JP7276270B2 - tension device - Google Patents

Description

The present invention relates to tensioning devices .

A winding machine for winding a wire on a winding core, comprising a main drum for feeding a wire drawn from a wire source, a tension bar for hooking the wire drawn from the main drum, and a wire source and the main drum. A winding machine has been proposed that includes a tension detection unit that detects the tension of a wire between them (see, for example, Patent Document 1). The winding machine further comprises a control unit that controls an arm motor that transmits rotational torque to the tension bar via a link mechanism or a drum motor that rotates the main drum so that the tension of the wire becomes a desired value; a calculation unit that calculates the tension of the wire based on the load detected by the load cell of the tension detection unit.

JP 2019-001617 A

However, in the winding machine described in Patent Document 1, the calculation unit and the control unit are independent of each other, and the information on the tension of the wire calculated by the calculation unit is output to the control unit. do not have. For this reason, the control section cannot obtain information indicating the tension of the wire calculated by the calculation section in substantially real time to control the arm motor or the drum motor. For this reason, the arm motor or the drum motor is not controlled accurately, and as a result, there is a possibility that the tension when the wire is wound around the core may vary.

SUMMARY OF THE INVENTION It is an object of the present invention to provide a tension device capable of suppressing variation in tension of a wire.

In order to achieve the above object, the tension device according to the present invention includes:
a plurality of tension detection units provided in each of a plurality of winding machines for winding a wire around a winding core and detecting a physical quantity reflecting the magnitude of the tension of the wire;
a control unit that controls the rotation speed of the drum motor of each of the plurality of winding machines based on the magnitude of the tension of the wire rod detected by the tension detection unit of each of the plurality of winding machines ;
A signal line connecting the tension detection unit and the control unit,
The tension detection unit is capable of transmitting information indicating the detected tension of the wire directly to the control unit via the signal line ,
The control unit is
a buffer that temporarily stores physical quantity information indicating the physical quantity detected by each of the plurality of tension detectors;
a physical quantity information acquisition unit that distinguishes and stores the physical quantity information acquired from each of the plurality of tension detection units in the buffer;
a tension calculation unit that calculates the tension of the wire rod from the physical quantity;
A tension control value for adjusting the tension of the wire by controlling the rotation speed of the drum motor is calculated by comparing the range of the standard value of the tension of the wire with the calculated tension of the wire. a tension control value calculator;
and a control value transmission section for transmitting tension control value information indicating the tension control value to a motor driving section for driving a drum motor provided in each of the plurality of winding machines.
Further, the tension device according to the present invention is
The physical quantity information acquisition unit may acquire information indicating the tension detected by each of the plurality of tension detection units in a time period of 0.3 msec to 500 msec.

Further, the tension device according to the present invention is
The tension detection unit is
a pair of first rollers on which the wire rod is hooked;
It is arranged between the pair of first rollers whose rotating shafts are parallel to each other, and is movable in a direction perpendicular to the direction in which the pair of first rollers are aligned and in a direction perpendicular to the direction of the rotating shafts of the pair of rollers perpendicular to the direction in which the rollers are aligned. together with a second roller on which the wire is hooked;
a load cell that detects the force applied to the second roller;
an analog-to-digital converter that converts an analog signal corresponding to the force applied to the second roller output from the load cell into a digital signal and outputs the physical quantity that reflects the force applied to the second roller;
and a base that collectively supports the pair of first rollers, the second rollers, the load cell, and the analog-to-digital converter.

Further, the tension device according to the present invention is
The tension detection unit is
a pair of first rollers on which the wire rod is hooked;
It is arranged between the pair of first rollers whose rotating shafts are parallel to each other, and is movable in a direction perpendicular to the direction in which the pair of first rollers are aligned and in a direction perpendicular to the direction of the rotating shafts of the pair of rollers perpendicular to the direction in which the rollers are aligned. together with a second roller on which the wire is hooked;
a load cell that detects the force applied to the second roller,
The load cell
It is a Roberval type load cell,
A roller supporting portion that supports the second roller is fixed to one end of the elongated longitudinal direction, and the other end is in the direction of the arrangement of the pair of first rollers and the direction of the rotation axis of the pair of rollers on the base. a strain-generating portion fixed at a position displaced from the second roller in an orthogonal direction;
and strain gauges disposed at at least four locations in the strain-generating portion.

Further, the tension device according to the present invention is
a standard determination unit that determines whether a tension value indicating the magnitude of the tension of the wire detected by the tension detection unit is within a preset standard range;
and a command unit that generates stop command information for stopping the drum motor when the standard determination unit determines that the tension value is out of the standard range.

Further, the tension device according to the present invention is
a monitoring unit for monitoring whether the tension value indicating the magnitude of the tension of the wire detected by the tension detection unit is out of a preset management range within the standard range;
and a notification unit that, when the monitoring unit determines that the tension value has deviated from the management range, generates notification information that notifies that the tension value has deviated from the management range. .

Further, the tension device according to the present invention is
a display device;
a management information generation unit that generates management information for managing the tension of the wire from a tension value indicating the tension of the wire detected by the tension detection unit;
and a display control unit that causes the display device to display the management information.

Further, the tension device according to the present invention is
Each of the plurality of winding machines is
a drum for feeding the wire;
a drum motor that drives the drum;
a nozzle for guiding the wire unwound from the drum to the winding core;
A long pulley is provided at one end in the longitudinal direction and the other end is rotatably supported, and the wire rod is hooked on the pulley between the drum and the nozzle. and a tension bar biased in a direction in which the pulley is pressed against the wire by a biasing member.

