Patent Description:
A filament winding apparatus for winding a fiber bundle onto an outer peripheral surface of a core material has been conventionally known. PTL <NUM> discloses this kind of filament winding apparatus.

The filament winding apparatus of PTL <NUM> including a device for performing a repetitive operation and a device for performing a divergent operation, is configured that the device for performing the repetitive operation and the device for performing the divergent operation restart the operations at a different restart position at a time of restarting if the operations are stopped due to a power failure in the middle of a series of operations to wind a fiber bundle.

The nearest state of the art regarding the present invention is disclosed in <CIT>. This document already discloses a winding data creation method for a filament winding apparatus, the filament winding apparatus including a rail extending in a first direction, a winding path that winds a fiber bundle onto an outer peripheral surface of a core material, a winding drive motor that drives the winding part in rotation around a winding rotational axis along an axial direction of the core material, and a control section that controls the winding drive motor. This document, however, does not teach how to create the winding data in detailed steps. Accordingly, it is an object of the present invention to provide the detailed steps for an appropriate winding data creation method. This problem is solved with the features of present claims <NUM> and <NUM>.

The filament winding apparatus as disclosed in PTL <NUM> performs hoop winding in which an angle (winding angle) for winding a fiber bundle is substantially perpendicular to a front-rear direction of the apparatus, or performs helical winding in which the winding angle with respect to the front-rear direction of the apparatus has a predetermined value. Such filament winding apparatus is generally configured to wind the fiber bundle around one single core material while keeping the constant winding angle with respect to the core material.

For products manufactured by filament winding, taking into consideration the use, etc., there may be a need that the strength of the products is flexibly changed in a longitudinal direction of the core material. However, the conventional winding method as disclosed in PTL <NUM> and the like cannot meet such need.

The present invention has been made in view of the circumstances described above, an object of the present invention is to, in a filament winding apparatus, wind a fiber bundle around a core material while partially varying a winding angle with respect to the core material.

Problems to be solved by the present invention are as described above, and next, means for solving the problems and effects thereof will be described.

According to a first aspect of the present invention, a winding data creation method with the following configuration is provided. That is, the winding data creation method is to create a winding data for a filament winding apparatus including a rail extending in a first direction, a winding part that winds a fiber bundle onto an outer peripheral surface of a core material, a winding drive motor that drives the winding part in rotation around a winding rotational shaft along an axial direction of the core material, and a control section that controls the winding drive motor. The winding data creation method includes an initial setting value input step, a point setting step, a winding angle setting step, and a winding rotational speed calculation step. The initial setting value input step is to input an initial setting value including a length in a first direction of the core material in the first direction. The point setting step is to set a plurality of points so as to divide the length of the core material in the first direction. The winding angle setting step is to set a target winding angle that is an angle defined by an axial direction of the core material, and the fiber bundle wound around the core material between two points adjacent to each other in the first direction. The winding rotational speed calculation step is to calculate, at least based on the initial setting value to be inputted and the target winding angle to be set, a target winding rotational speed of the winding drive motor between the two points adjacent to each other, respectively.

Accordingly, the target winding angle with respect to the core material can be partially changed, which can finish products with partially different strength in a longitudinal direction of the core material, with just one series of winding work.

The winding data creation method is preferably configured as follows. That is, the filament winding apparatus includes a posture adjustment motor that adjusts a posture of the winding part in the first direction. The winding data creation method includes a posture information input step of inputting a target posture information of the winding part at each of the points that is set in the point setting step. The winding rotational speed calculation step is to calculate the target winding rotational speed of the winding drive motor, based on the initial setting value, the target winding angle, and the target posture information inputted in the posture information input step.

Accordingly, the fiber bundle can be wound around the core material having a curved shape, with the specified winding angle.

In the posture information input step of the winding data creation method, an operator conducts teaching in a state of adjusting the posture of the winding part such that the winding rotational shaft of the winding part coincides with a shaft of the core material, at each of the points that is set in the point setting step, to input the target posture information.

In this case, the posture information corresponding to an actual shape of the core material can be obtained.

In the posture information input step of the winding data creation method, based on a pre-inputted 3D data of the core material, the posture of the winding part at each of the points that is set in the point setting step can be also obtained as the target posture information by calculation.

In this case, the target posture information can be easily obtained without actually moving the winding part. Therefore, a pre-setting work is simplified even when there are many points.

In the posture information input step of the winding data creation method, it is preferable to input the target posture information at each point, in a case where the winding part is moved to one side in the first direction relative to the core material and a case where the winding part is moved to the other side in the first direction relative to the core material.

Accordingly, even when the posture of the winding part suitable for winding of the fiber bundle is varied depending on an orientation in which the winding part is moved relative to the core material in the first direction, winding of the fiber bundle with the various postures can be accepted by inputting the posture information for the orientation of relative movement.

In the winding data creation method, each point can be set at equal intervals in the first direction.

In this case, each point can be easily set.

The winding data creation method is preferably configured as follows. That is, the initial setting value inputted in the initial setting value input step further includes the number of fiber bundles, a width of the fiber bundle, a diameter of the core material.

This can more appropriately calculate the target winding rotational speed of the winding drive motor in accordance with winding conditions, respectively.

The winding data creation method preferably includes a displaying step of displaying a rate of coverage of the fiber bundle wound onto an outer peripheral surface of the core material, the rate of coverage calculated based on the winding angle to be set.

Accordingly, the operator can easily confirm the rate of coverage of the fiber bundle wound in accordance with the winding data.

According to a second aspect of the present invention, a filament winding apparatus with the following configuration is provided. That is, the filament winding apparatus includes a rail, a winding part, a winding drive motor, a drive control section, and a data creation section. The rail extends in a first direction. The winding part winds a fiber bundle onto an outer peripheral surface of a core material. The winding drive motor drives the winding part in rotation around a winding rotational shaft along an axial direction of the core material. The drive control section controls the winding drive motor. The data creation section creates data for controlling the winding drive motor. An initial setting value, a plurality of points, and a target winding angle can be set in the data creation section. The initial setting value includes a length of the core material in the first direction. The plurality of points divides the length of the core material in the first direction. The target winding angle is an angle defined by an axial direction of the core material and the fiber bundle between two points adjacent to each other in the first direction. The data creation section calculates, at least based on the initial setting value to be inputted and the target winding angle to be set, a target winding rotational speed of the winding drive motor between the two points adj acent to each other, respectively.

Next, an embodiment of the present invention will be described with reference to the drawings. <FIG> is a perspective view showing an overall configuration of a filament winding apparatus <NUM> according to one embodiment of the present invention. <FIG> is an exploded perspective view showing a winding device <NUM> including a winding unit <NUM> (hoop winding unit 6x) viewed from the rear. <FIG> is an exploded perspective view showing the winding device <NUM> viewed from the front.

The filament winding apparatus <NUM> shown in <FIG> is an apparatus configured to wind a fiber bundle F onto an outer peripheral surface of a core material <NUM>. The filament winding apparatus <NUM> includes a travel base <NUM>, core material support devices <NUM>, a winding device <NUM>, and a control section <NUM>.

"Front" in the following description means, in a direction where the travel base <NUM> extends, a side opposite to a position of a rotary table <NUM> which will be described later. "Rear" in the following description means, in the direction where the travel base <NUM> extends, a side where the rotary table <NUM> is positioned. "Left" and "Right" mean a left side and a right side when facing the front. The definition of these directions is for conveniently describing a positional relationship, etc. between components. An orientation, etc. for arranging the filament winding apparatus <NUM> is not limited.

As described later, the core material <NUM> has a curved shape, but a front-rear direction (first direction) is a direction substantially along an overall longitudinal direction of the core material <NUM>. A left-right direction (second direction) is orthogonal to the front-rear direction. A vertical direction (third direction) is orthogonal to the front-rear direction and the left-right direction respectively.

The travel base <NUM> is elongated in the front-rear direction. The travel base <NUM> supports the core material support devices <NUM>, the winding device <NUM> and the like from below in the vertical direction. The travel base <NUM> includes a plurality of rails <NUM> extending in the front-rear direction. Each of the rails <NUM> is provided on an upper surface of the travel base <NUM>. The winding device <NUM> is mounted to the rails <NUM> so as to move back and forth in the front-rear direction along the rails <NUM>.

