JP6500818B2 - Winding coil manufacturing method, winding coil inspection method, and inspection apparatus - Google Patents

Description

  The present invention relates to a winding coil manufacturing method, a winding coil inspection method, and an inspection apparatus according to a winding coil manufactured by winding a wire around a bobbin.

  2. Description of the Related Art Conventionally, in a winding apparatus that manufactures a winding coil by winding a wire around a bobbin, there has been proposed a technique for inspecting whether or not winding distortion of a wire wound around the bobbin has occurred. As such a technique, for example, Patent Document 1 discloses that a wire is irradiated to a wire winding portion of a bobbin, and the presence or absence of a wire is detected from intensity information of a reflected beam obtained from an optical sensor, thereby winding disturbance during wire winding. There is disclosed a method of inspecting the

JP-A-11-233360

  By the way, in recent years, there is a need to improve the performance of a coil, for example, to increase the allowable voltage of a winding coil. Under such a tendency, more stringent requirements are required for the alignment of the wire wound around the bobbin, for example, the requirement that the wires separated by a predetermined layer of the wire wound hierarchically do not contact with each other. . Moreover, in the conventional inspection method as described in patent document 1, there exists a problem that the alignment of such a wire can not be evaluated quantitatively.

  The present invention has been made in view of such problems, and an object thereof is a method for manufacturing a wound coil, a method for inspecting a wound coil, which can quantitatively evaluate the alignment of a wire wound around a bobbin of a wound coil, And providing an inspection apparatus.

  In order to solve the above-mentioned subject, a winding coil manufacturing method concerning the present invention winds a wire rod (9) supplied from wire rod supply part (10) around a bobbin (8), and manufactures a winding coil. (1), an imaging unit (3) for imaging the wire wound around the bobbin, and an inspection unit (7) for inspecting the alignment of the wire based on the imaged image imaged by the imaging unit A method of manufacturing a winding coil using an inspection device (2), wherein the imaging unit is wound around the bobbin for each predetermined winding step in the process of winding a wire rod around the bobbin to manufacture a winding coil. An imaging step (S01) of imaging a wire rod and creating a plurality of captured images; and a captured image of an arbitrary winding step for the plurality of captured images generated in the imaging step by the inspection unit; An extraction step (S02) for extracting a plurality of difference images each including only a wire wound on the bobbin in the arbitrary winding step by taking a difference between the picked-up image one step before the arbitrary winding step And the inspection unit compares, for the plurality of difference images extracted in the extraction step, the first difference image of the predetermined winding step with the second difference image different from the predetermined winding step by the plurality of steps. And an abnormality detection step of detecting an abnormality related to the alignment of the wire when the wire portion in the first difference image and the wire portion in the second difference image are close to each other by a predetermined amount or more (S05 And the winding device adjusts the control parameter of at least one of the bobbin and the wire rod supply unit when an abnormality is detected in the abnormality detection step. Comprises, an improvement step (S07) to improve the alignment property.

  Similarly, in order to solve the above problems, the winding coil inspection method according to the present invention manufactures a winding coil by winding a wire (9) supplied from a wire supply portion (10) around a bobbin (8). A winding device (1), an imaging unit (3) for imaging a wire wound around the bobbin, and an inspection unit (7) for inspecting the alignment of the wire based on the imaged image imaged by the imaging unit An inspection apparatus (2) including: a winding coil inspection method using the coil, wherein the imaging section winds a wire around the bobbin to manufacture a winding coil, the bobbin for each predetermined winding step An imaging step (S01) of imaging a wire wound around the imaging device to create a plurality of captured images, and an imaging image of an arbitrary winding step for the plurality of captured images generated in the imaging step by the inspection unit And a captured image one step before the arbitrary winding step, thereby extracting a plurality of difference images each including only a wire wound on the bobbin in the arbitrary winding step Step (S02), for the plurality of difference images extracted in the extraction step, the inspection unit performs a first difference image of a predetermined winding step, and a second difference image that differs by a plurality of steps from the predetermined winding step Of the first difference image and the wire part of the second difference image are approaching each other by a predetermined amount or more, and the abnormality detection for detecting an abnormality related to the alignment of the wire And a step (S05).

  Similarly, in order to solve the above-mentioned subject, an inspection device (2) concerning the present invention winds a wire rod (9) supplied from wire rod supply part (10) around a bobbin (8), and manufactures a winding coil. An inspection device (2) for a winding device (1), an imaging unit (3) for imaging a wire wound around the bobbin, and alignment of the wire based on a captured image taken by the imaging unit The inspection unit (7) for inspecting the flexibility, and the imaging unit winding the wire around the bobbin to manufacture a winding coil, the wire being wound around the bobbin at each predetermined winding step The imaging unit picks up a plurality of pickup images, and the inspection unit picks up a pickup image of an arbitrary winding step and an imaging of one step before the arbitrary winding step with respect to the plurality of pickup images generated by the imaging unit A plurality of difference images each including only a wire wound on the bobbin in the arbitrary winding step are extracted by taking differences with the image, and predetermined winding is performed on the extracted plurality of difference images. A wire portion in the first difference image and a wire portion in the second difference image by comparing the first difference image of the step and the second difference image different by a plurality of steps from the predetermined winding step , Are approaching a predetermined amount or more, an abnormality relating to the alignment of the wire is detected.