According to the present invention, the tension detector is connected to the control unit via the signal line, and transmits information indicating the detected tension of the wire directly to the control unit via the signal line. Then, the control unit controls the rotational speed of the drum motor based on the magnitude of the tension of the wire detected by the tension detector. As a result, the control unit can obtain information indicating the tension of the wire rod detected by the tension detector in substantially real time, and can control the rotational speed of the drum motor, thereby suppressing variations in the tension of the wire rod.

It is a figure showing composition of a winding machine concerning an embodiment of the invention. It is a figure which shows the structure of the tension|tensile_strength detection part which concerns on embodiment. It is a block diagram which shows the hardware constitutions of the control unit which concerns on embodiment. 3 is a block diagram showing the functional configuration of a control unit according to the embodiment; FIG. 7 is a flowchart showing an example of a flow of winding machine control processing executed by a control unit according to the embodiment; 4 is a flowchart showing an example of the flow of tension monitoring processing executed by the control unit according to the embodiment; It is a figure which shows the structure of the tension|tensile_strength detection part which concerns on a modification.

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. A winding machine according to the present embodiment is a device for winding a wire around a winding core. This winding machine includes a drum that feeds a wire, a drum motor that drives the drum, a nozzle that guides the wire that is fed from the drum to the core, a tension bar, a tension detector, a control unit, and a tension detector. and a signal line connecting the control unit. The tension bar is long and has a pulley provided at one end in the longitudinal direction, and the other end is rotatably supported by the pulley. is pressed against the wire by a biasing member. The tension detector can detect the tension of the wire between the pulley and the nozzle, and transmit information indicating the detected tension of the wire directly to the control unit via the signal line. The control unit controls the rotational speed of the drum motor based on the magnitude of the wire tension detected by the tension detector.

As shown in FIG. 1, the winding machine 1 according to the present embodiment forms a coil by winding a wire C1 around a winding core Co1. The winding machine 1 feeds the wire C1 from a wire source (not shown) storing the wire C1 toward the core Co1, and adjusts the tension of the wire C1 wound around the core Co1. The winding machine 1 is also connected to a production management server 2 or other production facilities 3 via a network NW1. The network NW1 is, for example, a LAN (Local Area Network) built in a factory.

The winding machine 1 includes a plurality of winding units 100 and a control unit 90 that controls the plurality of winding units 100, as shown in FIG. The winding unit 100 includes a base 10, a drum 20 attached to the base 10 and feeding the wire C1 supplied from a wire source, a drum motor 21 rotating the drum 20, a motor driving section 22, and a core support unit. 40 and a nozzle 80 . The winding unit 100 also includes a tension bar 30 to which the wire C1 is hooked, a biasing member 33 that biases the tension bar 30, and a tension detector 70 that detects the tension applied to the wire C1. Here, a tension device for controlling the tension of the wire rod C1 is configured from the tension detector 70, the control unit 90, and a signal line SL1, which will be described later.

The core support unit 40 includes a core support portion 401 that supports the core Co1 rotatably around the winding axis around which the wire rod C1 is wound, and a winding core support portion that rotates around the winding axis. It has a core driving motor 402 and a driver 403 that controls the winding core driving motor 402 . When the driver 403 receives operation start command information (to be described later) from the control unit 90, the driver 403 controls the core drive motor 402 to rotationally drive the core support 401 in the direction indicated by the arrow AR1 at a preset number of revolutions. Further, the facility 3 stops the winding core driving motor 402 upon receiving stop command information, which will be described later. The nozzle 80 has a cylindrical shape and guides the wire rod C1 drawn out from the drum 20 to the winding core.

A wire rod C<b>1 is wound around the outer periphery of the drum 20 . The drum 20 is connected to a shaft (not shown) of a drum motor 21 and driven to rotate by the drum motor 21 in a direction indicated by an arrow AR2. The drum motor 21 is, for example, a servomotor whose rotary shaft rotates by electric power supplied from the motor driving section 22 . The motor driving section 22 has a driver 222 and a digital-to-analog converter (hereinafter referred to as “DAC”) 221 . When the DAC 221 receives initial tension control value information or tension control value information, which will be described later, from the control unit 90, the initial tension control value indicated by the received initial tension control value information or the tension control value indicated by the tension control value information is converted into a voltage signal. It converts and outputs to the driver 222 . The driver 222 rotationally drives the drum motor 21 at a rotational speed according to the voltage signal input from the DA 221 .

The tension bar 30 has a long rod portion 31 and a guide portion 32 provided at one longitudinal end portion of the rod portion 31 . The other end of the rod portion 31 in the longitudinal direction is rotatably supported by a rotating pin 311 . As a result, the tension bar 30 as a whole can be turned around the turning pin 311 . The guide portion 32 has a holding portion 321 provided at one end of the rod portion 31 and a pulley 322 rotatably connected to the holding portion 321 . Here, the wire rod C1 is wound around the outer periphery of the pulley 322, is turned by the pulley 322, and is guided to the winding core Co1. The biasing member 33 is, for example, an elongated coil spring, and has one end in the longitudinal direction fixed to the rod portion 31 of the tension bar 30 via a fixing member 312 and the other end to the base 10 via a fixing member 331 . Fixed. The tension bar 30 is urged in a direction in which the pulley 322 is pressed against the wire C1 by the urging member 33 while the wire C1 is hooked on the pulley 322 between the drum 20 and the nozzle 80 . This suppresses the occurrence of slack in the wire rod C1.

