Patent Description:
A stator of an inner rotor type motor is formed by winding a wire on magnetic poles projecting from an inner peripheral side in a stator core formed by laminating a plurality of annular members. A stator of an outer rotor type motor is formed by winding a wire on a plurality of magnetic poles radially projecting from an outer peripheral side of a stator core. A winding apparatus has been proposed which includes a nozzle formed with a wire feed hole and a nozzle moving mechanism for moving the nozzle to wind a wire on each magnetic pole of the stator core.

In wire winding, a nozzle is circulated around a wound member and a wire fed through a wire feed hole of the nozzle is wound around the wound member. If a magnetic pole having a rectangular cross-section is the wound member, a so-called wire bulging phenomenon may occur in which the wire is not bent at a right angle on corner parts of the magnetic pole (wound member) and is lifted without being held in close contact with flat surface parts between the corner parts. Such bulging of the wire makes winding on an adjacent magnetic pole difficult if the wound member is a magnetic pole of a stator, and a trouble may occur in which the number of turns of the wire on the adjacent magnetic pole is reduced.

To prevent the bulging of a wire wound on a wound member having a rectangular cross-section, a method has been proposed in which two pins are provided on both sides of a nozzle and the wire is wound while being reformed by alternately causing the pins to project and retract (see, for example, <CIT>, wherein a winding apparatus according to the preamble of claim <NUM> is disclosed). In this method, since the wire is wound on the wound member while being reformed by the pins, the lift of the wire from surrounding flat surface parts can be suppressed. Technological background is disclosed in <CIT>, <CIT>, and <CIT>.

However, in the above conventional winding apparatus, the positions of the pins with respect to the wire cannot be changed. Thus, how to reform the wire could not be adjusted. That is, in the above conventional winding apparatus, the wire is reformed always constantly and the reformation given to the wire cannot be strengthened or weakened. Thus, if the wire is wound over a plurality of layers on the wound member, how the wire bulges differ between the first layer and the last layer.

The present invention aims to provide a winding apparatus and a winding method for wire capable of reforming a wire fed from a nozzle and changing a degree of reformation.

According to one aspect of the present invention, a winding apparatus for winding a wire around a wound member is defined in claim <NUM> and includes a supporting tool configured to support the wound member, a nozzle formed with a wire feed hole, the wire passing through the wire feed hole, a relative moving mechanism configured to relatively move the nozzle with respect to the supporting tool, a rod provided adjacent to the nozzle to be moved together with the nozzle by the relative moving mechanism, the rod being provided in parallel to the wire feed hole and deviated from the wire feed hole in a radial direction of the wire feed hole, and a rod rotating mechanism configured to rotate the rod about the wire feed hole around the wire feed hole. The rod is integrally formed to the nozzle.

According to other aspect of the present invention, a winding method for winding a wire fed from a nozzle around a wound member using the winding apparatus is defined in claim <NUM>. The method is performed by relatively moving the nozzle around the wound member, includes causing the rod to follow the nozzle relatively moving with respect to the wound member around the wound member by rotating the rod about the wire feed hole of the nozzle around the wire feed hole, and winding the wire turned toward the wound member by coming into contact with the rod after being fed from the nozzle on the wound member.

Next, a related example useful for understanding the present invention, but which does not include all features of the claims, is described with reference to the drawings.

A wire winding apparatus <NUM> in a related example is shown in <FIG>. In the following description, the configuration of the winding apparatus <NUM> is described, assuming that three axes of X, Y and Z orthogonal to each other are set in each figure, an X axis extends substantially in a horizontal front-rear direction, a Y axis extends substantially in a horizontal lateral direction and a Z axis extends in a vertical direction.

The winding apparatus <NUM> winds a wire <NUM> fed from a nozzle <NUM> on magnetic poles 13b of a stator core <NUM>. The magnetic poles 13b of the stator core <NUM> have a rectangular cross-sectional shape. Specifically, a case is shown in which members to be wound in the present related example are the magnetic poles 13b of the stator core <NUM> having a rectangular cross-section (<FIG>). Further, as shown in <FIG>, the stator core <NUM> is of an outer rotor type and includes an annular part 13a having a circular ring shape and a plurality of the magnetic poles 13b radially projecting outwardly of the annular part 13a from the outer peripheral surface of the annular part 13a.

As shown in <FIG>, the winding apparatus <NUM> includes a machine stand <NUM> installed in an installation place. A table <NUM> is provided on the machine stand <NUM>. A supporting tool <NUM> for supporting the stator core <NUM> is provided on the table <NUM>. Further, a rocking servo motor <NUM> including a rotary shaft 19a extending in a Z-axis direction and a mounting plate <NUM> shifted from the rocking servo motor <NUM> in a Y-axis direction and adjacent to the rocking servo motor <NUM> are provided on the table <NUM>. The supporting tool <NUM> includes a rod-like core member 18a having the stator core <NUM> horizontally placed on an upper end edge (upper end surface) thereof and extending in the vertical direction, and a pressing member 18b for pressing the stator core <NUM> placed on the upper end edge of the rod-like core member 18a from above.

The rod-like core member 18a has a lower end thereof mounted on the rotary shaft 19a of the rocking servo motor <NUM>, and an upper part thereof is formed to have an outer diameter slightly smaller than that of the annular part 13a (<FIG>) of the stator core <NUM>. Linear motion guide rails <NUM> are mounted to extend in the vertical direction on a side of the mounting plate <NUM> facing the rocking servo motor <NUM>. An elevating member <NUM> is mounted on the guide rails <NUM> to be vertically movable.

The pressing member 18b is so mounted on the elevating member <NUM> that a vertical axis in a center thereof coincides with a center axis of the rod-like core member 18a and the pressing member 18b is rotatable about the vertical axis. A lower part of the pressing member 18b for actually pressing the stator core <NUM> placed on the upper end edge of the rod-like core member 18a from above is formed to have an outer diameter slightly smaller than that of the annular part 13a of the stator core <NUM> (<FIG> and <FIG>). Further, the annular part 13a of the stator core <NUM> is sandwiched by the rod-like core member 18a and the pressing member 18b, and the magnetic poles 13b radially project outward from the annular part 13a. The nozzle <NUM> is configured to be able to circulate around each magnetic pole 13b.