  Thereby, in the process of winding the wire on the bobbin, using two or more difference images each including only the wire wound on the bobbin in an arbitrary winding step, the two difference images including the wires of two different layers are compared Thus, it is possible to accurately detect an abnormality in alignment caused by the proximity of the wires of two different layers. Thus, the alignment of the wire wound on the bobbin of the winding coil can be quantitatively evaluated by using, as an evaluation criterion, the degree of closeness between two different layers of wire based on the difference image.

  According to the present invention, it is possible to provide a winding coil manufacturing method, a winding coil inspection method, and an inspection apparatus capable of quantitatively evaluating the alignment of a wire wound around a bobbin of a winding coil.

FIG. 1 is a view showing a schematic configuration of a winding coil manufacturing system on which a winding coil manufacturing method and a winding coil inspection method according to an embodiment of the present invention are mounted. FIG. 2 is a flow chart showing the procedure of a wire alignment evaluation method implemented by the winding coil manufacturing system shown in FIG. FIG. 3 is a schematic view showing an example of a captured image and a difference image used in the present embodiment. FIG. 4 is a schematic view for explaining the procedure for evaluating the alignment of the wires in the present embodiment. FIG. 5 is a schematic view for explaining the procedure for evaluating the alignment of the wires in the present embodiment. FIG. 6 is a schematic view showing an example of a captured image and a difference image exemplified as a modification of the embodiment. FIG. 7 is a schematic view for explaining the procedure for evaluating the alignment of the wires in the modification of the embodiment. FIG. 8 is a schematic view for explaining the procedure for evaluating the alignment of the wires in the modification of the embodiment.

  Hereinafter, embodiments of the present invention will be described with reference to the attached drawings. In order to facilitate understanding of the description, the same constituent elements in the drawings are denoted by the same reference numerals as much as possible, and redundant description will be omitted.

[Embodiment]
One embodiment of the present invention will be described with reference to FIGS. First, with reference to FIG. 1, a configuration of a winding coil manufacturing system 20 on which a winding coil manufacturing method and a winding coil inspection method according to the present embodiment are mounted will be described. The winding coil manufacturing system 20 includes a winding device 1 and an inspection device 2.

  The winding apparatus 1 is an apparatus for manufacturing a winding coil by winding a wire 9 around a bobbin 8. The winding device 1 includes a bobbin 8, a wire rod supply unit 10, servomotors 11 and 12, and a motor controller 5.

  The bobbin 8 is a cylindrical body around which the wire 9 is wound. The bobbin 8 includes a shaft 8a provided along the rotation axis, and a pair of flanges 8b provided on both ends in the axial direction of the shaft 8a and protruding in the outer diameter direction. The bobbin 8 is wound with a wire around the outer peripheral surface of the shaft 8a in the range between the pair of flanges 8b.

  The wire supply unit 10 is a device for supplying a wire 9 for winding around the bobbin 8. The wire rod supply unit 10 has a nozzle portion 10 a for feeding the wire rod 9 onto the bobbin 8. The nozzle portion 10 a is disposed to face the outer peripheral surface of the shaft portion 8 a of the bobbin 8. A position on the bobbin 8 to which the wire 9 is supplied from the wire supply unit 10 (hereinafter referred to as a “wire supply position”) is determined according to the arrangement of the nozzle portion 10a along the axial direction of the shaft 8a. The wire supply unit 10 is configured to move the wire supply position along the axial direction of the bobbin 8. The wire feeding unit 10 is configured to draw the wire 9 from a wire feeding mechanism (not shown) and feed the wire 9 to the bobbin 8 with a predetermined tension from the nozzle portion 10a.

  The servomotor 11 is a power source that generates a driving force for rotating the bobbin 8. The bobbin 8 can be rotated at any rotational speed around the rotation axis by the driving force of the servomotor 11.

  The servomotor 12 is a power source that generates a driving force for moving the wire supply position of the wire supply unit 10 with respect to the bobbin 8. The servomotor 12 can move the wire supply unit 10 at an arbitrary moving speed along the axial direction of the bobbin 8 by rotating the ball screw 13 connected to the wire supply unit 10.

  The motor controller 5 is a control device for controlling the operation of the servomotors 11 and 12. The motor controller 5 outputs control commands necessary to control the rotational speed of the bobbin 8 and the wire supply position by the wire supply unit 10 to desired ones to the servomotors 11 and 12. The motor controller 5 also receives encoder pulses from the servomotors 11 and 12.

