JP7464480B2 - Winding supply device - Google Patents

Description

The present invention relates to a winding supply device that supplies windings to be wound around a stator.

Patent Document 1 discloses a winding structure that uses rectangular wire for the coil windings in the stator core of a brushless motor, thereby improving the space factor of the windings in the slots. It also discloses a configuration in which rectangular wire is used for the windings in the slots, while round wire is used at the start and end of the coil, making it easier to connect to the busbar.

JP 2013-99084 A

Windings that combine rectangular and round wires appropriately can be obtained by a molding machine that can continuously change the cross-sectional shape of the windings. In this case, for example, if the position of the round wire is misaligned, rectangular wires may end up at the beginning and end of the coil, causing inconvenience. Therefore, it is necessary to properly detect the shape of the windings.

The present invention aims to provide a winding supply device that can properly detect the cross-sectional shape of a winding.

In order to solve the above problem, one aspect of the present invention is to
A winding supply device that supplies a winding to be wound around a winding target,
a winding supply unit that continuously supplies the winding, the cross-sectional shape of which changes with respect to a supply direction of the winding to the winding target;
a change detection unit that detects a change in the cross-sectional shape of the winding supplied by the winding supply unit.

The present invention makes it possible to provide a winding supply device that can properly detect the cross-sectional shape of the winding.

1A to 1C are diagrams illustrating a coil manufacturing process using the winding supply device of the present embodiment. FIG. 2 is a perspective view showing a configuration of a molding machine. FIG. 4 is a diagram showing a winding forming sequence. FIG. 4 is a diagram showing a state of a round wire attached to a bus bar. FIG. 4 is a diagram showing the state of a rectangular wire attached to a bus bar. FIG. 2 is a diagram showing the state of a rectangular wire attached to a bus bar. FIG. 2 is a cross-sectional view showing a state in which a rectangular wire is wound around a stator core. 4 is a bottom view (viewed from the direction of line IV-IV in FIG. 5) showing the configuration of a detection mechanism of the cross-sectional shape detection device. FIG. 5 is a side view taken along line VV in FIG. 4. FIG. 4 is a side view showing a state in which the round wire is sandwiched between rollers. FIG. 4 is a diagram showing an example of the configuration of a nozzle of a swivel section. FIG. 13 is a diagram showing a state in which the nozzle is rotated in a rightward (clockwise) direction. FIG. 13 is a diagram showing a state in which the nozzle is rotated leftward (counterclockwise).

The following describes the embodiments with reference to the attached drawings.

Figure 1 shows the coil manufacturing process using the winding supply device of this embodiment, Figure 2 is a perspective view showing the configuration of the forming machine, Figure 3 is a diagram showing the winding forming sequence, Figure 3A shows the state of the round wire attached to the bus bar, Figure 3B shows the state of the rectangular wire attached to the bus bar, Figure 3C shows the state of the rectangular wire attached to the bus bar, and Figure 3D is a cross-sectional view showing the state of the rectangular wire wound around the stator core.

As shown in FIG. 1, the coil manufacturing process is configured using a forming machine 4 (an example of a winding supply unit) that processes and forms the round wire 11 sent out from the reel 10 in the direction indicated by the arrow 100 into a rectangular wire 12, a cross-sectional shape detection device 5 (an example of a change detection unit) that detects the cross-sectional shape of the round wire 11 or rectangular wire 12 sent out from the forming machine 4, a turning unit 6 located downstream of the cross-sectional shape detection device 5 that controls the circumferential direction of the rectangular wire 12, and a winding machine 7 that winds the rectangular wire 12 supplied from the turning unit 6 around a stator core (an example of a winding target). The turning unit 6 and the winding machine 7 may be configured as a single device (winding device). In addition, in this embodiment, a stator core is exemplified as a winding target, but the winding target is arbitrary and can be applied to an armature core, etc. In addition, the present invention is also applicable to the case where a coil is wound around a non-magnetic body, and the function and use of the coil are arbitrary.

The forming machine 4 continuously supplies windings whose cross-sectional shape changes with respect to the supply direction from the start of winding to the completion of winding for the coil to be attached to the stator core. The forming machine 4 also continuously changes between a first state in which it supplies rectangular wire 12 whose cross-sectional shape is rectangular, and a second state in which it supplies round wire 11 whose cross-sectional shape is circular.