A lower end of the rod-like core member 18a is mounted on the rotary shaft 19a of the rocking servo motor <NUM>, and the rod-like core member 18a rotates together with the rotary shaft 19a when the rotary shaft 19a of the servo motor <NUM> rotates. In this way, the stator core <NUM> sandwiched by the rod-like core member 18a and the pressing member 18b rotates about a center axis of the supporting tool <NUM> composed of the rod-like core member 18a and the pressing member 18b. The stator core <NUM> is placed on the upper end edge of the rod-like core member 18a and configured such that a center thereof coincides with a center axis of the supporting tool <NUM>. The magnetic poles 13b around the stator core <NUM> are configured to be rockable by the rotation of the stator core <NUM>.

As just described, the rocking servo motor <NUM> is configured to function as a member moving mechanism for moving the stator core <NUM> such that the magnetic poles 13b rock. An elevation cylinder <NUM> for moving the elevating member <NUM> upward and downward together with the pressing member 18b is provided on the mounting plate <NUM> above the elevating member <NUM>.

Further, the winding apparatus <NUM> is provided with a nozzle moving mechanism <NUM> for moving a moving table <NUM> provided with the nozzle <NUM> in three axis directions. The nozzle moving mechanism <NUM> is constituted by a combination of the moving table <NUM> and X-axis, Y-axis and Z-axis direction telescopic actuators <NUM> to <NUM> for moving the moving table <NUM> in the three axis directions. Each of these telescopic actuators <NUM> to <NUM> is composed of a ball screw 44b to 46b to be rotational driven by a servo motor 44a to 46a, a follower 44c to 46c threadably engaged with the ball screw 44b to 46b to move in parallel, and the like.

In the present related example, the moving table <NUM> is mounted on the follower 44c of the X-axis direction telescopic actuator <NUM> movably in the X-axis direction, and the X-axis direction telescopic actuator <NUM> is mounted on the follower 46c of the Z-axis direction telescopic actuator <NUM> movably in the Z-axis direction. Further, the Z-axis direction telescopic actuator <NUM> is mounted on the follower 45c of the Y-axis direction telescopic actuator <NUM> movably in the Y-axis direction, and the Y-axis direction telescopic actuator <NUM> is mounted on the machine stand <NUM>.

The servo motor 44a to 46a in each telescopic actuator <NUM> to <NUM> is connected to a control output of an unillustrated controller. The nozzle moving mechanism <NUM> is configured to be able to arbitrarily move the nozzle <NUM> provided on the moving table <NUM> in the three axis directions together with the moving table <NUM> on the basis of a command from the controller.

The wire <NUM> is wound on a reel <NUM>, and the reel <NUM> serves as a supply source for the wire <NUM>. The reel <NUM> is placed in another place separated from the nozzle moving mechanism <NUM>, e.g. on the machine stand <NUM> or the like. A straightening device <NUM> for straightening the wire <NUM> fed from the reel <NUM> serving as the supply source is provided on the machine stand <NUM>.

The straightening device <NUM> includes a pair of routing pulleys <NUM>, <NUM> for routing the wire <NUM> fed from the reel <NUM> into an "<NUM> shape", and a fixed pulley <NUM> and a movable pulley <NUM> for turning the wire <NUM> having passed through the pair of routing pulleys <NUM>, <NUM> into an "S shape". The wire <NUM> is configured to be turned by the fixed pulley <NUM> and the movable pulley <NUM> moves in a direction toward the moving table <NUM>. The movable pulley <NUM> is biased in a direction away from the moving table <NUM> by a coil spring <NUM>. The coil spring <NUM> prevents the wire <NUM> from being slackened when the moving table <NUM> moves by biasing the movable pulley <NUM>.

The nozzle <NUM> is provided on the tip of the moving table <NUM> facing the stator core <NUM> via a servo motor <NUM>. As shown in detail in <FIG> and <FIG>, a supporting wall <NUM> stands on the tip of the moving table <NUM> facing the stator core <NUM>. The servo motor <NUM> is so mounted on the supporting wall <NUM> that a rotary shaft 25a thereof is horizontal. The servo motor <NUM> is formed with a through hole 25b in a center of the rotary shaft 25a. A nozzle holder <NUM> is mounted on the tip of the rotary shaft 25a facing the stator core <NUM>.

As shown in <FIG>, the nozzle holder <NUM> is a bottomed tubular member including a tubular part 27a and a bottom part 27b. The tubular part 27a has a rectangular cross-section (see <FIG>). A communication hole 27c communicating with a center hole of the tubular part 27a is formed in a center of the bottom part 27b. Further, a tubular mounting part 27d into which the rotary shaft 25a of the servo motor <NUM> is fittable is formed to surround the communication hole 27c on a side of the bottom part 27b opposite to a side continuous with the tubular part 27a. The tubular mounting part 27d is fit to the rotary shaft 25a and screwed, whereby the nozzle holder <NUM> is mounted on the tip of the rotary shaft 25a of the servo motor <NUM> while causing the communication hole 27c formed in the bottom part 27b to be continuous with the through hole 25b of the rotary shaft 25a.

The nozzle <NUM> is sized to be insertable into the tubular part 27a of the nozzle holder <NUM>, and a wire feed hole 11a is provided to penetrate through a center of the nozzle <NUM>. The nozzle <NUM> is so housed in the nozzle holder <NUM> that the through hole 25b of the rotary shaft 25a of the servo motor <NUM> and the wire feed hole 11a are continuous.

The tubular part 27a of the nozzle holder <NUM> having a rectangular cross-section is formed with internally threaded holes 27e respectively in parts constituting short sides of the rectangular cross-sectional shape, and the internally threaded holes 27e are formed to extend in a direction perpendicular to the through hole 27c. By threadably engaging a male screw <NUM> into each internally threaded hole 27e and bringing an end part of the male screw <NUM> into contact with the nozzle <NUM> housed in the tubular part 27a, the nozzle <NUM> is fixed in the nozzle holder <NUM>.

