JP4965538B2 - Coil winding system - Google Patents

Description

The present invention relates to a coil winding machine for manufacturing a motor used in household electrical appliances, automobiles and the like, and relates to a movement control method for a winding frame provided with a step winding frame constituting the coil winding machine. In particular, the present invention relates to a method for controlling the movement of the winding frame so that the coil is not wound around the step portion.
The present invention also relates to a coil winding system in which a step winding frame is detachable and coil windings having different peripheral lengths can be performed in a plurality of patterns.

  A coil for a motor is formed by winding a plurality of blades 201 in which a wire is spirally wound around a winding frame of a coil winding machine, and then implanted at predetermined intervals in the same circumference as shown in FIG. The coil inserted in the coil insertion jig 200 is inserted into the predetermined slot 301 of the stator 300 and transferred. However, the circumferences of the coils 401 to 405 wound by the coil winding machine are all set to be the same in accordance with the portion that requires the most length when inserted into the slot 301 and formed. Depending on the portion of the slot 301 to be inserted, the length of the coil end may be inserted more than necessary, and the size of the coil end increases and the stator becomes larger. At the same time, extra copper loss occurs and the motor efficiency decreases. There was a problem of doing. Therefore, conventionally, a coil winding machine for manufacturing a motor provided with a step for changing the circumference of the coil has been proposed, and is described in, for example, Japanese Patent Application Laid-Open No. 2003-164122 cited as Patent Document 1.

Patent Document 1 proposes a coil winding machine as shown in FIG. 16 so that each coil has a different circumference. FIG. 15 is a view showing the coil winding machine, and FIG. 16 is a view showing a winding state of the coil. And FIG. 17 is the figure which showed the state which attached the level | step difference to the winding frame of a coil winding machine.
The coil winding machine 100 is arranged with respect to the coil insertion jig 200 as shown in FIG. 15, and this coil winding machine 100 is held by a support plate 131 in which a winding frame 110 is movable up and down, As shown in FIG. 16, the coils 401 to 405 wound around the winding frame 110 are discharged downward by the push plate 133 at the lower end of 132. On the outside of the reel 110, a flyer 120 through which ten strip-shaped wires 400 forming coils 401 to 405 are inserted is rotatably provided, and the flyer 120 revolves around the reel 110 at high speed. As a result, as shown in FIG. 16, the wire 400 is spirally wound around the lowering reel 110.

  The reel 110 is provided with a fixed reel 111 and a movable reel 112 with respect to the support plate 131. As shown in FIG. 17, the movable reel 112 is integrated with a guide shaft 161 in which the first to fourth reel pieces 151 to 154 are inserted through the substrate 156 and can slide in the horizontal direction. The guide plate 162 fixed to 161 is urged toward the fixed reel 111 side on the left side of the drawing by a compression spring (not shown). Cams 171 to 174 are formed integrally with the cam shaft 170 at the shaft center A of the reel 110, and the reel pieces 151 to 154 pressed against the cams 171 to 174 by the rotation of the cam shaft 170 are respectively compressed springs. It is pushed outward against the urging force to form a step. Therefore, as shown in FIG. 16, the wire 400 is wound from the first turn to the fifth turn between the fixed winding frame 111 and coils 401 to 405 having different peripheral lengths are formed.

Thereafter, the winding frame 110 is lowered, and the blade 201 of the coil insertion jig 200 is inserted into the gap 113 with the fixed winding frame 111. As shown in FIG. 16, when the winding of the coil is completed, the cam shaft 170 is reversed to eliminate the stepped portion of the movable winding frame 112, and the first to fifth coils wound around the respective winding frame pieces 151 to 154. 401 to 405 are in a relaxed state. Therefore, when the coil drop 132 is lowered, the coils 401 to 405 are released, and a state similar to the state shown in FIG. 18 is obtained. Then, as described above, the coils 401 to 405 mounted on the coil insertion jig 200 are inserted into the predetermined slots 301 of the stator 300 and transferred. At this time, since the circumferential lengths of the coils 401 to 405 are different depending on the portion of the slot 301 to be inserted, the total coil length inserted into the stator can be shortened to reduce the copper loss.
JP 2003-164122 A (page 2-6, FIGS. 1, 4, 7, and 13)