  In the present embodiment, the winding device 1 rotates the bobbin 8 under the control of the motor controller 5 and reciprocates the wire supply portion 10 along the axial direction of the bobbin 8 to make the wire 9 the bobbin 8. It is comprised so that the winding pattern which winds hierarchically hierarchically can be implemented. The winding pattern is, for example, as shown in the upper part of FIG. 3, a wire continuously connected along the axial direction of the bobbin 8 in the range between the pair of flanges 8b of the shaft 8a of the bobbin 8 A group of 9 is a single layer, and a plurality of layers of wire 9 are stacked in the radial direction of the bobbin 8.

  The inspection device 2 is a device that inspects the quality of the winding coil manufactured by the winding device 1. In the present embodiment, the inspection device 2 evaluates the alignment of the wire 9 wound around the bobbin 8 by the winding device 1.

  Here, "the alignment of the wire 9" means that each of the wires 9 hierarchically wound around the bobbin 8 is disposed at an original proper position based on the winding pattern by the winding device 1 described above. It can also be expressed as an index to evaluate the

  If winding disturbance occurs when the wire 9 is wound around the bobbin 8, a gap may be formed, for example, at the winding end portion in the vicinity of the flange portion 8b. If the wire 9 of the upper layer (radially outer side) gets into this gap, there is a possibility that the wire 9 of the lower layer (radially inner side) which should not come in contact may contact with the wire 9. Such a state can be expressed as a state in which the alignment of the wire 9 is deteriorated. If the alignment of the wires 9 is deteriorated and the wires of different layers come in contact with each other, the higher the potential difference between the layers becomes, the film of the wires 9 is broken by the contact and the possibility of shorting increases. . Therefore, in the present embodiment, the inspection apparatus 2 detects an abnormal state in which there is a possibility that the wires 9 of the layers separated by a plurality of predetermined layers (for example, five layers) or more may come in contact with each other. It is used as an evaluation criterion to determine what has been done.

  As shown in FIG. 1, the inspection apparatus 2 includes an area camera 3 (imaging unit), an illumination 4, a synchronization acquisition unit 6, and an arithmetic unit 7 (inspection unit).

  The area camera 3 captures an image of the wire 9 wound around the bobbin 8. The area camera 3 is installed immediately above the bobbin 8. For example, as shown in the upper part of FIG. 3, when the wire 9 is wound along the outer diameter direction from the position of the outer peripheral surface of the shaft portion 8 a of the bobbin 8 as illustrated in the upper part of FIG. It is set so that the range of the shaft portion 8a sandwiched by the pair of flange portions 8b can be imaged along the range up to the position of the largest diameter of and the axial direction of the bobbin 8.

  The illumination 4 is disposed to face the area camera 3 with the bobbin 8 interposed therebetween, and emits light to the portion of the bobbin 8 included in the imaging area of the area camera 3. When the illumination 4 emits light toward the bobbin 8 and the area camera 3, the captured image I captured by the area camera 3 is, for example, as shown in FIG. 3 or the like, of the wire 9 wound around the bobbin 8. It becomes a silhouette image.

  The synchronization acquisition unit 6 receives an encoder pulse from the motor controller 5, performs signal processing, and generates a synchronization signal to the area camera 3. In other words, the synchronization acquisition unit 6 acquires information on the rotation angle of the bobbin 8 and the wire supply position of the wire supply unit 10 based on the encoder pulses of the servomotors 11 and 12 input from the motor controller 5, and these information A synchronization signal of a predetermined cycle is generated based on The area camera 3 can perform imaging in a predetermined cycle according to the synchronization signal.

  As described above, the process in which the area camera 3 periodically images based on the synchronization signal is also the process of "imaging the wire 9 wound around the bobbin 8 at each predetermined winding step and creating a plurality of captured images I". Can be expressed. The period of the synchronization signal, that is, the winding step is the timing at which the wire 9 of each layer of the hierarchy is wound around the bobbin 8 in the present embodiment, with respect to the wire 9 wound hierarchically around the bobbin 8. That is, as in a series of captured images I shown in the upper part of FIG. 3, the winding of the wire 9 of each of the first to Nth layers is completed on the bobbin 8 and the rotational position of the bobbin 8 has a predetermined same phase. Every time, the synchronization acquisition unit 6 outputs a synchronization signal to the area camera 3, and the area camera 3 performs imaging.

  The arithmetic device 7 inspects the alignment of the wire 9 based on the captured image I captured by the area camera 3. More specifically, the arithmetic unit 7 processes the captured image I captured by the area camera 3 to create a plurality of difference images D between the respective winding steps, and the wire portions in the difference images D are An abnormality in the alignment of the wire rod 9 can be detected in accordance with the degree of superposition. In addition, when the arithmetic device 7 detects an abnormality in the alignment of the wire 9, it can adjust the winding parameters (control parameters related to the rotation of the bobbin and the movement of the wire supply portion, etc.) to improve the alignment. . The details of the inspection method by the arithmetic unit 7 will be described later with reference to FIGS.

