduced.

[Embodiment 1]
A coil manufacturing method and a coil manufacturing apparatus according to Embodiment 1 will be described. Below, a coil manufacturing apparatus is first demonstrated with reference to FIG.

<Coil manufacturing equipment>
The coil manufacturing apparatus 1 includes a feeding device 10, an inspection device 30, and a winding device 50. The coil manufacturing apparatus 1 uses the drum D around which the winding W having a mark indicating a defective portion of the insulating coating is wound, and uses the winding W while inspecting and cutting the defective coating portion of the winding W. To manufacture a coil.

(Feeding device)
The feeding device 10 is a device that feeds the winding W from the drum D around which the winding W having a mark indicating a defective coating portion is wound. The feeding device 10 includes a tension adjusting mechanism (dancer) (not shown) that adjusts the tension applied to the wound winding W. A correction device (straightener) 20 that corrects the winding wrinkles of the winding W is provided on the downstream side (rear stage) of the feeding device 10.

(Winding device)
The winding device 50 is a device that forms the coil C by winding the wound winding W. The winding device 50 includes a feeding mechanism 51 that sends the winding W, a winding mechanism 52 that bends the winding W sent from the feeding mechanism 51 and spirally winds, and a cutter that cuts the winding W. 53.

  In this example, the feed mechanism 51 is configured to sandwich the winding W with a pair of rollers and move the winding W by rotating the roller with a driving motor. The drive motor uses a servo motor. By controlling the rotation speed (rotation speed) of the servo motor, the rotation speed (rotation speed) of the roller is controlled, and the amount of movement of the winding W (movement speed) ) Can be controlled. By detecting the rotation speed (rotation speed) of the servo motor with an encoder, the movement amount (movement speed) of the winding W can be measured. Further, the feed mechanism 51 can perform forward feed for sending the winding W to the winding mechanism 52 and reverse feed for rotating the roller in the reverse direction to return the winding W to the reverse direction.

  As the shape of the coil, for example, various shapes such as a circular shape, an elliptical shape, a race track shape, a polygonal shape such as a triangular shape or a quadrangular shape can be adopted as the end face shape viewed from the axial direction of the coil. For example, a cylindrical coil can be formed by bending the winding W into a circular shape with the winding mechanism 52, and a rectangular tube coil can be formed by bending the winding W into a polygonal shape. it can. Further, an edgewise coil can be formed by using a rectangular wire for the winding W and winding the winding W edgewise. Furthermore, it is also possible to form a connection coil formed of a series of windings W and having a shape in which a plurality of coils are connected.

  Examples of the winding mechanism 52 include a configuration in which the winding W is wound around a winding shaft having an outer shape corresponding to the shape of the coil. In addition, it is possible to attach a bobbin (core) to the winding shaft and wind the winding W around the bobbin, or to directly wind the winding W around the core using the core (magnetic core) as a winding shaft.

  Moreover, when forming the coil which has a corner | angular part, having the corner | angular part formation mechanism which bends the coil | winding W and forms a corner | angular part as the winding mechanism 52 is mentioned. Examples of the corner portion forming mechanism include a configuration having a bending axis corresponding to the corner portion and a bender that bends along the bending axis while pressing the winding against the bending axis so as to be a predetermined corner portion. By repeating the bending process while sequentially sending the linear winding W to the corner forming mechanism, a rectangular tube-shaped coil having the corner and the straight portion is obtained.

  After the winding 53 is wound by the winding mechanism 52, the cutter 53 cuts the winding W at a position that is the end of the coil. By cutting the winding W and disconnecting the coil C from the winding W, the coil C is discharged from the winding device 50. In this example, the feed mechanism 51 adjusts the feed amount of the winding W so that the length of the both ends of the coil (the amount of winding drawn from the winding portion to the start or end) becomes a specified length. Cut with a cutter 53. Specifically, after the winding of the winding W by the winding mechanism 52 is completed (after the final bending process), the winding W is moved to a predetermined position so that the length of the terminal end of the coil becomes a specified length. It is sent to the cutter 53 and cut. Thereafter, in order to form the next coil, the tip of the cut winding W is returned to a predetermined position of the winding mechanism 52 so that the length of the start end of the coil becomes a specified length. Start winding. In addition, the winding W sent from the feeding mechanism 51 is not bent by the winding mechanism 52, and the winding W can be passed through the winding mechanism 52 while being straight and sent to the cutter 53. . The cutter 53 also functions as a cutter (cutter for cutting a defective portion) that cuts the winding W at a position corresponding to the defective coating portion in the inspection apparatus 30 described later.