As shown in FIG. 2, the molding machine 4 includes a roller pair 41 that applies a compressive force in the horizontal direction in FIG. 2 to the round wire 11 sent out from the reel 10 in the direction indicated by the arrow 100, and a roller pair 42 that applies a compressive force in the vertical direction in FIG. 2 to the winding that has passed through the roller pair 41. As shown in FIG. 3, the round wire 11 has the flat wire 12 compressed in the horizontal direction by the roller pair 41, and then the flat wire 12 is compressed in the vertical direction by the roller pair 42. The order in which the winding is compressed in the horizontal and vertical directions does not matter. In addition, a roller pair may be added and the winding may be compressed multiple times in the same direction (horizontal or vertical). Furthermore, the winding may be compressed in only one direction once or multiple times.

The distance between the roller pairs 41 and the width between the roller pairs 42 are controlled by a drive mechanism (not shown). The operation of this drive mechanism is controlled by the calculation control unit 52. The shape of the rectangular wire 12 is determined by the distance between the roller pairs 41 and the width between the roller pairs 42.

In addition, when the distance between the roller pairs 41 and 42 is the same as or larger than the diameter of the round wire 11, the round wire 11 is not deformed in the forming machine 4 and the cross-sectional shape is maintained. In this case, the round wire 11 is supplied from the forming machine 4 to the winding machine 7 via the cross-sectional shape detection device 5 and the turning unit 6.

The cross-sectional shape detection device 5 detects changes in the cross-sectional shape of the windings supplied by the molding machine 4.

The cross-sectional shape detection device 5 includes a detection mechanism 51 that detects changes in the width of the winding by pinching the winding, and a position detector 53 that detects the position of a lever 95 (described later) included in the detection mechanism 51. The width of the winding detected by the detection mechanism 51 includes both the width of the rectangular wire 12 in the horizontal direction defined by the roller pair 41 and the width of the rectangular wire 12 in the vertical direction defined by the roller pair 42.

The cross-sectional shape detection device 5 includes a calculation control unit 52 that detects changes in the cross-sectional shape of the winding (round wire 11 or rectangular wire 12) based on changes in the width of the winding detected via the detection mechanism 51. Configuration examples of the detection mechanism 51 and the position detector 53 will be described later.

As shown in FIG. 1, the calculation control unit 52 is connected to the molding machine 4, the position detector 53, the turning unit 6, and the winding machine 7, and controls the molding machine 4, the detection mechanism 51, the turning unit 6, and the winding machine 7 to operate in conjunction with one another. For example, the calculation control unit 52 can appropriately control the operation timing of the molding machine 4, the turning unit 6, and the winding machine 7 based on information from the position detector 53.

Next, we will explain the mounting state of the coil wound around the stator core.

As shown in FIG. 3A, a round wire 11 is positioned at the start and end of the coil, and the start and end of the round wire 11 are inserted into the bus bar 81. In this case, the round wire 11 has no directional shape in the circumferential direction, so there is an advantage that the start and end can be easily inserted into the bus bar 81. On the other hand, even if the start and end of the coil are made of a rectangular wire 12, it is possible to insert the start and end into the bus bar 82 as shown in FIG. 3B. However, as shown in FIG. 3C, if the winding is twisted, the circumferential orientation of the rectangular wire 12 deviates from the correct orientation, and it becomes necessary to correct the orientation when inserting the rectangular wire 12 into the bus bar 82.

In addition, by using round wire 11 at the beginning of the coil winding and at the end of the coil winding, the winding tends to deform evenly in all directions around the circumference in those areas, making it easier to pull out (handle) the winding.

In addition, when inserting the start and end ends into the busbars 81, 82, it is necessary to strip the coating of the windings. However, by constructing the start and end ends from round wire 11, there is an advantage in that the coating can be removed using conventional equipment. Also, unlike the case of stripping the coating of rectangular wire 12, there is no need to adjust the circumferential direction of the windings in the circumferential direction, and the coating can be easily stripped. This allows the number of steps (processes) to be reduced.