  The motor controller 5, the synchronization acquisition unit 6, and the arithmetic device 7 described above are physically a computer having a central processing unit (CPU), a random access memory (RAM), a read only memory (ROM), and the like. All or a part of each function of the motor controller 5 and the synchronization acquisition unit 6 described above and each function of the arithmetic unit 7 described later with reference to FIGS. 2 to 5 uses the application program stored in the ROM as the RAM It is realized by reading and writing data in RAM and ROM by loading and executing in the CPU. Further, in the configuration example shown in FIG. 1, the motor controller 5, the synchronization acquisition unit 6, and the arithmetic device 7 are illustrated as separate devices, but the functions of the motor controller 5, the synchronization acquisition unit 6, and the arithmetic device 7 are It is also possible to implement by one computer device collectively.

  Next, with reference to FIGS. 2-5, the inspection method and manufacturing method of the winding coil which concern on this embodiment using said winding apparatus 1 and the inspection apparatus 2 are demonstrated. Below, according to the procedure of the flowchart of FIG. 2, it demonstrates, referring FIGS. 3-5 suitably.

  In step S01 (imaging step), in the process of winding the wire 9 by the winding device 1 around the bobbin 8 by the area camera 3 to manufacture a winding coil, the captured image I of the wire 9 wound around the bobbin 8 is obtained Be done. The area camera 3 captures an image of the wire 9 wound around the bobbin 8 at each predetermined winding step according to the synchronization signal input from the synchronization acquisition unit 6, and creates a plurality of captured images I. As described above, in the present embodiment, the area camera 3 performs imaging at every timing when the wire 9 of each layer in the layer is wound around the bobbin 8 with respect to the wire 9 wound around the bobbin 8 hierarchically. Therefore, as shown in the upper part of FIG. 3, the plurality of captured images I acquired in this step are the zeroth layer image in a state where the wire 9 is not wound around the bobbin 8, and the wire of the first layer on the bobbin 8 First layer image in a state in which 9 is wound, second layer image in a state in which the wire 9 of the second layer is wound around the bobbin 8, third layer in a state where the wire 9 of third layer is wound around the bobbin 8 A series of image groups including an image,..., An N-th layer image in a state in which the N-th wire 9 is wound around the bobbin 8 is an order of images of the outermost layer in the order. Further, as shown in FIG. 3, each captured image I becomes a silhouette image of the wire 9 wound around the bobbin 8 by the light emitted from the illumination 4 to the imaging region of the area camera 3. The area camera 3 outputs the created captured image I to the arithmetic device 7. If the process of step S01 is completed, it will progress to step S02.

  In step S02 (extraction process), the arithmetic device 7 creates a difference image D using the plurality of captured images I acquired in step S01. The difference image D is a difference between an image of an arbitrary winding step (i-th layer) among a plurality of captured images I and an image one step before the arbitrary winding step (i-1th layer). Image created by taking The difference image D is obtained by extracting an image of only the wire 9 wound on the bobbin 8 in an arbitrary winding step (i-th layer). For example, as shown in FIG. 3, the difference image D created by taking the difference between the first layer image and the zero layer image in the captured image I is an image in which only the first layer wire 9 is extracted, The difference image D created by taking the difference between the second layer image of the image I and the first layer image is an image in which only the wire 9 of the second layer is extracted, and the third layer image of the captured image I and the second layer The difference image D created by taking the difference from the eye image is an image in which only the third wire 9 is extracted, and the difference between the Nth layer image and the N−1th layer image of the captured image I is taken The created difference image D is an image in which only the wire 9 of the Nth layer is extracted. If the process of step S02 is completed, it will progress to step S03.

  In step S03 (processing step), an expansion image DB of each layer is created by the arithmetic unit 7 using the difference image D of each layer created in step S02. The expanded image DB is an image created by performing expansion processing to expand the portion of the wire 9 in the difference image D at a predetermined ratio. For example, as shown in FIG. 4 and FIG. 5, the expansion image DB1 of the first layer is created by expanding the shape of the black circle corresponding to the wire 9 at a predetermined ratio in the first layer difference image D1. A third layer expanded image DB3 is created by expanding the shape of the black circle corresponding to the wire 9 in the third layer difference image D3 at a predetermined ratio. If the process of step S03 is completed, it will progress to step S04.

  In step S04 (overlapping step), the arithmetic device 7 performs overlap analysis using the expanded image DB of each layer created in step S03. The arithmetic unit 7 evaluates by superimposing the expansion image of a predetermined winding step (i-th layer) and the expansion image of a winding step (i + X-th layer) different from the predetermined winding step by a predetermined number of steps (X layers). Create the image E for As described above, in the present embodiment, the inspection apparatus 2 detects the state in which the wires 9 in layers separated by a predetermined plurality of X layers (for example, five layers) or more may be in contact with each other. Used as an evaluation criterion to determine that an abnormality has occurred in sex. For this reason, in this step, the arithmetic unit 7 creates a plurality of evaluation images E superimposed on the expanded images of layers separated by a predetermined X layer or more from the expanded image of the first layer. For example, as shown in FIG. 4 and FIG. 5, by using the first layer of expanded image DB1 and the third layer of expanded image DB3 to overlap, it is used to evaluate the alignment between the first and third layers. The evaluation image E13 of is generated. If the process of step S04 is completed, it will progress to step S05.