  A known configuration can be adopted as the configuration of the winding device 50.

(Inspection equipment)
The inspection apparatus 30 is an apparatus for inspecting a defective film portion of the wound winding W. The inspection device 30 includes a mark detector 31 that detects a mark applied to the winding W, and a cutter 53 that forms the winding W at a position corresponding to the defective film portion based on the mark detected by the mark detector 31. A cutting control unit 35 for cutting. The inspection device 30 (mark detector 31) is disposed between the feeding device 10 and the cutter 53. In this example, the mark detector 31 is disposed between the feeding mechanism 51 and the winding mechanism 52, and the inspection device 30 is incorporated in the winding device 50.

  The mark detector 31 detects a mark using a color sensor, for example. In this example, when a mark is detected by the mark detector 31, a mark detection signal is sent from the mark detector 31 to the cutting control unit 35, and the bending process by the winding mechanism 52 is stopped. Then, the cutting control unit 35 controls the feed mechanism 51 based on the mark detection position detected by the mark detector 31 to send the winding W to the cutter 53, and the position corresponding to the defective film portion indicated by the mark. Then, the cutter 53 is controlled to cut the winding W. For example, after the mark passes through the cutter 53, the winding W is cut at a position on the upstream side (left side in the drawing) of the range where the mark is attached. Thereby, it can cut | disconnect in the position where a film | membrane defective part is contained in the side removed by cut | disconnecting. Here, since the moving distance of the winding W between the mark detector 31 and the cutter 53 is determined, how much the winding W is sent to the cutter 53 after the mark is detected by the mark detector 31. , Based on the distance between the mark detector 31 and the cutter 53.

<Coil manufacturing method>
Next, the coil manufacturing method will be described with reference to the coil manufacturing apparatus 1 shown in FIG. 2 as appropriate and with reference to FIGS. 3 and 4. The coil manufacturing method includes an unwinding step (S1), an inspection step (S2), and a winding step (S3). To manufacture a coil. In this coil manufacturing method, the drum D around which the winding W having the mark indicating the defective portion of the insulating coating is wound is used.

(Feeding process)
The feeding process S1 is a process of feeding the winding W from the drum D. Specifically, the drum D around which the winding W is wound is attached to the feeding device 10, and the winding W is fed out from the drum D.

(Inspection process)
The inspection step S2 is a step of inspecting a coating defect portion of the wound winding W. The inspection step S2 includes a mark detection step S21 for detecting a mark, and a defective portion cutting step S22 for cutting the winding W at a position corresponding to the coating failure portion based on the mark detected in the mark detection step (FIG. 4). The flow of the inspection step S2 of Embodiment 1 will be described using FIG. In the mark detection step S21, a mark is detected by the mark detector 31. When the mark is detected by the mark detector 31, a mark detection signal is sent from the mark detector 31 to the cutting control unit 35. In the defective portion cutting step S <b> 22, the cutting control unit 35 cuts the winding W with the cutter 53 based on the mark detection signal from the mark detector 31. As described above, the cutting control unit 35 controls the feed mechanism 51 based on the mark detection position to feed the winding W to the cutter 53, for example, at a position where the mark indicating the defective film portion has passed the cutter 53. The winding W is cut. The winding W is cut by the cutter 53 at a position corresponding to the defective film portion. The feed amount of the winding W after the mark is detected by the mark detector 31 is determined based on the distance between the mark detector 31 and the cutter 53. The winding including the cut film defective portion is collected.