Further, a rod (reforming bar) <NUM> is provided adjacent to the nozzle <NUM> on the rotary shaft 25a of the servo motor <NUM>. The rod <NUM> is a bar-like member made of metal and having a circular cross-section, and the rod <NUM> has such an outer diameter as to be insertable into the tubular part 27a in the nozzle holder <NUM>. The rod <NUM> is housed in the nozzle holder <NUM> to be in parallel to the wire feed hole <NUM>1a of the nozzle <NUM> and deviated from the wire feed hole 11a in a radial direction of the wire feed hole 11a. The rod <NUM> is mounted in the nozzle holder <NUM> together with the nozzle <NUM> by the male screws <NUM> tightened from both sides in a direction intersecting the wire feed hole 11a. As the nozzle <NUM> is moved via the moving table <NUM> by the nozzle moving mechanism <NUM>, the rod <NUM> mounted in the same nozzle holder <NUM> as the nozzle <NUM> also moves together with the nozzle <NUM>.

Further, as shown in <FIG>, the rod <NUM> is so provided that a projecting end thereof projects further from the nozzle holder <NUM> than the tip edge of the nozzle <NUM>. That is, the projecting end of the rod <NUM> projects further in the X-axis direction toward the stator core <NUM> than the tip of the nozzle <NUM> (see <FIG>). If the wire <NUM> fed from the wire feed hole 11a of the nozzle <NUM> is bent at the tip edge of the nozzle <NUM>, the bent wire <NUM> can come into contact with the rod <NUM> further projecting than the tip edge of the nozzle <NUM>. Thus, a projecting amount P of the rod <NUM> projecting from the tip edge of the nozzle <NUM> is adjusted to be at least larger than an outer diameter of the wire <NUM>. An outer surface of a tip part of the rod <NUM> with which the wire <NUM> comes into contact is finished by polishing such that the wire <NUM> is slidable.

Further, as described above, the rod <NUM> is provided in the nozzle holder <NUM> in a manner deviating with respect to the rotary shaft 25a formed with the through hole 25b coaxial with the wire feed hole 11a. Thus, the nozzle holder <NUM> and the servo motor <NUM> constitute a rod rotating mechanism for rotating the rod <NUM> about the wire feed hole 11a of the nozzle <NUM> around the wire feed hole 11a.

As shown in <FIG>, the moving table <NUM> is provided with a passing plate <NUM>. The passing plate <NUM> is formed with a hole (not shown) through which the wire <NUM> supplied from the reel <NUM> via the straightening device <NUM> passes. The wire <NUM> having passed through the passing plate <NUM> via this unillustrated hole reaches the servo motor <NUM> provided on the moving table <NUM> and is inserted through the nozzle <NUM> through the through hole 25b. A chuck device <NUM> capable of gripping the wire <NUM> having passed through the passing plate <NUM> is provided on the passing plate <NUM>.

Next, a winding method using the winding apparatus <NUM> is described.

In the winding method using the winding apparatus <NUM>, the stator core <NUM> is first supported by the supporting tool <NUM>. Specifically, in supporting the stator core <NUM>, the nozzle moving mechanism <NUM> keeps the nozzle <NUM> away from the supporting tool <NUM>. In that state, a rod 24a of the elevating cylinder <NUM> provided on the mounting plate <NUM> is caused to sink, whereby the elevating member <NUM> is moved upward and the pressing member 18b mounted on the elevating member <NUM> is moved upward as indicated by a dashed-dotted line of <FIG>. In this way, a space is formed below the pressing member 18b and between the rod-like core member 18a and the pressing member 18b.

Then, the stator core <NUM> is horizontally placed on the upper edge of the rod-like core member 18a via that space. Further, the rod 24a of the elevating cylinder <NUM> is caused to project to move the elevating member <NUM> downward as indicated by a two-dot chain line of <FIG>. In this way, the stator core <NUM> placed on the upper edge of the rod-like core member 18a is pressed from above by the pressing member 18b as shown in <FIG> by the pressing member 18b moving downward together with the elevating member <NUM>.

Thereafter, the nozzle <NUM> is moved in three-dimensional directions with respect to the stator core <NUM> by the nozzle moving mechanism <NUM> capable of moving the nozzle <NUM> at least in the Z-axis direction and the rocking servo motor <NUM> for operating the stator core <NUM> to rock the magnetic poles 13b. In this way, the end part of the wire <NUM> fed from the tip of the nozzle <NUM> via the wire feed hole 11a is fixed by being entwined around an unillustrated entwining pin or wire clamping device.

Subsequently, actual winding is performed. In actual winding, the nozzle <NUM> is reciprocally moved along the Z-axis direction by the nozzle moving mechanism <NUM> and the stator core <NUM> is alternately rotated in forward and reverse directions by the rocking servo motor <NUM> so that the magnetic pole 13b being wire-wound rocks. By a combination of these operations, the nozzle <NUM> is rotationally moved around the magnetic pole 13b in a rectangular shape along the cross-sectional shape of the magnetic pole 13b. In this way, a relative moving mechanism for relatively moving the nozzle <NUM> with respect to the supporting tool <NUM> is constituted by the nozzle moving mechanism <NUM> and the rocking servo motor <NUM> serving as the member moving mechanism.

A rotational movement of the nozzle <NUM> in a rectangular shape is specifically described with reference to <FIG>. A case is described in which the rotational movement starts from a state where the tip of the nozzle <NUM> is inserted in a slot 13c formed between the magnetic pole 13b and the magnetic pole 13b adjacent thereto on one side as shown in <FIG>. In this case, only the nozzle <NUM> is first moved upward without rocking the magnetic poles 13b by the rocking servo motor <NUM>.