As shown in FIG. 3D, in the winding machine 7, the rectangular wire 12 is wound around the core body 31 to form a laminated core piece 30 (an example of a winding target). The laminated core piece 30 is a member that constitutes the stator core of a brushless motor. Specifically, the stator core is formed by connecting a plurality of laminated core pieces 30 divided in the circumferential direction in an annular shape. At both ends in the circumferential direction of the core body 31, connecting parts 32A and 32B are formed that are connected to adjacent laminated core pieces 30 by press-fitting. One connecting part 32A has a convex shape, and the other connecting part 32B has a concave shape that can receive the connecting part 32A. A tooth part 33, which is a salient pole, is integrally extended from approximately the center of the circumferential direction on the radial inner side of the core body 31 toward the radial inner side (the rotation center side) of the stator core.

A flange 34 extending in the circumferential direction is formed at the radially inner end of the teeth 33. A slot 60 for winding the rectangular wire 12 is formed around the teeth 33, surrounded by the teeth 33, the core body 31, and the flange 34. Here, the coil accommodating portion 61 in the slot 60 is located inside the imaginary line (double-dashed line 60A in FIG. 3D) connecting the circumferential end of the core body 31 and the circumferential end of the flange 34.

Two recesses 35 are formed on the outer surface of the radially inner end of the teeth portion 33, and three teeth are formed for one laminated core piece 30 by the two recesses 35. Meanwhile, the portion of the flange portion 34 facing the slot 60 is formed with a slanted wall portion (slot inner wall portion) 34A that gradually widens toward the opening of the slot 60. As a result, the slot 60 is configured so that its opening width gradually widens from the slot bottom portion 33A toward the slot 60 opening side.

An insulating member 36 is attached between the rectangular wire 12 and the core body 31. The rectangular wire 12 is wound around the teeth 33 while the insulating member 36 insulates the rectangular wire 12 that constitutes the coil from the laminated core pieces 30 (core body 31).

As shown in FIG. 3D, the rectangular wire 12 wound around the teeth 33 to form the coil is made up of multiple rectangular wires 12a, 12b, 12c, and 12d with different cross-sectional shapes. In this way, by continuously winding the rectangular wires 12 with varying cross-sectional shapes around the teeth 33, the space factor of the winding in the slot 60 can be improved. As described above, the width and thickness of the rectangular wire 12 (rectangular wires 12a, 12b, 12c, and 12d) are controlled by the spacing between the roller pairs 41 and 42 of the molding machine 4.

In FIG. 3D, the upward or downward arrows drawn vertically through the group of rectangular wires 12 wound around the teeth 33 indicate the winding order of the rectangular wires 12. For example, the rectangular wires 12 are wound in order starting from the first layer (the layer closest to the axis 37) while rotating the laminated core piece 30 (core body 31) around the axis 37. In the example of FIG. 3D, the rectangular wires 12 are laminated in five layers to form a coil, and the rectangular wires 12 are wound around the teeth 33 from top to bottom in FIG. 3D for the first, third, and fifth layers, and from bottom to top in FIG. 3D for the second and fourth layers.

Figure 4 is a bottom view showing the configuration of the detection mechanism of the cross-sectional shape detection device (viewed from the direction of line IV-IV in Figure 5), and Figure 5 is a side view seen from the direction of line V-V in Figure 4.

As shown in Figures 4 and 5, the detection mechanism 51 includes a pair of rollers 91, 92 that sandwich the winding (round wire 11 or rectangular wire 12) in the width direction, a slide member 93 to which the rollers 92 are attached, and a lever 95 that amplifies and outputs the gap between the pair of rollers 91, 92 and the change in the gap. Note that Figure 5 shows the state in which the rectangular wire 12 is sandwiched between the rollers 91, 92.

The roller 91 is rotatably attached to a fixed shaft 91A extending in the vertical direction of FIG. 5, and rotates around the axis 91x (FIG. 5) of the fixed shaft 91A. The roller 92 has an axis 92A extending in the vertical direction of FIG. 5, and is rotatably attached to a slide member 93 via the axis 92A. The roller 92 is rotatable around the axis 92x of the axis 92A. In addition, an annular groove 92b that accommodates a part of the winding (round wire 11 or rectangular wire 12) is formed on the outer periphery of the roller 92, and the position of the winding (round wire 11 or rectangular wire 12) (position in the vertical direction in FIG. 5) is regulated by the groove 92b.