(Winding process)
The winding step S3 is a step of forming the coil C by winding the winding W after the inspection step S2. The winding W that has passed through the inspection device 30 (mark detector 31) is sent to the winding mechanism 52. In the winding step S3, the winding W is wound by the winding mechanism 52 to form the coil C. Specifically, the winding mechanism 52 performs winding while feeding the winding W by the feeding mechanism 51. When the winding of the winding W is completed by the winding mechanism 52, the feeding mechanism 51 is controlled to send the winding W to the cutter 53, and the winding W is cut at a position where the coil ends, and the coil C is cut off. Thereafter, the winding W is returned to the winding mechanism 52 side, and the next winding is started. The formed coil C is discharged from the winding device 50. Here, when the winding W is cut by the inspection step S2 during the winding step S3, the winding wound halfway is collected from the winding device 50.

<Effect>
The coil manufacturing method according to Embodiment 1 has the following effects.
(1) By using a drum wound with a winding having a mark indicating a defective film portion, it is possible to reduce the number of times the drum is replaced as compared with the conventional case, and to realize stable coil production. Therefore, the productivity of the coil can be improved and the production cost of the coil can be reduced.
(2) An inspection process for inspecting a defective coating portion of the winding is provided. In this inspection step, a mark attached to the winding is detected, and the winding is formed at a position corresponding to the defective coating portion based on the mark. By cutting, it is possible to remove a defective portion of the winding that becomes a coating failure when the coil is formed, and the quality of the coil is not deteriorated as compared with the conventional case.
(3) By cutting the winding at a position corresponding to the defective coating portion, it is possible to reduce the amount of windings discarded as compared with the case where the coil including the defective coating portion is sorted and removed after the coil is manufactured.

  The coil manufacturing apparatus according to the first embodiment can implement the above-described coil manufacturing method.

[Embodiment 2]
Embodiment 2 is a form applied when manufacturing the coil which has a corner | angular part. Hereinafter, the coil manufacturing apparatus and the coil manufacturing method according to the second embodiment will be described with reference to FIGS. 5 and 6.

<Coil manufacturing equipment>
FIG. 5 shows an apparatus configuration of the coil manufacturing apparatus 2 according to the second embodiment. Below, the same code | symbol is attached | subjected about the structure similar to the coil manufacturing apparatus 1 of Embodiment 1 shown in FIG. 2, description is abbreviate | omitted, and it demonstrates centering on difference.

  Since the coil manufacturing apparatus 2 forms the coil C having corner portions, the winding device 50 has a corner portion forming mechanism that forms the corner portions by bending the winding W. As the corner portion forming mechanism, for example, a configuration having a bending axis corresponding to the corner portion and a vendor that bends the winding along the bending axis can be given.

(Inspection equipment)
The inspection apparatus 30 further includes a mark position measurement unit 33 and a formation position determination unit 34 in addition to the configuration of the first embodiment. The mark position measurement unit 33 measures the distance from the position at the start of the coil in the winding W to the mark detection position. The position that becomes the starting end of the coil is the tip of the winding W (the cutting position when the winding W is cut), and the distance from the position that becomes the starting end of the coil to the mark detection position is the starting end of the coil. It can be calculated from the amount of movement (feed amount) of the winding W from when the position passes the mark detector 31 until the mark detector 31 detects the mark. In this example, the mark position measurement unit 33 acquires motor control information such as the rotation speed of the servo motor detected by the encoder from the feed mechanism 51, and measures the movement amount of the winding W that has passed through the mark detector 31. Keep it. When the mark is detected by the mark detector 31, a mark detection signal is sent from the mark detector 31 to the mark position measuring unit 33, and the mark position measuring unit 33 determines the start end of the coil from the amount of movement of the winding W. A distance L from the position to the mark detection position is calculated.

  The formation position determination unit 34 determines whether or not the defective film portion is located at a predetermined position (here, a corner) when the coil C is formed based on the detection position of the mark. In this example, the formation position determination unit 34 has determination information for determining which position of the winding W corresponds to which position of the coil C based on the shape of the coil C formed by the winding device 50. Yes. For example, the outline of each of the straight part and one corner constituting one turn of the coil, the number of turns of the coil, and the number of straight parts and corners per turn are set in advance as determination information. If the winding is wound to form a coil, does the mark detection position (coating defect part) at a distance L from the starting position of the coil correspond to the corner of any turn? Can be calculated. Based on this determination information, the formation position determination unit 34 determines whether or not the detection position of the mark of the winding W corresponds to, for example, the position of the corner of the coil.