Here, the tension generated in the wire C1 during winding of the wire C1 around the core Co1 is the tension generated by the speed difference between the delivery speed of the wire C1 from the drum 20 and the winding speed of the core Co1, and the tension bar 30 and the resultant force. The tension generated in the wire C1 increases as the delivery speed of the wire C1 becomes lower than the winding speed of the core Co1.

The tension detector 70 detects the tension of the wire rod C1 between the pulley 322 of the tension bar 30 and the nozzle 80 . That is, the tension detection unit 70 detects the tension of the wire C1 at a position immediately before the nozzle 80 relatively close to the winding core Co1 where the tension of the wire C1 is required to be managed. As shown in FIG. 2, the tension detector 70 includes a pair of first rollers 71A and 71B on which the wire rod C1 is engaged, a second roller 72 arranged between the pair of first rollers 71A and 71B, and a load cell 732 that detects the force applied to the second roller 72 . Here, the wire rod C1 is alternately wound around the first roller 71A on one side, the second roller 72, and the first roller 71B on the other side in this order. In addition, the second roller 72 rotates in a direction orthogonal to the alignment direction of the pair of first rollers 71A and 71B whose rotation axes are parallel to each other and the direction of the rotation axis of the pair of first rollers 71A and 71B perpendicular to this alignment direction, that is, , in the direction AR3 along the X-axis direction. The tension detector 70 also includes an analog-to-digital converter (hereinafter referred to as "ADC") 74, a pair of first rollers 71A and 71B, a second roller 72, a load cell 732, and a base that collectively supports the ADC 74. 79 and . The tension detector 70 also has a detection circuit (not shown) connected to the load cell 732 and a voltage source (not shown) that applies voltage to the detection circuit. In addition, the tension detector 70 is connected to the control unit 90 via a signal line SL1.

Load cell 732 is a Roberval type load cell. The load cell 732 has an elongated strain-generating portion 7321 and four strain gauges 7322 . The strain-generating portion 7321 is elongated, and a roller support portion 733 that rotatably supports the second roller 72 is fixed to one end portion in the longitudinal direction. The strain-generating portion 7321 is made of nickel-chromium-molybdenum steel, stainless steel, aluminum alloy, or the like. The other end of the strain-generating portion 7321 is fixed to the base 79 by a strain-generating portion support portion 731 . Here, the other end of the strain-generating portion 7321 is shifted from the base 79 in the direction parallel to the direction in which the pair of first rollers 71A and 71B are arranged, that is, from the second roller 72 toward the +Z-axis direction. It is fixed in an offset position. The four strain gauges 7322 are arranged at four locations on the strain-generating portion 7321, respectively. The strain gauge 7322 has a resistor made of, for example, a copper-nickel alloy. Four strain gauges 7322 are connected to form a Wheatstone bridge with a detection circuit. As a result, variations in the resistance value of the strain gauge 7322 can be detected with high accuracy. In addition, the influence of ambient temperature is reduced by appropriately setting the arrangement of the four strain gauges.

The ADC 74 converts analog signals indicating the amount of strain according to the force applied to the second roller 72 output from each of the four strain gauges 7322 of the load cell 732 into digital signals. Then, the ADC 74 can transmit a digital signal including information indicating the amount of strain, that is, the detected tension of the wire rod C1, directly to the control unit 90 via the signal line SL1.

The control unit 90 controls the tension generated in the wire C1 by controlling the feeding speed of the wire C1 from the drum 20, that is, the rotation speed of the drum motor 21. FIG. The control unit 90 has a buffer module 950, a main module 910, a display device 904, and an input device 905, as shown in FIG. The buffer module 950 has, for example, an FPGA (Field Programmable Gate Array) and a memory, and acquires and acquires strain amount information by acquiring and demodulating a digital signal indicating the strain amount output from the tension detection unit 70. Temporarily holds distortion amount information. The buffer module 950 is also connected to the ADC 74 of the tension detector 70 via a serial bus such as an ^I2C bus. The buffer module 950, as shown in FIG. 4, has a strain amount buffer 931 that temporarily stores strain amount information indicating the strain amount detected by the tension detection unit 70, and acquires the strain amount information from the tension detection unit 70. and a distortion amount acquisition unit 911 .

The strain amount acquisition unit 911 acquires strain amount information by demodulating the digital signal input from the tension detection unit 70 and stores the acquired strain amount information in the strain amount buffer 931 . Here, the strain amount acquisition unit 911 stores the strain amount information for each of the plurality of winding units in the storage area corresponding to the address assigned in advance to each of the plurality of winding units 100 in the strain amount buffer 931. . Here, the strain amount acquiring section 911 acquires the strain amount information detected by the tension detecting section 70 of each of the plurality of winding units 100 in 0.1 msec or more and 250 msec or less. Therefore, for example, the strain amount acquisition unit 911 acquires the strain amount information detected by the tension detection units 70 of all the four winding units 100 in a time period of 0.3 msec to 500 msec. Further, the strain amount acquisition unit 911 acquires the strain amount information detected by the tension detection unit 70 of each of the plurality of winding units 100 every time it receives buffer information acquisition completion notification information (to be described later) from the main module 910. Storing in the distortion amount buffer 931 is repeated.