The slide member 93 is slidable in the left-right direction (the direction indicated by the arrow S) in Figs. 4 and 5, and is biased to the left in Figs. 4 and 5 by a compression spring 94. The biasing force of the compression spring 94 is transmitted to the roller 92 via the shaft 92A, and the roller 92 is pressed against the roller 91, so that the distance between the rollers 91 and 92 corresponds to the width (the left-right dimension in Figs. 4 and 5) of the winding (round wire 11 or rectangular wire 12).

Figure 5A is a side view showing the state in which the round wire is sandwiched between the rollers. As shown in Figure 5A, the width (diameter) of the round wire 11 is larger than the width of the rectangular wire 12, so the distance between the rollers 91, 92 is larger than in the case of Figure 5.

As shown in Figures 4 and 5, the lever 95 is rotatably attached to a fixed shaft 95A extending in the vertical direction in Figure 4. A shaft 93A extending in the vertical direction in Figure 4 is fixed to the slide member 93, and the shaft 93A engages with the lever 95 at the tip side of the shaft 93A (the lower end side in Figure 4). As the shaft 93A engaged with the lever 95 moves (left-right movement in Figures 4 and 5), the lever 95 swings as indicated by the arrow R in Figure 5 around the axis 95x (Figure 4) of the fixed shaft 95A.

As shown in Figures 4 and 5, the position detector 53 (Figure 1) includes a number of sensors 53a, 53b, and 53c. The sensors 53a, 53b, and 53c are, for example, magnetic sensors that detect the approach of the lever 95.

The position detector 53 is also provided with a slit 53s into which the tip of the lever 95 (the left end in Figs. 4 and 5) can be inserted. The sensors 53a, 53b, and 53c each output a signal indicating whether the tip of the lever 95 is in close proximity to the respective sensor 53a, 53b, and 53c to the calculation control unit 52. These signals enable the calculation control unit 52 to detect the position of the tip of the lever 95. An optical sensor may be used as the sensor constituting the position detector 53, and the position of the tip of the lever 95 may be detected based on the position of a light beam blocked by the tip of the lever 95.

The number of sensors can be any number. For example, when detecting only whether the winding supplied between the rollers 91 and 92 is a round wire 11, it is possible to distinguish the type of winding (round wire 11 or rectangular wire 12) with only one sensor placed at an appropriate position. In addition, by increasing the number of sensors, it is possible not only to distinguish between the round wire 11 and the rectangular wire 12, but also to distinguish and detect the width (shape) of the rectangular wire 12 (e.g., 12a, 12b, 12c, 12d).

When the cross-sectional shape of the winding supplied from the molding machine 4 changes, the distance between the rollers 91 and 92, i.e., the position of the roller 92 (the left-right position in Figures 4 and 5) changes according to the cross-sectional shape of the winding. The change in the position of the roller 92 is transmitted to the shaft 93A via the slide member 93, and the position of the shaft 93A moves left-right in Figures 4 and 5.

Because the shaft 93A is engaged with the lever 95, the movement of the shaft 93A is converted into a rotation of the lever 95 around the fixed shaft 95A. At this time, the distance from the axis 95x of the fixed shaft 95A to the tip of the lever 95 is significantly larger than the distance from the axis 95x of the fixed shaft 95A to the axis 93x of the shaft 93A (Figure 4), so the change in the distance between the rollers 91 and 92 is amplified and converted into the movement of the tip of the lever 95. Therefore, by detecting the position of the tip of the lever 95, it is possible to accurately grasp the cross-sectional shape of the winding. In addition, since the cross-sectional shape of the winding and its change are detected based on the distance between the rollers 91 and 92, costs can be reduced compared to, for example, detecting the cross-sectional shape using image processing.

Figure 6 shows an example of the nozzle configuration of the swivel section. Figure 6 shows the nozzle as seen from the downstream side of the rectangular wire 12.