  The cutting control unit 35 cuts the winding W when the formation position determination unit 34 determines that the defective film portion is located at a predetermined position (here, a corner). In this example, the cutting control unit 35 cuts the winding W by the cutter 53 when the formation position determining unit 34 determines that the mark detection position is located at the corner of the coil. Specifically, the bending process in the winding mechanism 52 is stopped, and the feed mechanism 51 is controlled based on the mark detection position to feed the winding W to the cutter 53, and the mark indicating the defective film portion is cut. The winding W is cut at a position passing through 53. On the other hand, for example, in the case of a coil having a corner portion and a straight portion, the winding W is not cut when the defective coating portion of the winding is located in the straight portion.

<Coil manufacturing method>
The coil manufacturing method according to the second embodiment has the same basic steps as the coil manufacturing method according to the first embodiment shown in FIG.

  The winding step S3 includes a corner portion forming step of bending the winding W to form corner portions, and the winding step S3 forms a coil having corner portions. For example, the winding device 50 having the above-described corner portion forming mechanism is bent while feeding the winding W to form the corner portion.

(Inspection process)
The inspection process S2 further includes a mark position measurement process S23 and a formation position determination process S24 in addition to the inspection process of the first embodiment shown in FIG. 4 (see FIG. 6). In the mark position measuring step S23, the distance from the position at the starting end of the coil in the winding W to the mark detection position is measured. In the formation position determination step S24, it is determined whether or not the defective film portion is located at a predetermined position (here, a corner) when the coil C is formed, based on the detection position of the mark. The defective portion cutting step S32 cuts the winding W when it is determined in the formation position determining step S24 that the defective film portion is located at a predetermined position (here, a corner).

  The flow of the inspection process S2 of the inspection process 1 of the second embodiment will be described with reference to FIG. In the mark detection step S21, when a mark is detected by the mark detector 31, a mark detection signal is sent from the mark detector 31 to the mark position measuring unit 33. In the mark position measurement step S23, the movement amount of the winding W is measured by the mark position measurement unit 33, and the distance L from the movement amount of the winding W to the position where the mark is detected from the position at the starting end of the coil. Is calculated. Next, in the formation position determination step S24, when the coil C is formed by the formation position determination unit 34 based on the mark detection position (distance L) measured by the mark position measurement unit 33, the mark detection position is the coil position. It is determined whether or not it is located at a corner. Then, in the defective portion cutting step S22, when the formation position determining unit 34 determines that the mark detection position is located at the corner of the coil, the cutting control unit 35 winds with the cutter 53 at a position corresponding to the film defective portion. Cut the line W.

<Effect>
In the coil manufacturing method and the coil manufacturing apparatus according to the second embodiment, when the coil is formed, the coating defect portion of the winding is located at a predetermined position (for example, a corner portion of the coil) where the problem of the coating defect is likely to occur. The winding can be cut if Therefore, it is possible to reduce the amount of discarded windings while avoiding the problem of defective coating of the coil due to the defective coating portion of the winding.

[Embodiment 3]
In the third embodiment, a mode in which winding of a winding is started after securing a winding having a length corresponding to the coil will be described. Hereinafter, a coil manufacturing method and a coil manufacturing apparatus according to Embodiment 3 will be described with reference to FIG.

<Coil manufacturing equipment>
FIG. 7 shows an apparatus configuration of the coil manufacturing apparatus 3 according to the third embodiment. Below, the same code | symbol is attached | subjected about the structure similar to the coil manufacturing apparatus 1 of Embodiment 1 shown in FIG. 2, description is abbreviate | omitted, and it demonstrates centering on difference.

  In the coil manufacturing apparatus 3, the inspection device 30 is disposed between the feeding device 10 and the winding device 50, and the inspection device 30 is provided on the upstream side (front stage) of the winding device 50. Further, a correction device (straightener) 20 is provided between the inspection device 30 and the winding device 50. In this coil manufacturing apparatus 3, apart from the cutter 53 of the winding apparatus 50, the inspection apparatus 30 has a defective part cutting cutter 32 that cuts the winding W. The defective part cutting cutter 32 is controlled by the cutting control unit 35 and functions as a cutter for cutting the winding W at a position corresponding to the defective film part based on the mark detected by the mark detector 31. The defective part cutting cutter 32 is provided on the downstream side (back stage) of the mark detector 31.