  By the way, in the coil winding machine described in Patent Document 1, the coils 401 to 405 are wound around the step-like winding frame 110 from the first turn to the fifth turn as shown in FIG. Thus, not only the case where each circumference is neatly divided into the coils 401 to 405 but also the wire 400 fed to the respective step portions generated by the winding frame pieces 151 to 154 may be caught, and overcoming may occur. This is because the movement (lowering) control of the reel 110 during winding is performed so that the reel 110 is evenly fed at a constant speed as shown in FIG. The vertical axis of the graph shown in FIG. 19 is the winding position, that is, the height from the winding start position with respect to the descending reel 110, and the horizontal axis is the rotational speed of the flyer 120 with the position shown in FIG. 15 as the initial state. It is. Therefore, in order to avoid such a drawback in the conventional movement control method, that is, the coil straddling the stepped portion, it is necessary to make the pitch of each circumference sufficiently large. However, this increases the total length of the winding frame, which causes another problem of increasing the size of the coil winding machine.

  Therefore, an object of the present invention is to provide a reel movement control method capable of stably transferring a stepped portion in order to solve such a problem.

Coil winding system of the present invention, compared bobbin having a stepped winding frame unit coil winding portion has a straight linear winding frame unit and stairs shape of the step, is flyer pivots while supplying the wire When the flyer turns while supplying the wire, the winding frame moves in the direction of the central axis of the flyer 's turning so that coil winding with a different circumference is performed on the winding frame, The step reel unit is detachably attached to the reel and includes a first step reel unit and a second step reel unit having different step shapes, the first step reel unit, The shape of the reel is changed by exchanging the second step reel unit .
And the coil winding system of the present invention moves to the reel with the stocker that holds the first step reel unit in advance and the first step reel unit taken out from the stocker, The second step reel unit previously attached to the reel is removed, the first step reel unit is attached to the reel, and the removed second step reel unit is returned to the stocker. It is desirable to have a changer .

Further, according to the coil winding system of the present invention, the stepped reel unit is detachably attached to the reel, and has the first stepped reel unit and the second stepped reel unit having different step shapes. And since the shape of a winding frame is changed by replacing | exchanging a 1st level | step difference winding frame unit and a 2nd level | step difference winding frame unit, the coil from which circumference differs can be formed arbitrarily.

  Next, an embodiment of a reel movement control method according to the present invention will be described below with reference to the drawings. First, the coil winding machine of this embodiment will be described. In the coil winding machine of the present embodiment, as in the conventional example shown in Patent Document 1 described above, a flyer 120 through which a wire 400 serving as a coil is inserted is rotatably provided outside the winding frame. The flyer 120 is configured to turn around the reel at high speed, and the wire 400 is spirally wound around the descending reel.

  The coil winding machine of this embodiment is provided with a step in the winding frame so that the coil peripheral length can be variably set. In particular, the step winding frame for changing the coil peripheral length can be replaced. It is characterized by a simple structure. FIG. 1 is a side view showing such a reel. 2 and 3 are a side view and a plan view showing the reel when the replaceable step reel is replaced.

  The reel 1 is provided with a step reel 3 and a linear reel 4 with respect to a reel base 2 attached so as to be movable in the vertical direction, and in particular, three step reels 3A that can be replaced as the step reel 3. , 3B, 3C are prepared. This is because the coil winding machine of the present embodiment is for attaching the U-phase, V-phase and W-phase coils to the stator in order to manufacture a three-phase motor. Therefore, the three step winding frames 3A, 3B, and 3C have a stepped shape in which steps are formed so that coil windings having circumferential lengths corresponding to the U phase, the V phase, and the W phase are performed.

