JP7447378B2 - Wire winding device and winding method - Google Patents

Description

The present invention relates to a wire winding device and a wire winding method.

In the process of manufacturing wire rods, there is a device that winds wire rods in multiple layers around a bobbin in alignment. This device can wind the wire in alignment by rotating the bobbin and guiding the wire to the winding position on the bobbin using a guide. When the wire is wound from one end of the bobbin to the other end of the bobbin, the wire moves to the upper layer and then reverses to the opposite side. By repeating this process, the wire is wound in multiple layers around the bobbin in an aligned manner. For example, Patent Document 1).
However, this device has a problem in that it cannot suppress gaps between adjacent wire rods or overlapping of wire rods due to disturbances.

Therefore, for example, in Patent Document 2, even if the bobbin end is deformed, the timing of the reciprocating movement of the bobbin is set based on images taken with a camera, thereby suppressing gaps and overlaps between the wire rods at the bobbin end. It is disclosed that it can be done.

Japanese Patent Application Publication No. 2000-86082 JP2017-206365A

However, the winding device described in Patent Document 2 cannot correct the misalignment between the winding position and the guide position due to other disturbances, such as variations in cable diameter, and as shown in FIG. There was a problem in that it was difficult to prevent the vehicle from climbing over.

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a wire rod winding device and a wire winding method that easily and reliably suppress gaps between wire rods and riding up of the wire rods.

The present invention provides a winding device for winding a wire rod in a multilayer alignment around a bobbin, comprising: a traverser that determines the winding position of the wire rod on the bobbin; a guide that guides the wire rod to the winding position; a camera that images the winding state of the wire; and a control unit that performs calculations for controlling the moving speed of the traverser based on the winding state and controls the moving speed of the traverser based on the results of the calculations. It is characterized by having the following.

Furthermore, it is preferable to have a guide displacement mechanism for changing the distance between the guide and the bobbin.

The present invention also provides a winding method for winding a wire rod in multiple layers in an aligned manner around a bobbin, including an imaging step of taking an image of the winding state of the wire rod onto the bobbin with a camera, and a movement of a traverser based on the image taken with the camera. The traverser is characterized by comprising a calculation step of performing calculation for controlling the speed, and a control step of controlling the moving speed of the traverser based on the result of the calculation.

Furthermore, in the imaging step, it is preferable that the imaging is performed at least once for each rotation of the bobbin.

According to the present invention, it is possible to provide a wire rod winding device and a wire winding method that can easily and reliably suppress gaps between wire rods and riding up of the wire rods.

FIG. 1 is a schematic diagram of a wire winding device showing a first embodiment. It is a flowchart which shows the winding method of a wire rod. It is a figure which shows typically the image of the winding state imaged with the camera. FIG. 3 is a schematic diagram showing an ideal guide position. FIG. 3 is a schematic diagram showing a guide delay. It is a schematic diagram of a wire winding device showing a second embodiment. FIG. 2 is a schematic diagram showing an example of the occurrence of gaps in the prior art.

Embodiments of the present invention will be described in detail below with reference to the drawings.

<First embodiment>
FIG. 1 is a schematic diagram of a wire winding device in a first embodiment. It includes a motor 3 that rotates the bobbin 2, a guide 6 that guides the wire 1 to a winding position, and a traverser 4 that moves the guide 6 in the axial direction of the bobbin 2 and determines the winding position of the bobbin 2 of the wire 1. Furthermore, a camera 7 takes an image of the winding state of the wire rod 1 on the bobbin 2, and calculations are performed to control the speed of the traverser 4 based on the winding state (image) taken by the camera 7, and the moving speed of the traverser 4 is It is characterized by having a control section 8 that controls.

The wire 1 is the object of this embodiment, and is wound around a bobbin 2 in multiple layers in alignment. The material of the wire 1 is not particularly limited, and for example, copper, aluminum, fiber, etc. can be used. Furthermore, the wire rod 1 may be a stranded wire, a coated wire, a flat wire, or the like.