Returning to FIG. 3, the main module 910 is a microcomputer such as Raspberry Pi (registered trademark), and includes a CPU (Central Processing Unit) 901, a ROM (Read Only Memory) 903, and a RAM (Random Access Memory) 902. , a storage 907, a display interface 941, an input interface 951, a serial interface 961, an output interface 962, a network interface 908, and a bus 909 connecting each unit. The ROM 903 or storage 907 stores programs for realizing various functions of the main module 910 by the CPU 901 . A display interface 941 is connected to a display device 904 such as a liquid crystal display, and transfers various information input from the CPU 901 to the display device 904 . The input interface 951 , when connected to the input device 905 such as a key input device and a touch panel, transfers various operation information input by the user via the input device 905 to the CPU 901 . Network interface 908 is, for example, a wireless module, and communicates with server 2 and other equipment 3 via network NW1. A serial interface 961 is an interface suitable for serial communication such as a USB (Universal Serial Bus), and is connected to the buffer module 950 via a serial bus. The output interface 962 is, for example, a serial interface, and is connected to the DAC 221 and driver 222 of the motor drive section 22 and the driver 403 of the core support unit 40 via a communication bus.

The CPU 901 reads a program stored in the ROM 903 or the storage 907 into the RAM 902 and executes it, thereby obtaining a tension calculation unit 912, a tension control value calculation unit 913, a control value transmission unit 914, a tension control value It functions as an acquisition unit 915 , a standard determination unit 916 , a command unit 917 , a management information generation unit 918 , a display control unit 919 , a monitoring unit 920 , a notification unit 921 , a compression unit 922 and a transmission unit 923 . The storage also has a standard information storage unit 932, a tension storage unit 933, and a calibration information storage unit 934 that store tension standard value information indicating the standard value of the tension of the wire C1. The standard information storage unit 932 stores tension standard value information in association with product identification information for identifying a coil product manufactured by winding the corresponding wire C1 around the core Co1. In addition, the standard information storage unit 932 stores initial tension control value information indicating an initial tension control value, which is an initial value of the tension control value to be transmitted to the motor drive unit 22 of the winding unit 100 when starting the manufacture of the coil product. , is stored in association with the product identification information. The tension standard value information and the initial tension control value information stored in the standard information storage unit 932 are input by the user via the input device 905, for example. The tension storage unit 933 stores tension information generated based on the strain amount information detected by the tension detection unit 70 .

The calibration information storage unit 934 stores calibration information for calibrating the distortion amount. Here, the calibration information is information indicating a linear function that obtains the tension applied to the wire rod C1 using the strain amount indicated by the strain amount information detected by the tension detection unit 70 as an argument. For this calibration information, for example, in the winding unit 100, with the drum 20 stopped, two types of pre-selected weights having different weights are fixed to the tip of the wire rod C1. generated by

The tension calculation unit 912 acquires the strain amount information stored in the strain amount buffer 931 of the buffer module 950, and uses the linear function indicated by the calibration information stored in the calibration information storage unit 934 to calculate the strain indicated by the acquired strain amount information. From the quantity, the corresponding tension of the wire rod C1 is calculated. Then, the tension calculation unit 912 notifies the tension control value calculation unit 913 of tension information indicating the calculated tension. At this time, the tension calculator 912 associates the tension information described above with the winding unit identification information that identifies the corresponding winding unit 100 and stores the tension information in the tension storage 933 in chronological order. Further, when the strain amount information stored in the strain amount buffer 931 is acquired, the tension calculation unit 912 transmits buffer information acquisition completion notification information for notifying that acquisition of the strain amount information is completed to the buffer module 950 . Furthermore, the tension calculation unit 912 notifies the tension control value calculation unit 913 and the standard determination unit 916 of tension information indicating the calculated tension, and causes the tension storage unit 933 to store the tension information. Here, when the tension information indicates a voltage value corresponding to the tension of the wire C1, the tension calculation unit 912 converts the voltage value indicated by the tension information into a physical quantity represented by a unit of force (for example, N), and then calculates the tension. You may make it memorize|store in the memory|storage part 933. FIG.

The tension control value calculation unit 913 compares the tension standard range indicated by the tension standard value information stored in the standard information storage unit 932 with the tension indicated by the tension information notified from the tension calculation unit 912, A tension control value to be notified to the motor driving section 22 of the unit 100 is calculated. Here, the tension control value is a command value reflecting the rotation speed of the drum motor 21, for example. Further, the tension control value calculation unit 913 calculates, for example, the difference value between the tension indicated by the tension information notified from the tension calculation unit 912 and the center value of the tension standard range, and only the speed corresponding to the difference value is calculated. A tension control value that increases or decreases the rotation speed of the drum motor 21 is calculated.

When the user inputs the product identification information of the coil product to be manufactured via the input device 905, the tension control value acquisition unit 915 acquires information indicating the initial tension control value corresponding to the input product identification information from the standard information storage unit. 932. Then, the tension control value acquisition unit 915 notifies the control value transmission unit 914 of initial tension control value information indicating the acquired initial tension control value.

When the initial tension control value information is notified from the tension control value acquisition unit 915 , the control value transmission unit 914 transmits the notified initial tension control value information to the motor drive unit 22 of the winding unit 100 . Further, when the tension control value information is notified from the tension control value calculation unit 913 after the winding unit 100 starts operating, the control value transmission unit 914 transmits the notified tension control value information to the motor of the winding unit 100 . Send to drive unit 22 .

