JPH08124777A - Method and apparatus for detecting winding irregularity of coil - Google Patents

Abstract

PURPOSE: To provide a method and an apparatus for detecting winding irregularity of a coil which can detect the generation of winding irregularity while the coil is wound by a winding machine. CONSTITUTION: In a coil winding machine, a wire 30 passing a nozzle 41 of a wire feeding equipment 31 is wound around a bobbin 21, by rotating the bobbin 21 around an center axis line and by reciprocating the bobbin 21 or the nozzle 41 in the center axis line direction. The number of wound layers of the wire 30 on the bobbin is obtained from the number of reciprocation movements of the bobbin 21 or the nozzle 41. On the basis of the number of the wound layers, a reference wound diameter when the wire of the number of wound layers is normally wound in multilayer on the bobbin is calculated. The real outer diameter of a coil is measured with an outer diameter sensor 51 which detects the outer peripheral position of the wire wound around the bobbin 21. When the difference between the real outer diameter of the coil and the reference wound outer diameter becomes larger than a specific value, it is judged for the winding irregularity to be generated.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a winding machine used for manufacturing an electromagnetic coil or the like by winding a wire on a bobbin, and relates to a method and a detecting device for detecting the winding unevenness of the coil generated in the winding. .

[0002]

2. Description of the Related Art In general, a winding machine used for winding a wire around a bobbin to manufacture a coil includes rotating the bobbin around a central axis and supplying the wire to the bobbin or the bobbin. A winding machine of the type in which a wire rod passing through the nozzle is wound around the bobbin while reciprocally driving the nozzle of the apparatus in the direction of the central axis of the bobbin is used.

[0003]

By the way, the coil used for ignition of the engine is also wound by the above-mentioned winding machine. This coil has a wire rod with a diameter of 0.2 mm or less and is extremely thin, and has a bobbin cross section. Since the wire rod has a square shape and the wire rod speed fluctuates, the wire rod 30 wound around the bobbin 21 at high speed is easily bent and uneven winding is likely to occur as shown in FIG. If this winding unevenness occurs, there is a great risk of causing a short circuit inside the laminated body of the wire material, and the outer diameter of the coil becomes large, causing interference with other parts and insufficient insulation due to the narrowing of the potting space of the insulating resin. Although there are many problems such as occurrence, the conventional winding machine is not provided with a device for detecting winding unevenness, so that a defective product in which winding unevenness has occurred cannot be discriminated. In the figure, 21c is the central axis of the bobbin, 4
Reference numeral 1 is a nozzle for supplying a wire rod.

The present invention solves the above-mentioned problems of the prior art, and it is an object of the present invention to provide a coil winding unevenness detecting method and device capable of detecting the occurrence of winding unevenness during winding of a coil by a winding machine. is there.

[0005]

A coil winding unevenness detecting method according to the present invention is characterized in that the bobbin is rotationally driven around a central axis and the nozzle of the bobbin or a wire rod supplying device for supplying a wire rod to the bobbin is In a coil winding machine that reciprocally drives in the direction of the central axis of the bobbin to wind the wire passing through the nozzle on the bobbin, the number of winding layers on the bobbin of the wire is obtained from the number of reciprocations of the bobbin or the nozzle, and the winding layer Based on the number, the standard winding outer diameter when the wire rod having the number of winding layers is normally wound and laminated on the bobbin is calculated, and the outer peripheral position of the wire rod wound on the bobbin during winding of the wire rod is calculated. The actual outer diameter of the coil is measured by a sensor for detecting, and when the difference between the actual outer diameter of the coil and the standard winding outer diameter exceeds a predetermined value, it is determined that winding unevenness has occurred.

Further, the coil winding unevenness detecting device of the present invention rotates and drives the bobbin around the central axis, and the bobbin or the nozzle of the wire rod supplying device for supplying the wire rod to the bobbin is connected to the bobbin in the direction of the central axis of the bobbin. In a coil winding machine that reciprocally drives to wind a wire passing through the nozzle around the bobbin, the number of winding layers that counts the number of reciprocations of the bobbin or the nozzle and outputs the number of winding layers of the wire on the bobbin. A counting means, a means for calculating the wire rod outer diameter when the wire rod of this number of winding layers is normally wound and laminated on the bobbin and outputting it as a standard winding outer diameter, and the bobbin during winding the wire rod. Outer diameter measuring means for detecting the outer circumference position of the wound wire and outputting the actual outer diameter of the coil, and winding unevenness when the difference between the actual outer diameter of the coil and the standard outer diameter of the coil is larger than a predetermined value. Output generated signal Characterized by comprising a that means.