The core material support devices <NUM> support the core material <NUM>. Two core material support devices <NUM> are arranged side by side with a predetermined distance in the front-rear direction. The pair of core material support devices <NUM> is arranged so as to face each other. Each core material support device <NUM> is fixed to the travel base <NUM>.

The two core material support devices <NUM> support the core material <NUM> such that an intermediate portion in a longitudinal direction of the core material <NUM> is raised above the travel base <NUM>. One of the two core material support devices <NUM> holds a front end (one end in the longitudinal direction) of the core material <NUM>, and the other core material support device <NUM> holds a rear end (the other end in the longitudinal direction) of the core material <NUM>.

When the two core material support devices <NUM> support the core material <NUM>, the core material <NUM> basically extends in the front-rear direction. An appropriate gap is formed in the vertical direction between the upper surface of the travel base <NUM> and the core material <NUM> supported by the two core material support devices <NUM>.

The core material <NUM> has an elongated shape, for example, with its cross section having a circular rod-like shape. In this embodiment, the core material <NUM>, with its longitudinal direction three-dimensionally changing, has a curved shape.

The core material <NUM> can be mounted to and detached from each core material support device <NUM>. Therefore, in accordance with a desired shape, the core material <NUM> having various shapes can be replaced and mounted to the filament winding apparatus <NUM>.

The winding device <NUM> is configured as a device for winding a fiber bundle onto the outer peripheral surface of the core material <NUM>, while traveling along the rails <NUM>. The fiber bundle is made of, for example, fiber materials such as carbon fiber. The fiber bundle may be impregnated with liquid resin (for example, uncured thermosetting resin).

The winding device <NUM> is provided, on the travel base <NUM>, between the two core material support devices <NUM>. The winding device <NUM> keeps a state in which the core material <NUM> supported by the two core material support devices <NUM> penetrates the winding device <NUM> when moving back and forth in the front-rear direction along the rails <NUM>.

As shown in <FIG> and <FIG>, the filament winding apparatus <NUM> includes a front-rear traveling drive motor (first drive source) <NUM>, a left-right traveling drive motor (second drive source) <NUM>, a rotary drive motor (third drive source) <NUM>, a lifting motor (fourth drive source) <NUM>, and a pitching drive motor (fifth drive source) <NUM>. Each component in the winding device <NUM> is driven by each of the above-described drive motors. Details of a configuration for driving will be described later.

The control section <NUM> shown in <FIG> including a controller <NUM>, a display <NUM>, and an operation part <NUM>, controls operations of each component in the winding device <NUM>.

The controller <NUM> is configured as a control board, for example. The controller <NUM> is electrically connected to the above-described drive motors for driving each component in the winding device <NUM>. The controller <NUM> controls each drive motor in accordance with operations of the operation part <NUM>.

The display <NUM> can display various information regarding a winding work (such as a progress of the winding work).

The operation part <NUM> is used for manually controlling the front-rear traveling drive motor <NUM>, the left-right traveling drive motor <NUM>, the rotary drive motor <NUM>, the lifting motor <NUM>, the pitching drive motor <NUM>, and a winding drive motor <NUM>, or used for inputting various winding information.

The operator inputs the winding information (an initial setting value, a winding angle, etc.) regarding the core material <NUM> to be wound, via the operation part <NUM>. Based on the inputted winding information, the control section <NUM> controls a target rotational speed of the winding unit <NUM>, a target traveling speed in which the winding device <NUM> travels in the front-rear direction, and a target posture of the winding device <NUM> corresponding to respective positions in the front-rear direction.

Next, details of the winding device <NUM> will be described with reference to <FIG>. <FIG> is a front view showing the winding device <NUM>.

As shown in <FIG> and <FIG>, the winding device <NUM> includes a base frame <NUM>, a main frame <NUM>, a lifting frame (sub-frame) <NUM>, and a winding unit (guide unit) <NUM>.

As shown in <FIG>, the base frame <NUM> made of a plate-shaped member, is arranged with its thickness direction facing up and down. The base frame <NUM> is mounted so as to move in the front-rear direction along the rails <NUM> provided on the upper surface of the travel base <NUM>. The base frame <NUM> is driven to move back and forth in the front-rear direction by a linear motion mechanism including the front-rear traveling drive motor <NUM> and a rack and pinion.

Specifically, a front-rear traveling rack <NUM> extending in the front-rear direction is arranged on the upper surface of the travel base <NUM>. The front-rear traveling rack <NUM> is fixed to the travel base <NUM>. The front-rear traveling rack <NUM> has teeth for meshing with the front-rear traveling pinion <NUM>.

The front-rear traveling pinion <NUM> is rotatably supported below the base frame <NUM>. The front-rear traveling pinion <NUM> is driven in rotation by the front-rear traveling drive motor <NUM> provided on the upper surface of the base frame <NUM>.

The front-rear traveling drive motor <NUM> drives the front-rear traveling pinion <NUM> in rotation. The front-rear traveling pinion <NUM> to be rotated moves in the front-rear direction so as to roll with respect to the front-rear traveling rack <NUM>. As a result, the base frame <NUM> (and thus the winding device <NUM>) moves in the front-rear direction.

A support base <NUM> for supporting the main frame <NUM> is provided across an upper surface of the base frame <NUM>. The support base <NUM> is formed in a substantially U-shape with its lower side open, as viewed in the front-rear direction. Left and right rails <NUM> extending in the left-right direction are provided on the upper surface of the support base <NUM>.

The main frame <NUM> is formed in a substantially U-shape with its upper side open, as viewed in the front-rear direction. The main frame <NUM> arranged above the support base <NUM> is mounted to the support base <NUM>. The main frame <NUM> can move back and forth in the left-right direction along the left and right rails <NUM> provided on the upper surface of the support base <NUM>. The main frame <NUM> is rotatable around a rotational axis (first rotational axis) A1 extending in the vertical direction, with respect to the support base <NUM>.

The main frame <NUM> supports the winding unit <NUM> such that the winding unit <NUM> can be rotated around a pitching axis (second rotational axis) A2 extending in the left-right direction. In the following description, a turning of the winding unit <NUM> around the pitching axis A2 may be refereed as "pitching".

As shown in <FIG> and <FIG>, the main frame <NUM> includes a left-right traveling base <NUM>, a base <NUM>, a left arm <NUM>, and a right arm <NUM>.

The plate-like left-right traveling base <NUM> is mounted so as to move along the left and right rails <NUM> provided on the upper surface of the support base <NUM>. A left-right traveling rack <NUM> is fixed on a lower surface of the left-right traveling base <NUM>. The left-right traveling rack <NUM> has teeth for meshing with a left-right traveling pinion <NUM>.

The left-right traveling pinion <NUM> is provided above the base frame <NUM> and below the support base <NUM>. The left-right traveling pinion <NUM> is supported so as to be rotated around a shaft extending in the front-rear direction. The left-right traveling pinion <NUM> meshes with a first gear <NUM> that is arranged in the vicinity of and slightly below the left-right traveling pinion <NUM>. The left-right traveling pinion <NUM> is driven in rotation due to rotation of the first gear <NUM>.

As shown in <FIG> and <FIG>, the first gear <NUM> is driven in rotation by the left-right traveling drive motor <NUM> provided on the upper surface of the base frame <NUM>. The first gear <NUM> meshes with the left-right traveling pinion <NUM>, and then transmits a rotation driving force from the left-right traveling drive motor <NUM> to the left-right traveling pinion <NUM>.

The left-right traveling drive motor <NUM> causes the left-right traveling pinion <NUM> to be rotated via the first gear <NUM>. The left-right traveling pinion <NUM> to be rotated feeds the teeth of the left-right traveling rack <NUM> toward left and right. As a result, the left-right traveling base <NUM> (and thus the main frame <NUM>) is moved in the left-right direction.