The standard determination unit 916 compares the standard range of tension indicated by the tension standard value information stored in the standard information storage unit 932 with the magnitude of the tension indicated by the tension information notified from the tension calculation unit 912, and determines the wire rod C1. is within the above-mentioned standard range. Then, when the standard determination unit 916 determines that the tension value of the wire C1 is out of the standard range described above, the standard determination unit 916 transmits out-of-standard notification information to the command unit 917 to notify that the tension value of the wire C1 is out of the standard range. Notice.

When the user operates the input device 905 to start the operation of the winding machine 1, the command unit 917 controls the core drive motor 402 and the drum motor 21 of the core support unit 40 accordingly. Operation start command information for commanding start of operation is transmitted to the winding core support unit 40 and the motor driving section 22 . At this time, the command section 917 transmits operation start notification information to the other equipment 3 to notify that the operation start instruction information has been transmitted to the core support unit 40 and the motor driving section 22 . In addition, when the nonstandard notification information is notified from the standard determination unit 916, the command unit 917 generates stop command information for stopping the core drive motor 402 and the drum motor 21 of the core support unit 40, Send to facility 3. Upon receiving the stop command information from the command unit 917, the facility 3 stops the drum motor 21 and the winding core drive motor 402 based on the received stop command information.

The management information generation unit 918 generates management information for managing the tension of the wire C1 from the tension value indicating the tension of the wire C1 detected by the tension detection unit 70 . The management information generation unit 918 acquires the tension information in the past preset management value calculation target period stored in the tension storage unit 933 every time the preset tension monitoring time arrives, and the acquired tension information is Calculate the mean and standard deviation of the indicated tension values. Here, the management value calculation target period is set, for example, to a period in which the tension value is not outside the standard range from one week before to two days before the current time. In addition, the management information generation unit 918 acquires the tension information from the previous management information generation time to the current time from the tension storage unit 933 each time a preset management information generation time arrives, and the acquired tension information indicates The average value and standard deviation of the tension applied to the wire rod C1 are calculated from the past tension values. Then, the management information generation unit 918 causes the tension storage unit 933 to store management information including information indicating the calculated average value and standard deviation of the tension applied to the wire rod C1.

The display control unit 919 acquires the management information stored in the tension storage unit 933 and causes the display device 904 to display the tension value of the wire rod C1 included in the acquired management information. Here, the display control unit 919 acquires the standard value information from the standard information storage unit 932, and causes the display device 904 to display the standard value indicated by the acquired standard value information and the tension value of the wire C1 included in the management information.

The monitoring unit 920 monitors whether or not the tension value indicating the tension of the wire rod C1 detected by the tension detecting unit 70 is out of the predetermined control range within the standard range described above. Here, the monitoring unit 920 acquires information indicating the average value and the standard deviation included in the management information stored in the tension storage unit 933, for example, and obtains a value higher than the average value by an amount equivalent to three times the standard deviation. The control upper limit is set, and a value lower than the average value by an amount corresponding to three times the standard deviation is set as the control lower limit. In this case, the monitoring unit 920 performs monitoring using the tension value range between the above-described upper management limit and lower management limit as the management range. When the tension value indicating the tension of the wire C1 is out of the control range, the monitoring unit 920 notifies the notification unit 921 of out-of-control-range notification information indicating that the tension value is out of the control range. When notified of the out-of-control notification information from the monitoring unit 920 , the notification unit 921 generates notification information for notifying that the tension value of the wire rod C<b>1 is out of the control range, and transmits the generated notification information to the server 2 .

The compression unit 922 combines and compresses a plurality of pieces of tension information stored in the tension storage unit 933 to generate compression information to be transmitted to the server 2 . The compression unit 922 combines and compresses 10 to 1000 pieces of tension information using, for example, a well-known numerical information compression technique, and notifies the transmission unit 923 of the information obtained by compression. Alternatively, the compression section 922 may notify the transmission section 923 of compression information including only information indicating the average value, standard deviation, maximum value, and minimum value of the tension values stored in the tension storage section 933 . The transmission unit 923 transmits the information notified from the compression unit 922 to the server 2 .

Next, winding machine control processing executed by the main module 910 of the control unit 90 according to the present embodiment will be described with reference to FIG. This winding machine control process is started, for example, when the user operates the input device 905 to start the operation of the winding machine 1 after the winding machine 1 is powered on. be. First, the tension control value acquisition unit 915 acquires initial tension control value information from the standard information storage unit 932 (step S101), and the control value transmission unit 914 transmits the initial tension control value information to the motor driving unit of the winding unit 100. 22 (step S102). Next, the command section 917 sends operation start command information for instructing the core drive motor 402 and the drum motor 21 of the core support unit 40 to start operating to the core support unit 40 and the motor drive section 22 . Send. In addition, the command section 917 transmits operation start notification information to the other equipment 3 to notify that the operation start instruction information has been transmitted to the core support unit 40 and the motor driving section 22 (step S103).

Subsequently, the tension calculator 912 acquires strain amount information stored in the strain amount buffer 931 of the buffer module 950 (step S104). At this time, the tension calculation unit 912 transmits the aforementioned buffer information acquisition completion notification information to the buffer module 950 . Upon receiving the buffer information acquisition completion notification information, the strain amount acquisition unit 911 of the buffer module 950 acquires new strain amount information from the tension detection unit 70 .