If the tip of the nozzle <NUM> comes out from the slot 13c, an upward movement of the nozzle <NUM> is stopped. Then, the rocking of the magnetic poles 13b is started as indicated by a solid-line arrow of <FIG>, and the rocking is finished when the tip of the nozzle <NUM> comes to be located above a slot 13c between the magnetic pole 13b being wire-wound and the magnetic pole 13b adjacent thereto on the other side as shown in <FIG>. In this way, the tip of the nozzle <NUM> moves along an end edge of the magnetic pole 13b outside the slot 13c.

After the tip of the nozzle <NUM> reaches the slot 13c sandwiched by the magnetic pole 13b being wire-wound and the other magnetic pole 13b adjacent thereto and the rocking of the magnetic poles 13b is stopped, the nozzle <NUM> is moved downward. A downward movement of the nozzle <NUM> is stopped when the tip of the nozzle <NUM> comes out downward from the slot 13c adjacent to the magnetic pole 13b being wire-wound.

Subsequently, the magnetic poles 13b are rocked in the reverse direction indicated by a broken-line arrow in <FIG>, and the rocking is finished when the tip of the nozzle <NUM> comes to be located below the first slot 13c.

Specifically, after the nozzle <NUM> comes out downward from the slot 13c adjacent to the magnetic pole 13b being wire-wound, the downward movement of the nozzle <NUM> is stopped. Subsequently, the rocking of the magnetic poles 13b is started and the rocking is finished when the tip of the nozzle <NUM> reaches a position below the first slot 13c. In this way, the tip of the nozzle <NUM> moves in a rectangular shape along the outer periphery of the magnetic pole 13b having a rectangular cross-section around the magnetic pole 13b as shown in <FIG>.

As shown in <FIG>, if the nozzle <NUM> is moved in the rectangular shape around the magnetic pole 13b, which is a wound member having a rectangular cross-section, the wire <NUM> fed via the wire feed hole 11a of the nozzle <NUM> is wound on that magnetic pole 13b.

On the other hand, if the wire <NUM> is wound around the magnetic pole 13b having the rectangular cross-section, such a phenomenon may occur in which the wire <NUM> bulges on corner parts in a rectangular shape by being lifted without being bent at a right angle and without being held in close contact with flat surface parts between the corner parts.

In contrast, the rod <NUM> is provided adjacent to the nozzle <NUM> in the present related example. As shown in <FIG>, the rod <NUM> moves together with the nozzle <NUM> to chase the nozzle <NUM> from behind, and follows the nozzle <NUM>. In this way, the wire <NUM> fed from the tip of the nozzle <NUM> via the wire feed hole 11a comes into contact with the rod <NUM> following the nozzle <NUM> and extends along the outer surface of the magnetic pole 13b after being bent in a lateral direction perpendicular to a moving direction of the rod <NUM>, i.e. toward the magnetic pole 13b.

Thus, the wire <NUM> comes into contact with the rod <NUM> before extending along the outer surface of the magnetic pole 13b from the tip of the nozzle <NUM> and is convexly curved toward the magnetic pole 13b. As a result, the wire <NUM> is reformed to be curved convexly toward the magnetic pole 13b. As just described, in the winding apparatus <NUM> in which the rod <NUM> is provided adjacent to the nozzle <NUM>, the wire <NUM> can be reformed by causing the rod <NUM> to follow the nozzle <NUM> to chase after the nozzle <NUM>. A convex part of the curved wire <NUM> reformed in this way approaches the outer surface of the magnetic pole 13b and the wire <NUM> is easily brought into contact with the outer surface of the magnetic pole 13b as compared to the case where the wire <NUM> is not reformed by the rod <NUM>. Thus, the lift of the wire <NUM> from the flat surface parts around the magnetic pole 13b can be suppressed by winding the wire <NUM> on the magnetic pole 13b serving as the wound member with the wire <NUM> reformed in advance by the rod <NUM>. In other words, the wire <NUM> fed from the nozzle <NUM> can be wound on the magnetic pole 13b while being caused to extend along the outer surface of the rectangular magnetic pole 13b by being reformed by the rod <NUM>.

Further, the winding apparatus <NUM> includes the servo motor <NUM> constituting the rod rotating mechanism for rotationally moving the rod <NUM> about the wire feed hole 11a around the wire feed hole 11a. Thus, even if the nozzle <NUM> is moved in the rectangular shape around the magnetic pole 13b having the rectangular cross-section, the rod <NUM> can be reliably caused to follow the nozzle <NUM> from behind in the moving direction of the nozzle <NUM> by rotationally moving the position of the rod <NUM> with respect to the wire feed hole 11a.

Specifically, in the winding apparatus <NUM>, the rod <NUM> can be caused to follow the nozzle <NUM> passing through the slot 13c and moving along the magnetic pole 13b (moving in the lateral direction in <FIG>) outside the magnetic pole 13b without being limited to the case where the rod <NUM> is caused to follow the nozzle <NUM> having passed through the slot 13c as shown in <FIG>.

Thus, both the wire <NUM> fed from the nozzle <NUM> passing through the slot 13c and the wire <NUM> fed from the nozzle <NUM> moving along and outer side the magnetic pole 13b after passing through the slot 13c can be reformed. Therefore, the lift of the wire <NUM> from each peripheral surface of the magnetic pole 13b having the rectangular cross-section can be effectively suppressed.

Further, in order to wind the wire <NUM> in alignment on the magnetic pole 13b, the nozzle <NUM> is rotationally moved around the magnetic pole 13b and the position of the nozzle <NUM> with respect to the magnetic pole 13b is shifted in the X-axis direction by an amount of a diameter of the wire <NUM> on every turn of the wire <NUM>. In this way, the wire <NUM> can be effectively wound in alignment on the magnetic pole 13b. Here, in the winding apparatus <NUM> in the present related example, the nozzle <NUM> can be moved in the X-axis direction by the nozzle moving mechanism <NUM>.