  In step S05 (abnormality detection process), the arithmetic device 7 uses the evaluation image E created in step S04 to evaluate the alignment of the wire 9 wound around the bobbin 8. The arithmetic device 7 determines whether each of the evaluation images E is in contact with black circles corresponding to the wires 9 of two different layers, and determines whether the wires of each layer overlap one another.

  As a result of the determination, if there is no black circle corresponding to wire rod 9 of two different layers in evaluation image E, arithmetic device 7 aligns wire rod 9 between the two corresponding layers. Evaluate sex as normal. For example, in the example shown in FIG. 4, in the evaluation image E 13, the black circle corresponding to the wire 9 in the first layer and the black circle corresponding to the wire 9 in the third layer do not contact. It is judged that there is no overlap between the layer 9 and the third layer wire 9, and the alignment is evaluated as normal.

  On the other hand, as a result of the determination, the computing device 7 may contact black circles corresponding to the wire 9 of two different layers in the evaluation image E, and when the wires of each layer overlap, the wire 9 It is evaluated that the alignment of the is abnormal. For example, in the example shown in FIG. 5, in the evaluation image E13, the black circle corresponding to the wire 9 in the first layer and a part of the black circle corresponding to the wire 9 in the third layer are in contact. The overlap between the first layer and the third layer wire 9 is determined to be overlapping, and the alignment of the wire 9 is evaluated as abnormal. If the process of step S05 is completed, it will progress to step S06.

  In step S06, as a result of the evaluation in step S05, the arithmetic device 7 determines whether or not there is an abnormality in the alignment of the wire 9 wound around the bobbin 8. If there is an abnormality in the alignment (YES in step S06), the process proceeds to step S07. If there is no abnormality in the alignment (NO in step S06), the control flow ends.

  In step S07 (improvement process), it is determined that the alignment of the wire 9 wound around the bobbin 8 is abnormal, so that the winding parameter is adjusted by the winding device 1. The arithmetic unit 7 feeds back to the motor controller 5 of the winding device 1 that there is an abnormality in the alignment. The motor controller 5 adjusts a winding parameter, that is, a control parameter of at least one of the bobbin 8 and the wire supply unit 10. Specifically, the motor controller 5 reduces the winding force of the wire 9 on the bobbin 8 by adjusting the command value to the servomotor 11 so as to lower the rotational speed of the bobbin 8, for example. Alternatively, the motor controller 5 adjusts the command value to the servomotor 12 so as to increase the reciprocation width of the wire supply position by the wire supply unit 10 in the axial direction, so that in each layer of the wire 9 wound around the bobbin 8 The gaps formed at both ends in the direction (in the vicinity of the flange portion 8b) are reduced. By performing such parameter adjustment, the winding apparatus 1 can improve the alignment of the wires 9 of the winding coil to be manufactured thereafter. When the process of step S07 is completed, the present control flow ends.

  Next, the effects of the inspection method and manufacturing method of the winding coil according to the present embodiment using the winding device 1 and the inspection device 2 will be described. In addition, the inspection method of the winding coil which concerns on this embodiment includes step S01 to step S05 shown to the flowchart of FIG. 2, and the manufacturing method of the winding coil which concerns on this embodiment includes step S01 to step S07.

  In the winding coil inspection method according to the present embodiment and the inspection apparatus 2 for implementing this method, in step S01 (imaging step), the area camera 3 winds the wire 9 around the bobbin 8 to manufacture a winding coil. The wire rod 9 wound around the bobbin 8 is imaged at each predetermined winding step (timing when the winding of each layer is completed), and a plurality of captured images I are created. In step S 02 (extraction process), the arithmetic device 7 processes the plurality of captured images I generated in the imaging process with the captured images of an arbitrary winding step and the captured image of one step before the arbitrary winding step. A plurality of difference images D are extracted by taking differences between them. Each of the plurality of difference images D is an image including only the wire 9 wound on the bobbin 8 in an arbitrary winding step. In step S05 (abnormality detection step), the first difference image of a predetermined winding step (for example, the first layer difference shown in FIGS. 4 and 5) with respect to the plurality of difference images D extracted in the extraction step A wire portion in the first difference image by comparing the image D1) with a second difference image (for example, the third layer difference image D3 shown in FIGS. 4 and 5) different from the predetermined winding step by a plurality of steps; When the wire portion in the second difference image approaches the predetermined amount or more, an abnormality related to the alignment of the wire 9 is detected.

  Thereby, in the process of winding the wire 9 around the bobbin 8, using a plurality of difference images D each including only the wire 9 wound around the bobbin 8 in an arbitrary winding step, 2 including the wire 9 of two different layers 2 By comparing the two difference images D, it is possible to accurately detect an abnormality in alignment caused by the closeness between the wires 9 of two different layers. As described above, by using the degree of approach of the wires 9 of two different layers based on the difference image D as an evaluation reference, the alignment of the wires 9 wound around the bobbin 8 of the winding coil can be quantitatively evaluated.