  In the coil manufacturing apparatus 3, the coil manufacturing apparatus 3 is formed on the upstream side (front stage) of the winding apparatus 50 and on the path through which the winding W between the mark detector 31 of the inspection apparatus 30 and the winding apparatus 50 passes. And a surplus length path 40 that secures a length corresponding to a series of long coils. Then, after passing through the inspection device 30 and a winding W having a length corresponding to the coil is secured, the winding is sent to the winding device 50. That is, the winding W is sent to the coil winding device 50 in a state where the winding W having a length corresponding to the coil is secured in the extra length path 40. Therefore, since the winding W having a length corresponding to the coil that passed the inspection of the defective coating portion is sent to the winding device 50, the coil C can be reliably formed by the winding device 50. In this example, a surplus length path 40 is provided between the mark detector 31 and the defective part cutting cutter 32, and a second feed mechanism 41 that feeds the winding W is provided on the exit side of the surplus length path 40. Is provided.

  When the mark is detected by the mark detector 31, a mark detection signal is sent from the mark detector 31 to the cutting control unit 35, and based on the mark detection position, a defective portion cutting cutter is formed at a position corresponding to the defective film portion. The winding W is cut by 32. In this example, the winding W is sent to the defective portion cutting cutter 32 by the feed mechanism 41, and the winding W is cut at a position where the mark indicating the defective coating portion has passed the defective portion cutting cutter 32. For example, the winding including the cut film defective portion may be separately provided with a discharge path (not shown) downstream of the defective portion cutting cutter 32 (not shown), and transferred to the discharge path to be collected. Is also possible.

  The extra length path 40 of the coil manufacturing apparatus 3 is not particularly limited as long as the length of a series of coils to be formed can be secured. For example, the extra length path 40 can be provided by arranging the inspection apparatus 30 and the winding apparatus 50 apart from each other and lengthening the path of the winding W between the both apparatuses. However, when the linear distance between both apparatuses is increased and the linear extra length path 40 is provided, the size of the entire manufacturing apparatus increases. Therefore, it is preferable to provide the necessary extra length path 40 on the path of the winding W between the two apparatuses while shortening the linear distance between the two apparatuses. As a method of providing such an extra length path 40, for example, as shown in the upper part of FIG. 8, the winding W is temporarily wound around the roller 40a, or as shown in the middle part of FIG. For example, a loop-shaped extra-length path may be provided by rotating the winding W between 40b. In addition, as shown in the lower part of FIG. 8, a zigzag surplus length path may be provided so as to travel along a plurality of rollers 40 c that are shifted in the vertical direction or the horizontal direction.

<Coil manufacturing method>
In the coil manufacturing method according to the third embodiment, in the coil manufacturing method according to the first embodiment shown in FIG. 3, the inspection step S <b> 2 is further performed on a winding having a length corresponding to a series of coils to be formed. After passing through S2, the winding step S3 is performed after securing a winding having a length corresponding to the coil. Thereby, after passing through inspection process S2, the winding W which passed the test | inspection of the film defect part can be wound in winding process S3 by ensuring the winding of the length for a coil.

<Effect>
In the coil manufacturing method and the coil manufacturing apparatus according to the third embodiment, since the winding that passed the inspection of the defective film portion can be wound, the winding is cut in the middle of winding when the winding is wound. And the coil can be formed. In particular, when winding a winding around a bobbin (winding core) or winding a winding directly around a core (magnetic core), the winding is defective in the inspection process (inspection device) before starting winding. Since the location can be cut and removed in advance, the winding including the defective coating portion can be easily collected. Further, the winding having the defective coating portion is not wound halfway, and the substantial equipment operation time can be increased. The coil manufacturing apparatus (coil manufacturing method) according to the third embodiment further includes the mark position measurement unit (mark position measurement step) and the formation position determination unit (formation position determination step) described in the second embodiment. Is also possible.