  The step winding frame 3 is formed with a stepped step portion on which a coil is directly wound, and a slide groove 11 for exchanging is formed at an upper end portion thereof. As shown in FIG. 16, the linear winding frame 4 having the gap portion 12 into which the blade 201 of the coil insertion jig 200 is inserted is fixed to the winding frame base 2, and the guide rail 13 corresponding to the slide groove 11 is projected. ing. Therefore, when the stepped reel 3 moves in a direction penetrating the paper surface of FIG. 1, the slide groove 11 fits into the guide rail 13 and is attached to the reel base 2, and the reel 1 capable of coil winding. Is configured to be created. The stepped reel 3 is attached to and detached from the reel base 2 in the order in which the U-phase, V-phase, and W-phase coils are formed.

As shown in FIGS. 2 and 3, a changer 50 is used for attaching and detaching the step reels 3A, 3B, 3C. The changer 50 takes out a predetermined stepped reel 3 from a stocker (not shown) on which the stepped reel 3 is installed, removes the other stepped reel 3 mounted in advance on the reel base 2, and removes it from the stocker. The stepped reel 3 is replaced with a stepped reel 3 and the removed stepped reel 3 is returned to the stocker. The specific exchange operation will be described later based on the drawings showing the procedure.

  The changer 50 is configured by a base 51 having an L-shaped side surface as shown in FIG. 2 and a U-shaped flat surface as shown in FIG. 3, and this base 51 is connected to an arm (not shown), and the reel 1 It is provided so as to reciprocate between the storage and the stocker. The changer 50 has a holder 52 having two holding portions 52a and 52b each having an E-shaped flat surface as shown in FIG. is doing. The holder 52 is integrated with a slider 53 that can move horizontally with respect to the base 51, and can move in the X direction shown in FIG. Such movement of the holder 52 is configured to operate the slider 53 by, for example, an external actuator.

  When the stepped reel 3 is replaced by the changer 50, the changer 50 moves in the direction of the arrow Y shown in FIG. 3 with respect to the reel base 2 so that the U portion of the base 51 is fitted to the reel base 2. It has become. Then, in the fitted state, for example, one movable reel 3A is simultaneously transferred from the changer 50 to the reel base 2 and the other movable reel 3B is simultaneously transferred from the reel base 2 to the changer 50 in the same direction. It has become. In order to enable this transfer, guide rails 55 and 56 are also provided in the changer 50 so as to be disposed with the guide rail 13 of the winding frame base 2 interposed therebetween. FIG. 3 shows such guide rails 13, 55, 56.

  As shown in FIG. 2, the guide rails 55 and 56 of the changer 50 are provided below the base 51 via a block 57. This is because the guide rails 55 and 56 enter under the reel base 2 and can be arranged at a position close to the guide rail 13. Further, as shown in FIG. 2, the holder 52 that holds the step reel 3 is arranged at a height that slides under the guide rail 55 (56, 13) without interference. Therefore, when the holder 52 moves according to the slider 53, the holder 52 pushes the stepped reel 3 and slides the guide rails 13, 55, 56 to move.

  Next, an exchange operation for exchanging the stepped reel 3 using the changer 50 with respect to the reel 1 having such a configuration will be described. Here, in particular, a case will be described where the step winding frame 3A for the U-phase coil winding is replaced with the step winding frame 3B for the V-phase coil winding. 4 to 11 conceptually show each of these steps. In the figure, the stocker 80, the reel 1 and the changer 50 are shown in a simplified plan view. With respect to the changer 50, only the holder 52 and the guide rails 55 and 56 shown in FIGS. 1 to 3 are shown.

  The U-phase, V-phase, and W-phase step reels 3A, 3B, 3C are held by a stocker 80 as shown in FIG. Go get it. 4 and 5 show such a state. As shown in FIG. 4, the holder 52 of the changer 50 grips the stepped reel 3A with one holding portion 52a and slides in the direction of the arrow. As a result, the step winding frame 3 slides with the slide groove 11 fitted into the guide rail 55, and is transferred to the changer 50. The changer 50 moves from the stocker 80 to the reel 1 while holding the step reel 3A as shown in FIG. 5, and is arranged as shown in FIG. At this time, in the changer 50, as shown in FIGS. 2 and 3, the base 51 is fitted to the reel base 2, and the guide rails 55, 13, and 56 are arranged in a straight line.