  Moreover, the manufacturing method of the winding coil which concerns on this embodiment is provided with step S07 (improvement process) in addition to said each processing step. In step S07, when an abnormality is detected in step S05 (abnormality detection step), the winding device 1 adjusts at least one of the control parameters of the bobbin 8 and the wire supply unit 10 to adjust the alignment of the wire 9 Improve. This optimizes the alignment of the wire 9 and makes it possible to produce a high quality coil with high alignment.

  Further, the inspection method and manufacturing method of the winding coil according to the present embodiment include step S03 (processing step) and step S04 (overlaying step) as a previous stage of step S05 (abnormality detecting step). In step S03, the arithmetic unit 7 executes the first difference image (for example, the first layer difference image D1 shown in FIGS. 4 and 5) and the second difference image (for example, the third layer difference image D3 shown in FIGS. The expansion processing is performed to expand the wire portion in at a predetermined ratio, and an expansion image (for example, expansion images DB1 and DB3 shown in FIGS. 4 and 5) is created. In step S04, a first difference image (for example, an expansion image DB1 shown in FIGS. 4 and 5) and a second difference image (for example, an expansion image DB3 shown in FIGS. 4 and 5) after expansion processing has been performed in the processing step. When the wire portion in the first difference image and the wire portion in the second difference image overlap, an abnormality related to the alignment of the wire 9 is detected.

  As a result, it is possible to detect not only the physical contact state between the wires 9 of two different layers but also the approaching state of a predetermined value or more by observing the presence or absence of the superposition of the expanded image. It is possible to improve the accuracy of detecting an abnormality in the alignment of

  Further, in the inspection method and manufacturing method of the winding coil according to the present embodiment, the captured image I captured by the area camera 3 in step S01 (imaging step) is a silhouette image of the wire 9 wound around the bobbin 8 It is. As a result, in the arithmetic device 7, the captured image I becomes a black and white binary image, and the evaluation image E created based on the captured image I also becomes a binary image. For this reason, it becomes possible to perform simply detection of superposition of wire rods 9 of two different layers using image E for evaluation, and can perform alignment evaluation of wire rods 9 promptly.

  Further, in the method of manufacturing a winding coil according to the present embodiment, in step S07 (improvement step), when an abnormality is detected in the alignment of the wire 9 in step S05 (abnormality detection step) in the winding device 1 Reduce the winding force of the wire 9 by lowering the rotational speed of the bobbin 8 or increase the axial reciprocation width of the wire supply position by the wire supply unit 10 to reduce the gap formed at both ends in the axial direction in each layer. . By performing such control parameter adjustment, the alignment of the wire rod 9 can be more appropriately improved, and the winding conditions of the winding device 1 can be further optimized. As a result, the winding device 1 can manufacture a winding coil having higher alignment.

[Modification]
The modification of the said embodiment is demonstrated with reference to FIGS. 6-8. Each of FIGS. 6 to 8 corresponds to FIGS. 3 to 5 referred to in the above embodiment. In the above embodiment, in step S01 (imaging step) of FIG. 2, the area camera 3 captures an image of the wire 9 wound hierarchically around the bobbin 8 at every timing when the wire 9 of each layer in the hierarchy is wound around the bobbin 8 However, the timing at which the area camera 3 captures the wire 9 (predetermined winding step) is not limited to this.

  For example, as shown in FIG. 6, the timing at which the wire 9 is wound around the bobbin 8 during a predetermined number of revolutions (one revolution in FIG. 6) of the bobbin 8 may be a winding step. In this case, as in a series of captured images I shown in the upper part of FIG. 6, the synchronization acquisition unit 6 sends a synchronization signal to the area camera 3 each time the winding of the wire 9 of each of the first to N-th turns is completed. Then, the area camera 3 captures an image. In addition, although the case where predetermined rotation speed is 1 rotation is illustrated in the example of FIG. 6, predetermined rotation speed can also be 2 rotations or more.

  When the process of the flowchart in FIG. 2 is performed, the plurality of captured images I acquired in step S01 is a zero-turn image in a state where the wire 9 is not wound around the bobbin 8 as shown in the upper part of FIG. First winding image in a state in which wire rod 9 of the first rotation is wound around bobbin 8, second winding image in a state in which wire rod 9 of second rotation is wound around bobbin 8, wire rod 9 of the third rotation on bobbin 8 A series of image groups including up to the outermost layer image in order of the third wound image in the wound state,..., The N-th wound image in the state where the wire 9 of the Nth rotation is wound around the bobbin 8 Become.