After all the magnetic poles 13b are wire-wound in this way and the winding on all the magnetic poles 13b is finished, the stator core <NUM> is removed from the supporting tool <NUM>. Specifically, in this removal, the nozzle moving mechanism <NUM> moves the nozzle <NUM> away from the stator core <NUM>. In that state, the rod 24a of the elevating cylinder <NUM> provided on the mounting plate <NUM> is caused to sink and the pressing member 18b is moved upward together with the elevating member <NUM> as indicated by the dashed-dotted line of <FIG>. In this way, the pressing of the stator core <NUM> by the pressing member 18b is released and a space is formed above the stator core <NUM>. Then, the stator core <NUM> placed on the upper end of the rod-like core member 18a is removed from the rod-like core member 18a via that space and a series of winding methods are finished.

A modification of the present related example is shown in <FIG>. The same components as those of the apparatus in the previous related example are denoted by the same reference signs and repeated description is omitted.

As shown in <FIG>, in a winding apparatus <NUM> in the modification, a stator core <NUM> to be wire-wound is of an inner rotor type. The stator core <NUM> includes an annular part 63a having a circular ring shape and a plurality of magnetic poles 63b projecting toward a center of the annular part 63a from the inner peripheral surface of the annular part 63a.

As shown in <FIG>, a supporting tool <NUM> for carrying the stator core <NUM> is provided on a machine stand <NUM> in the winding apparatus <NUM>. The supporting tool <NUM> includes a fixed table 68a disposed on the machine stand <NUM>, a turntable 68b mounted on the fixed table 68a rotatably in a horizontal plane, the stator core <NUM> being mountable and fixable above the rotary table 68b, and an unillustrated rocking servo motor for rotating the turntable 68b.

The winding apparatus <NUM> includes the machine stand <NUM> provided with the supporting tool <NUM> and installed in an installation place, and a nozzle moving mechanism <NUM> provided on the machine stand <NUM> to drive a nozzle <NUM> in three axis directions. The nozzle moving mechanism <NUM> is formed by combining driving units <NUM>, <NUM> and <NUM> of the three axis directions and includes a front-rear direction driving unit <NUM>, a lateral direction driving unit <NUM> and a vertical direction driving unit <NUM>. These driving units <NUM>, <NUM> and <NUM> are substantially the same driving mechanisms along driving directions X, Y and Z.

First, the vertical direction driving unit <NUM> is described. The vertical direction driving unit <NUM> includes a vertical direction guide 73a disposed along the driving direction Z, a vertical direction rotary shaft 73b disposed in parallel to the vertical direction guide 73a and having an external thread disposed on a surface, a vertical direction moving part 73c threadably engaged with the vertical direction rotary shaft 73b by a ball screw and movable along the vertical direction guide 73a, a vertical direction connecting part 73d to be connected to the vertical direction moving part 73c, and a vertical direction drive source 73e for rotationally driving the vertical direction rotary shaft 73b. The vertical direction rotary shaft 73b is connected to the vertical direction drive source 73e by a universal joint 73f. A moving range of the vertical direction moving part 73c in the driving direction Z is set by a range of the external thread disposed on the vertical direction rotary shaft 73b.

Each of the front-rear direction driving unit <NUM> and the lateral direction driving unit <NUM> is disposed along the driving direction X, Y shown in <FIG> as a structure similar to the vertical direction driving unit <NUM>. The front-rear direction driving unit <NUM> is fixed to the machine stand <NUM> and includes a front-rear direction drive source 71e, and the lateral direction driving unit <NUM> is disposed to be movable in a front-rear direction with respect to the front-rear direction driving unit <NUM> via a front-rear direction connecting part 71d. The lateral direction driving unit <NUM> includes a lateral direction drive source 72e, and the vertical direction driving unit <NUM> is disposed to be movable in the lateral direction with respect to the lateral direction driving unit <NUM> via a lateral direction connecting part 72d. For example, a servo motor capable of highly accurate control is used as each of the drive sources 71e, 72e and 73e.

The upper end of a supporting plate <NUM> long in the vertical direction and insertable into the stator core <NUM> is mounted on the tip of the vertical direction connecting part 73d of the vertical direction driving unit <NUM>. As shown in <FIG>, a rotary body <NUM> is rotatably supported in a lower part of the supporting plate <NUM> with a rotary shaft thereof extending in a horizontal direction. A pulley <NUM> is coaxially provided on the rotary body <NUM>. The nozzle holder <NUM> described in the above related example is further coaxially provided on the pulley <NUM>.

The rotary body <NUM> and the pulley <NUM> are formed with first and second communication holes 77a, 78a continuous along center axes of rotation thereof. The communication hole 27c of the nozzle holder <NUM> is continuous with these first and second communication holes 77a, 78a. As in the above related example, the nozzle <NUM> is so inserted into the tubular part 27a of the nozzle holder <NUM> that a wire feed hole 11a communicates with the communication hole 27c. Further, a rod <NUM> is further inserted adjacent to the nozzle <NUM> into the tubular part 27a. The nozzle <NUM> and the rod <NUM> are mounted in the tubular part 27a by male screws <NUM>.

A servo motor <NUM> for rotationally moving the rod <NUM> about the wire feed hole 11a of the nozzle <NUM> is provided in an upper part of the supporting plate <NUM>. A pulley <NUM> is provided on a rotary shaft 75a of the servo motor <NUM>. A belt <NUM> is provided between the pulley <NUM> and the pulley <NUM> coupled to the nozzle holder <NUM>.

As in the above related example, the nozzle <NUM> having the wire feed hole 11a penetrating in a center and the rod <NUM> are inserted through the tubular part 27a of the nozzle holder <NUM>. The nozzle <NUM> and the rod <NUM> are so fixedly provided in the nozzle holder <NUM> that the communication hole 27c of the nozzle holder <NUM> and the wire feed hole 11a in the nozzle <NUM> are continuous.

The rod <NUM> is provided to deviate from the wire feed hole 11a in the nozzle <NUM>, and the nozzle holder <NUM> rotates together with the pulley <NUM> via the belt <NUM> if the servo motor <NUM> is driven. As just described, the nozzle holder <NUM> and the servo motor <NUM> constitute a rod rotating mechanism for rotationally moving the rod <NUM> about the wire feed hole 11a of the nozzle <NUM> around the wire feed hole 11a.