The elongated base <NUM> is arranged above the left-right traveling base <NUM>. The base <NUM> is supported by the left-right traveling base <NUM> so as to be rotated around the rotational axis (first rotational axis) A1 extending in the vertical direction. As the left-right traveling base <NUM> moves in the left-right direction, the rotational axis A1 accordingly moves in the left-right direction. When the base <NUM> is not rotated around the rotational axis A1, a longitudinal direction of the base <NUM> coincides with the left-right direction. That is, when the base <NUM> is positioned so as to extend in the left-right direction, a rotation angle θV of the base <NUM> is <NUM>°. In the following, a positional relationship between components will be described, on the basis of a state in which the rotation angle θV of the base <NUM> is <NUM>°.

The base <NUM> is formed in a substantially U-shape with its upper side open, as viewed in the left-right direction. A rotary drive motor <NUM> and a worm gear mechanism <NUM> are provided on the upper surface of the base <NUM>. The worm gear mechanism <NUM> includes a worm <NUM> and a worm wheel <NUM> meshing with the worm <NUM>.

The worm <NUM> is supported so as to be rotated around a shaft extending in a direction parallel to the longitudinal direction of the base <NUM>. The worm <NUM> is driven in rotation by the rotary drive motor <NUM>. Screw teeth for meshing with the teeth on an outer peripheral of the worm wheel <NUM> are formed on an outer peripheral surface of the worm <NUM>.

The worm wheel <NUM> is supported on the upper surface of the base <NUM> so as to be rotated around the rotational shaft A1. The worm wheel <NUM> is provided so as not to be rotated relative to the left-right traveling base <NUM>.

The rotary drive motor <NUM> drives the worm <NUM> in rotation. The worm <NUM> to be rotated tries to feed the teeth of the worm wheel <NUM>, but the worm wheel <NUM> cannot be rotated relative to the left-right traveling base <NUM>. Therefore, along with rotation of the worm <NUM>, the base <NUM> is rotated around the rotational shaft A1 with respect to the worm wheel <NUM> and the left-right traveling base <NUM>. The rotary drive motor <NUM> functions as a posture adjustment motor that adjusts a posture of a hoop winding part <NUM> which will be described later, in the front-rear direction.

In the filament winding apparatus <NUM> of this embodiment, the base <NUM> (main frame <NUM>) can be rotated within an range of the angle ±<NUM>°. That is, the rotation angle θV that is an angle defined by the longitudinal direction of the base <NUM> and the left-right direction, meets a condition of -<NUM>° ≤ θV ≤ <NUM>°. Accordingly, even when the core material <NUM> has a portion substantially parallel to the left-right direction, the winding unit <NUM> (hoop winding part <NUM>) can be oriented along such portion.

The left arm <NUM> is formed in a substantially U-shape, as viewed in the vertical direction. The left arm <NUM> arranged at a left end of the base <NUM> is provided so as to protrude upward from the base <NUM>. A left vertical rail <NUM> is provided on a right side surface of the left arm <NUM> so as to extend in the vertical direction. A left screw feeding shaft <NUM> is rotatably supported on the right side surface of the left arm <NUM> such that an axial direction of the left screw feeding shaft <NUM> is oriented to the vertical direction.

The right arm <NUM> is formed in a substantially U-shape, as viewed in the vertical direction. The right arm <NUM> arranged at a right end of the base <NUM> is provided so as to protrude upward from the base <NUM>. A right vertical rail <NUM> is provided inside the right arm <NUM> so as to extend in the vertical direction. A right screw feeding shaft <NUM> is rotatably supported inside the right arm <NUM> such that an axial direction of the right screw feeding shaft <NUM> is oriented to the vertical direction.

As shown in <FIG>, a right rotary drive gear <NUM> that drives the right screw feeding shaft <NUM> in rotation is mounted to a lower portion of the right screw feeding shaft <NUM>, so as not to be rotated relative to the right screw feeding shaft <NUM>. The right rotary drive gear <NUM> meshes with a lifting drive gear <NUM> (see <FIG>) that is driven in rotation by the lifting motor <NUM>. The right rotary drive gear <NUM> is driven in rotation along with rotation of the lifting drive gear <NUM>.

As shown in <FIG>, the lifting motor <NUM> is provided below the right arm <NUM>. The lifting motor <NUM> drives the lifting drive gear <NUM> in rotation, the lifting drive gear <NUM> that meshes with the right rotary drive gear <NUM>. As a result, the right screw feeding shaft <NUM> is rotated.

A toothed pulley (not shown) is mounted at a lower end of the left screw feeding shaft <NUM> and at a lower end of right screw feeding shaft <NUM> respectively, so as to be rotated only together. Rotation of the right screw feeding shaft <NUM> is transmitted to the left screw feeding shaft <NUM> via transmission pulleys <NUM> provided in an upper portion of the base <NUM>, and a toothed belt <NUM>. Accordingly, due to driving of the lifting motor <NUM>, the left screw feeding shaft <NUM> and the right screw feeding shaft <NUM> are simultaneously rotated around their respective shaft centers in the same orientation and at the same speed.

The lifting frame <NUM> is mounted to the left arm <NUM> and the right arm <NUM> so as to move in the vertical direction. The lifting frame <NUM> includes a left lifting base <NUM> and a right lifting base <NUM>. The left lifting base <NUM> and the right lifting base <NUM> are moved up and down while always keeping the same height as each other.

As shown in <FIG>, the left lifting base <NUM> is mounted so as to move up and down along the left vertical rail <NUM> provided in the left arm <NUM>. The left lifting base <NUM> includes left screw coupling parts <NUM>. The left lifting base <NUM> is screw-coupled to the left screw feeding shaft <NUM> via the left screw coupling parts <NUM>. Accordingly, in conjunction with rotation of the left screw feeding shaft <NUM>, the left lifting base <NUM> is moved in the vertical direction.

A left rotation arm supporter <NUM> is provided on a right side surface of the left lifting base <NUM>. The left rotation arm supporter <NUM> supports a left rotation arm <NUM> in the winding unit <NUM> so as to be rotatable.

As shown in <FIG>, the right lifting base <NUM> is mounted so as to move up and down along the right vertical rail <NUM> provided on the right arm <NUM>. As shown in <FIG>, the right lifting base <NUM> includes right screw coupling parts <NUM>. The right lifting base <NUM> is screw-coupled to the right screw feeding shaft <NUM> via the right screw coupling parts <NUM>. Accordingly, in conjunction with rotation of the right screw feeding shaft <NUM>, the right lifting base <NUM> is moved in the vertical direction.

A right rotation arm supporter <NUM> is provided on a left side surface of the right lifting base <NUM>. The right rotation arm supporter <NUM> supports a right rotation arm <NUM> in the winding unit <NUM> so as to be rotatable.

The left rotation arm supporter <NUM> and the right rotation arm supporter <NUM> face each other in the left-right direction. The pitching axis A2 is arranged so as to pass through the right rotation arm supporter <NUM> and the left rotation arm supporter <NUM>. The pitching axis A2 passes through respective centers of the left rotation arm supporter <NUM> and the right rotation arm supporter <NUM>, as viewed in the left-right direction.

The right lifting base <NUM> supports a pitching drive motor <NUM> and an unit rotation worm <NUM>.

The unit rotation worm <NUM> is rotatably supported by a shaft arranged coaxially with a rotational shaft of the pitching drive motor <NUM>. The unit rotation worm <NUM> is driven in rotation by the pitching drive motor <NUM>. Screw teeth for meshing with teeth on an outer peripheral of a unit rotation worm wheel <NUM>, are formed on an outer peripheral surface of the unit rotation worm <NUM>.

The winding unit <NUM> is configured as a hoop winding unit 6x for hoop winding the fiber bundle F in <FIG> with respect to the core material <NUM>. The hoop winding means a winding method in which the fiber bundle F is wound in a direction substantially perpendicular to an axial direction of the core material <NUM>. The winding unit <NUM> has, as viewed in the front-rear direction, an opening portion (opening) <NUM>, with its center in which the core material <NUM> passes through. The opening portion <NUM> is formed so as to penetrate the winding unit <NUM> in the front-rear direction.