  The coil manufacturing method and the coil manufacturing apparatus according to one embodiment of the present invention can be suitably used for manufacturing coils used in various electric devices such as a reactor, a choke coil, a motor, and a transformer.

1, 2, 3 Coil manufacturing apparatus 10 Feeding apparatus 20 Correction apparatus 30 Inspection apparatus 31 Mark detector 32 Defective part cutting cutter 33 Mark position measuring part 34 Forming position determination part 35 Cutting control part 40 Extra length path 40a, 40b, 40c Roll 41 Second feeding mechanism 50 Winding device 51 Feeding mechanism 52 Winding mechanism 53 Cutter 100 Winding manufacturing device 110 Feeding device 120 Wire drawing machine 121 Wire drawing die 130 Softening furnace 140 Varnish coating device 141 Insulating varnish tank 142 Coating die 150 Baking furnace 160 Defective part inspection device 170 Marking device 180 Winding device A, D Drum R Wire rod E Conductor W Winding C Coil

Claims (12)

An unwinding step of unwinding the winding from a drum having wound a winding having a conductor, an insulating film covering the conductor, and a mark indicating a defective portion of the insulating film;
A winding step of winding the wound winding to form a coil;
An inspection step of inspecting the defective portion of the winding,
The inspection process includes
A mark detection step of detecting the mark;
A defective portion cutting step of cutting the winding at a position corresponding to the defective portion based on the mark detected in the mark detecting step. The inspection process includes
A mark position measuring step for measuring a distance from a position to be a starting end of the coil in the winding to a detection position of the mark;
A formation position determination step for determining whether or not the defective portion is positioned at a predetermined position when the coil is formed based on the detection position of the mark,
The coil manufacturing method according to claim 1, wherein the defective portion cutting step cuts the winding when it is determined in the formation position determining step that the defective portion is located at the predetermined position. The winding step includes a corner forming step of bending the winding to form a corner,
The coil manufacturing method according to claim 2, wherein the predetermined position in the formation position determination step is the corner.   The coil manufacturing method according to claim 1, wherein the winding is a rectangular wire having a rectangular cross section.   The said winding process is a coil manufacturing method of Claim 4 which forms the edgewise coil by winding the said winding edgewise.   After performing the inspection step on the winding having a length corresponding to the length of the coil to be formed and passing the inspection step, the winding having a length corresponding to the coil is secured, and then the winding The coil manufacturing method of any one of Claims 1-5 which implements a rotation process. A feeding device that feeds out the winding from a drum on which a winding having a conductor, an insulating coating covering the conductor, and a mark indicating a defective portion of the insulating coating is wound;
A winding device for winding the wound winding to form a coil;
An inspection device for inspecting the defective portion of the winding,
The inspection device includes:
A mark detector for detecting the mark;
A cutter for cutting the winding;
A coil manufacturing apparatus comprising: a cutting control unit configured to cut the winding by the cutter at a position corresponding to the defective portion based on the mark detected by the mark detector. The inspection device includes:
A mark position measuring unit that measures a distance from a position that is a starting end of the coil in the winding to a detection position of the mark;
A formation position determination unit that determines whether or not the defective portion is positioned at a predetermined position when the coil is formed based on the detection position of the mark;
The coil manufacturing apparatus according to claim 7, wherein the cutting control unit cuts the winding when the formation position determining unit determines that the defective portion is located at the predetermined position. The winding device has a corner forming mechanism that forms a corner by bending the winding,
The coil manufacturing apparatus according to claim 8, wherein the predetermined position in the formation position determination unit is the corner.   The coil manufacturing apparatus according to any one of claims 7 to 9, wherein the winding is a rectangular wire having a rectangular cross section.   The coil manufacturing apparatus according to claim 10, wherein the winding device forms an edgewise coil by winding the windings edgewise. On the path through which the winding between the mark detector of the inspection device and the winding device passes, there is a surplus length path that secures the length of a series of coils to be formed,
The coil according to any one of claims 7 to 11, wherein the coil is passed to the winding device after passing through the inspection device and the winding having a length corresponding to the coil is secured. manufacturing device.

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