As shown in <FIG>, a first pulley <NUM> for turning the wire <NUM> having passed through the wire feed hole 11a of the nozzle <NUM> is provided on the supporting plate <NUM>. The vertical direction connecting part 73d is formed with a hole <NUM> through which the wire <NUM> passes. The vertical direction connecting part 73d is provided with a second pulley <NUM> for further turning the wire <NUM> passed through the nozzle <NUM> and turned by the first pulley <NUM> toward the hole <NUM>. The wire <NUM> fed from an unillustrated wire supply source passes through the hole <NUM> formed in the vertical direction connecting part 73d, is turned by the second pulley <NUM> and further turned by the first pulley <NUM>, and passes through the wire feed hole <NUM>1a of the nozzle <NUM>.

Next, a winding method using such a winding apparatus <NUM> is described.

First, the wire <NUM> is passed through the nozzle <NUM> and fed from the tip of the nozzle <NUM>. In starting winding, the nozzle moving mechanism <NUM> moves the nozzle <NUM> in three-dimensional directions and fixes an end part of the wire <NUM> by entwining the wire <NUM> around an unillustrated entwining pin or wire clamping device.

Thereafter, the nozzle moving mechanism <NUM> is driven to move the nozzle <NUM> at a horizontal position to a slot 63c between the magnetic pole 63b intended to be wire-wound and the magnetic pole <NUM> adjacent thereto in the stator core <NUM> as shown in <FIG>.

Then, actual winding is performed next. In actual winding, the nozzle <NUM> is reciprocally moved along the Z-axis direction by the nozzle moving mechanism <NUM> and the turntable 68b is rotated in forward and reverse directions together with the stator core <NUM> by the rocking servo motor of the supporting tool <NUM> so that the magnetic pole 63b being wire-wound rocks. By a combination of these operations, the nozzle <NUM> is rotationally moved in a rectangular shape around the magnetic pole 63b along the cross-sectional shape of the magnetic pole 63b.

As shown in <FIG>, in a rotational movement of the nozzle <NUM> in a rectangular shape, only the nozzle <NUM> is moved downward or upward without rocking the magnetic poles 63b by the rocking servo motor in the supporting tool <NUM> if the tip of the nozzle <NUM> is located in the slot 63c sandwiched by the magnetic pole 63b being wire-wound and the magnetic pole 63b adjacent thereto.

The rocking of the magnetic poles 63b is started when the tip of the nozzle <NUM> comes out from that slot 63c, and the rocking is finished when the tip of the nozzle <NUM> comes to be located below or above the adjacent slot 63c between the magnetic pole 63b being wire-wound and the magnetic pole 63b adjacent thereto.

Specifically, the rocking of the magnetic poles 63b is started with the tip of the nozzle <NUM> coming out downward or upward from the first slot 63c, and that rocking is finished when the tip of the nozzle <NUM> reaches another adjacent slot 63c. In this way, the nozzle <NUM> can be rotationally moved in the rectangular shape around the magnetic pole 63b along the cross-sectional shape of the magnetic pole 63b.

As just described, if the nozzle <NUM> is moved in the rectangular shape around the magnetic pole 63b serving as a wound member having a rectangular cross-section, the wire <NUM> fed via the wire feed hole 11a of the nozzle <NUM> is wound on the magnetic pole 63b.

On the other hand, if the wire <NUM> fed after passing through the wire feed hole <NUM>1a of the nozzle <NUM> is wound around the magnetic pole 63b serving as the wound member having the rectangular cross-section, such a phenomenon may occur in which the wire <NUM> bulges on corner parts in the rectangular shape by being lifted without being bent at a right angle and without being held in close contact with flat surface parts between the corner parts.

In contrast, the rod <NUM> is provided adjacent to the nozzle <NUM> in the present modification. Thus, as shown in <FIG>, the rod <NUM> moves together with the nozzle <NUM> to chase the nozzle <NUM> from behind, and follows the nozzle <NUM>.

In this way, the wire <NUM> fed from the tip of the nozzle <NUM> via the wire feed hole 11a comes into contact with the rod <NUM> following the nozzle <NUM> and extends along the outer surface of the magnetic pole 63b after being bent in a lateral direction perpendicular to a moving direction of the rod <NUM>, i.e. toward the magnetic pole 63b. Thus, the wire <NUM> comes into contact with the rod <NUM> to be curved before extending along the outer surface of the magnetic pole 63b from the tip of the nozzle <NUM>, and is reformed to be curved in that way.

Accordingly, also in this winding apparatus <NUM> for winding the wire on the inner rotor type stator core <NUM>, the rod <NUM> is provided adjacent to the nozzle <NUM> and the wire <NUM> can be reformed by moving the rod <NUM> to chase after the nozzle <NUM>. By winding the wire <NUM> on the magnetic pole 63b serving as the wound member with the wire <NUM> reformed in advance by the rod <NUM>, the lift of the wire <NUM> from the flat surface parts around the magnetic pole 63b can be suppressed.

Further, the winding apparatus <NUM> includes the servo motor <NUM> serving as the rod rotating mechanism for rotationally moving the rod <NUM> about the wire feed hole 11a of the nozzle <NUM> around the wire feed hole 11a. Thus, even if the nozzle <NUM> is moved in the rectangular shape around the magnetic pole 63b having the rectangular cross-section, the rod <NUM> can be reliably caused to follow the nozzle <NUM> by rotationally moving the position of the rod <NUM> with respect to the wire feed hole 11a.

Thus, the rod <NUM> can be caused to follow the nozzle <NUM> having passed through the slot 63c and moving along the magnetic pole 63b outside the magnetic pole 63b without being limited to the case where the rod <NUM> is caused to follow the nozzle <NUM> passing through the slot <NUM>. In this way, both the wire <NUM> fed from the nozzle <NUM> passing through the slot 63c and the wire <NUM> fed from the nozzle <NUM> moving along and outer side the magnetic pole 63b after passing through the slot 63c can be reformed. Therefore, the lift of the wire <NUM> from each peripheral surface of the magnetic pole 63b serving as the wound member having the rectangular cross-section can be effectively suppressed.