As shown in <FIG>, the hoop winding unit 6x includes a winding unit frame (unit frame) <NUM>, the hoop winding part (winding part) <NUM>, a hoop winding tightening part <NUM>, and a winding drive part <NUM>.

The winding unit frame <NUM> is made of a plate-like member. The winding unit frame <NUM> is formed in a U-shape with its front open, as viewed in the vertical direction. The winding unit frame <NUM> supports a circular rotary table <NUM> included in the winding drive part <NUM>, so as to be rotated around a winding rotational shaft (tightening rotational shaft) A3 extending in the front-rear direction. The winding unit frame <NUM> has, as viewed in the front-rear direction, a substantially circular opening 63a. The winding rotational shaft A3 passes through a center of the opening 63a.

The left rotation arm <NUM> protruding outward is mounted on a left side surface of the winding unit frame <NUM>. The right rotation arm <NUM> protruding outward is mounted on a right side surface of the winding unit frame <NUM>.

The left rotation arm <NUM> and the right rotation arm <NUM> are provided symmetrically in a substantially center part in the vertical direction of the winding unit frame <NUM>. The left rotation arm <NUM> is rotatably supported by the left rotation arm supporter <NUM>. The right rotation arm <NUM> is rotatably supported by the right rotation arm supporter <NUM>. That is, the winding unit <NUM> is supported so as to be rotated around the pitching axis A2 with respect to the lifting frame <NUM> via the left rotation arm <NUM> and the right rotation arm <NUM>. Along with a vertical motion of the lifting frame <NUM>, the pitching axis A2 is also moved up and down. A pitching angle θH of the winding unit frame <NUM> with an upright posture, is <NUM>°. In the following, a positional relationship between components will be described on the basis of a state in which the pitching angle θH of the winding unit frame <NUM> is <NUM>°.

The unit rotation worm wheel <NUM> is mounted to the right rotation arm <NUM> so as not to be rotated relative to each other. In a state in which the winding unit <NUM> is mounted to the lifting frame <NUM>, the unit rotation worm wheel <NUM> meshes with the unit rotation worm <NUM> supported by the right lifting base <NUM>.

The pitching drive motor <NUM> drives the unit rotation worm <NUM> in rotation. Since the unit rotation worm <NUM> to be rotated feeds the teeth of the unit rotation worm wheel <NUM>, the unit rotation worm wheel <NUM> is rotated. Accordingly, the winding unit <NUM> faces up and down around the pitching axis A2. The pitching drive motor <NUM> functions as a posture adjustment motor that adjusts a posture of the hoop winding part <NUM> in the front-rear direction.

In the filament winding apparatus <NUM> of this embodiment, the winding unit <NUM> can face up and down within a range of the angle ±<NUM>°. That is, if the pitching angle θH is <NUM>°, the pitching angle θH in a state in which the winding unit frame <NUM> extends in the vertical direction as viewed in the left-right direction, such pitching angle θH meets a condition of -<NUM>° ≤ θH ≤ <NUM>°. Accordingly, even when the core material <NUM> has a portion substantially parallel to the vertical direction, the winding unit <NUM> (hoop winding part <NUM>) can be oriented along such portion.

The hoop winding part <NUM> is provided on a side opposite to the winding drive part <NUM>, across the winding unit frame <NUM>. As shown in <FIG>, the hoop winding part <NUM> is arranged on a front surface of the winding unit frame <NUM>. The hoop winding part <NUM> includes a rotating base <NUM>, a plurality of bobbin supporters <NUM>, a plurality of circumference guiding parts <NUM>, a winding guiding part (fiber bundle guiding part) <NUM>.

As shown in <FIG>, the rotating base <NUM> made of two annular plates arranged in the front-rear direction, is mounted to the rotary table <NUM> so as not to be rotated relative to each other. In the following description, one of two annular plates located on a side close to the rotary table <NUM> may be referred to as a first annular plate 71a, and the other annular plate located on a side far from the rotary table <NUM> may be referred to as a second annular plate 71b.

The first annular plate 71a and the second annular plate 71b are respectively supported by the rotary table <NUM>. The rotary table <NUM>, the first annular plate 71a and the second annular plate 71b are arranged side by side, in the order from the rear to the front. The rotary table <NUM>, the first annular plate 71a and the second annular plate 71b are parallel to each other. Respective centers of the rotary table <NUM>, the first annular plate 71a and the second annular plate 71b are located on the winding rotational axis A3.

The first annular plate 71a carries the plurality of bobbin supporters <NUM> (four bobbin supporters <NUM>, in this embodiment). Each bobbin supporter <NUM> is arranged perpendicular to a front surface of the first annular plate 71a so as to extend in the front-rear direction. The plurality of bobbin supporters <NUM> is arranged side by side at equal intervals in a circumferential direction of the first annular plate 71a. Accordingly, the winding device <NUM> of this embodiment can hoop wind the four fiber bundles F simultaneously onto the outer peripheral surface of the core material <NUM>. The number of fiber bundles F may be changed if necessary.

In the following description, in order to identify each of the bobbin supporters <NUM>, one of the bobbin supporters <NUM> drawn in the upper right portion in <FIG> may be referred to as a first bobbin supporter 72a. Other bobbin supporters <NUM> may be referred to as a second bobbin supporter 72b, a third bobbin supporter 72c, and a fourth bobbin supporter 72d in the clockwise order from the first bobbin supporter 72a in <FIG>.

The second annular plate 71b carries the plurality of circumference guiding parts <NUM> (eight circumference guiding parts <NUM>, in this embodiment). As shown in <FIG>, each circumference guiding part <NUM> is arranged perpendicular to a front surface of the second annular plate 71b so as to extend in the front-rear direction. The plurality of circumference guiding parts <NUM> is arranged side by side at equal intervals in a circumferential direction of the second annular plate 71b.

In the following description, in order to identify each of the circumference guiding parts <NUM>, the lower circumference guiding part <NUM> that is one of the two circumference guiding parts <NUM> drawn in the rightmost in <FIG>, may be referred to as a first circumference guiding part 73a. Other circumference guiding parts <NUM> may be referred to as a second circumference guiding part 73b, a third circumference guiding part 73c, a fourth circumference guiding part 73d, a fifth circumference guiding part 73e, a sixth circumference guiding part 73f, a seventh circumference guiding part <NUM>, and an eighth circumference guiding part <NUM>, in the clockwise order from the first circumference guiding part 73a in <FIG>.

Each of the first circumference guiding part 73a and the second circumference guiding part 73b is configured as one single roller, for example. The first circumference guiding part 73a and the second circumference guiding part 73b guide the fiber bundle F (a thick dotted line in <FIG>) fed from a bobbin which is supported by the first bobbin supporter 72a.

Each of the third circumference guiding part 73c and the fourth circumference guiding part 73d is configured as a multiple-roller in which two rollers are arranged in the front-rear direction. The third circumference guiding part 73c and the fourth circumference guiding part 73d can guide two fiber bundles F side by side in the front-rear direction without crossing each other. The third circumference guiding part 73c and the fourth circumference guiding part 73d guide the fiber bundles F (a thick dotted line and a thin solid line in <FIG>) fed from bobbins which are supported by the first bobbin supporter 72a and the second bobbin supporter 72b.

Each of the fifth circumference guiding part 73e and the sixth circumference guiding part 73f is configured as a multiple-roller in which three rollers are arranged in the front-rear direction. The fifth circumference guiding part 73e and the sixth circumference guiding part 73f can guide three fiber bundles F side by side in the front-rear direction without crossing thereamong. The fifth circumference guiding part 73e and the sixth circumference guiding part 73f guide the fiber bundles F (a thick dotted line, a thin solid line and a thin dotted line in <FIG>) fed from bobbins which are supported by the first bobbin supporter 72a, the second bobbin supporter 72b and the third bobbin supporter 72c.