In the changer 50, when the slider 53 slides, the holder 52 moves in the direction indicated by the arrow in FIG. 6 to the state shown in FIG. Thereby, the step winding frame 3 </ b> A changes from the guide rail 55 to the guide rail 13. Then, the changer 50 that has finished mounting the U-phase stepped reel 3A to the reel 1 moves to the stocker 80 to take the next V-phase stepped reel 3B. At this time, in the winding frame 1 in which the step winding frame 3A is mounted on the winding base 2 as shown in FIG. 1, coil winding is performed to form a U-phase coil. At this time, in the present embodiment, movement control of the descending reel 1 is performed so that the coil performs stable transfer on the step portion of the step reel 3 as described later. Then, the flyer 120 turns around the reel 1 at a high speed around the descending reel 1 as in the conventional example shown in FIG. 16, and the wire 400 is wound spirally.

  Meanwhile, as shown in FIG. 8, the changer 50 that has been removed from the V-phase stepped reel 3B is fitted with the stepped reel 3B on the holding portion 52a side of the holder 52. Then, when it is grasped by the holding portion 52 a and slides in the direction of the arrow, the slide groove 11 is fitted into the guide rail 55 and the step winding frame 3 </ b> B is transferred to the changer 50. Therefore, the changer 50 moves from the stocker 80 to the reel 1 while holding the stepped reel 3B as shown in FIG. 9, and is arranged as shown in FIG. That is, the vacant holding portion 52b of the holder 52 is fitted into the stepped winding frame 3A that is mounted on the winding frame 1 and has finished the U-phase coil winding.

  Then, when the holder 52 moves in the direction of the arrow shown in FIG. 10, the stepped reels 3A and 3B move simultaneously on the guide rails 55, 13 and 56 arranged in a straight line as shown in FIG. 3A, the step winding frame 3A mounted on the winding frame base 2 is removed, and then the step winding frame 3B is mounted on the winding frame base 2. The removed step winding frame 3A is returned to a predetermined position of the stocker 80 as shown in FIG. 4, and then the W-phase movable winding 3C is held by the holding portion 52a of the holder 52, and similarly the V-phase. Replacement of the movable winding 3B is completed.

  Next, the movement control of the reel 1 descending with respect to the turning flyer when performing coil winding will be described. In the present embodiment, for example, as shown in FIG. 12, the coil winding is performed so that the wire 400 is spirally wound around the descending reel 1. At this time, coils having different circumferential lengths are formed on the steps 31 to 36 of the step winding frame 10. Conventionally, since the descending speed (see FIG. 19) is constant, if ten strips of the wire 400 have a certain width, they may straddle, for example, both the steps 31 and 32 in the same turn. there were. Therefore, in the present embodiment, the lowering control of the winding frame 1 is performed in order to perform stable step changes so that the coils of the same circumference are reliably wound around the steps 31, 32.

  13 and 14 are graphs showing the descending state of the reel 1, the vertical axis is the winding position, that is, the height from the winding start position with respect to the descending reel 110, and the horizontal axis is the figure. 15 is the rotation speed of the flyer 120 with the position shown in FIG. First, the control method shown in FIG. 13 executes step control in which the reel 1 is lowered by repeatedly moving and stopping. In this step control, the winding is performed when the flyer 120 is at a certain angle. Lower frame 1. That is, the wire 400 is lowered when the wire 400 feed position is on the straight reel 4 side without a step, and the movement is stopped so that the height does not change when the wire 400 feed position turns on the step reel 3 side. To do.

On the other hand, the control method shown in FIG. 14 executes the variable speed control in which the descent speed is adjusted so as not to stop completely, unlike the control method shown in FIG. It is. That is, the lowering speed of the winding frame 1 is changed in accordance with the feeding position of the wire 400 in the flyer 120. Specifically, when the feeding position of the wire 400 is on the stepped winding frame 3 side, the winding is performed. The descending speed of the frame 1 is decreased, and conversely, the descending speed is increased when the frame 1 is on the linear reel 4 side.
Accordingly, in the method for controlling the lowering of the reel 1, the step control shown in FIG. 13 and the variable speed control shown in FIG. 14 are executed, so that when the coil is wound around the steps 31 to 36, Thus, the heights of the steps 31 to 36 do not change or hardly change, so that winding is not performed across different steps.