The turning unit 6 is equipped with a nozzle 62 that supplies the rectangular wire 12 toward the winding machine 7. This nozzle 62 is turned in the circumferential direction of the rectangular wire 12 in FIG. 6 by a turning mechanism (not shown) controlled by the calculation control unit 52. As the nozzle 62 turns, the rectangular wire 12 supplied from the nozzle 62 also turns in the circumferential direction at the same time.

Figure 6A shows the state where the nozzle is rotated in a clockwise direction, and Figure 6B shows the state where the nozzle is rotated in a counterclockwise direction. The shape of the nozzle 62 is arbitrary.

The orientation of the nozzle 62 is appropriately controlled to prevent the winding (coil) from collapsing when winding the winding (rectangular wire 12) in the winding machine 7. For example, when winding the first layer in FIG. 3D is completed and the second layer is started, the nozzle 62 can be tilted (FIG. 6A or FIG. 6B) to prevent the winding from collapsing. The same applies when moving from the second layer to the third layer, the third layer to the fourth layer, and the fourth layer to the fifth layer.

In this case, the timing to tilt the nozzle 62 can be recognized by the operating state of the rotation mechanism 71 of the winding machine 7. That is, the winding state of the winding can be managed by the rotation angle (number of rotations) of the laminated core piece 30 from the start of the winding operation, and the timing to tilt the nozzle 62 is the same. Since the rotation angle of the laminated core piece 30 is determined by the operation of the rotation mechanism 71, the calculation control unit 52 that controls the rotation mechanism 71 can grasp the winding state of the winding in real time. For example, in FIG. 3D, the first layer of the flat wire 12 is completed by rotating the laminated core piece 30 about five times after the winding of the first layer of the flat wire 12 is started, and then the second layer is started. Similarly, the second and third layers are wound about five times, the fourth layer is wound about four times, and the fifth layer is wound about twice, and the winding of each layer is completed. Therefore, the calculation and control unit 52 controls the rotation mechanism of the rotation unit 6 so as to tilt the nozzle 62 at the timing when the winding transitions to the next layer, based on the rotation angle of the laminated core piece 30 recognized via the operating state of the rotation mechanism 71.

In this embodiment, the cross-sectional shape of the winding can be detected in real time via the cross-sectional shape detection device 5, so the detection result of the cross-sectional shape of the winding can be reflected in the operation of the turning unit 6 or the winding machine 7. For example, if a winding (round wire 11 or rectangular wire 12) with a specified cross-sectional shape is not supplied from the molding machine 4 at the original timing, the operation timing of the turning unit 6 and the winding machine 7 can be adjusted to match the cross-sectional shape of the winding actually supplied from the molding machine 4. Conversely, the operation timing of the molding machine 4 can be adjusted to match the operation timing of the turning unit 6 and the winding machine 7.

When adjusting the operation timing of the turning unit 6 and the winding machine 7 to match the cross-sectional shape of the winding actually supplied from the forming machine 4, a marker for determining a predetermined winding timing (for example, the timing to start winding) may be applied to the winding itself. In this case, the cross-sectional shape of the winding supplied from the forming machine 4 can be used as the marker. For example, the part where the round wire 11 and the rectangular wire 12 are repeated a predetermined number of times (for example, once or twice) at short intervals can be used as the marker. Since the marker can be detected by the cross-sectional shape detection device 5, the turning unit 6 and the winding machine 7 can be operated with an operation timing that matches this detection timing. Therefore, it is possible to ensure that the winding operation is performed at a timing that matches the change in the cross-sectional shape of the winding supplied from the forming machine 4.

As described above, according to this embodiment, the cross-sectional shape detection device 5 can detect changes in the cross-sectional shape of the winding, so that the manufacturing process of the coil wound around the stator core (the winding target) can be managed with high precision. For example, the round wire can be reliably positioned at the start and end of the coil.

Although each embodiment has been described in detail above, it is not limited to a specific embodiment, and various modifications and changes are possible within the scope of the claims. It is also possible to combine all or some of the components of the above-mentioned embodiments.

The following additional notes are provided regarding the above examples.