The material of the bobbin 2 is not particularly limited, and plastic, aluminum, wood, iron, etc. can be used. Further, in this embodiment, the body 2a has flanges 2b at both ends, but a cylindrical bobbin without flanges may be used, and the shape of the body 2a may also be a triangular prism or a square prism. There may be.

The motor 3 rotates the bobbin 2 via the rotating shaft 5, and a reduction gear can be attached between the motor 3 and the rotating shaft 5 to improve the rotational force (torque).

The guide 6 is a mechanism for guiding the wire rod 1 to prevent gaps between the wire rods and to avoid running over the wire rods. The structure of the guide 6 may be a mechanism in which the cable is passed through a cylindrical member, a mechanism in which the cable is held between a plurality of rollers, or a mechanism in which the cable is held in a rod-like or plate-like member.

The traverser 4 reciprocates the guide 6 in the direction of the rotation axis of the bobbin 2, and winds up the wire 1 so that the wire 1 does not overlap while winding from one end of the bobbin 2 to the other end. As the traverser 4, a mechanism that rotates a ball screw using a motor and converts rotational motion into linear motion can be applied. This mechanism has high accuracy and can detect the current coordinates using a rotary encoder, making it suitable for this winding device.

The camera 7 is arranged so as to be able to take an image from the tangential direction of the bobbin body 2a. Thereby, the winding state of the wire 1 can be imaged, and the moving speed of the traverser 4 can be variably controlled based on the imaged data. The camera 7 may be attached to the traverser 4 together with the guide 6. In that case, it is not necessary to view the entire bobbin 2, and even when using a large bobbin, imaging with a high number of pixels is possible. As the type of camera 7, a stereo camera, a CCD camera, a CMOS camera, etc. can be applied.
Furthermore, by measuring the gap between the wires based on the captured image of the wire 1, it is also possible to rewind the wire if a gap exceeding a specified value occurs.

The control unit 8 detects the winding state of the wire 1 from the image taken by the camera 7, and controls the moving speed of the traverser 4 to move the traverser 4 to a position moved by one pitch from the winding position as shown in FIG. Controls the traverser 4. The control unit 8 can use a personal computer (PC), a programmable computer (PLC), or the like. The ideal position of the guide 6 is such that there is no deviation between the winding position and the position of the guide 6 in the bobbin axial direction, as shown in FIG.

The winding device does not move the traverser 4 at a predetermined constant speed, but moves the traverser 4 at a variable speed depending on the imaged winding state, and as shown in FIG. Even if there is variation (wire rod 1a), it is possible to suppress gaps between the wire rods.

<How to wind the wire>
Next, a method for winding a wire in this embodiment will be explained using the flowchart of FIG. 2.

S1 is a step of determining winding conditions before starting winding. The main winding conditions include the rotational speed of the bobbin 2, line tension, the moving speed and reciprocating coordinates of the traverser 4, and the set winding length.

Multilayer aligned winding is performed in S2 to S9. S2 is a step in which winding is started based on the winding conditions set in S1. The motor 3 is rotated and the wire 1 is wound onto the bobbin 2. The motor 3 rotates until the predetermined length is wound in S8.

In S3 to S6, the moving speed of the traverser 4 is adjusted based on the image captured by the camera 7. First, S3 is a step in which the camera 7 images the winding state of the wire rod 1 wound around the bobbin 2. By arranging it in the tangential direction of the bobbin body 2a, it is possible to take an image as shown in FIG.

S4 is a step of detecting the current winding position 11 from the image captured in S3. A position moved by the diameter of the wire 1 in the winding direction from the current winding position 11 becomes a position 12 to be wound next.

S5 is a step of calculating the traverser speed from the winding position 12 calculated in S4 and the current position of the traverser 4. Calculated by a personal computer (PC) or programmable computer (PLC) to reduce the traverser speed if the current position of the traverser 4 is ahead of the next position 12 to be wound, and to increase the traverser speed if it is behind. do.