After that, the tension calculation unit 912 uses the linear function indicated by the calibration information stored in the calibration information storage unit 934 to calculate the corresponding tension of the wire rod C1 from the strain amount indicated by the acquired strain amount information (step S105 ). At this time, the tension calculation unit 912 notifies the tension control value calculation unit 913 and the standard determination unit 916 of tension information indicating the calculated tension, and causes the tension storage unit 933 to store the tension information.

Next, the standard determination unit 916 compares the standard range of tension indicated by the tension standard value information stored in the standard information storage unit 932 with the magnitude of the tension indicated by the tension information notified from the tension calculation unit 912. , and determines whether or not the tension value of the wire rod C1 is within the aforementioned standard range (step S106). Here, it is assumed that the standard determination unit 916 determines that the tension value of the wire rod C1 is within the standard range (step S106: No). In this case, the tension control value calculation unit 913 compares the tension standard range indicated by the tension standard value information stored in the standard information storage unit 932 with the tension indicated by the tension information notified from the tension calculation unit 912. , the aforementioned tension control value is calculated (step S107). Then, the control value transmission section 914 transmits tension control value information indicating the tension control value calculated by the tension control value calculation section 913 to the motor driving section 22 of the winding unit 100 (step S108). Subsequently, the process of step S104 is executed again.

On the other hand, it is assumed that the standard determination unit 916 determines that the tension value of the wire rod C1 is out of the standard range (step S106: Yes). In this case, the standard determination unit 916 notifies the instruction unit 917 of out-of-standard notification information that notifies that the tension value of the wire C1 is out of the standard range. Then, the command section 917 generates stop command information for stopping the core drive motor 402 and the drum motor 21 of the core support unit 40, and transmits it to the equipment 3 (step S109). After that, the control value transmission unit 914 stops transmitting the tension control value information to the motor driving unit 22 (step S110), and the winding machine control process ends.

Next, tension monitoring processing executed by main module 910 of control unit 90 according to the present embodiment will be described with reference to FIG. This tension monitoring process is executed in parallel with the aforementioned winding machine control process. This tension management process is also started when the user operates the input device 905 to start the operation of the winding machine 1 after the winding machine 1 is powered on. First, the management information generator 918 determines whether or not a preset tension monitoring time has arrived (step S201). Here, when the management information generation unit 918 determines that the tension monitoring time has not yet arrived (step S201: No), the process of step S207, which will be described later, is executed. On the other hand, when the management information generation unit 918 determines that the tension monitoring time has come (step S201: Yes), the management information generation unit 918 acquires the tension information in the past preset management value calculation target period stored in the tension storage unit 933 ( Step S202), the average value and standard deviation of the tension values indicated by the acquired tension information are calculated (step S203).

Next, the monitoring unit 920 identifies the management range based on the average value and the standard deviation of the tension values indicated by the tension information in the past preset management value calculation target period (step S204). Subsequently, the monitoring unit 920 determines whether the latest tension value of the wire rod C1 stored in the tension storage unit 933 is outside the control range (step S205). When the monitoring unit 920 determines that the tension value of the most recent wire rod C1 is within the control range (step S205: No), the process of step S207, which will be described later, is executed. On the other hand, when the monitoring unit 920 determines that the latest tension value of the wire C1 is out of the control range (step S205: Yes), the notification unit 921 notifies that the tension value of the wire C1 is out of the control range. Notification information is generated and transmitted to the server 2 (step S206).

After that, the management information generation unit 918 determines whether or not the preset management information generation timing has arrived (step S207). Here, if the management information generation unit 918 determines that the management information generation time has not come yet (step S207: No), the process of step S201 is executed again. On the other hand, when the management information generation unit 918 determines that the management information generation time has come (step S207: Yes), it acquires the tension information from the previous management information generation time to the current time from the tension storage unit 933, and The average value, standard deviation, maximum value and minimum value of the tension applied to the wire rod C1 are calculated from the past tension values indicated by the information. Then, the management information generator 918 generates management information including information indicating the calculated average value, standard deviation, maximum value and minimum value, and stores it in the tension storage unit 933 (step S208). Next, the compression unit 922 generates compression information from the tension information stored in the tension storage unit 933 (step S209), and the transmission unit 923 transmits the generated compression information to the server 2 (step S210). Subsequently, the process of step S201 is executed again.

As described above, according to the winding machine 1 according to the present embodiment, the tension detector 70 is connected to the control unit 90 via the signal line SL1, and the information indicating the detected tension of the wire rod C1 is It is transmitted directly to the control unit 90 via the signal line SL1. Then, the control unit 90 controls the rotational speed of the drum motor 21 based on the magnitude of the tension of the wire rod C1 detected by the tension detection section 70 . As a result, the control unit 90 can acquire information indicating the tension of the wire rod C1 detected by the tension detector 70 in substantially real time, and can control the rotational speed of the drum motor 21. Therefore, the tension of the wire rod C1 can be Variation can be suppressed.

Further, according to the winding machine 1 of the present embodiment, the tension detecting section 70 detects the tension of the wire C1 between the pulley 322 of the tension bar 30 and the nozzle 80 . Then, the control unit 90 controls the rotational speed of the drum motor 21 based on the magnitude of the tension of the wire rod C1 detected by the tension detection section 70 . As a result, it is possible to accurately detect the tension applied to the wire rod C1 when the wire rod C1 is actually wound around the core Co1, so that the drum motor 21 can be accurately controlled. Therefore, it is possible to suppress variation in tension when the wire rod C1 is wound around the core Co1.