Each of the seventh circumference guiding part <NUM> and the eighth circumference guiding part <NUM> is configured as a multiple-roller in which four rollers are arranged in the front-rear direction. The seventh circumference guiding part <NUM> and the eighth circumference guiding part <NUM> can guide four fiber bundles F side by side in the front-rear direction without crossing thereamong. The seventh circumference guiding part <NUM> and the eighth circumference guiding part <NUM> guide the fiber bundles F (a thick dotted line, a thin solid line, a thin dotted line and a thin chain line in <FIG>) fed from bobbins which are supported by the first bobbin supporter 72a, the second bobbin supporter 72b, the third bobbin supporter 72c, and the forth bobbin supporter 72d.

As shown in <FIG>, the winding guiding part <NUM> protrudes forward from the rotary table <NUM>. The winding guiding part <NUM> is supported by the rotary table <NUM> and the first annular plate 71a. The winding guiding part <NUM> is provided at a slightly outside part in a radial direction of the rotary table <NUM> and the first annular plate 71a. The winding guiding part <NUM> is rotated around the winding rotational axis A3 along with rotation of the rotary table <NUM> and the first annular plate 71a.

The winding guiding part <NUM> carries a plurality of (three, in this embodiment) tension bars 74a and a ring guide 74b. Each tension bar 74a applies tension to the corresponding fiber bundle F by rubbing between each tension bar 74a and the corresponding wound fiber bundle F. As shown in <FIG>, such fiber bundle F is wound around each tension bar 74a in order, and then wound onto the outer peripheral surface of the core material <NUM> via the ring guide 74b.

As shown in <FIG>, the fiber bundle F (the thick dotted line in <FIG>) fed from the bobbin that is supported by the first bobbin supporter 72a is wound around all of the circumference guiding parts <NUM>, in the order of the first circumference guiding part 73a to the eighth circumference guiding part <NUM>, and then guided to the winding guiding part <NUM>.

The fiber bundle F (the thin solid line in <FIG>) fed from the bobbin that is supported by the second bobbin supporter 72b is wound around six of the circumference guiding parts <NUM>, in the order of the third circumference guiding part 73c to the eighth circumference guiding part <NUM>, and then guided to the winding guiding part <NUM>.

The fiber bundle F (the thin dotted line in <FIG>) fed from the bobbin that is supported by the third bobbin supporter 72c is wound around four of the circumference guiding parts <NUM>, in the order of the fifth circumference guiding part 73e, the sixth circumference guiding part 73f, the seventh circumference guiding part <NUM>, and the eighth circumference guiding part <NUM>, and then guided to the winding guiding part <NUM>.

The fiber bundle F (the thin chain line of <FIG>) fed from the bobbin that is supported by the forth bobbin supporter 72d is wound around two of the circumference guiding parts <NUM>, in the order of the seventh circumference guiding part <NUM> and the eighth circumference guiding part <NUM>, and then guided to the winding guiding part <NUM>.

As shown in <FIG>, the hoop winding tightening part <NUM> is supported by the rotary table <NUM> so as to protrude forward of the hoop winding part <NUM>. The hoop winding tightening part <NUM> and the hoop winding part <NUM> are arranged side by side in the front-rear direction. The hoop winding tightening part <NUM> winds a tape T onto the outer peripheral surface of the core material <NUM> that is hoop-wound by the hoop winding part <NUM>. The tape T may be, for example, a heat-shrinkable tape or a tape impregnated with an uncured thermosetting resin in a liquid state.

The hoop winding tightening part <NUM> is provided at a position away from the winding rotational axis A3 (slightly outside in the radial direction of the rotary table <NUM>), as viewed in the front-rear direction. The hoop winding tightening part <NUM> is rotated around the winding rotational axis A3 along with rotation of the rotary table <NUM>. As shown in <FIG>, the hoop winding tightening part <NUM> includes a base plate <NUM>, a tightening tape bobbin <NUM>, a first guide roller <NUM> and a second guide roller <NUM>.

The base plate <NUM> is made of a plate-like member. The base plate <NUM> supports the tightening tape bobbin <NUM>, the first guide roller <NUM> and the second guide roller <NUM> such that they protrude forward.

The tape T for winding and tightening is wound onto the tightening tape bobbin <NUM>. The tape T drawn from the tightening tape bobbin <NUM> is wound around the first guide roller <NUM> and the second guide roller <NUM> in order, and then the fiber bundle F is wound onto the outer peripheral surface of the hoop-wound core material <NUM>.

As shown in <FIG> and the like, the winding drive part <NUM> includes the winding drive motor <NUM>, a first transmission pulley <NUM>, a transmission belt <NUM>, a second transmission pulley <NUM>, a transmission gear <NUM>, a rotary gear <NUM>, and the rotary table <NUM>.

The winding drive motor <NUM> is provided upward of and on a left side of the winding unit frame <NUM>. The first transmission pulley <NUM> is mounted to an output shaft of the winding drive motor <NUM> so as not to be rotated relative to each other.

The transmission belt <NUM> is wound around the first transmission pulley <NUM> and the second transmission pulley <NUM>, and transmits rotation of the first transmission pulley <NUM> to the second transmission pulley <NUM>. As shown in <FIG>, a tension roller <NUM> applying tension to the transmission belt <NUM> may be provided in the vicinity of an intermediate portion of the transmission belt <NUM> in the vertical direction.

The second transmission pulley <NUM> and the transmission gear <NUM> are rotatably supported by the winding unit frame <NUM> on a lower left side of the winding unit frame <NUM>. The second transmission pulley <NUM> and the transmission gear <NUM> arranged side by side in the front-rear direction are provided so as not to be rotated relative to each other.

The rotary gear <NUM> is provided at a center of the winding unit frame <NUM>, as viewed in the front-rear direction. That is, a center of the rotary gear <NUM> is positioned on the winding rotational axis A3. The rotary gear <NUM> meshes with the transmission gear <NUM>. The rotary gear <NUM> having an annular shape is supported by the rotary table <NUM> so as not to be rotated relative to each other.

The rotary table <NUM> made of an annular plate is arranged coaxially with the rotary gear <NUM>. The rotary table <NUM> is arranged forward of the rotary gear <NUM>. The rotary table <NUM> is rotatably supported by the winding unit frame <NUM>.

A driving force of the winding drive motor <NUM> is transmitted to the rotary gear <NUM> and the rotary table <NUM> via the first transmission pulley <NUM>, the transmission belt <NUM>, the second transmission pulley <NUM>, and the transmission gear <NUM>. Rotation of the rotating table <NUM> allows the hoop winding part <NUM> and the hoop winding tightening part <NUM> which are supported by the rotary table <NUM> to be rotated around the winding rotational axis A3.

Accordingly, the fiber bundle F guided by the winding guiding part <NUM> and the tape T guided by the second guide roller <NUM> are wound onto the outer peripheral surface of the core material <NUM>. The hoop winding tightening part <NUM> is provided at a position displaced from the hoop winding part <NUM> in the front-rear direction. Therefore, after the fiber bundle F is wound around the core material <NUM>, the tape T is then wound onto the outer peripheral surface of the core material <NUM>.

In this embodiment, the winding device <NUM> travels along the core material <NUM> such that the hoop winding part <NUM> precedes the hoop winding tightening part <NUM> in a traveling direction of the winding device <NUM>. Accordingly, with one traveling of the winding device <NUM>, the fiber bundle F and the tape T can be wound onto the outer peripheral surface of the core material <NUM>. <FIG> shows an example in which the fiber bundle F and the tape T are wound onto the outer peripheral surface of the core material <NUM> with one traveling of the winding device <NUM> rearward. However, in a first traveling, the fiber bundle F may be firstly wound onto the outer peripheral surface of the core material <NUM> by means of the hoop winding part <NUM>. In a second traveling, the tape T may be then wound onto the outer peripheral surface in which the fiber bundle F has already been wound in the first traveling, by means of the hoop winding tightening part <NUM>. The traveling direction of the winding device <NUM> may be reversed between the first traveling and the second traveling.

The drive motors (specifically, the front-rear traveling drive motor <NUM>, the left-right traveling drive motor <NUM>, the rotary drive motor <NUM>, the lifting motor <NUM>, and the pitching drive motor <NUM>) included in the winding device <NUM> are controlled by the control section <NUM> in <FIG>. For such control, for example, as shown in <FIG>, a position of the winding unit <NUM> can be described to define an XYZ rectangular coordinate system with an X-axis that is a left-right axis, a Y-axis that is an up-down axis, and a Z-axis that is a front-rear axis.