Further, in order to wind the wire <NUM> in alignment on the magnetic pole 63b, the nozzle <NUM> is rotationally moved around the magnetic pole 63b and the position of the nozzle <NUM> with respect to the magnetic pole 63b is shifted in the X-axis direction by an amount of a diameter of the wire <NUM> on every turn of the wire <NUM>. In this way, the wire <NUM> can be effectively wound in alignment on the magnetic pole 63b. In the winding apparatus <NUM> in the present modification, the nozzle <NUM> can be moved in the X-axis direction by driving the front-rear direction drive source 71e of the front-rear direction driving unit <NUM> to move the front-rear direction connecting part 71d in the X-axis direction.

Here, the magnetic poles 13b, 63b in the above related example and modification respectively have the rectangular cross-sectional shape. If the nozzle <NUM> is inserted as closely to the magnetic pole 13b, 63b being wire-wound as possible without contacting the wire <NUM> wound on the magnetic pole 13b, 63b, a clearance formed between the nozzle <NUM> and the magnetic pole 13b, 63b being wire-wound can be reduced. In this way, the wire <NUM> is reformed to be curved with a relatively small radius of curvature by the rod <NUM> and, along with that, the wire <NUM> is wound on the magnetic pole 13b, 63b near the nozzle <NUM>, wherefore a winding disturbance can be avoided.

Further, the above winding apparatus <NUM>, <NUM> includes the servo motor <NUM>, <NUM> constituting the rod rotating mechanism for rotationally moving the rod <NUM> about the wire feed hole 11a around the wire feed hole 11a. Thus, by shifting the position of the rod <NUM> located behind the nozzle <NUM> in a traveling direction in a width direction (direction perpendicular to the traveling direction) with respect to the traveling direction by the servo motor <NUM>, <NUM> as shown in <FIG>, a curved degree of the wire <NUM> coming into contact with the rod <NUM> to be turned toward the magnetic pole 13b, 63b can be changed.

<FIG>, <FIG> and <FIG> show examples of moving paths of the nozzle <NUM> and the rod <NUM>. In <FIG>, <FIG> and <FIG>, the moving path of the nozzle <NUM> is indicated by a solid-line arrow. <FIG> shows a case where the rod <NUM> is caused to follow in the same path from behind the nozzle <NUM> in the traveling direction. That is, in the example of <FIG>, the rod <NUM> moves on the moving path of the nozzle <NUM> indicated by the solid-like arrow. On the other hand, in the example shown in <FIG>, the position of the rod <NUM> located behind the nozzle <NUM> in the traveling direction is shifted toward the magnetic pole 13b, 63b side by the servo motor <NUM>, <NUM> as shown by a broken-like arrow without changing an interval between the nozzle <NUM> and the magnetic pole 13b, 63b with respect to the example shown in <FIG>. If the nozzle <NUM> is moved as indicated by the solid-line arrow in <FIG>, a radius of curvature of the curved wire <NUM> reformed by the rod <NUM> is relatively smaller than that shown in <FIG> and the wire <NUM> can be reformed to be relatively strongly curved.

On the contrary, in the example shown in <FIG>, the position of the rod <NUM> located behind the nozzle <NUM> in the traveling direction is shifted in a direction away from the magnetic pole 13b, 63b by the servo motor <NUM>, <NUM> as shown by a broken-like arrow without changing the interval between the nozzle <NUM> and the magnetic pole 13b, 63b with respect to the example shown in <FIG>. If the nozzle <NUM> is moved as indicated by the solid-line arrow in <FIG>, a radius of curvature of the curved wire <NUM> reformed by the rod <NUM> is relatively larger than that shown in <FIG> and the wire <NUM> can be reformed to be relatively weakly and moderately curved.

Thus, the curved degree of the wire <NUM> coming into contact with the rod <NUM> to be turned toward the magnetic pole 13b, 63b can be changed by shifting the position of the rod <NUM> located behind the nozzle <NUM> in the traveling direction in the width direction perpendicular to the traveling direction of the nozzle <NUM>. In this way, a degree of reformation given to the wire <NUM> fed from the nozzle <NUM> can be easily changed. Therefore, a bulging degree of the wire <NUM> being wound on the magnetic pole 13b, 63b can be adjusted.

Further, in the above related example and the modification of the present related example, the nozzle <NUM> is reciprocally moved along the Z-axis direction by the nozzle moving mechanism <NUM>, <NUM> and the stator core <NUM>, <NUM> is rotated in the forward and reverse directions to rock the magnetic poles 13b, 63b being wire-wound. In the above related example and the modification of the present related example, the wire <NUM> is wound by rotationally moving the nozzle <NUM> in the rectangular shape around the magnetic pole 13b, 63b by combining these operations.

Such a method is particularly effective when a plurality of members to be wound are radially formed like the magnetic poles 13b, 63b. By rocking the magnetic pole 13b, 63b serving as the wound member, the slot 13c, 63c into which the nozzle <NUM> enters can be constantly held in parallel to the nozzle <NUM>. Thus, it is possible to avoid such a situation where the nozzle <NUM> and the slot 13c, 63c intersect and the entrance of the nozzle <NUM> into the slot 13c, 63c becomes difficult.

In the above related example and the modification of the present related example, the nozzle moving mechanism <NUM>, <NUM> has been described to drive the nozzle <NUM> in the three axis directions. However, the nozzle moving mechanism <NUM>, <NUM> may be capable of moving the nozzle <NUM> in one or two axis directions as long as the nozzle <NUM> can be reciprocally moved along the Z-axis direction.