Therefore, according to the coil winding machine of the present embodiment, the step winding frame 3 can be exchanged, and thus coils having different circumferential lengths can be arbitrarily formed by preparing a predetermined step winding frame.
Then, by performing the descending operation corresponding to the steps 31 to 36 of the step reel 3 and performing step control and variable speed control as shown in FIG. 13 or FIG. .., Coil winding is performed for each of the steps 31, 32. When step control and variable speed control are compared, the variable speed control has a smoother movement, so the mechanical load for moving the reel 1 is smaller, and the feed pitch within each of the steps 31 to 36 is reduced. It is more preferable because it can be narrowed.

The present invention is not limited to the above-described embodiment, and various modifications can be made without departing from the spirit of the present invention.
For example, in the above-described embodiment, the stepping control and the variable speed control of the lowering movement control are described for the exchangeable reel 1 of the step reel 3 as shown in FIG. It is naturally effective to perform movement control as in the present invention even if a variable type as in the conventional example is used.

It is the side view which showed the reel in which a level | step difference reel is replaceable. It is the side view which showed the winding frame at the time of replacing | exchanging the level | step difference winding frame which can be replaced | exchanged. It is the top view which showed the winding frame at the time of replacing | exchanging the exchangeable level winding frame. It is the figure which showed the attachment process with respect to the winding frame of a level | step difference winding frame. It is the figure which showed the attachment process with respect to the winding frame of a level | step difference winding frame. It is the figure which showed the attachment process with respect to the winding frame of a level | step difference winding frame. It is the figure which showed the replacement | exchange process of the level | step difference winding frame with which the winding frame was mounted | worn. It is the figure which showed the replacement | exchange process of the level | step difference winding frame with which the winding frame was mounted | worn. It is the figure which showed the replacement | exchange process of the level | step difference winding frame with which the winding frame was mounted | worn. It is the figure which showed the replacement | exchange process of the level | step difference winding frame with which the winding frame was mounted | worn. It is the figure which showed the exchange process of the level | step difference winding frame with which the winding frame was mounted | worn. It is the figure which showed the coil winding state with respect to the winding frame of embodiment. It is the figure which showed the movement control (step control) when a winding frame descend | falls as a graph. It is the figure which showed the movement control (speed variable control) when a winding frame descend | falls as a graph. It is the figure which showed the conventional coil winding machine. It is the figure which showed the winding state of the coil in the conventional coil winding machine. It is the figure which showed the state which provided the level | step difference in the winding frame in the conventional coil winding machine. It is the figure which showed the state which left the coil wound up with the coil winding machine to the coil insertion jig. It is the figure which showed the movement control (constant speed control) when a winding frame descend | falls in the graph.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Winding frame 2 Winding frame base 3 (3A, 3B, 3C) Step winding frame 4 Linear winding frame 11 Slide groove 13, 55, 56 Guide rail 50 Changer 53 Holder 80 Stocker

Claims (2)

To reel having a stepped winding frame unit coil winding portion has a straight linear winding frame unit and stairs shape of the step, flyer pivots while supplying wire is disposed, flyer supplies the wire While turning, while the winding frame moves in the direction of the central axis of the flyer 's turning, coil winding with different circumferential length is performed on the winding frame,
The step reel unit is detachably attached to the reel, and includes a first step reel unit and a second step reel unit having different step shapes,
A coil winding system , wherein the shape of the reel is changed by exchanging the first step reel unit and the second step reel unit . The coil winding system according to claim 1,
A stocker that holds the first step reel unit in advance;
Holding the first step reel unit taken out from the stocker, move to the reel, remove the second step reel unit previously mounted on the reel, and remove the first step reel unit. A coil winding system comprising: a changer configured to return the second stepped reel unit attached to and removed from the reel to the stocker .

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