Accordingly, as shown in <FIG>, the winding device <NUM> travels along the rails <NUM> while adjusting the position and the posture of the winding unit <NUM> such that the center of the opening <NUM> in the winding unit <NUM> always coincides with the center of the core material <NUM>. That is, the winding rotational shaft A3 of the hoop winding part <NUM> always coincides with the axial direction of the core material <NUM>. Accordingly, even in the core material <NUM> having a curved shape, the fiber bundle F can be wound onto the outer peripheral surface of the core material <NUM> according to its shape.

In this embodiment, the fiber bundle F can be wound around the core material <NUM> which is originally curved, according to such curved shape. Therefore, it is superior in that winding of the fiber bundle F is not disordered, as compared with a configuration in which a linear core material around which the fiber bundle has already been wound is curved.

The winding unit <NUM> may be configured as a helical winding unit 6y for helical winding shown in <FIG>. The helical winding means a winding method for winding the fiber bundle F in a direction tilted by a predetermined angle from the axial direction of the core material <NUM>.

<FIG> is a perspective view showing a configuration of the helical winding unit 6y. <FIG> is a partial enlarged view showing a configuration of the helical winding unit 6y. <FIG> is a cross-sectional perspective view showing a configuration of a central guiding part <NUM> of the helical winding unit 6y. In the following description of the helical winding unit 6y, members identical or similar to those of the above-described embodiment may not be described and instead the same reference signs as in the above-described embodiment are given on the drawings.

As shown in <FIG>, the helical winding unit 6y includes a helical winding part (winding part) <NUM> instead of the hoop winding part <NUM> and the hoop winding tightening part <NUM>. The helical winding part <NUM> includes a base circular plate <NUM>, a plurality of bobbin mounting parts <NUM>, a plurality of helical winding circumference guiding parts <NUM>, and a central guiding part <NUM>. The helical winding circumference guiding parts <NUM> and the central guiding part <NUM> form a fiber bundle guide section for guiding the plural fiber bundles F simultaneously.

The base circular plate <NUM> having an annular shape, its center position coincides with the center of the opening <NUM> in the helical winding unit 6y. The base circular plate <NUM> is provided on a side opposite to the winding drive part <NUM> in the front-rear direction, across the winding unit frame <NUM>. The base circular plate <NUM> that is mounted to the rotary table <NUM> in the winding drive part <NUM>, is rotated in conjunction with rotation of the rotary table <NUM>.

The bobbin mounting parts <NUM> are provided perpendicular to a front surface of the base circular plate <NUM> so as to protrude forward from the base circular plate <NUM>. A plurality of bobbins <NUM> around which the fiber bundle F is wound is mounted to the corresponding bobbin mounting part <NUM>.

The plurality of bobbin mounting parts <NUM> is arranged side by side at equal intervals in a circumferential direction of the base circular plate <NUM>. Each helical winding circumference guiding part <NUM> is provided in the vicinity of the corresponding bobbin mounting part <NUM>. Each helical winding circumference guiding part <NUM> is arranged side by side at equal intervals in the circumferential direction of the base circular plate <NUM>.

Each helical winding circumference guiding part <NUM> includes one by one, first intermediate rollers <NUM> and second intermediate rollers <NUM> arranged in the front-rear direction. As shown in <FIG>, each first intermediate roller <NUM> is provided at a position farther from the base circular plate <NUM> than the corresponding second intermediate roller <NUM>. In other words, each first intermediate roller <NUM> is provided forward of the corresponding second intermediate roller <NUM>.

Each second intermediate roller <NUM> is mounted to the base circular plate <NUM> so as to slide in a radial direction. Each second intermediate roller <NUM> is biased in an orientation of moving outward in the radial direction of the base circular plate <NUM>, by means of an appropriate biasing member (specifically, a spring).

As shown in <FIG> and <FIG>, the fiber bundle F from each bobbin <NUM> that is mounted to each bobbin mounting part <NUM> is wound around the corresponding first intermediate roller <NUM> and the corresponding second intermediate roller <NUM> in order, and then guided to the central guiding part <NUM>. The tension applied to the fiber bundle F is appropriately adjusted by spring force in which the biasing member exerts on each second intermediate roller <NUM>. As such, each second intermediate roller <NUM> functions as a tension roller.

The central guiding part <NUM> having a substantially cylindrical shape, is provided at the center of the helical winding section <NUM> such that an axial direction of the central guiding part <NUM> coincides with the winding rotational shaft A3. An annular guiding part <NUM> is formed smaller than an annular area where each first intermediate roller <NUM> and each second intermediate roller <NUM> are arranged side by side.

In other words, the annular guiding part <NUM> is provided at a position closer to a center than each first intermediate roller <NUM> and each second intermediate roller <NUM>, as viewed in the front-rear direction. The fiber bundle F guided by each second intermediate roller <NUM> is guided from an outside in the radial direction of the central guiding part <NUM> to the core material <NUM> passing through an inside of the central guiding part <NUM>, as shown in <FIG> and <FIG>.

As shown in <FIG>, the central guiding part <NUM> includes a first annular plate <NUM>, a second annular plate <NUM>, an annular guiding part <NUM>, and auxiliary guiding parts <NUM>. All of the first annular plate <NUM>, the second annular plate <NUM>, the annular guiding part <NUM>, and the auxiliary guiding parts <NUM> are respectively formed in an annular shape and arranged such that their central axes coincide.

The first annular plate <NUM> has a mounting part <NUM> extending in a radial direction. Although the base circular plate <NUM> is not shown in <FIG>, the first annular plate <NUM> is mounted to the base circular plate <NUM> via the mounting part <NUM>. Accordingly, the first annular plate <NUM> is rotated in conjunction with rotation of the base circular plate <NUM>. The first annular plate <NUM> is connected to the annular guiding part <NUM> on one side in the front-rear direction.

The second annular plate <NUM> has an annular shape like the first annular plate <NUM>. The second annular plate <NUM> is connected to the annular guiding part <NUM> on a side opposite to the first annular plate <NUM> in the front-rear direction.

The annular guiding part <NUM> having an annular shape, has a predetermined thickness in an axial direction. An outer diameter of the annular guiding part <NUM> is smaller than that of the first annular plate <NUM> and the second annular plate <NUM>. An inner diameter of the annular guiding part <NUM> is larger than that of the first annular plate <NUM> and the second annular plate <NUM>.

The annular guiding part <NUM> has fiber bundle guide holes <NUM> that penetrate the annular guiding part <NUM> in the radial direction. The plurality of fiber bundle guide holes <NUM> is formed side by side at equal intervals in a circumferential direction of the annular guiding part <NUM>, in accordance with the number of bobbin mounting parts <NUM> (in other words, the number of helical winding circumference guiding parts <NUM>). Each fiber bundle guide hole <NUM> guides the fiber bundle F guided from the corresponding second intermediate roller <NUM> to the center side of the central guiding part <NUM>.

Each of the auxiliary guiding parts <NUM> is made of two plates having an annular shape. As shown in <FIG>, an outer diameter of each auxiliary guiding part <NUM> is larger than an inner diameter of the first annular plate <NUM> and the second annular plate <NUM>, and smaller than an inner diameter of the annular guiding part <NUM>. The inner diameter of each auxiliary guiding part <NUM> is smaller than that of the first annular plate <NUM> and the second annular plate <NUM>.

The two plates forming each auxiliary guiding part <NUM> are respectively connected to a front surface of the first annular plate <NUM> and a rear surface of the second annular plate <NUM>. The auxiliary guiding parts <NUM> are provided coaxially with the first annular plate <NUM> and the second annular plate <NUM>.

With this configuration, as shown in <FIG>, an inner peripheral surface of each auxiliary guiding part <NUM> is closer to a shaft of the central guiding part <NUM> than the inner peripheral surface of the first annular plate <NUM> and the second annular plate <NUM>. That is, the fiber bundle F guided by each auxiliary guiding part <NUM> can be guided to a position closer to the core material <NUM> passing through the center of the central guiding part <NUM>, via the auxiliary guiding parts <NUM>. This can further stabilize behaviors of the fiber bundle F to be wound around the core material <NUM>.