In the coil winding unevenness detecting apparatus of the present invention, the winding layer number counting means detects the position in the reciprocating direction of the bobbin or the nozzle which is reciprocally driven by the reciprocating driving device of the winding machine and outputs a position signal. Position measuring means for outputting,
This position signal is compared with the position of a predetermined turning point of the bobbin or nozzle, and when the bobbin or nozzle reaches the turning point, a turn-back command is issued to the reciprocating drive device and the number of winding layers is reduced by one. If it is configured with a means for adding and outputting as a new number of winding layers, one device can be used for both counting the number of winding layers and outputting the folding command, so that the device can be simplified and the accuracy of the position measuring means can be improved. With this, the bobbin or nozzle can be turned back at an accurate position while being measured, and windings can be prevented from being concentrated and stacked around the collar of the bobbin to cause winding unevenness. , Particularly preferred.

[0008]

In the present invention, while the wire is wound on the bobbin by the coil winding machine, the measured value of the actual outer diameter of the coil of the wire wound on the bobbin and the wire having the number of winding layers during the winding are Compare the standard winding outer diameter when it is normally wound and laminated on the bobbin, and if the difference between the two is greater than the specified value, it is determined that winding unevenness has occurred. The occurrence of uneven winding can be detected.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT An embodiment of the present invention will be described below with reference to FIGS. In FIG. 1, 1 is a coil winding machine,
Reference numeral 2 is a frame mounted and fixed on a foundation, and 3 is a carriage supported by the frame 2 so as to be capable of reciprocating in the horizontal X-axis direction. A guide rod 5 having a fixed base portion is slidably fitted to the frame 2, and the carriage 3 is supported by the guide rod. Reference numeral 6 is a motor for reciprocating the carriage 3, and the frame 2
The screw rod 7 attached to the output shaft is screwed into the screw block 8 for attachment to the carriage 3, and the carriage 3 is reciprocally driven by forward and reverse rotation of the motor 6. Reference numeral 9 is a motor control device for starting, stopping, and setting the speed of the motor 6.

A spindle 12 having a rotation center axis 11 extending in the X-axis direction is rotatably supported by a bearing on the carriage 3, and is rotated in a direction indicated by an arrow Q by a motor 13 attached to the carriage 3. Driven. Reference numeral 14 is a motor control device for starting, stopping, and setting the speed of the motor 13. Reference numeral 15 is a rotation angle sensor for measuring the rotation angle of the motor 13, that is, the rotation angle of the bobbin 21 to which the wire rod 30 is wound. The bobbin 21 has a rectangular (rectangular) cross section as shown in FIG. 5, and has four winding points W _{1 to} W ₄ as shown in FIG. 25 is the spindle 1
The bobbin 21 is detachably attached to the attachment jig 25.

Reference numeral 22 denotes a terminal provided at one end of the bobbin 21, and the wire rod 30 wound around the terminal 22 passes through the notch 23 provided at the flange portion 21a of the bobbin 21 and inside the winding portion W ₁ . And is wound around the winding point W ₁ and then introduced into the winding point W ₂ through a notch (not shown) provided in the collar of the bobbin between the adjacent winding points W _2. Then, the winding is performed at the winding point W ₂ , and similarly, after the winding is sequentially performed at the winding points W ₃ and W ₄ , the wire rod 30 is wound around the terminal (not shown) at the other end of the bobbin 21. Although the winding of one bobbin 21 is completed, the following description of the winding and the winding unevenness detection process will be given for the winding at the winding point W ₁ .

On the other hand, 31 is a wire rod supply device for the wire rod drum 3
The wire rod 30 wound around the wire 2 passes through guides 33 and 34 (not shown for the mounting structure), tensioning devices 35 and 36, and guide rollers 37 and 38 attached to the frame 2 and a vertically downward nozzle. It is supplied to the bobbin 21 through 41.
The nozzle 41 is fixedly attached to the nozzle holder-42, and the nozzle holder-42 is fixed to a support rod 43 extending in the horizontal direction. Both ends of the support rod 43 are supported by the frame 2 via a three-axis driving device (not shown), and can be linearly moved in the Y-axis and Z-axis directions perpendicular to the X-axis shown in FIG. 1 and can be rotated about the Y-axis. Nozzle 4 as shown in the figure
The frame 1 is fixed to the frame 2 with the frame 1 facing downward in the Z-axis direction. When the wire 30 is wound around the terminal 22 by other means, the support rod 43 may be always fixed to the frame 2.

Reference numeral 51 is a wire rod 30 wound around the bobbin 21.
This is an outer diameter sensor composed of a laser displacement sensor for detecting the outer peripheral position of the bobbin 21. In this embodiment, a vertically upward laser beam 52 is directed toward the central axis 21c of the bobbin 21, as shown in FIG. In addition, the outer diameter sensor 51 is disposed substantially opposite to the nozzle 41 (specifically, at a position eccentric by 1/2 of the major diameter U of the bobbin 21), and is attached to the support rod 43 on a substantially L-shaped bracket 53. It is fixedly installed. And Ray
The center of the beam 52 passes through the nozzle 41 and the bobbin 21.
The nozzle 41 and the outer diameter sensor 51 are set at substantially the same position in the X-axis direction so that the wire 30 wound on the upper side is irradiated. The spot diameter (irradiation diameter) of the laser beam 52 is preferably about the same as the wire diameter d of the wire 30 as shown in FIG.

Reference numeral 55 is a position sensor composed of a laser displacement sensor which is a position measuring means of the bobbin 21 in the X-axis direction. The position sensor is mounted on the carriage 3 and faces the X-axis direction. The front surface (fixed surface) 2a of the frame 2 is irradiated with 56 to position the carriage 3 with respect to the front surface 2a, that is, the bobbin 21.
Is measured in the X-axis direction. When the bobbin 21 before the winding of the wire 30 is irradiated with the laser beam 52 of the outer diameter sensor 51 on the bobbin 21, the carriage 6 is moved in the X-axis direction by the motor 6. As shown in FIG. 2, the laser beam 52 has a collar portion 2 on both sides of the winding portion W _1.
When reaching 1a and 21b, the output of the outer diameter sensor 51 changes greatly with respect to the output of the position sensor 55. As the position of this change point, the coil winding start position L ₁ and coil end position L ₂
Is calculated (as the output value of the position sensor 55), it is stored in the memory of the microcomputer 58 and is used for bobbin folding back and counting the number of winding layers at the time of executing the routine of winding and winding unevenness detection described later. It is supposed to do.

Further, the bobbin 21 in this embodiment has a rectangular shape, and the rotation of the bobbin 21 about the central axis 21c changes the outer radius r of the bobbin 21 shown in FIG. Rotation angle θ
The value of the outer radius r with respect to the rotation angle θ from the reference position of = 0 (in this embodiment, a vertical line passing through the central portion of the lower side of the bobbin 21 in the reference state in which the long diameter portion is laterally shown in FIG. 5A) is Remember it in the form of a number table. This numerical table can be obtained by a polar coordinate calculation formula, but the bobbin 21 is rotated once by the motor 13 and the bobbin outer peripheral position measurement value by the outer diameter sensor 51 is stored in correspondence with θ for each minute angle Δθ. It can be created.

Then, r (θ) which is a function of this rotation angle θ
Based on the equation (1), the micro computer 58 uses the standard winding which is the outer peripheral diameter of the wire 30 (diameter = d) when the wire M layer is normally wound on the bobbin 21 by the following formula (1). The external diameter Dm is provided with a computing unit for computing the layer number output M of the winding layer number counter and the rotation angle output θ of the rotation angle sensor 15.

Dm = 2r (θ) + (2-√3 + √3 × M) × d (1)

The above equation (1) is created based on the dimensional relationship of FIG. 4, but since the diameter d of the wire rod is used as the cross-sectional dimension of the wire rod 30, when the bobbin 21 has a cylindrical shape. Except that, in the present embodiment, θ = 0, 9
It is an accurate formula when 0,180,270.

Next, a process of detecting winding and unevenness of winding of the coil by using the apparatus having the above-mentioned structure will be described. First, before starting winding, the wire rod 3 from the wire rod feeder 31
The tip end of No. 0 is wound around the terminal 22 of the bobbin 21 mounted on the mounting jig 25. This may be performed by a device such as a manipulator (not shown), or is generally performed by a winding machine. In addition, the support rod 43 in FIG.
And in the Z-axis direction and rotated by 90 ° in the direction of the arrow P, and in cooperation with the movement of the carriage 3 in the X-axis direction by the motor 6, the nozzle 41 positioned near the terminal 22 is moved. It may be performed by turning around the terminal 22. Wire rod 30 after being wound around the terminal 22
Is introduced into the winding portion W ₁ from the introduction point 26 (see FIG. 5) through the notch 23, and the bobbin 21 and the wire rod 30 are removed.
As the reference state of (A), the winding preparation is completed.

Hereinafter, the steps after the preparation of the winding (mainly the routine executed by the microcomputer 58).
Will be described with reference to the flowcharts of FIGS. 6 and 7. When a process start command is given, the winding layer number counter of the microcomputer 58 is reset and the number of winding layers is M = 1.
Is set (step 61), and the computing unit of the microcomputer 58 calculates the standard winding outer diameter Dm in the state in which the wire material of the first layer is wound by the equation (1) (step 62).
Then, by driving the carriage 3 and measuring the outer peripheral position of the bobbin before winding by the position sensor 55, the position shown in FIG.
From the relationship of the output of each sensor shown in
₁ and the winding end position L ₂ are measured and stored (step 6
3), the bobbin 21 is rotated by the motor 13 in the direction of arrow Q to start winding (step 64).

After the start of winding, the bobbin position L is measured by the position sensor 55 (step 65) and compared with the winding start position L ₁ and the winding end position L ₂ (step 6).
6) If it is in the intermediate value between the two, it means that the winding is in the same winding layer. Also when the output value of the position sensor 55 becomes L ₁ or L ₂ is, microcomputer - motor 58 motor - the motor controller 9 outputs a bobbin folded signal (step 67), the winding of the wound layer number counter One is added to the number of layers M (step 68), and the standard winding outer diameter Dm is calculated for this new M by the equation (1) (step 69).

In step 71, the outer diameter sensor 51 measures the outer diameter D of the wire wound on the bobbin 21 being wound on the M layer (step 71), and the rotation angle sensor 15 winds the bobbin 21. The rotation angle θ from the attached reference position is measured (step 72), and the standard winding outer diameter Dm calculated by the equation (1) based on the bobbin outer peripheral radius r (θ) corresponding to this θ and the outer periphery. Difference from diameter D ΔD
Is determined by the following equation (2) to determine whether or not it exceeds twice (diameter converted value) the allowable winding unevenness stacking dimension Sn (see FIG. 4) corresponding to a predetermined allowable winding unevenness layer number n (step 73). When it exceeds, it is determined that the winding irregularity exceeds the allowable value and the defective winding product is generated (step 78), and an alarm command is issued to an alarm device (not shown) or a stop command is issued to the coil winding machine 1. And informs about the occurrence of defective products.

ΔD = | D−Dm |> 2Sn = √3 × d × n (2)

In the above equation (2), n is a limit number of layers of winding unevenness (upper limit value) which is permissible for the standard winding state (without causing insulation breakdown or other problems), and the applied voltage to the coil and the magnetic flux density. It depends on the thickness of the insulation coating of the wire and other conditions, and is determined based on actual usage and experiments according to the coil specifications.
In the case of the engine ignition coil having 0.050 mm and the total number of winding layers = 60 layers, n = 9 layers.

On the other hand, when ΔD is less than the allowable value, the total rotation angle Σθ of the bobbin 21 from the start of winding is measured as the integrated value of the rotation angle of the rotation angle sensor 15 (step 74),
This is divided by 360 ° to obtain the coil winding number N (step 75), and this is compared with a predetermined total winding number Nt defined in the coil specifications (step 76) to determine the total winding number. If it is less than Nt, the process is returned to step 65 and the above steps are repeated until the number of windings is N without any defective product (step 78).
When it reaches Nt, it is judged that a good coil is completed (step 77), and the winding at the winding point W ₁ of the bobbin 21 is completed. At the other winding points W _{2 to} W ₄ ,
Winding and winding unevenness can be detected in the same process.

The above steps 65 to 76 can be repeated at a predetermined short time interval (for example, 0.1 to 0.2 ms) in response to a command from the microcomputer 58, whereby uneven winding occurs in the winding. The occurrence of can be reliably detected.

The present invention is not limited to the above embodiment, and for example, the outer diameter sensor 51 and the position sensor 55.
Other types of non-contact or contact type sensors may be used, and the position sensor 55 may be a sensor that directly detects the position of the bobbin 21 in the X-axis direction. Further, the position sensor 55 (may be of another type) may be used exclusively for counting the number of winding layers, and the bobbin or nozzle turnback command may be issued by other means. Further, the outer diameter sensor 51 may be provided at an arrangement position other than the above-mentioned embodiment as long as it is a position that can detect the outer peripheral position of the wire after being wound around the bobbin.

In order to determine the occurrence of winding unevenness, instead of using the equation (2), the number of winding unevenness-generating layers (lower limit value) that is unacceptable for the standard winding state (dielectric breakdown etc. occurs) n
Alternatively, the determination may be made based on the following equation (2 ').

ΔD = | D−Dm | ≧ √3 × d × n (2 ′)

In addition to the coil winding machine 1 of the type in which the bobbin is reciprocally driven in the direction of the central axis, the present invention also reciprocally drives a nozzle for supplying a wire rod in the direction of the central axis of the bobbin to pass the nozzle. Can also be applied to a case where a coil winding machine of the type in which a coil is wound around a bobbin that is rotationally driven at a fixed position is used. Further, the bobbin may have a circular cross section, and in this case, the bobbin outer diameter 2r in the above formula (1) is
(Θ) has a constant value, and the standard winding outer diameter Dm can be easily calculated.

[0031]

As described above, according to the present invention,
The occurrence of winding irregularity can be detected during winding of the coil by the winding machine, and it is possible to prevent the occurrence of short circuit or other accidents or failures due to the use of the defective coil having irregular winding.
This contributes to improving the quality of the coil.

[Brief description of drawings]

FIG. 1 is a device layout view of a winding unevenness detection device according to an embodiment of the present invention.

FIG. 2 is a diagram showing a relationship between outputs of a position sensor and an outer diameter sensor in the apparatus of FIG.

3 is a schematic longitudinal sectional view showing a normal winding state during winding of the wire rod in the apparatus of FIG.

FIG. 4 is a schematic vertical cross-sectional view showing a winding unevenness generation state during winding of the wire rod in the apparatus of FIG.

5 is a cross-sectional view (cross section perpendicular to the central axis) of the bobbin in the apparatus of FIG. 1, FIG. 5 (a) is a reference state at the start of winding the bobbin, and FIG. 5 (b) is after the start of winding. The state of being rotated by an angle θ is shown.

FIG. 6 is a flowchart showing an operation process of the apparatus of FIG.

FIG. 7 is a flowchart showing an operation process of the apparatus of FIG.

FIG. 8 is a cross section of a bobbin showing a behavior of a wire rod when wound by a general coil winding machine (a cross section perpendicular to a central axis line).
FIG.

[Explanation of symbols]

1 ... Coil winding machine, 2 ... Frame, 3 ... Reciprocating carriage, 6 ... Motor, 9 ... Motor control device, 12 ... Spindle, 13 ...
Motor, 14 ... Motor control device, 21 ... Bobbin, 21c
... central axis line, 25 ... mounting jig, 30 ... wire rod, 31 ... wire rod feeding device, 41 ... nozzle, 43 ... support rod, 51 ... outer diameter sensor, 53 ... bracket, 55 ... position sensor, 58 ... micro computer .

Claims (3)

[Claims] 1. A bobbin is driven to rotate about a central axis, and a nozzle of the bobbin or a wire rod supply device for supplying a wire rod to the bobbin is reciprocally driven in the central axis direction of the bobbin to pass through the nozzle. In a coil winding machine that winds a wire on the bobbin, the number of winding layers on the bobbin of the wire is obtained from the number of reciprocations of the bobbin or nozzle, and the number of winding layers is normally based on the number of winding layers. The actual outer diameter of the coil is measured by a sensor that calculates the standard outer diameter of the wire wound on the bobbin and detects the outer peripheral position of the wire wound on the bobbin during winding of the wire. A winding unevenness detection method for a coil, comprising: determining that winding unevenness has occurred when a difference between an outer diameter and the standard winding outer diameter exceeds a predetermined value. 2. A bobbin is driven to rotate about a central axis, and the bobbin or a nozzle of a wire rod supply device for supplying a wire rod to the bobbin is reciprocally driven in the central axis direction of the bobbin to pass through the nozzle. In a coil winding machine for winding a wire rod on the bobbin, a winding layer number counting means for counting the number of reciprocations of the bobbin or the nozzle and outputting the number of winding layers on the bobbin, and a wire rod having this winding layer number. Means for calculating the outer diameter of the wire when it is normally wound and laminated on the bobbin and outputting it as the standard outer diameter of the wire, and detecting the outer peripheral position of the wire wound on the bobbin while winding the wire. And an outer diameter measuring means for outputting the actual outer diameter of the coil, and means for outputting a winding unevenness generation signal when the difference between the actual outer diameter of the coil and the standard winding outer diameter exceeds a predetermined value. Coil characterized by Uneven winding detection device. 3. A position measuring means for detecting the position of the bobbin or the nozzle reciprocally driven by a reciprocating drive device of the winding machine in a reciprocating direction, and a position measuring means for outputting the position signal, and this position. A signal is compared with the position of a predetermined turning point of the bobbin or nozzle, and when the bobbin or nozzle reaches the turning point, a turn-back command is issued to the reciprocating drive device and the number of winding layers is incremented by one. 3. A coil winding nonuniformity detection device according to claim 2, further comprising means for outputting as a new number of winding layers.