Further, even if a plurality of members to be wound are radially formed like the magnetic poles 13b, 63b, the nozzle moving mechanism <NUM>, <NUM> capable of moving the nozzle <NUM> in the three axis directions may be used if the nozzle <NUM> can enter the slots 13c, 63c. That is, the wire <NUM> may be wound on the magnetic pole 13b, 63b by moving the nozzle <NUM> also in the Y-axis direction while moving the nozzle <NUM> in the vertical direction and rotationally moving the nozzle <NUM> in the rectangular shape by a combination of these operations.

Further, in the above winding apparatus <NUM>, <NUM>, both the nozzle <NUM> and the nozzle <NUM> separately formed are mounted in the nozzle holder <NUM>. Thus, even when the wire diameter of the wire <NUM> to be wound on the magnetic poles 13b, 63b serving as the members to be wound is changed and the nozzle <NUM> is replaced by one including a wire feed hole 11a having a different inner diameter or when the rod <NUM> is replaced by one having a different outer diameter, it is sufficient to replace both or either one of those in the nozzle holder <NUM> and its exchange becomes easier.

In an embodiment of the invention, the rod <NUM> is integrally formed to the nozzle <NUM>.

Further, although a case where the servo motors are used as the drive sources has been described in the above example and embodiment, stepping motors may be used as the drive sources.

The configuration, functions and effects of the examples and the embodiment of the present invention are summarized below.

The winding apparatus <NUM>, <NUM> for winding the wire <NUM> around the wound member (magnetic pole 13b, 63b) includes the supporting tool <NUM>, <NUM> for supporting the wound member (magnetic pole 13b, 63b), the nozzle <NUM> formed with the wire feed hole 11a through which the wire <NUM> passes, the relative moving mechanism for relatively moving the nozzle <NUM> with respect to the supporting tool <NUM>, <NUM>, the rod <NUM> provided adjacent to the nozzle <NUM> to be moved together with the nozzle <NUM> by the relative moving mechanism, and the rod rotating mechanism for rotating the rod <NUM> about the wire feed hole 11a around the wire feed hole 11a.

Further, in the winding apparatus <NUM>, <NUM>, the relative moving mechanism includes the nozzle moving mechanism (<NUM>, <NUM>) for moving the nozzle <NUM> at least in a direction perpendicular to an axis of the wound member (magnetic pole 13b, 63b), and the servo motor <NUM> for moving the wound member (magnetic pole 13b, 63b) in a direction perpendicular to both the axis of the wound member (magnetic pole 13b, 63b) and the moving direction of the nozzle <NUM>.

Further, in the winding apparatus <NUM>, <NUM>, the rod rotating mechanism includes the nozzle holder <NUM> for holding the nozzle <NUM> and the rod <NUM>, and the servo motor <NUM>, <NUM> for rotating the nozzle holder <NUM> about the wire feed hole <NUM>1a of the nozzle <NUM>.

Further, in the winding method of the present embodiment for winding the wire <NUM> fed from the nozzle <NUM> around the wound member (magnetic pole 13b, 63b) side by relatively moving the nozzle <NUM> around the wound member (magnetic pole 13b, 63b), the rod <NUM> is caused to follow the nozzle <NUM> relatively moving with respect to the wound member (magnetic pole 13b, 63b) around the wound member (magnetic pole 13b, 63b) and the wire <NUM> coming into contact with the rod <NUM> to be turned toward the wound member (magnetic pole 13b, 63b) after being fed from the nozzle <NUM> is wound on the wound member (magnetic pole 13b, 63b).

In the winding apparatus <NUM>, <NUM>, the rod <NUM> is provided adjacent to the nozzle <NUM> and the rod rotating mechanism is provided to rotationally move the rod <NUM>. Thus, in the case of winding the wire <NUM>, the rod <NUM> follows the nozzle <NUM> if the nozzle <NUM> is relatively moved around the wound member (magnetic pole 13b, 63b).

According to the present related example and the modification of the present related example, the wire <NUM> fed from the nozzle <NUM>, thereafter, comes into contact with the rod <NUM> and is curved from the nozzle <NUM> to move toward the wound member (magnetic pole 13b, 63b) by being turned toward the wound member (magnetic pole 13b, 63b). In this way, the wire <NUM> can be wound on the wound member (magnetic pole 13b, 63b) while being reformed in advance.

Even if the traveling direction of the nozzle <NUM> is changed, the rod <NUM> can be reliably caused to follow the nozzle <NUM>, whose traveling direction has been changed, by rotationally moving the position of the rod <NUM> with respect to the nozzle <NUM> behind the nozzle <NUM> in the traveling direction by the rod rotating mechanism.

Further, a curved degree of the wire <NUM> turned toward the wound member (magnetic pole 13b, 63b) by coming into contact with the rod <NUM> can be changed by shifting the position of the rod <NUM> located behind the nozzle <NUM> in the traveling direction in the width direction with respect to the traveling direction by the rod rotating mechanism. That is, a degree of reformation given to the wire <NUM> fed from the nozzle <NUM> can be easily changed. Therefore, a bulging degree of the wire <NUM> being wound on the wound member (magnetic pole 13b, 63b) can be adjusted.

Claim 1:
A winding apparatus (<NUM>, <NUM>) for winding a wire (<NUM>) around a wound member (13b, 63b), comprising:
a supporting tool (<NUM>, <NUM>) configured to support the wound member (13b, 63b);
a nozzle (<NUM>) formed with a wire feed hole (11a), the wire (<NUM>) passing through the wire feed hole (11a);
a relative moving mechanism configured to relatively move the nozzle (<NUM>) with respect to the supporting tool (<NUM>, <NUM>); and
a rod (<NUM>) provided adjacent to the nozzle (<NUM>) to be moved together with the nozzle (<NUM>) by the relative moving mechanism, the rod (<NUM>) being provided in parallel to the wire feed hole (11a) and deviated from the wire feed hole (11a) in a radial direction of the wire feed hole (11a),
characterized by
a rod rotating mechanism configured to rotate the rod (<NUM>) about the wire feed hole (11a) around the wire feed hole (11a), wherein
the rod (<NUM>) is integrally formed to the nozzle (<NUM>).