The helical winding section <NUM> with the above-described configuration can guide the plurality of fiber bundles F radially to the core material <NUM>. The helical winding section <NUM> is rotated along with rotation of the rotary table <NUM>, and thereby the plurality of fiber bundles F can be simultaneously wound around the core material <NUM>.

Next, creation of a winding data as a control data for which the control section <NUM> controls each of the motors, will be described. In the following description, in accordance with the above-described XYZ coordinate system, the left-right direction may be referred to as an X direction, the vertical direction may be referred to as a Y direction, and the front-rear direction may be referred to a Z direction. In the following, a case where the hoop winding unit 6x is used as the winding unit <NUM> will be described.

In the filament winding apparatus <NUM> of this embodiment, the controller <NUM> included in the control section <NUM> controls operations of each drive motor in accordance with pre-prepared winding data. Accordingly, the controller <NUM> controls such that the base frame <NUM> in the winding device <NUM> travels along the rails <NUM> while adjusting the position and the posture of the hoop winding part <NUM> in accordance with a shape (curvature) of the core material <NUM>. In conjunction with such motion, the hoop winding part <NUM> is rotated, and thereby the fiber bundle F is wound onto the outer peripheral surface of the core material <NUM>.

The controller <NUM> creates the winding data. Various information is required to create the winding data. The various information includes an initial setting value for winding the fiber bundle F and a winding position posture information for which the position and the posture of the winding device <NUM> are changed along the core material <NUM> having a curved shape.

The initial setting value includes, for example, a length L in the Z direction of the core material <NUM> around which the fiber bundle F is wound, the number N of the fiber bundles F to be hoop-wound, a width W of the fiber bundle F, a diameter D of the core material <NUM>, and the like. The operator inputs the above-described initial setting value to the controller <NUM> via the operation part <NUM> included in the control section <NUM> (a step S101 in <FIG>, an initial setting value input step).

Next, the operator inputs the winding position posture information. Since the core material <NUM> is curved, the position and the posture of the winding device <NUM> suitable for winding the fiber bundle F around the core material <NUM> is varied depending on a position where the fiber bundle F is wound around the core material <NUM>. The above-described information regarding the position and the posture is gathered into the winding position posture information. Although the core material <NUM> with various shapes can be replaced and mounted to the core material support devices <NUM>, the winding position posture information is varied depending on the shape of the core material <NUM>.

The winding position posture information includes an X coordinate value Xn, a Y coordinate value Yn, a Z coordinate value Zn, a rotation angle θVn, and a pitching angle θHn, which are determined for each point where the hoop winding part <NUM> passes during winding.

The X coordinate value Xn, the Y coordinate value Yn, and the Z coordinate value Zn represent a position of the hoop winding part <NUM> in the XYZ rectangular coordinate system. Therefore, combination of the X coordinate value Xn, the Y coordinate value Yn, and the Z coordinate value Zn is a position information identifying the position of the hoop winding part <NUM>. An original point of the XYZ rectangular coordinate system can be set at any position.

The rotation angle θVn and the pitching angle θHn represent a posture of the hoop winding part <NUM> (in other words, the orientation of the winding rotational axis A3). Therefore, combination of the rotation angle θVn and pitching angle θHn is a posture information identifying the posture of the hoop winding part <NUM>.

The plurality of points of the winding position posture information is determined so as to include a range where the fiber bundle F is wound around the core material <NUM>. As shown in <FIG>, the operator sets division points (points) P1, P2,. such that the length L in the Z direction of the core material <NUM> is divided into several parts at equal intervals (a step S102 in <FIG>, a point setting step). The number of divided parts is appropriately determined depending on the length of the core material <NUM> and an accuracy required for winding. For example, it is conceivable that the length L in the Z direction of the core material <NUM> is divided into <NUM> parts, for example. Accordingly, the core material <NUM> is virtually divided into several parts in the Z direction.

The operator specifies the number of division points via the operation part <NUM>, for example. Accordingly, a target division point Pn (provided that n is an integer greater than or equal to <NUM>) is automatically generated. The controller <NUM> automatically calculates the Z coordinate value Zn of the target division point Pn in the winding position information shown in <FIG>, based on the length L in the Z direction of the core material <NUM> and the number of division points.

Next, the operator uses the operation part <NUM> included in the control section <NUM> to conduct teaching, for the target division point Pn, for the position and the posture of the winding unit <NUM> suitable for winding the fiber bundle F around the target division point Pn. Teaching is performed for a case where the winding device <NUM> performs winding while traveling forward and a case where the winding device <NUM> performs winding while traveling rearward, respectively. The operator conducts teaching at each division point Pn on an outward route and teaching at each division point Pn on a return route, while causing the winding device <NUM> to be reciprocated in the Z direction along the rails <NUM>. Therefore, when the number of division points Pn is <NUM>, the number of teaching points TPn is <NUM>.

In a state in which the core material <NUM> is actually set in the core material support devices <NUM>, the operator uses the control section <NUM> to cause the winding device <NUM> to be moved to the target teaching point TPn, and then teach the position and the posture of the winding device <NUM> at the target teaching point TPn. Accordingly, the position posture information including the position information and the posture information is inputted to the controller <NUM> (a step S103 in <FIG>, a posture information input step).

At one of the teaching points TPn, for example, the operator operates to adjust the position and the posture of the hoop winding part <NUM> by manually moving each of the left-right traveling drive motor <NUM>, the rotary drive motor <NUM>, the lifting motor <NUM>, and the pitching drive motor <NUM>, such that the core material <NUM> passes through the center of rotation of the hoop winding part <NUM> (that is, such that the winding rotational axis A3 of the hoop winding part <NUM> coincides with the shaft of the core material <NUM>).

The operator conducts a predetermined teaching operation with respect to the operation part <NUM>, after adjusting the position and the posture of the hoop winding part <NUM> such that the winding rotational axis A3 coincides with the shaft of the core material <NUM>. The controller <NUM> obtains the X coordinate value Xn, the Y coordinate value Yn, the Z coordinate value Zn, the pitching angle θHn, and the rotation angle θVn at a time of performing the teaching operation. These values may be obtained by a detection result of a sensor (not shown) mounted to the winding device <NUM>, or may be obtained by calculation of a control value with respect to each drive motor. The controller <NUM> confirms that the obtained Z coordinate value Zn has the substantially same value as the Z coordinate value at the corresponding teaching point. After that, the controller <NUM> stores the X coordinate value Xn, the Y coordinate value Yn, the Z coordinate value Zn, the pitching angle θHn, and the rotation angle θVn.

The operator completes to perform teaching for one of the teaching points TPn, and then operates to perform teaching for the subsequent teaching point TPn. The operator operates the operation part <NUM> to move the drive motors in the winding device <NUM>, and to perform teaching operations for each of the <NUM> teaching points.

In the posture information input step, as describe above, the operator operates to actually move the winding device <NUM> such that the winding device <NUM> matches with each of the divided parts in the core material <NUM>, and thereby the position posture information at the target teaching point TPn is inputted. This can perform teaching according to the actual core material <NUM>. However, alternatively, the position posture information of the winding device <NUM> at the target teaching point TPn may be calculated and stored by using data indicating the shape of the core material <NUM>, for example. Such data can be, for example, a three-dimensional model data indicating the shape of the core material <NUM>. Alternatively, data indicating an outline of the centerline of the core material <NUM> in a three-dimensional space, may be acceptable.

Next, the operator uses the operation part <NUM> to set a winding angle αn of the fiber bundle F between two division points Pn and Pn+<NUM> adjacent to each other in the Z direction (a step S104 in <FIG>, a winding angle setting step). As shown in <FIG>, the winding angle α is an angle defined by a tangential direction of the fiber bundle F wound onto the outer peripheral surface of the core material <NUM> and a direction where an axis A4 of the core material <NUM> extends.