[Appendix 1]
A winding supply device that supplies a winding to be wound around a winding target (30),
a winding supply unit (4) that continuously supplies a winding whose cross-sectional shape changes in the supply direction;
a change detection unit (5) that detects a change in the cross-sectional shape of the winding supplied by the winding supply unit.

According to the configuration of Appendix 1, the change detection unit detects changes in the cross-sectional shape of the winding supplied by the winding supply unit, so that the manufacturing process of the coil wound around the winding target can be managed with high precision.

[Appendix 2]
the winding supply unit continuously changes between a plurality of states including a first state in which the winding (12) having the rectangular cross-sectional shape is supplied and a second state in which the winding (11) having the circular cross-sectional shape is supplied;
2. The winding supply device according to claim 1, wherein the change detection unit detects a change between the rectangular cross-sectional shape and the circular cross-sectional shape.

The configuration of Appendix 2 makes it possible to distinguish between rectangular and circular cross-sectional shapes.

[Appendix 3]
3. The winding supply device according to claim 1, wherein the change detection unit detects a change in a width of the winding and detects a change in the cross-sectional shape of the winding based on the detected change in width.

The configuration of Appendix 3 detects changes in the width of the windings, making it possible to detect changes in the width of the windings in a simple manner.

[Appendix 4]
4. The winding supply device according to claim 3, wherein the change detection unit includes a detection mechanism (51) that is linked to a change in width of the winding by clamping the winding in a width direction.

The configuration of Appendix 4 includes a detection mechanism that detects changes in the width of the winding by clamping the winding in the width direction, making it possible to detect changes in the width of the winding at low cost.

[Appendix 5]
In the winding supply device according to claim 4,
The detection mechanism includes a pair of rollers (91, 92) that sandwich the winding in a width direction,
A lever (95) that amplifies and outputs the gap between the pair of rollers;
Equipped with
The change detection unit includes a position detector (53) that detects a position of the lever, and detects a change in width of the winding based on the position of the lever detected by the position detector.

According to the configuration of Appendix 5, a lever is provided that amplifies and outputs the gap between a pair of rollers, and the change in the width of the winding is detected based on the position of the lever detected by the position detector, so that the gap between the rollers can be detected with high accuracy.

[Appendix 6]
In the winding supply device according to any one of Supplementary Note 1 to Supplementary Note 5,
A winding portion (6) that winds the winding in a circumferential direction,
The winding supply device, wherein the turning unit is located upstream of a winding machine (7) that winds the winding around the winding target and downstream of the change detection unit.

According to the configuration of Supplementary Note 6, a turning section is provided that turns the winding in the circumferential direction, which can prevent the winding from becoming unwound.

4 Molding machine 5 Cross-sectional shape detection device 6 Swivel section 7 Winding machine 11 Round wire 12 Rectangular wire 53 Position detector 91 Roller 92 Roller 95 Lever

Claims (4)

A winding supply device that supplies a winding to be wound around a winding target,
a winding supply unit that continuously supplies the winding, the cross-sectional shape of which changes with respect to a supply direction of the winding to the winding target;
a change detection unit that detects a change in the cross-sectional shape of the winding supplied by the winding supply unit ,
the change detection unit includes a detection mechanism that is linked to a change in width of the winding by sandwiching the winding in a width direction,
The change detection unit detects a change in width of the winding, and detects a change in the cross-sectional shape of the winding based on the detected change in width . the winding wire supply unit continuously changes between a plurality of states including a first state in which the cross-sectional shape of the winding wire is rectangular and a second state in which the cross-sectional shape of the winding wire is circular;
The winding wire supply device according to claim 1 , wherein the change detection unit detects a change between the rectangular cross-sectional shape and the circular cross-sectional shape. 2. The winding supply device according to claim 1 ,
The detection mechanism includes a pair of rollers that sandwich the winding in a width direction;
a lever that amplifies and outputs the gap between the pair of rollers;
Equipped with
The change detection unit includes a position detector that detects a position of the lever, and detects a change in width of the winding based on the position of the lever detected by the position detector. The winding supply device according to any one of claims 1 to 3 ,
A winding portion is provided for winding the winding in a circumferential direction,
The winding supply device, wherein the turning unit is located upstream of a winding machine that winds the winding around the winding target and downstream of the change detection unit.