  In addition, the difference image D created in step S02 is an image of an arbitrary winding step (i-th winding in the example of FIG. 6) among the plurality of captured images I, and one step before this arbitrary winding step (figure In the example of No. 6, the image is created by taking the difference with the image of the (i-1) turn, and is wound around the bobbin 8 at an arbitrary predetermined rotation speed (i.sup.th turn in the example of FIG. 6) An image of only the wire rod 9 is extracted. For example, as shown in FIG. 6, a difference image D created by taking the difference between the first turn image and the 0 turn image in the captured image I is an image in which only the first turn wire 9 is extracted, The difference image D created by taking the difference between the second turn image and the first turn image of the image I is an image in which only the wire 9 of the second turn is extracted, and the third turn image and the second turn of the captured image I The difference image D created by taking the difference from the eye image is an image in which only the third wire rod 9 is extracted, and the difference between the N-th roll image and the N-1-th roll image of the captured image I The created difference image D is an image in which only the wire 9 of the N-th turn is extracted.

  In addition, the evaluation image E created in step S04 is an expanded image of a predetermined winding step (i-th winding) and a winding step (i + X winding) different from the predetermined winding step by a predetermined number of steps (for X windings). Created by overlaying the dilated image of the eye). In other words, the evaluation image E is created by superimposing the expanded images of the wires 9 separated from each other by the predetermined number of turns (X turns) in the same layer. For example, as shown in FIG. 7 and FIG. 8, by overlapping the expanded image DB1 obtained by processing the first difference image D1 in an arbitrary same layer and the expanded image DB3 obtained by processing the third difference image D3. An evaluation image E13 to be used for evaluating the alignment between the first and third volumes is created.

  In the alignment evaluation in step S05, for example, in the example shown in FIG. 7, in the evaluation image E13, the black circle corresponding to the first winding wire 9 and the black circle corresponding to the third winding wire 9 are not in contact with each other. Therefore, the arithmetic unit 7 determines that there is no overlap between the first and third turns of the wire material 9, and evaluates that the alignment is normal. On the other hand, in the example shown in FIG. 8, for example, in the evaluation image E13, the black circle corresponding to the first winding wire 9 and a part of the black circle corresponding to the third winding wire 9 are in contact with each other. 7 determines that there is overlap between the first and third turns of the wire rod 9, and it is evaluated that the alignment of the wire rod 9 is abnormal.

  Thus, as shown in FIGS. 6-8, the area camera at every timing at which the wire 9 is wound around the bobbin 8 during a predetermined number of rotations of the bobbin 8 for the wire 9 wound hierarchically around the bobbin 8 Even in the configuration in which 3 generates the captured image I, the alignment of the wire 9 can be evaluated by applying the same method as that of the above embodiment. Therefore, also in this configuration, the same effects as the inspection method and the manufacturing method of the winding coil according to the above embodiment can be obtained.

  The embodiments of the present invention have been described above with reference to specific examples. However, the present invention is not limited to these specific examples. That is, those to which those skilled in the art appropriately modify the design of these specific examples are also included in the scope of the present invention as long as they have the features of the present invention. For example, each element included in each specific example described above and its arrangement, material, conditions, shape, size, and the like are not limited to those illustrated, and can be appropriately changed. Moreover, each element with which each embodiment mentioned above is equipped can be combined as much as technically possible, and what combined these is also included in the scope of the present invention as long as the feature of the present invention is included.

  In the above embodiment, when the difference image D is processed to create the expanded image DB, and the portions corresponding to the wire 9 in the two expanded images DB overlap each other, these two types of wire 9 have a predetermined amount Although the structure which detects the state which has approached and abnormality in alignment of a wire has generate | occur | produced above was illustrated above, the other method of detecting the approach state of the wire 9 can also be used. For example, the approach state of the wire can be detected using the difference image D instead of the expanded image DB of the above embodiment. In this case, it monitors whether or not the distance between portions corresponding to the wire 9 in the two difference images D is less than a predetermined threshold, and detects an abnormality in the alignment of the wire when the distance is reduced to the threshold or less. be able to.

  Moreover, in the said embodiment, although the captured image I which the area camera 3 produces was made into the silhouette image of the wire 9 wound around the bobbin 8 by using the illumination 4, the captured image was imaged by the forward light It can also be used as I.

1: Winding device 2: Inspection device 3: Area camera (imaging unit)
7: Arithmetic unit (inspection section)
8: Bobbin 9: Wire rod 10: Wire rod supply unit S01: Imaging step S02: Extraction step S03: Processing step S04: Overlay step S05: Abnormality detection step S07: Improvement step

Claims (8)