In particular, even if the core Co1 has a prismatic shape and the tension of the wire C1 is likely to fluctuate, the tension applied to the wire C1 can be detected in real time. Variation in the tension of the wire rod C1 can be suppressed during manufacturing, and the quality of the coil product can be improved.

By the way, when the distance between the load cell 732 of the tension detection unit 70 and the ADC 74 becomes longer, there is a possibility that the noise component superimposed on the analog signal output from the load cell 732 increases. Here, in order to reduce noise components, it is conceivable to provide a low-pass filter between the load cell 732 and the ADC to remove noise components with relatively high frequencies. However, in this case, when the tension of the wire C1 fluctuates in a relatively short period, there is a possibility that the tension fluctuation of the wire C1 cannot be detected with high accuracy. On the other hand, in the tension detector 70 according to the present embodiment, a load cell 732 that detects the force applied to the second roller 72 and an analog signal corresponding to the force applied to the second roller 72 output from the load cell 732 are output. ADC 74 that converts to a digital signal are collectively supported by one base 79 . As a result, the distance between the load cell 732 and the ADC 74 can be shortened, so that noise components superimposed on the analog signal output from the load cell 732 can be reduced.

The load cell 732 according to the present embodiment is a Roberval type load cell, and has a long length. 2 has a strain-generating portion 7321 fixed at a position displaced from the roller 72 in the +Z direction. As a result, the force applied to the second roller 72 can be detected with high accuracy, so that the drum motor 21 can be accurately controlled.

Further, in the control unit 90 according to the present embodiment, the standard determining section 916 determines whether or not the tension value indicating the magnitude of the tension of the wire rod C1 detected by the tension detecting section 70 is within the aforementioned standard range. When the command unit 917 determines that the tension value of the wire C1 is out of the standard range, it generates stop command information for stopping the drum motor 21 and transmits it to the equipment 3 . Thereby, it is possible to recognize that the winding machine 1 has an abnormality on the equipment 3 side.

Moreover, the management information generation unit 918 according to the present embodiment generates management information for managing the tension of the wire C1 from the tension value indicating the tension of the wire C1 detected by the tension detection unit 70 . Then, the display control unit 919 causes the display device 904 to display the generated management information.

Furthermore, the monitoring unit 920 according to the present embodiment monitors whether the tension value of the wire C1 indicated by the tension information is out of the above-described control range, and the reporting unit 921 detects whether the tension value of the wire C1 is out of the control range. When it is determined that the tension value of the wire rod C1 is out of the control range, notification information is generated to notify that the tension value of the wire rod C1 is out of the control range. As a result, the user can be notified of the occurrence of a phenomenon that is a sign of an abnormality in the winding machine 1 from the behavior of the tension value of the wire C1, so that the so-called predictive maintenance of the winding machine 1 can be performed.

Also, one control unit 90 according to the present embodiment controls a plurality of winding units 100 . As a result, centralized management of the plurality of winding units 100 can be performed by the control unit 90 alone, so that the management load of the plurality of winding units 100 can be reduced.

Although the embodiments of the present invention have been described above, the present invention is not limited to the configurations of the above-described embodiments. For example, as shown in FIG. 7, the strain-generating portion 7321 of the load cell 732 is long, and along the direction in which the first rollers 71A and 71B are arranged, the direction side toward the first rollers 71A and 71B from the core support unit 40, That is, the roller support portion 733 is fixed to one end on the +Z direction side, and the other end on the -Z direction side supports the core along the direction in which the second roller 72 and the first rollers 71A and 71B are arranged on the base 79. It may be fixed at a position shifted in the direction toward the unit 40, that is, in the -Z direction.

In the embodiment, an example has been described in which the user registers the tension standard value information and the initial tension control value information in the standard information storage unit 932 via the input device 905 . However, for example, the control unit 90 acquires the standard value information transferred from the server 2, and stores the acquired standard value information in the standard information storage unit 932 Standard value information acquisition unit (not shown) may have

In the embodiment, the monitoring unit 920 sets a value higher than the average value of the tension values of the wire C1 by an amount corresponding to three times the standard deviation as the control upper limit value, and three times the standard deviation than the average value. An example has been described in which a value lower by an amount corresponding to is set as the lower control limit value. However, not limited to this, for example, the monitoring unit 920 sets a value higher than the average value of the tension values of the wire rod C1 by the standard deviation or an amount equivalent to twice the standard deviation as the management upper limit value, Alternatively, the lower control limit may be set to a value lower by the standard deviation or an amount equivalent to twice the standard deviation.

Although the embodiments and modifications of the present invention have been described above, the present invention is not limited to these. The present invention includes appropriate combinations of the embodiments and modifications, and appropriate modifications thereof.

INDUSTRIAL APPLICABILITY The present invention is suitable for a winding machine that manufactures a coil component by winding a wire around a winding core.