S6 is a step in which the traverser 4 is controlled to perform winding at the traverser speed calculated in S5.

Note that it is preferable that the image of the winding state be captured at least once for each rotation of the bobbin 2. By doing so, it becomes possible to adjust the traverser speed in real time, and the winding can be carried out at the next winding position 12.

Further, if the winding speed is high and many gaps occur, it is preferable to delay the guide 6 with respect to the current winding position 11 as shown in FIG. In this case, the delay amount Z can be set to about 0.5 to 4 times the wire diameter, and the larger the wire diameter, the smaller the delay amount Z is. By adjusting the traverser speed based on the calculation result, it is possible to make the next winding position without any deviation or to keep the deviation constant, and it is possible to suppress gaps and riding up.

S7 is a step of calculating the length of the wire 1 wound around the bobbin 2 from the outer diameter and rotational speed of the bobbin 2. One method is to measure the number of revolutions of the bobbin 2 with an encoder attached to the motor 3, and calculate the winding length from this value. It is also possible to bring a roller into contact with the wire 1 and calculate the winding length from the rotational speed and outer diameter of the roller.

In S8, the winding length set in S1 is compared with the winding length calculated in S7, and S3 to S8 are repeated until the calculated winding length becomes the preset winding length, and the winding length set in S1 is When the winding length is reached, the process advances to S9 and the winding is finished.

<Second embodiment>
The second embodiment will be described with reference to FIG. (a) is a schematic cross-sectional view seen from the axial direction of rotation of the bobbin 2, and (b) is a view seen from the side. As shown in FIG. 6, it is preferable to further include a guide displacement mechanism 9 that can move the guide 6 to the inside of the outermost part of the bobbin collar 2b. An air cylinder, a traverser, a multi-axis robot, etc. can be applied to the guide displacement mechanism 9. By bringing the guide 6 closer to the bobbin body 2a in this manner, winding stability is improved and it is possible to further suppress gaps between wire rods and riding up. However, depending on the position of the traverser 4, the guide 6 and the bobbin collar 2b may come into contact with each other, so the position of the guide 6 is made movable in the tangential direction of the bobbin as shown in FIG. In this case, the guide 6 is moved closer to the bobbin flange 2b so that the guide 6 can escape to the outside of the bobbin flange 2b in the vicinity of the bobbin flange 2b. In particular, the distance X from the current winding position 11 to the tip of the guide 6 is made closer to 10 to 30 times the wire diameter of the wire rod 1 in the bobbin body 2a, and closer to the radius of the bobbin collar 2b in the vicinity of the bobbin collar 2b. It is best to release it so that it grows.

Although the present invention has been described above using the above embodiments, the present invention is not limited to the above embodiments. The contents can be changed within the scope that does not impair the spirit of the invention.

1 Wire rod 1a Wire rod with varying wire diameter 2 Bobbin 2a Bobbin body 2b Bobbin collar 3 Motor 4 Traverser 5 Rotating shaft 6 Guide 7 Camera 8 Control section 9 Guide displacement mechanism 10 Gap between wire rods 11 Current winding position 12 Next Winding position X Distance Z from the current winding position 11 to the tip of the guide 6 Delay amount of the guide 6 with respect to the current winding position 11

Claims (1)

A winding device that winds a wire rod in multiple layers in an aligned manner around a bobbin,
a traverser that determines the winding position of the wire on the bobbin;
a guide for guiding the wire to the winding position;
a camera that images the winding state of the wire on the bobbin;
a control unit that performs a calculation to control the moving speed of the traverser based on the winding state, and controls the moving speed of the traverser based on the result of the calculation;
has
a guide displacement mechanism for changing the distance between the guide and the bobbin in a tangential direction of the bobbin;
The guide displacement mechanism moves the guide closer to the body of the bobbin in a tangential direction of the bobbin at a position of the body of the bobbin, and moves the guide closer to the body of the bobbin in the tangential direction of the bobbin at a position of the flange of the bobbin. can be moved further away than the flange of the
A wire rod winding device characterized by: