JP3539626B2

JP3539626B2 - Method of manufacturing spiral roller plate and method of manufacturing spiral roller plate

Info

Publication number: JP3539626B2
Application number: JP22358899A
Authority: JP
Inventors: 勝己長坂; 正裕浅野; 外志彦藤本; 克己松本; 勝義白石; 隆鴇澤
Original assignee: Denso Corp
Current assignee: Denso Corp
Priority date: 1999-08-06
Filing date: 1999-08-06
Publication date: 2004-07-07
Anticipated expiration: 2019-08-06
Also published as: JP2001054261A

Description

【０００１】
【産業上の利用分野】
本発明は、成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置に関する。本発明はたとえば電磁鋼帯をその主面を重ねて螺旋状に巻き取ることにより回転電機のステ−タコアやロ−タコアを形成する場合に適用できる。
【０００２】
【従来の技術】
特公昭３８ー７４０２号公報は、両外周面が所定の楔状隙間を有して対面する姿勢で一対の切頭円錐ロ−ラ（以下、単にテーパローラともいう）を設け、電磁鋼帯を上記楔状隙間に挿通して塑性加工することにより、電磁鋼帯の一側面側に湾曲する螺旋輪板を作成し、この螺旋輪板を主面が重なるように積み重ねてステ−タコアを作製することを提案している。以下、このように楔状隙間を挟んで配置された成形ロ−ラ対を用いた帯状金属板の塑性加工により螺旋輪板を作製する製造方法を、以下、成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置というものとする。
【０００３】
【発明が解決しようとする課題】
しかしながら、上記した公報の成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置では、成形ロ−ラ対で塑性変形された電磁鋼帯は、その自重に任せて自在に積み重ねられるだけであるので、成形ロ−ラ対による塑性変形加工後、螺旋輪板の各タ−ンの位置合わせを行い、厚さ方向に一体化して円筒コアとする作業が容易でなかった。
【０００４】
このため、本発明者らは、成形ロ−ラ対からでた螺旋輪板を成形ロ−ラ対と同期回転する巻き取りドラムで巻き取ることにより、成形ロ−ラ対による塑性変形加工完了とほぼ同時に、円筒コア形成を完了することを考えた。
【０００５】
ところが、この巻き取りドラムによる螺旋輪板巻き取りを行う成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置では、生産性向上などのために成形ロ−ラ対の回転数を変更する場合、電磁鋼帯の塑性変形精度が低下するという問題があった。
【０００６】
本発明は、上記問題点に鑑みなされたものであり、成形ロ−ラ（又は巻き取りドラム）の回転数変更にかかわらず良好な品質を確保できる成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置を提供することを、その解決すべき課題としている。
【０００７】
【課題を解決するための手段】
上記課題を解決するために、請求項１記載の成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置では、塑性変形用の楔状隙間を挟んで対面配置された一対の成形ロ−ラの回転により帯状体を一側面側に湾曲させた後、成形ロ−ラ対から出た湾曲済みの帯状体を巻き取りドラムに巻き取る製造工程を採用する。
【０００８】
本構成では特に、成形ロ−ラ又は巻き取りドラムの回転数変化に応じて成形ローラが帯状体を押圧する押圧力を変更することを特徴とするので、成形ロ−ラ（又は巻き取りドラム）の回転数変更にかかわらず良好な品質を確保できる。なお、成形ロ−ラの回転数が増加すれば当然、巻き取りドラムの回転数も増大するのは当然である。また、成形ロ−ラ対の回転はその一方だけをモ−タ駆動してもよく、その両方をモ−タ駆動してもよい。以下、モ−タ駆動される成形ロ−ラを駆動ロ−ラと呼び、モ−タ駆動されない成形ロ−ラを従動ロ−ラと呼ぶこともある。本明細書でいう成形ロ−ラ対の回転数とは駆動ロ−ラの回転数をいう。
【０００９】
以下、更に詳しく説明する。
【００１０】
本発明者らは、成形ロ−ラ対により帯状体を塑性変形加工して螺旋輪板を製造する場合において、生産性向上のために帯状体送り速度を向上するべく成形ロ−ラ（および巻き取りドラム）の回転数を増大させると、帯状体の塑性変形精度が微妙に悪化することに気がついた。この原因を追求したところ次の問題が生じていることを見いだした。
【００１１】
巻き取りドラムは、円筒コア作製のために成形ロ−ラから出た塑性変形済みの帯状体を所定の引っ張り力で巻き取っていく。成形ロ−ラ対からでた帯状体は所定曲率に湾曲しており、巻き取りドラムはこの湾曲した帯状体の略接線方向へ引っ張り、湾曲した帯状体はその湾曲した方向に移動し、この移動は略旋回運動となる。
【００１２】
この状態で、成形ロ−ラの回転数変化に応じて巻き取りドラムの回転数が変化すると、これは帯状体の接線方向（螺旋輪板の）への帯状体の速度変化を招き、この速度変化により帯状体の旋回質量に作用する遠心力の変化を招く。この帯状体の遠心力変化は、楔状隙間における駆動ロ−ラの略軸方向に作用するため、結局、楔状隙間の帯状体に楔状隙間の狭い側から広い側に向けて作用する力が変動する。
【００１３】
この力の変動は、楔状隙間における帯状体の軸方向位置を変動させることになるため、成形ロ−ラ対の帯状体加工具合（特にその曲率）が変わり、これにより帯状体塑性変形精度の低下が生じる。
【００１４】
すなわち、帯状体に作用する遠心力変動により、楔状隙間における帯状体位置が変化し、これにより帯状体の塑性変形後の厚さに相当する帯状体位置における楔状隙間の幅が変動してしまう。巻き取りドラムが成形ロ−ラ対の軸心と直角方向へ帯状体を引っ張れば上記分力は解消するが、楔状隙間から出る帯状体は帯状体の一側寄りに所定曲率で湾曲しているためにどうしてもその略接線方向へ引っ張らざるを得ない。
【００１５】
そこで、本発明の螺旋輪板製造装置では、成形ロ−ラ又は巻き取りドラムの回転数変化に応じて、楔状隙間の帯状体に対する成形ロ−ラの押圧力を変更することにより、上記回転数変化による帯状体の遠心力変化による影響を相殺する。このようにすれば、帯状体成形加工速度の変更にかかわらず上記遠心力変動問題に対する塑性変形精度の低下を防止することができる。
【００１６】
請求項２記載の構成によれば請求項１記載の成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置において更に、巻き取りドラム又は駆動ロ−ラの回転数と前記押圧力との最適な関係を記憶し、回転数を変更する場合にこの関係に基づいて前記押圧力を自動変更するので、簡単な工程で塑性変形精度の向上を図ることができる。
【００１７】
請求項３記載の構成によれば請求項１又は２記載の成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置において更に、押圧力を、成形ロ−ラ又は巻き取りドラムの回転数変化に正の相関を有する関係に基づいて変更するので一層、塑性変形精度を向上することができる。
【００１８】
上記遠心力は帯状体の送り速度すなわち巻き取りドラムの回転数にほぼ比例するので、巻き取りドラムや成形ロ−ラの回転数変化に正の相関を有する関係にしたがって成形ロ−ラの帯状体への押圧力を変化させることにより帯状体を安定した形状へ塑性変形加工することができる。
【００１９】
請求項４記載の構成によれば請求項３記載の成形ロ−ラ対式螺旋輪板製造方法及び螺旋輪板製造装置において更に、前記関係は、正比例関係とされるので、制御に複雑なマップなどを必要とせず、簡単な工程、構成で良好な塑性変形精度を実現することができる。
【００２０】
上記課題を解決するために、請求項５記載の螺旋輪板製造装置では、成形ロ−ラ対の駆動ロ−ラ（モータ駆動される成形ロ−ラ）と、巻き取りドラムとを別個に回転数制御（トルク制御を含む）可能に配置し、これら駆動ロ−ラを駆動するロ−ラ駆動モ−タとを回転させて、帯状体を塑性変形させて螺旋輪板を形成し、同時にドラムに巻き取る。成形ロ−ラ対は、上記駆動ロ−ラに対して楔状隙間を挟んで近接配置される従動ロ−ラを有し、従動ロ−ラはモ−タ駆動されなくてもよい。
【００２１】
本構成では特に、この従動ロ−ラを帯状体を挟んで駆動ロ−ラに向けて所定の押圧力で押圧するロ−ラ押圧機構を設け、更に、このロ−ラ押圧機構は、従動ロ−ラを帯状体を介して駆動ロ−ラに押し付ける押圧力を前記成形ロ−ラ又は前記巻き取りドラムの回転数変化に応じて調整可能な機構を有している。
【００２２】
このようにすれば、成形ロ−ラの回転数変更にもかかわらず帯状体の塑性変形加工精度を高精度に保つことが可能な螺旋輪板製造装置を実現することができる。
【００２３】
以下、更に詳しく説明する。
【００２４】
本発明者らは、成形ロ−ラ対により帯状体を塑性変形加工して螺旋輪板を製造する場合において、生産性向上のために帯状体送り速度を向上するべく成形ロ−ラ（および巻き取りドラム）の回転数を増大させると、帯状体の塑性変形精度が微妙に悪化することに気がついた。この原因を追求したところ次の問題が生じていることを見いだした。
【００２５】
巻き取りドラムは、円筒コア作製のために成形ロ−ラから出た塑性変形済みの帯状体を所定の引っ張り力で巻き取っていく。成形ロ−ラ対からでた帯状体は所定曲率に湾曲しており、巻き取りドラムはこの湾曲した帯状体の略接線方向へ引っ張り、湾曲した帯状体はその湾曲した方向に移動し、この移動は略旋回運動となる。
【００２６】
この状態で、成形ロ−ラの回転数変化に応じて巻き取りドラムの回転数が変化すると、これは帯状体の接線方向（螺旋輪板の）への帯状体の速度変化を招き、この速度変化により帯状体の旋回質量に作用する遠心力の変化を招く。この帯状体の遠心力変化は、楔状隙間における駆動ロ−ラの略軸方向に作用するため、結局、楔状隙間の帯状体に楔状隙間の狭い側から広い側に向けて作用する力が変動する。
【００２７】
この力の変動は、楔状隙間における帯状体の軸方向位置を変動させることになるため、成形ロ−ラ対の帯状体加工具合（特にその曲率）が変わり、これにより帯状体塑性変形精度の低下が生じる。
【００２８】
すなわち、帯状体に作用する遠心力変動により、楔状隙間における帯状体位置が変化し、これにより帯状体の塑性変形後の厚さに相当する帯状体位置における楔状隙間の幅が変動してしまう。巻き取りドラムが成形ロ−ラ対の軸心と直角方向へ帯状体を引っ張れば上記分力は解消するが、楔状隙間から出る帯状体は帯状体の一側寄りに所定曲率で湾曲しているためにどうしてもその略接線方向へ引っ張らざるを得ない。
【００２９】
しかし、本発明の螺旋輪板製造装置では、この従動ロ−ラを帯状体を挟んで駆動ロ−ラに向けて所定の押圧力で押圧するロ−ラ押圧機構を設け、更に、このロ−ラ押圧機構は、従動ロ−ラを帯状体を介して駆動ロ−ラに押し付ける押圧力を調整可能な機構を有しているので、駆動ロ−ラの回転数変更およびそれに伴う巻き取りドラムの回転数変更に応じて、このロ−ラ押圧機構による従動ロ−ラを駆動ロ−ラへ押圧する押圧力を調整することができ、この調整により、上記駆動ロ−ラの回転数変更に伴う帯状体の遠心力変動による塑性変形精度の低下を防止することができる。
【００３０】
請求項６記載の構成によれば請求項５記載の螺旋輪板製造装置において更に、巻き取りドラム又は駆動ロ−ラの回転数と前記押圧力との最適な関係を記憶し、回転数を変更する場合にこの関係に基づいて前記押圧力を自動変更するので、簡単な工程で塑性変形精度の向上を図ることができる。
【００３１】
請求項７記載の構成によれば請求項５又は６記載の螺旋輪板製造装置において更に、駆動ロ−ラを所定回転数値で駆動し、巻き取りドラムを定トルク駆動し、駆動ロ−ラの回転数値の切り替えに応じてロ−ラ押圧機構の押圧力を変更するので、駆動ロ−ラの回転数の変更にかかわらず、それに応じて、ロ−ラ押圧機構が出力する押圧力及び巻き取りドラムが出力するトルク値を変更するので、駆動ロ−ラの回転数変更により派生する２つの問題、すなわち、駆動ロ−ラの回転数変更により上記帯状体に作用する遠心力が変動する問題、及び、駆動ロ−ラの回転数変更により駆動ロ−ラと帯状体との間の滑りの程度が変化して、巻き取りドラムが楔状隙間の帯状体に与える引っ張り力が変動する問題を解決することができ、これらの影響による塑性変形精度の低下を防止ないし低減することができる。
【００３２】
【発明の実施の形態】
本発明の成形ロ−ラ対式螺旋輪板製造方法を用いた回転電機のステ−タコアの製造例を図面を参照して以下に説明する。
【００３３】
【実施例】
図１は本発明の製造方法を実現する製造装置の模式斜視図であり、図２はその動作を示す模式正面図であり、図３は帯状体２の部分平面図である。
（構造）
図１において、１は成形ロ−ラ対、２は帯状体であり、成形ロ−ラ対１は円柱ロ−ラ３およびテ−パロ−ラ４からなる。帯状体２は、図３に示すように、一側端部に長尺方向へ一定間隔で設けられた切り欠き部２ａをもち、他側端部に一定ピッチでスロット２ｂを有し、電磁鋼帯をパンチングして形成されている。
【００３４】
成形ロ−ラ対１をなす両ロ−ラ３、４は上下に配置され、両ロ−ラ３、４の軸心は垂直方向同位置にてそれぞれ水平に設定されている。円柱ロ−ラ３は後述のベ−ス１７に立設された支持架構１７ａに回転自在に支承され、テ−パロ−ラ４は軸受けを通じて後述のスライドユニット７の駆動端に固定されている。テ−パロ−ラ４の先端部の外周面には切頭円錐面４１が設けられ、この切頭円錐面４１は円柱ロ−ラ３の外周面に楔状隙間ｇを挟んで対面しており、帯状体２はこの楔状隙間ｇに挟まれている。
【００３５】
５は、支持架構１７ａのテ−ブル部１７ｂ上に固定されて円柱ロ−ラ３にトルク伝達減速機構６を通じて結合されるロ−ラ駆動モ−タであり、７は、テ−パロ−ラ４の軸受け部（図示せず）を上下方向（円柱ロ−ラ３に向けて）進退可能に案内するスライドユニット（上下案内機構）である。
【００３６】
８は、ローラ押圧機構であって、支持架構１７ａに固定されてテ−パロ−ラ４をスライドユニット７を介して円柱ロ−ラ３に対して進退させるとともに、テ−パロ−ラ４に帯状体２に対する所定の押圧力（塑性変形力）を付与するリニアアクチュエータであり、この実施例ではエアシリンダを用いている。
【００３７】
９は、両ロ−ラ３、４の軸心よりも左前方に位置して軸心が垂直に配置された巻き取りドラムであり、支持架構１７ａのテ−ブル部１７ｂから回転自在に垂下されている。巻き取りドラム９は、テ−ブル部１７ｂ上に固定されたドラム駆動モ−タ１８により駆動されている。巻き取りドラム９には湾曲成形された帯状体すなわち螺旋輪板２が巻きつけられている。巻き取りドラム９の外周面には互いに周方向所定角度離れてガイドプレ−ト１０が軸方向へ突設されており、ガイドプレ−ト１０は帯状体すなわち螺旋輪板２の内周面にあらかじめ形成されたスロット２ｂに嵌合して、螺旋輪板２の各タ−ンのスロット２ｂの周方向位置合わせを行うとともに、螺旋輪板２を所定トルクで巻き取ることにより、このトルクを成形ロ−ラ対１の部位の帯状体２に与えている。
【００３８】
１２は、成形ロ−ラ対１にて塑性変形加工される以前の帯状体２を成形ロ−ラ対１の楔状隙間ｇの所定位置に送入するためのガイドである。
【００３９】
１３は、ベ−ス１７上に左右方向移動可能に設けられた排出スライダ１６上に回転自在かつ上下方向移動自在に立設された鍔付きドラムであり、鍔付きドラム１３は図１において、巻き取りドラム９の直下に同軸配置され、かつ、鍔付きドラム１３の上端面は巻き取りドラム９の下端面に相対回転不能にして、ドラム駆動モ−タ１８により巻き取りドラム９とともに回転されている。すなわち、両ドラム９、１３の対向端面には互いに嵌合する嵌合部（たとえばピン結合又はキ−結合）を有している。巻き取りドラム９に巻き取られた螺旋輪板２はそれらの自重により鍔付きドラム１３の鍔上に落下し、円筒状に積層される。鍔付きドラム１３の外周面にも、互いに周方向所定角度離れてガイドプレ−ト１４が軸方向へ突設されており、ガイドプレ−ト１４は帯状体すなわち螺旋輪板２のスロット２ｂに嵌合して、螺旋輪板２の各タ−ンのスロット２ｂの最終的な周方向位置合わせを行う。
【００４０】
１５は、テ−ブル部１７ｂに左右方向進退自在に垂下された切断機構であり、切断機構１５は巻き取りドラム９の巻き取り完了後に、巻き取りドラム９に向けて接近し、巻き取りドラム９に巻着された帯状体すなわち螺旋輪板２を所定位置で切断する。
（動作）
次に、上述した製造装置の動作を説明する。
【００４１】
最初、鍔付きドラム１３は図１に示すように巻き取りドラム９に一体回転可能に嵌合しているものとする。
【００４２】
円柱ロ−ラ３及び巻き取りドラム９はそれぞれ所定回転数で回転され、テ−パロ−ラ４は楔状隙間ｇの帯状体２を介して円柱ロ−ラ３に所定の押し付け力で押し付けられ、これにより楔状隙間ｇの帯状体２は巻き取りドラム９側へ湾曲変形されて螺旋輪板２となる。この螺旋輪板２は、巻き取りドラム９に巻き取られ、自重により落下して鍔付きドラム１３の周囲に積層される。所定長の塑性変形加工及びその同時巻き取りが完了した後、切断機構１５で螺旋輪板２を切断する。
【００４３】
次に、鍔付きドラム１３を降下させて巻き取りドラム９との嵌合を解除し、その後、排出スライダ１６を左動させて、鍔付きドラム１３から積層螺旋輪板からなる円筒コアを取り出す。
（回転数制御）
次に、制御装置１００が行う円柱ロ−ラ３を駆動するロ−ラ駆動モ−タ５と、巻き取りドラム９を駆動するドラム駆動モ−タ１８との回転制御について説明する。
【００４４】
成形ロ−ラ対１の前後の帯状体２の速度（以下、帯状体送り速度ともいう）は、巻き取りドラム９の巻き取り部の周速ｖｄに等しく、２π・巻き取り部の半径ｒｄ・巻き取り部の回転数ｎｄとなる。円柱ロ−ラ３の周速ｖｒは、２π・円柱ロ−ラ３の半径ｒｒ・円柱ロ−ラ３の回転数ｎｒとなる。
【００４５】
楔状隙間ｇにおいて、帯状体２は円柱ロ−ラ３に対して滑りＳ（＝（ｖｒ−ｖｄ）／ｖｒ）を生じており、滑りＳは、この円柱ロ−ラ３の周速ｖｒが大きくなるほど大きくなる。
【００４６】
そこで、滑りＳが円柱ロ−ラ３の周速ｖｒに比例すると仮定すれば、
Ｓ＝ｋ・ｖｒとなる。ｋは比例定数である。
【００４７】
上記各式から、同一の帯状体２に対して円柱ロ−ラ３の回転数ｎｒを変更した場合における好適な巻き取りドラム９の回転数を算出することができる。すなわち、巻き取りドラム９の最適周速ｖｄは、Ｓ＝（ｖｒ−ｖｄ）／ｖｒ＝ｋ・ｖｒから、ｖｄ＝−ｋ・ｖｒ・ｖｒ＋ｖｒの解となる。
【００４８】
また、滑りＳが一定であると仮定しても有効であり、この場合には、巻き取りドラム９の最適周速ｖｄは、Ｓ＝（ｖｒ−ｖｄ）／ｖｒ＝ｋから、ｖｄ＝−ｋ・ｖｒ＋ｖｒ＝（１−ｋ）ｖｒの解となる。
【００４９】
生産性向上などの理由により円柱ロ−ラ３の回転数変更に際し、巻き取りドラム９の回転数を上記式にしたがって制御すれば、巻き取りドラム９に過大な負荷が掛かったり、あるいは巻き取りドラム９と成形ロ−ラ対１との間で帯状体２が弛んだりすることがなく、かつ、巻き取りドラム９が帯状体２を通じて楔状隙間ｇにて帯状体２に与える引っ張り力の変動を低減して塑性変形加工形状の変動を抑止することができる。
【００５０】
また、上記した円柱ロ−ラ３の回転数変更ではなく、帯状体２の種類の変更においても、それに応じて生じる上記滑りＳの変化に応じて巻き取りドラム９の回転数を変更することができる。帯状体２の種類の変更としては、その断面形状の変更や組成の変更などがある。
【００５１】
逆に、巻き取りドラム９の回転数を変更する場合にそれに応じて上記式に基づいて円柱ロ−ラ３の回転数を変更してもよい。
（押圧力制御）
次に、リニアアクチュエータ８の押圧力の制御について以下に説明する。
【００５２】
リニアアクチュエータ８は、支持架構１７ａの側壁に固定されてテ−パロ−ラ４をスライドユニット７を介して昇降させる。リニアアクチュエータ８は、エアシリンダであって、支持架構１７ａの側壁に固定されたケース８０と、直動軸８１を有する。なお、このエアシリンダに付属して、空気圧源と、制御装置１００からの制御信号に応じて空気圧を調節する制御弁とを有している。
【００５３】
スライドユニット７は、支持架構１７ａの側壁に固定されたケ−ス７０と、このケ−ス内に昇降自在に保持されるガイド部材とを有している。
【００５４】
テ−パロ−ラ４の軸部は、スライドユニット７内に上下方向移動自在に支持される軸受け部に回転自在に支承され、この軸受け部は上記ガイド部材を介してリニアアクチュエータ８の直動軸８１の先端に連結されている。
【００５５】
上記エアシリンダへの供給空気圧の調節によりリニアアクチュエータ８の直動軸８１が上下に昇降し、直動軸８１は上記ガイド部材を通じてテ−パロ−ラ４の上記軸受け部及びそれに回転自在に支承されるテ−パロ−ラ４を昇降させ、上記楔状隙間ｇの大きさを制御する。
【００５６】
この実施例では、楔状隙間ｇの帯状体２を塑性変形加工する場合、テ−パロ−ラ４にはその反力が掛かり、この反力はテ−パロ−ラ４の軸部を下降方向に付勢するが、エアシリンダに供給される空気圧が直動軸８１の上昇スラストに変換され、この上昇スラストがガイド部材を通じて常にテ−パロ−ラ４の軸部を上昇方向に付勢しているので、結局、上記反力と上昇スラストが一致する点で、楔状隙間ｇの大きさが安定する。
【００５７】
上述したように、駆動ロ−ラ３及びそれに伴う巻き取りドラム９の回転数変更により帯状体２の遠心力変動に起因して、楔状隙間ｇにおける帯状体２の軸方向位置はギャップ小側に変位しようとするが、この実施例では、上記回転数変更に応じて、好ましくはそれに正の相関を有して、更に好ましくはそれに正比例して、上記エアシリンダによる押圧力を変更する制御を行っているので、楔状隙間ｇにおける帯状体２の軸方向位置は変化することがなく、塑性変形加工精度が低下することがない。
（制御例）
図４に制御装置１００の制御例を示す。
【００５８】
なお、両モ−タ５、１８はインバ−タ駆動されるブラシレスＤＣモ−タであり、上記インバ−タの出力周波数制御により回転数値を変更可能となっている。
【００５９】
まず、ロ−ラ駆動モ−タ５の回転数指令値Ｎ１の変更が外部から入力されたかどうかを調べ（Ｓ１００）、入力されていなければ従来の回転数値指令値Ｎ１，Ｎ２で両モ−タ５、１８を駆動する（Ｓ１０７）。なお、この駆動状態にて、巻き取りドラム９の巻き取り部の周速は円柱ロ−ラ３の周速よりも所定量小さく設定されている。
【００６０】
ロ−ラ駆動モ−タ５の回転数指令値Ｎ１の変更が外部から入力された場合には、両モ−タの回転数値の好適な関係を記憶する内蔵のマップにこの回転数指令値Ｎ１を代入してドラム駆動モ−タ１８の回転数指令値Ｎ２を読み出し（Ｓ１０２）、これら回転数指令値Ｎ１，Ｎ２をレジスタに記憶する（Ｓ１０４）。
【００６１】
次に、巻き取りドラム１８の周速またはそれに比例するドラム駆動モ−タ１８の回転数とリニアアクチュエータ８の押圧力との好適な関係（遠心力による楔状隙間における帯状体位置変化がない条件）を記憶する内蔵のマップに、ドラム駆動モ−タ１８の回転数を代入してリニアアクチュエータ８の押圧力Ｐを求める（Ｓ１０５）。
【００６２】
次に、リニアアクチュエータ８を求めた押圧力Ｐで作動させ（Ｓ１０６）、両モ−タ５、１８をこれら回転数指令値Ｎ１，Ｎ２で駆動制御する（Ｓ１０７）。
【００６３】
このようにすれば、上述した理由により良好な成形を行うことができる。
【００６４】
（変形態様）
上記実施例では円柱ロ−ラ３をモ−タ駆動したがテ−パロ−ラ４をモ−タ駆動し、円柱ロ−ラ３をリニアアクチュエータ８で駆動してもよい。
【００６５】
円柱ロ−ラ３とテ−パロ−ラ４との対の代わりに一対のテ−パロ−ラ４を用いて成形ロ−ラ対１を構成してもよい。
【００６６】
【実施例２】
他の実施例を以下に説明する。
【００６７】
上記実施例では、両モ−タ５、１８をそれぞれあらかじめ決定したが、この実施例ではその代わりに、円柱ロ−ラ３の回転数を一定回転数値に維持し、巻き取りドラム９を定トルクで運転する。なお、両モ−タ５、１８はインバ−タ駆動されるブラシレスＤＣモ−タであり、ロ−ラ駆動モ−タ５はインバ−タの出力周波数制御により回転数値を変更可能となっており、ドラム駆動モ−タ１８は、ベクトル制御などによりトルク制御可能なモ−タ制御装置となっている。
【００６８】
図５に制御装置１００の制御例を示す。
【００６９】
まず、ロ−ラ駆動モ−タ５の回転数指令値Ｎ１の変更が外部から入力されたかどうかを調べ（Ｓ２００）、入力されていなければ、ロ−ラ駆動モ−タ５を従来の回転数値指令値Ｎ１で駆動制御し、ドラム駆動モ−タ１８を従来のトルク指令値Ｔ２で駆動制御する（Ｓ２０６）。なお、この駆動状態にて、巻き取りドラム９の巻き取り部の周速は円柱ロ−ラ３の周速よりも所定量小さく設定されている。
【００７０】
ロ−ラ駆動モ−タ５の回転数指令値Ｎ１の変更が外部から入力された場合には、ロ−ラ駆動モ−タ５の回転数指令値Ｎ１とドラム駆動モ−タ１８のトルク指令値Ｔ２との好適な関係を記憶する内蔵のマップにこの回転数指令値Ｎ１を代入してドラム駆動モ−タ１８のトルク指令値Ｔ２を読み出し（Ｓ２０２）、これら回転数指令値Ｎ１及びトルク指令値Ｔ２をレジスタに記憶する（Ｓ２０４）。
【００７１】
次に、ドラム駆動モ−タ１８の回転数を検出して、この回転数とリニアアクチュエータ８の押圧力との好適な関係（遠心力による楔状隙間における帯状体位置変化がない条件）を記憶する内蔵のマップに、検出したドラム駆動モ−タ１８の回転数を代入してリニアアクチュエータ８の押圧力Ｐを求める（Ｓ２０６）。
【００７２】
次に、リニアアクチュエータ８を求めた押圧力Ｐで作動させ（Ｓ２０８）、両モ−タ５、１８をこれら回転数指令値Ｎ１，Ｎ２で駆動制御する。（Ｓ２１０）。
【００７３】
このようにすれば、塑性変形により形成される湾曲確率を高精度に一定化することができる。
【図面の簡単な説明】
【図１】本発明の実施例１における成形ロ−ラ対式螺旋輪板製造装置を示す模式斜視図である。
【図２】図１の製造装置の要部を示す模式部分正面図である。
【図３】帯状体の部分平面図である。
【図４】両モ−タ及びリニアアクチュエータの制御動作の一例を示すフロ−チャ−トである。
【図５】両モ−タ及びリニアアクチュエータの制御動作の他例を示すフロ−チャ−トである。
【符号の説明】
１は成形ロ−ラ対、２は帯状体、３は円柱ロ−ラ（成形ロ−ラ対の一部）１、４はテ−パロ−ラ（成形ロ−ラ対の残部）、５はロ−ラ駆動モ−タ、８はリニアアクチュエータ、９は巻き取りドラム、１８はドラム駆動モ−タ[0001]
[Industrial applications]
The present invention relates to a method of manufacturing a spiral roller plate and a manufacturing apparatus for the spiral roller plate. The present invention can be applied, for example, to a case where a stator core or a rotor core of a rotating electric machine is formed by spirally winding an electromagnetic steel strip with its main surface overlapping.
[0002]
[Prior art]
Japanese Patent Publication No. 38-7402 discloses that a pair of truncated conical rollers (hereinafter, also simply referred to as “taper rollers”) are provided in such a manner that both outer peripheral surfaces face each other with a predetermined wedge-shaped gap, and the electromagnetic steel strip is formed into the wedge-like shape. It is proposed that a spiral core bend to one side of the electromagnetic steel strip be created by plastic working by inserting it into the gap, and that the spiral cores be stacked on top of each other so as to form a stator core. are doing. Hereinafter, a manufacturing method for producing a spiral wheel plate by plastic working of a band-shaped metal plate using a pair of formed rollers arranged with a wedge-shaped gap interposed therebetween will be described below. It shall be referred to as a method and a spiral wheel manufacturing apparatus.
[0003]
[Problems to be solved by the invention]
However, in the method and the apparatus for manufacturing a spiral roller plate of the above-mentioned publication, the electromagnetic steel strip plastically deformed by the roller pair can be freely stacked by relying on its own weight. Therefore, it is not easy to adjust the positions of the turns of the spiral wheel plate after the plastic deformation by the forming roller pair, and to integrate the turns in the thickness direction to form a cylindrical core.
[0004]
For this reason, the present inventors take up the spiral wheel plate that has come out of the pair of forming rollers with a winding drum that rotates synchronously with the pair of forming rollers, thereby completing the plastic deformation processing by the pair of forming rollers. At about the same time, we considered completing the cylindrical core formation.
[0005]
However, in the method and the apparatus for manufacturing a spiral roller plate that winds the spiral wheel using the winding drum, the rotational speed of the roller pair is changed in order to improve productivity and the like. In this case, there is a problem that the plastic deformation accuracy of the electromagnetic steel strip is reduced.
[0006]
SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and a method of manufacturing a forming roller pair type spiral wheel plate capable of ensuring good quality regardless of a change in the number of revolutions of a forming roller (or a winding drum). It is an object of the present invention to provide a spiral wheel plate manufacturing apparatus.
[0007]
[Means for Solving the Problems]
In order to solve the above-mentioned problems, in the method and the apparatus for manufacturing a spiral roller plate according to the first aspect of the present invention, a pair of molding rollers arranged face to face with a wedge-shaped gap for plastic deformation interposed therebetween. After the band is bent to one side by the rotation of the roller, a manufacturing process is employed in which the curved band coming out of the forming roller pair is wound around a winding drum.
[0008]
In this configuration, in particular, the forming roller (or the take-up drum) is characterized in that the pressing force of the forming roller pressing the band-like body is changed in accordance with the change in the number of revolutions of the take-up roller or the take-up drum. Good quality can be ensured irrespective of changes in the number of revolutions. If the rotational speed of the forming roller increases, it is natural that the rotational speed of the winding drum also increases. For the rotation of the forming roller pair, only one of them may be driven by a motor, or both may be driven by a motor. Hereinafter, the molding roller driven by the motor is referred to as a driving roller, and the molding roller not driven by the motor is sometimes referred to as a driven roller. The number of rotations of the forming roller pair referred to in this specification refers to the number of rotations of the driving roller.
[0009]
Hereinafter, this will be described in more detail.
[0010]
SUMMARY OF THE INVENTION The present inventors, when manufacturing a spiral wheel plate by plastically deforming a belt-like body using a pair of molding rollers, have to use a molding roller (and a winding roller) to increase the belt-feeding speed in order to improve productivity. When the number of rotations of the take-up drum) was increased, it was noticed that the plastic deformation accuracy of the strip was slightly deteriorated. In pursuit of this cause, they found that the following problems had arisen.
[0011]
The winding drum winds the plastically deformed belt-like body coming out of the forming roller to produce a cylindrical core with a predetermined tensile force. The band formed from the pair of forming rollers is curved to a predetermined curvature, the winding drum pulls in a direction substantially tangential to the curved band, and the curved band moves in the curved direction. Becomes a substantially swirling motion.
[0012]
In this state, if the rotation speed of the winding drum changes in accordance with the rotation speed change of the forming roller, this causes a change in the speed of the band in the tangential direction (of the spiral plate) of the band. The change causes a change in the centrifugal force acting on the swirl mass of the strip. This change in the centrifugal force of the band acts substantially in the axial direction of the drive roller in the wedge-shaped gap, and as a result, the force acting on the band of the wedge-shaped gap from the narrow side to the wide side of the wedge-shaped gap fluctuates. .
[0013]
This fluctuation of the force causes the axial position of the band in the wedge-shaped gap to fluctuate, so that the degree of processing of the band (particularly the curvature) of the pair of forming rollers changes, thereby lowering the plastic deformation accuracy of the band. Occurs.
[0014]
That is, the position of the band in the wedge-shaped gap changes due to the fluctuation of the centrifugal force acting on the band, and thereby the width of the wedge-shaped gap at the position of the band corresponding to the thickness of the band after the plastic deformation is changed. When the winding drum pulls the band in a direction perpendicular to the axis of the pair of forming rollers, the above component force is eliminated, but the band coming out of the wedge-shaped gap is curved at a predetermined curvature toward one side of the band. For this reason, it has to be pulled in a substantially tangential direction.
[0015]
Therefore, in the spiral wheel plate manufacturing apparatus of the present invention, the rotational speed is changed by changing the pressing force of the forming roller against the band-shaped body in the wedge-shaped gap according to the change in the number of rotations of the forming roller or the winding drum. The effect of the centrifugal force change of the band due to the change is offset. In this way, it is possible to prevent a decrease in plastic deformation accuracy with respect to the centrifugal force fluctuation problem regardless of a change in the band forming speed.
[0016]
According to a second aspect of the present invention, there is provided the method and the apparatus for manufacturing a spiral roller plate according to the first aspect, further comprising: a rotational speed of a winding drum or a driving roller; Is stored, and the pressing force is automatically changed based on this relationship when the number of rotations is changed, so that the plastic deformation accuracy can be improved by a simple process.
[0017]
According to a third aspect of the present invention, there is provided the method and the apparatus for manufacturing a spiral roller plate according to the first or second aspect, wherein the pressing force is further reduced by rotating the molding roller or the winding drum. Since the change is made based on a relationship having a positive correlation with the number change, the plastic deformation accuracy can be further improved.
[0018]
Since the centrifugal force is substantially proportional to the feed speed of the belt, that is, the number of revolutions of the winding drum, the belt of the molding roller has a positive correlation with a change in the number of revolutions of the winding drum and the molding roller. By changing the pressing force applied to the belt, the strip can be plastically deformed into a stable shape.
[0019]
According to the fourth aspect of the present invention, in the method and the apparatus for manufacturing a spiral roller plate according to the third aspect of the present invention, since the relationship is a direct proportional relationship, the map is complicated to control. It is possible to achieve good plastic deformation accuracy with a simple process and configuration without the need for any other means.
[0020]
In order to solve the above-mentioned problem, in a spiral wheel plate manufacturing apparatus according to the fifth aspect, a driving roller (a forming roller driven by a motor) of a forming roller pair and a winding drum are separately rotated. Numerical control (including torque control) is possible, and a roller drive motor for driving these drive rollers is rotated to plastically deform the belt-like body to form a spiral wheel plate, and at the same time, to form a drum. To take up. The forming roller pair has a driven roller disposed close to the driving roller with a wedge-shaped gap therebetween, and the driven roller may not be driven by a motor.
[0021]
In this configuration, in particular, there is provided a roller pressing mechanism for pressing the driven roller toward the driving roller with a predetermined pressing force across the belt-like body, and further, the roller pressing mechanism includes a driven roller. -The pressing force for pressing the roller through the belt to the drive roller In response to a change in the number of revolutions of the forming roller or the winding drum. It has an adjustable mechanism.
[0022]
With this configuration, it is possible to realize a spiral wheel plate manufacturing apparatus capable of maintaining the plastic deformation processing accuracy of the belt-shaped body with high accuracy despite the change in the number of revolutions of the forming roller.
[0023]
Hereinafter, this will be described in more detail.
[0024]
SUMMARY OF THE INVENTION The present inventors, when manufacturing a spiral wheel plate by plastically deforming a belt-like body using a pair of molding rollers, have to use a molding roller (and a winding roller) to increase the belt-feeding speed in order to improve productivity. When the number of rotations of the take-up drum) was increased, it was noticed that the plastic deformation accuracy of the strip was slightly deteriorated. In pursuit of this cause, they found that the following problems had arisen.
[0025]
The winding drum winds the plastically deformed belt-like body coming out of the forming roller to produce a cylindrical core with a predetermined tensile force. The band formed from the pair of forming rollers is curved to a predetermined curvature, the winding drum pulls in a direction substantially tangential to the curved band, and the curved band moves in the curved direction. Becomes a substantially swirling motion.
[0026]
In this state, if the rotation speed of the winding drum changes in accordance with the rotation speed change of the forming roller, this causes a change in the speed of the band in the tangential direction (of the spiral plate) of the band. The change causes a change in the centrifugal force acting on the swirl mass of the strip. This change in the centrifugal force of the band acts substantially in the axial direction of the drive roller in the wedge-shaped gap, and as a result, the force acting on the band of the wedge-shaped gap from the narrow side to the wide side of the wedge-shaped gap fluctuates. .
[0027]
This fluctuation of the force causes the axial position of the band in the wedge-shaped gap to fluctuate, so that the degree of processing of the band (particularly the curvature) of the pair of forming rollers changes, thereby lowering the plastic deformation accuracy of the band. Occurs.
[0028]
That is, the position of the band in the wedge-shaped gap changes due to the fluctuation of the centrifugal force acting on the band, and thereby the width of the wedge-shaped gap at the position of the band corresponding to the thickness of the band after the plastic deformation is changed. When the winding drum pulls the band in a direction perpendicular to the axis of the pair of forming rollers, the above component force is eliminated, but the band coming out of the wedge-shaped gap is curved at a predetermined curvature toward one side of the band. For this reason, it has to be pulled in a substantially tangential direction.
[0029]
However, in the spiral wheel plate manufacturing apparatus of the present invention, there is provided a roller pressing mechanism for pressing the driven roller toward the driving roller with a predetermined pressing force across the belt-like body. The roller pressing mechanism has a mechanism capable of adjusting the pressing force for pressing the driven roller against the driving roller via the belt-shaped body, so that the rotation speed of the driving roller can be changed and the winding drum can be changed accordingly. The pressing force of the roller pressing mechanism for pressing the driven roller against the driving roller can be adjusted in accordance with the change in the number of rotations. It is possible to prevent a decrease in plastic deformation accuracy due to a change in the centrifugal force of the belt-shaped body.
[0030]
According to a sixth aspect of the present invention, in the spiral wheel plate manufacturing apparatus according to the fifth aspect, an optimum relationship between the number of rotations of a winding drum or a driving roller and the pressing force is stored, and the number of rotations is changed. In this case, since the pressing force is automatically changed based on this relationship, the plastic deformation accuracy can be improved by a simple process.
[0031]
According to a seventh aspect of the present invention, in the spiral wheel plate manufacturing apparatus according to the fifth or sixth aspect, the driving roller is further driven at a predetermined rotation value, the winding drum is driven at a constant torque, and the driving roller is driven. Since the pressing force of the roller pressing mechanism is changed in accordance with the switching of the rotation value, regardless of the change in the number of rotations of the driving roller, the pressing force and the winding output by the roller pressing mechanism are correspondingly changed. Since the torque value output by the drum is changed, two problems derived from the change in the rotation speed of the drive roller, namely, the problem that the centrifugal force acting on the belt-like body changes due to the change in the rotation speed of the drive roller, Further, it is possible to solve the problem that the degree of slippage between the driving roller and the band changes due to the change in the number of revolutions of the driving roller, and that the pulling force applied by the winding drum to the band in the wedge-shaped gap varies. Can be due to these effects It is possible to prevent or reduce deterioration of sexual deformation accuracy.
[0032]
BEST MODE FOR CARRYING OUT THE INVENTION
An example of manufacturing a stator core of a rotating electric machine using the method of manufacturing a formed roller pair type spiral wheel plate of the present invention will be described below with reference to the drawings.
[0033]
【Example】
FIG. 1 is a schematic perspective view of a manufacturing apparatus for realizing the manufacturing method of the present invention, FIG. 2 is a schematic front view showing the operation thereof, and FIG. 3 is a partial plan view of the band 2.
(Construction)
In FIG. 1, reference numeral 1 denotes a molded roller pair, 2 denotes a belt-shaped body, and the molded roller pair 1 comprises a cylindrical roller 3 and a taper roller 4. As shown in FIG. 3, the belt-shaped body 2 has notches 2a provided at one end in a longitudinal direction at regular intervals, and has slots 2b at the other end at a constant pitch. The band is formed by punching.
[0034]
The rollers 3 and 4 forming the forming roller pair 1 are arranged vertically, and the axes of the rollers 3 and 4 are set horizontally at the same position in the vertical direction. The cylindrical roller 3 is rotatably supported by a support frame 17a erected on a base 17 described later, and the taper roller 4 is fixed to a driving end of a slide unit 7 described later through a bearing. A frusto-conical surface 41 is provided on the outer peripheral surface of the tip of the taper roller 4, and the frusto-conical surface 41 faces the outer peripheral surface of the cylindrical roller 3 with a wedge-shaped gap g interposed therebetween. The band 2 is sandwiched between the wedge-shaped gaps g.
[0035]
Reference numeral 5 denotes a roller drive motor fixed on the table portion 17b of the support frame 17a and connected to the cylindrical roller 3 through a torque transmission reduction mechanism 6. Reference numeral 7 denotes a taper roller. 4 is a slide unit (up and down guide mechanism) for guiding a bearing portion (not shown) so as to be able to move up and down (toward the cylindrical roller 3).
[0036]
Reference numeral 8 denotes a roller pressing mechanism, which is fixed to the support frame 17a to move the tape roller 4 forward and backward with respect to the cylindrical roller 3 via the slide unit 7, and to form a belt-like shape on the tape roller 4. This is a linear actuator for applying a predetermined pressing force (plastic deformation force) to the body 2, and in this embodiment, an air cylinder is used.
[0037]
Reference numeral 9 denotes a take-up drum which is located at the left front of the axis of the rollers 3, 4 and whose axis is vertically arranged, and is rotatably hung from a table portion 17b of a support frame 17a. ing. The winding drum 9 is driven by a drum drive motor 18 fixed on a table 17b. The winding drum 9 is wound with a band-shaped body formed in a curved shape, that is, the spiral wheel plate 2. A guide plate 10 is provided on the outer peripheral surface of the winding drum 9 at a predetermined angle in the circumferential direction so as to protrude in the axial direction, and the guide plate 10 is formed on the inner peripheral surface of the belt-shaped body, that is, the spiral wheel plate 2 in advance. By fitting into the formed slot 2b and aligning the slots 2b of each turn of the spiral wheel plate 2 in the circumferential direction, and winding the spiral wheel plate 2 with a predetermined torque, the torque is reduced. -It is given to the strip 2 at the site of the pair 1.
[0038]
Reference numeral 12 denotes a guide for feeding the belt-shaped body 2 before being plastically deformed by the forming roller pair 1 into a predetermined position of the wedge-shaped gap g of the forming roller pair 1.
[0039]
Numeral 13 denotes a flanged drum which is rotatably and vertically movable on a discharge slider 16 provided on a base 17 so as to be movable in the left-right direction. The upper end surface of the flanged drum 13 is coaxially arranged directly below the take-up drum 9, and is not rotatable relative to the lower end surface of the take-up drum 9, and is rotated together with the take-up drum 9 by a drum drive motor 18. . That is, the opposing end surfaces of both drums 9 and 13 have fitting portions (for example, pin connection or key connection) that fit each other. The spiral wheel plates 2 wound by the winding drum 9 fall on the flange of the flanged drum 13 by their own weight, and are stacked in a cylindrical shape. A guide plate 14 is also provided on the outer peripheral surface of the flanged drum 13 so as to protrude in the axial direction at a predetermined circumferential distance from each other, and the guide plate 14 fits into the slot 2b of the belt-shaped body, that is, the spiral wheel plate 2. At the same time, the final circumferential alignment of the slots 2b of each turn of the spiral wheel plate 2 is performed.
[0040]
Reference numeral 15 denotes a cutting mechanism which is suspended from the table portion 17b so as to be able to advance and retreat in the left-right direction. The cutting mechanism 15 approaches the winding drum 9 after winding of the winding drum 9 is completed. Is cut at a predetermined position.
(motion)
Next, the operation of the above-described manufacturing apparatus will be described.
[0041]
First, it is assumed that the flanged drum 13 is fitted to the winding drum 9 so as to be integrally rotatable as shown in FIG.
[0042]
The cylindrical roller 3 and the winding drum 9 are respectively rotated at a predetermined rotation speed, and the tape roller 4 is pressed against the cylindrical roller 3 with a predetermined pressing force through the band 2 having the wedge-shaped gap g. As a result, the belt-shaped body 2 having the wedge-shaped gap g is curvedly deformed toward the winding drum 9 and becomes the spiral wheel plate 2. The spiral wheel plate 2 is wound on a winding drum 9, falls by its own weight, and is stacked around a flanged drum 13. After the plastic deformation of a predetermined length and the simultaneous winding thereof are completed, the spiral wheel plate 2 is cut by the cutting mechanism 15.
[0043]
Next, the flanged drum 13 is lowered to release the engagement with the winding drum 9, and then the discharge slider 16 is moved to the left to take out the cylindrical core made of the laminated spiral wheel plate from the flanged drum 13.
(Rotation speed control)
Next, the rotation control of the roller driving motor 5 for driving the cylindrical roller 3 and the drum driving motor 18 for driving the winding drum 9 performed by the control device 100 will be described.
[0044]
The speed of the band 2 before and after the forming roller pair 1 (hereinafter also referred to as the band feeding speed) is equal to the peripheral speed vd of the winding portion of the winding drum 9 and 2π · the radius of the winding portion rd · This is the rotation speed nd of the winding unit. The peripheral speed vr of the cylindrical roller 3 is 2π, the radius rr of the cylindrical roller 3, and the rotation speed nr of the cylindrical roller 3.
[0045]
In the wedge-shaped gap g, the belt-shaped body 2 has a slip S (= (vr-vd) / vr) with respect to the cylindrical roller 3, and the circumferential speed vr of the cylindrical roller 3 is large. It gets bigger.
[0046]
Therefore, assuming that the slip S is proportional to the peripheral speed vr of the cylindrical roller 3,
S = k · vr. k is a proportionality constant.
[0047]
From the above equations, it is possible to calculate a suitable rotation speed of the winding drum 9 when the rotation speed nr of the cylindrical roller 3 is changed for the same band 2. That is, the optimum peripheral speed vd of the winding drum 9 is a solution of vd = −k · vr · vr + vr from S = (vr−vd) / vr = k · vr.
[0048]
It is also effective to assume that the slip S is constant. In this case, the optimum peripheral speed vd of the winding drum 9 is calculated from S = (vr−vd) / vr = k and vd = −k. Vr + vr = (1-k) vr.
[0049]
If the number of revolutions of the cylindrical roller 3 is changed in accordance with the above equation when changing the number of revolutions of the cylindrical roller 3 for reasons such as an improvement in productivity, an excessive load may be applied to the winding drum 9 or the number of revolutions of the winding drum 9 may increase. The belt 2 does not loosen between the belt 9 and the pair of forming rollers 1, and the fluctuation of the pulling force applied to the belt 2 by the winding drum 9 at the wedge-shaped gap g through the belt 2 is reduced. As a result, the variation in the shape of the plastic deformation processing can be suppressed.
[0050]
In addition to the above-described change in the number of rotations of the cylindrical roller 3 but also in the change in the type of the band 2, it is possible to change the number of rotations of the winding drum 9 in accordance with the change in the slip S generated accordingly. it can. Examples of the change in the type of the band 2 include a change in its cross-sectional shape and a change in its composition.
[0051]
Conversely, when the rotation speed of the winding drum 9 is changed, the rotation speed of the cylindrical roller 3 may be changed based on the above equation accordingly.
(Pressing force control)
Next, control of the pressing force of the linear actuator 8 will be described below.
[0052]
The linear actuator 8 is fixed to the side wall of the support frame 17a, and moves the tape roller 4 up and down via the slide unit 7. The linear actuator 8 is an air cylinder, and has a case 80 fixed to a side wall of the support frame 17a and a linear motion shaft 81. The air cylinder includes an air pressure source and a control valve that adjusts the air pressure according to a control signal from the control device 100.
[0053]
The slide unit 7 has a case 70 fixed to the side wall of the support frame 17a, and a guide member held up and down in the case.
[0054]
The shaft portion of the tape roller 4 is rotatably supported by a bearing portion movably supported in the slide unit 7 in the vertical direction. The bearing portion is a linear motion shaft of the linear actuator 8 via the guide member. 81 is connected to the tip.
[0055]
By adjusting the air pressure supplied to the air cylinder, the linear motion shaft 81 of the linear actuator 8 moves up and down, and the linear motion shaft 81 is rotatably supported by the bearing portion of the tape roller 4 through the guide member. The taper roller 4 is moved up and down to control the size of the wedge-shaped gap g.
[0056]
In this embodiment, when the belt-shaped body 2 having the wedge-shaped gap g is plastically deformed, a reaction force is applied to the taper roller 4, and this reaction force moves the shaft portion of the taper roller 4 in a downward direction. Although the air is supplied, the air pressure supplied to the air cylinder is converted into the ascending thrust of the linear motion shaft 81, and this ascending thrust constantly urges the shaft of the tape roller 4 in the ascending direction through the guide member. Therefore, the size of the wedge-shaped gap g is stabilized at the point where the above-mentioned reaction force and the upward thrust coincide.
[0057]
As described above, the axial position of the band 2 in the wedge-shaped gap g is shifted toward the small gap side due to the fluctuation of the centrifugal force of the band 2 due to the change in the rotation speed of the driving roller 3 and the accompanying rotation of the winding drum 9. In this embodiment, control is performed to change the pressing force of the air cylinder in accordance with the change in the number of rotations, preferably in direct proportion thereto, and more preferably in direct proportion thereto. Therefore, the axial position of the band 2 in the wedge-shaped gap g does not change, and the precision of the plastic deformation processing does not decrease.
(Control example)
FIG. 4 shows a control example of the control device 100.
[0058]
The motors 5 and 18 are brushless DC motors driven by an inverter, and the rotation value can be changed by controlling the output frequency of the inverter.
[0059]
First, it is checked whether or not the change of the rotation speed command value N1 of the roller drive motor 5 has been input from the outside (S100). If not, the two motors are operated with the conventional rotation value command values N1 and N2. 5 and 18 are driven (S107). In this driving state, the peripheral speed of the winding portion of the winding drum 9 is set to be smaller than the peripheral speed of the cylindrical roller 3 by a predetermined amount.
[0060]
When a change in the rotation speed command value N1 of the roller drive motor 5 is input from outside, the rotation speed command value N1 is stored in a built-in map that stores a preferable relationship between the rotation speed values of the two motors. Is substituted, and the rotational speed command value N2 of the drum drive motor 18 is read out (S102), and these rotational speed command values N1 and N2 are stored in a register (S104).
[0061]
Next, the preferred relationship between the peripheral speed of the winding drum 18 or the rotational speed of the drum drive motor 18 proportional thereto and the pressing force of the linear actuator 8 (conditions under which there is no change in the position of the band in the wedge-shaped gap due to centrifugal force) The pressing force P of the linear actuator 8 is determined by substituting the rotation speed of the drum drive motor 18 into a built-in map for storing (S105).
[0062]
Next, the linear actuator 8 is operated with the determined pressing force P (S106), and both motors 5 and 18 are drive-controlled by these rotational speed command values N1 and N2 (S107).
[0063]
In this case, good molding can be performed for the reasons described above.
[0064]
(Modification)
In the above embodiment, the cylindrical roller 3 is driven by a motor. However, the tape roller 4 may be driven by a motor, and the cylindrical roller 3 may be driven by a linear actuator 8.
[0065]
Instead of the pair of the cylindrical roller 3 and the tape roller 4, a pair of tape rollers 4 may be used to form the molded roller pair 1.
[0066]
Embodiment 2
Another embodiment will be described below.
[0067]
In the above embodiment, the motors 5 and 18 are respectively determined in advance. In this embodiment, however, the rotation speed of the cylindrical roller 3 is maintained at a constant value, and the winding drum 9 is driven at a constant torque. Drive with The motors 5 and 18 are brushless DC motors driven by an inverter, and the roller driving motor 5 can change the rotation value by controlling the output frequency of the inverter. The drum drive motor 18 is a motor control device capable of controlling torque by vector control or the like.
[0068]
FIG. 5 shows a control example of the control device 100.
[0069]
First, it is checked whether or not a change in the rotation speed command value N1 of the roller drive motor 5 has been input from the outside (S200). The drive is controlled by the command value N1, and the drive of the drum drive motor 18 is controlled by the conventional torque command value T2 (S206). In this driving state, the peripheral speed of the winding portion of the winding drum 9 is set to be smaller than the peripheral speed of the cylindrical roller 3 by a predetermined amount.
[0070]
When the change of the rotation speed command value N1 of the roller drive motor 5 is input from outside, the rotation speed command value N1 of the roller drive motor 5 and the torque command of the drum drive motor 18 are set. The torque command value T2 of the drum drive motor 18 is read by substituting the rotation speed command value N1 into a built-in map that stores a preferred relationship with the value T2 (S202), and the rotation speed command value N1 and the torque command are read. The value T2 is stored in the register (S204).
[0071]
Next, the number of rotations of the drum drive motor 18 is detected, and a preferable relationship between the number of rotations and the pressing force of the linear actuator 8 (condition in which there is no change in the position of the band in the wedge-shaped gap due to centrifugal force) is stored. The pressing force P of the linear actuator 8 is determined by substituting the detected rotation speed of the drum drive motor 18 into the built-in map (S206).
[0072]
Next, the linear actuator 8 is operated with the determined pressing force P (S208), and the motors 5 and 18 are drive-controlled by these rotational speed command values N1 and N2. (S210).
[0073]
By doing so, the probability of bending formed by plastic deformation can be made constant with high accuracy.
[Brief description of the drawings]
FIG. 1 is a schematic perspective view showing a forming roller pair-type spiral wheel plate manufacturing apparatus in Example 1 of the present invention.
FIG. 2 is a schematic partial front view showing a main part of the manufacturing apparatus of FIG.
FIG. 3 is a partial plan view of the belt-shaped body.
FIG. 4 is a flowchart showing an example of a control operation of both motors and a linear actuator.
FIG. 5 is a flowchart showing another example of the control operation of both motors and the linear actuator.
[Explanation of symbols]
1 is a molded roller pair, 2 is a strip, 3 is a cylindrical roller (part of the molded roller pair), 1, 4 is a taper roller (the rest of the molded roller pair), 5 is Roller drive motor, 8 is a linear actuator, 9 is a take-up drum, 18 is a drum drive motor

Claims

A belt-shaped body is continuously inserted into a wedge-shaped gap for plastic deformation formed between the outer peripheral surfaces of the pair of forming rollers and gradually increasing to one side in the axial direction, and one of the forming rollers is inserted into the wedge-shaped gap. By pressing with a predetermined pressing force in a direction to narrow, the band-shaped body bending step of bending the band-shaped body toward one side of the band-shaped body,
By rotating a take-up drum having an axis extending substantially perpendicular to the axis of the pair of forming rollers near the curved side of the pair of forming rollers, the take-up drum exited from the pair of forming rollers. A band-like body winding step of winding the curved band-like body around the winding drum,
A method of manufacturing a formed roller pair type spiral wheel plate comprising:
A method of manufacturing a pair of spiral rollers with a forming roller, wherein the pressing force is changed according to a change in the number of revolutions of the forming roller or the winding drum.

The method for manufacturing a pair of spiral rollers according to claim 1,
A forming roller pair-type spiral wheel plate, wherein an optimum relationship between the rotation speed and the pressing force is stored, and when the rotation speed is changed, the pressing force is automatically changed based on the relationship. Production method.

The method for manufacturing a pair of spiral rollers according to claim 1 or 2,
The method of manufacturing a pair of spiral rollers for a forming roller, wherein the pressing force is changed based on a relationship having a positive correlation with a change in the number of revolutions of the forming roller or the winding drum.

The method for manufacturing a molded roller pair type spiral wheel plate according to claim 3,
The method according to claim 1, wherein the relationship is a direct proportional relationship.

A forming roller pair consisting of a driving roller and a driven roller which are arranged to face each other with a wedge-shaped gap for plastic deformation gradually increasing to one side in the axial direction;
A roller driving motor that drives the driving roller to bend the band-shaped body of the wedge-shaped gap with the pair of forming rollers;
A winding drum disposed on the band discharge side of the forming roller pair and winding the deformed band;
A drum drive motor for driving the winding drum;
A roller pressing mechanism for pressing the driven roller toward the driving roller with a predetermined pressing force with the band-shaped body interposed therebetween;
With
The apparatus for manufacturing a spiral wheel plate, wherein the roller pressing mechanism has a mechanism for adjusting the pressing force according to a change in the number of revolutions of the forming roller or the winding drum .

The spiral wheel manufacturing apparatus according to claim 5,
An optimum relationship between the rotational speed of the drive roller or the winding drum and the pressing force is stored, and when the rotational speed of the drive roller or the winding drum changes, the optimal relationship is determined based on the relationship. A device for manufacturing a spiral wheel plate, comprising a control device for automatically changing the pressing force of a roller pressing mechanism.

In the spiral wheel manufacturing apparatus according to claim 5 or 6,
The control device drives the drive roller at a predetermined rotation value, drives the winding drum at a constant torque, and outputs the roller pressing mechanism in response to switching of the rotation value of the drive roller. A spiral wheel manufacturing apparatus, wherein the pressing force and the torque value output by the winding drum are changed.