1: Winding machine, 2: Server, 3: Equipment, 10: Substrate, 20: Drum, 21: Drum motor, 22: Motor drive unit, 30: Tension bar, 31: Rod unit, 32: Guide unit, 33: Biasing member 40: core support unit 70: tension detector 71A, 71B: first rollers 72: second rollers 74: ADC 79: base 90: control unit 222, 403: driver , 221: DAC, 311: rotation pin, 312, 331: fixing member, 321: holding portion, 322: pulley, 401: core support portion, 402: core drive motor, 732: load cell, 733: roller support portion , 901: CPU, 902: RAM, 903: ROM, 904: Display device, 905: Input device, 907: Storage, 908: Network interface, 909: Bus, 910: Main module, 911: Strain amount acquisition unit, 912: Tension calculation unit 913: Tension control value calculation unit 914: Control value transmission unit 915: Tension control value acquisition unit 916: Standard determination unit 917: Command unit 918: Management information generation unit 919: Display control unit , 920: monitoring unit, 921: reporting unit, 922: compression unit, 923: transmission unit, 931: strain amount buffer, 932: standard information storage unit, 933: tension storage unit, 934: calibration information storage unit, 941: display Interface 950: Buffer module 951: Input interface 961: Serial interface 962: Output interface 7321: Strain generating part 7322: Strain gauge C1: Wire rod Co1: Winding core NW1: Network SL1: Signal line

Claims (8)

a plurality of tension detection units provided in each of a plurality of winding machines for winding a wire around a winding core and detecting a physical quantity reflecting the magnitude of the tension of the wire;
a control unit that controls the rotation speed of the drum motor of each of the plurality of winding machines based on the magnitude of the tension of the wire rod detected by the tension detection unit of each of the plurality of winding machines ;
A signal line connecting the tension detection unit and the control unit,
The tension detection unit is capable of transmitting information indicating the detected tension of the wire directly to the control unit via the signal line ,
The control unit is
a buffer that temporarily stores physical quantity information indicating the physical quantity detected by each of the plurality of tension detectors;
a physical quantity information acquisition unit that distinguishes and stores the physical quantity information acquired from each of the plurality of tension detection units in the buffer;
a tension calculation unit that calculates the tension of the wire rod from the physical quantity;
A tension control value for adjusting the tension of the wire by controlling the rotational speed of the drum motor is calculated by comparing the range of the standard values of the tension of the wire with the calculated tension of the wire. a tension control value calculator;
a control value transmission unit that transmits tension control value information indicating the tension control value to a motor drive unit that drives a drum motor provided in each of the plurality of winding machines;
tension device. The physical quantity information acquisition unit acquires information indicating the tension detected by each of the plurality of tension detection units in a time period of 0.3 msec or more and 500 msec or less.
A tensioning device according to claim 1. The tension detection unit is
a pair of first rollers on which the wire rod is hooked;
It is arranged between the pair of first rollers whose rotating shafts are parallel to each other, and is movable in a direction perpendicular to the direction in which the pair of first rollers are aligned and in a direction perpendicular to the direction of the rotating shafts of the pair of rollers perpendicular to the direction in which the rollers are aligned. together with a second roller on which the wire is hooked;
a load cell that detects the force applied to the second roller;
an analog-to-digital converter that converts an analog signal corresponding to the force applied to the second roller output from the load cell into a digital signal and outputs the physical quantity that reflects the force applied to the second roller;
a base that collectively supports the pair of first rollers, the second rollers, the load cell, and the analog-to-digital conversion unit;
3. A tensioning device according to claim 1 or 2 . The tension detection unit is
a pair of first rollers on which the wire rod is hooked;
It is arranged between the pair of first rollers whose rotating shafts are parallel to each other, and is movable in a direction perpendicular to the direction in which the pair of first rollers are aligned and in a direction perpendicular to the direction of the rotating shafts of the pair of rollers perpendicular to the direction in which the rollers are aligned. together with a second roller on which the wire is hooked;
a load cell that detects the force applied to the second roller,
The load cell is
It is a Roberval type load cell,
A roller supporting portion that supports the second roller is fixed to one end of the elongated longitudinal direction, and the other end is in the direction of the arrangement of the pair of first rollers and the direction of the rotation axis of the pair of rollers on the base. a strain-generating portion fixed at a position displaced from the second roller in an orthogonal direction;
strain gauges disposed at least four locations in the strain-generating portion;
A tensioning device according to any one of claims 1 to 3 . a standard determination unit that determines whether a tension value indicating the magnitude of the tension of the wire detected by the tension detection unit is within a preset standard range;
a command unit that generates stop command information for stopping the drum motor when the standard determination unit determines that the tension value is out of the standard range;
A tensioning device according to any one of claims 1 to 4 . a monitoring unit for monitoring whether the tension value indicating the magnitude of the tension of the wire detected by the tension detection unit is out of a preset management range within the standard range;
A notification unit that generates notification information for notifying that the tension value is out of the control range when the monitoring unit determines that the tension value is out of the control range,
A tensioning device according to claim 5 . a display device;
a management information generation unit that generates management information for managing the tension of the wire from a tension value indicating the tension of the wire detected by the tension detection unit;
a display control unit that causes the display device to display the management information;
A tensioning device according to any one of claims 1 to 6 . Each of the plurality of winding machines is
a drum for feeding the wire;
a drum motor that drives the drum;
a nozzle for guiding the wire unwound from the drum to the winding core;
A long pulley is provided at one end in the longitudinal direction and the other end is rotatably supported, and the wire rod is hooked on the pulley between the drum and the nozzle. a tension bar biased in a direction in which the pulley is pressed against the wire by a biasing member;
A tensioning device according to any one of claims 1 to 7.

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