A winding apparatus (1) for manufacturing a winding coil by winding a wire (9) supplied from a wire supply portion (10) around a bobbin (8);
An imaging unit (3) for imaging a wire wound around the bobbin;
An inspection unit (7) which inspects the alignment of the wire based on the captured image captured by the imaging unit;
An inspection device (2) comprising
A winding coil manufacturing method using
In the process of winding the wire around the bobbin to manufacture a winding coil, the imaging unit captures an image of the wire wound around the bobbin at each predetermined winding step, and generates a plurality of captured images (S01 )When,
The inspection unit obtains a difference between a plurality of captured images generated in the imaging step, a captured image of an arbitrary winding step, and a captured image of one step before the arbitrary winding step. An extraction step (S02) of extracting a plurality of difference images each including only a wire rod wound on the bobbin in the arbitrary winding step;
The inspection unit compares a first difference image of a predetermined winding step with a second difference image different by a plurality of steps from the predetermined winding step, for the plurality of difference images extracted in the extraction step. An abnormality detecting step (S05) of detecting an abnormality relating to the alignment of the wire when the wire portion in the first difference image and the wire portion in the second difference image are close to each other by a predetermined amount or more;
An improvement process (S07) in which the winding apparatus adjusts the control parameter of at least one of the bobbin and the wire rod supply unit when an abnormality is detected in the abnormality detection process;
Method of manufacturing a wound coil comprising: The said abnormality detection process is
A processing step (S03) for performing expansion processing to expand a wire portion in the first difference image and the second difference image at a predetermined ratio;
The first difference image and the second difference image after expansion processing is performed in the processing step are superimposed, and a wire portion in the first difference image and a wire in the second difference image Overlaying step (S04) for detecting an abnormality relating to the alignment of the wire when overlapping with the part;
Equipped with
A method of manufacturing a wound coil according to claim 1. The captured image captured by the imaging unit in the imaging step is a silhouette image of a wire wound around the bobbin.
The method for manufacturing a wound coil according to claim 1. The winding device is configured to wind the wire hierarchically along the radial direction of the bobbin by rotating the bobbin and reciprocating the wire supply unit along the axial direction of the bobbin.
The predetermined winding step of imaging the wire in the imaging step is a timing at which the wire of each layer in the layer is wound around the bobbin,
The plurality of difference images extracted in the extraction step are images each including only one arbitrary layer of wire members among the wire members hierarchically wound around the bobbin,
The first difference image and the second difference image to be compared in the abnormality detection step are images of wires of layers separated from each other by a plurality of layers.
The winding coil manufacturing method according to any one of claims 1 to 3. The winding device is configured to wind the wire hierarchically along the radial direction of the bobbin by rotating the bobbin and reciprocating the wire supply unit along the axial direction of the bobbin.
The predetermined winding step of imaging the wire in the imaging step is a timing at which the wire is wound around the bobbin during a predetermined number of rotations of the bobbin,
The plurality of difference images extracted in the extraction step are images each including only the wire wound around the bobbin during any predetermined rotation speed among the wires wound hierarchically around the bobbin. Yes,
The first difference image and the second difference image, which are compared in the abnormality detection step, are images of wire members separated from each other by a predetermined number of turns in the same layer.
The winding coil manufacturing method according to any one of claims 1 to 3. In the improvement step, when an abnormality is detected in the abnormality detection step, the winding device reduces the rotational speed of the bobbin to reduce the winding force of the wire, or the wire by the wire supply unit Increase the axial reciprocation width of the feed position to reduce the gap between axial ends of each layer
A method of manufacturing a wound coil according to claim 4 or 5. A winding apparatus (1) for manufacturing a winding coil by winding a wire (9) supplied from a wire supply portion (10) around a bobbin (8);
An imaging unit (3) for imaging a wire wound around the bobbin;
An inspection unit (7) which inspects the alignment of the wire based on the captured image captured by the imaging unit;
An inspection device (2) comprising
A winding coil inspection method using
In the process of winding the wire around the bobbin to manufacture a winding coil, the imaging unit captures an image of the wire wound around the bobbin at each predetermined winding step, and generates a plurality of captured images (S01 )When,
The inspection unit obtains a difference between a plurality of captured images generated in the imaging step, a captured image of an arbitrary winding step, and a captured image of one step before the arbitrary winding step. An extraction step (S02) of extracting a plurality of difference images each including only a wire rod wound on the bobbin in the arbitrary winding step;
The inspection unit compares a first difference image of a predetermined winding step with a second difference image different by a plurality of steps from the predetermined winding step, for the plurality of difference images extracted in the extraction step. An abnormality detecting step (S05) of detecting an abnormality relating to the alignment of the wire when the wire portion in the first difference image and the wire portion in the second difference image are close to each other by a predetermined amount or more;
Wound coil inspection method comprising: An inspection apparatus (2) for a winding device (1) for manufacturing a winding coil by winding a wire (9) supplied from a wire supply portion (10) around a bobbin (8),
An imaging unit (3) for imaging a wire wound around the bobbin;
An inspection unit (7) which inspects the alignment of the wire based on the captured image captured by the imaging unit;
Equipped with
In the process of winding the wire around the bobbin to manufacture a winding coil, the imaging unit captures an image of the wire wound around the bobbin at each predetermined winding step, and creates a plurality of captured images.
The inspection unit obtains a difference between a plurality of picked-up images created by the imaging unit between a picked-up image of an arbitrary winding step and a picked-up image of one step before the arbitrary winding step. Extracting a plurality of difference images including only the wire wound on the bobbin in the optional winding step;
A wire portion in the first difference image by comparing a first difference image of a predetermined winding step with a second difference image different by a plurality of steps from the predetermined winding step with respect to the plurality of extracted difference images. And detecting an abnormality relating to the alignment of the wire, when the wire portion in the second difference image is approaching a predetermined amount or more.
Inspection device.

Images