In the winding angle setting step, the operator can operate to partially change the winding angle αn with respect to the core material <NUM> in accordance with product specifications, etc. The winding angle αn can be specified for each range between the division points Pn and Pn+<NUM> adjacent to each other. The operator can specify to wind with, for example, a large winding angle α in a range from a first division point P1 to a 32nd division point P32, and a small winding angle α in a range from the 32nd division point P32 to an 128th division point P128. This can obtain products with partial different strength, without special operations such as partial double winding.

Next, the controller <NUM> calculates a rate of coverage based on the specified winding angle αn and displays such rate of coverage on the display <NUM> (a step S105, a coverage rate displaying step).

The rate of coverage is, when the fiber bundle F is wound onto the outer peripheral surface of the core material <NUM>, a ratio of an area where the fiber bundle F covers the outer peripheral surface of the core material <NUM> to an area of the outer peripheral surface of the core material <NUM>. If the rate of coverage is less than <NUM>, the fiber bundle F is wound around the core material <NUM> while forming a gap between the fiber bundle F and an adjacent fiber bundle F to be wound. If the rate of coverage is greater than <NUM>, the fiber bundle F is wound around the core material <NUM> so as to partially overlap the adjacent fiber bundle F to be wound. The rate of coverage can be obtained by geometrical calculation using the winding angle αn and the width W of the fiber bundle, etc. The operator determines whether or not to change the set winding angle αn with reference to the rate of coverage to be displayed.

The operator conducts a predetermined confirmation operation for the operation part <NUM> if there is no problem with the rate of coverage to be displayed.

Next, the controller <NUM> calculates a winding rotational speed of the winding drive motor <NUM> between the two division points Pn and Pn+<NUM> adjacent to each other (a step S106 in <FIG>, a winding rotational speed calculation step), based on the inputted initial setting value, the position posture information, and the winding angle αn. Specifically, the winding rotational speed is calculated based on the posture information and the position information of the two teaching points TPn and TPn+<NUM>, and the winding angle αn between the corresponding division points Pn and Pn+<NUM>. The controller <NUM> generates winding data including a rotational speed of each drive motor for changing the position and the posture of the hoop winding part <NUM> at an appropriate speed according to the above-described position posture information, and the target winding rotational speed of the winding drive motor <NUM> for achieving the winding angle αn.

Accordingly, regardless of a traveling speed of the front-rear traveling drive motor <NUM>, the winding angle α of the fiber bundle F can be kept at the winding angle αn that is set by the operator, between the teaching points TPn. That is, the controller <NUM> can appropriately control the rotational speed of the winding drive motor <NUM> in accordance with the traveling speed of the winding device <NUM> in the Z direction, based on the calculated winding rotational speed.

As described above, the filament winding apparatus <NUM> of this embodiment includes the rail <NUM>, the hoop winding part <NUM>, the winding drive motor <NUM>, and the control section <NUM>. The rail <NUM> extends in the Z direction. The winding device <NUM> winds the fiber bundle F onto the outer peripheral surface of the core material <NUM>. The winding drive motor <NUM> drives the hoop winding part <NUM> in rotation around the winding rotational axis A3 along the axial direction of the core material <NUM>. The control section <NUM> controls the winding drive motor <NUM>. The winding data of the filament winding apparatus <NUM> is created by using the following method. A winding data creation method includes the initial setting value input step, the point setting step, the winding angle setting step, and the winding rotational speed calculation step. The initial setting value input step is to input an initial setting value including the length L in the Z direction of the core material <NUM> in the Z direction. The point setting step is to set the plurality of division points P1, P2,. such that the length L in the Z direction of the core material <NUM> is divided into several parts. The winding angle setting step is to set the winding angle αn that is an angle defined by the axial direction of the core material <NUM>, and the fiber bundle F between the two adjacent division points Pn and Pn+<NUM>. The winding rotational speed calculation step is to calculate, at least based on the initial setting value to be inputted and the winding angle αn to be set, the winding rotational speed of the winding drive motor <NUM> between the adjacent two division points Pn and Pn+<NUM>, respectively.

Accordingly, the winding angle α with respect to the core material <NUM> can be partially changed, which can finish products with partially different strength in the longitudinal direction of the core material <NUM>, with just one series of winding work.

The filament winding apparatus <NUM> of this embodiment includes the rotary drive motor <NUM> and the pitching drive motor <NUM>. The rotary drive motor <NUM> and the pitching drive motor <NUM> adjust the posture of the hoop winding part <NUM> in the Z direction. The winding data creation method includes the posture information input step. The posture information input step is to input the posture information (θVn, θHn) of the hoop winding part <NUM> at each of the division points P1, P2,. that is set in the point setting step. In the winding rotational speed calculation step, the winding rotational speed of the winding drive motor <NUM> is calculated based on the initial setting value, the winding angle αn, and the posture information inputted in the posture information input step.

Accordingly, the fiber bundle F can be wound around even the core material <NUM> having a curved shape, with the specified winding angle αn.

In this embodiment, in the posture information input step, teaching is performed in a state of adjusting the posture of the winding device <NUM> such that the winding rotational axis A3 of the hoop winding part <NUM> coincides with the axis of the core material <NUM>, at each of the division points P1, P2,. that is set in the point setting step, to input the posture information (θVn, θHn).

Accordingly, the posture information confirming the actual shape of core material <NUM> can be obtained.

However, in the posture information input step, based on a pre-inputted 3D data of the core material <NUM>, the posture of the hoop winding part <NUM> at each of the division points P1, P2,. that is set in the point setting step can be also obtained as the posture information (θVn, θHn) by calculation.

In this case, the posture information can be easily obtained without actually moving the hoop winding part <NUM>. Therefore, a pre-setting work is simplified even when there are many division points P1, P2,.

In this embodiment, the posture information input step is to input the posture information (θVn, θHn) at each of the division points P1, P2,. , in a case where the hoop winding part <NUM> is moved to one side in the Z direction relative to the core material <NUM> and a case where the hoop winding part <NUM> is moved to the other side in the Z direction relative to the core material <NUM>.

Accordingly, even when the posture of the hoop winding part <NUM> suitable for winding of the fiber bundle F is varied depending on an orientation in which the hoop winding part <NUM> is relatively moved in the Z direction, winding of the fiber bundle F with various postures can be accepted by inputting the posture information for the orientation of relative movement.

In this embodiment, each of the division points P1,P2,. can be set at equal intervals in the Z direction.

Accordingly, the division points P1,P2,. can be easily set.

In this embodiment, the initial setting value inputted in the initial setting value input step further includes the number N of fiber bundles F, the width W of the fiber bundle F, the diameter D of the core material <NUM>.

This can more appropriately calculate the winding rotational speed of the winding drive motor <NUM> in accordance with winding conditions, respectively.

In this embodiment, the winding data creation method includes a displaying step. The displaying step is to display the rate of coverage of the fiber bundle F wound onto the outer peripheral surface of the core material <NUM>, the rate of coverage calculated based on the winding angle αn to be set.

Accordingly, the operator can easily confirm the rate of coverage of the fiber bundle F wound in accordance with the winding data.

Although a preferred embodiment of the present invention has been described above, the above-described configuration can be modified, for example, as follows.

Instead of the winding angle α, the winding rotational speed of the fiber bundle F per unit length may be inputted. This input is substantially the same as an input of the winding angle α.

The operator may input a desired rate of coverage into the operation part <NUM>, to allow the controller <NUM> to calculate the winding angle α from the inputted rate of coverage. The operator may then input the displayed winding angle α as it is. Such input support function can improve convenience.

Similarly, the winding data can be also created when the helical winding unit 6y is used as the winding unit <NUM>. In this case, the helical winding section <NUM> corresponds to a winding part that is rotated around the winding rotational axis A3.

The division points P1, P2,. may be set at unequal intervals in the Z direction. For example, it is conceivable to set the division points sparsely at a portion where the core material <NUM> extends straight, and to set the division points densely at a curved portion in the core material <NUM>. Accordingly, the position and the posture of the winding device <NUM> are particularly finely adjusted for the curved portions in the core material <NUM> while avoiding an increase of the division points. This can cleanly wind the fiber bundle F.

In the above-described embodiment, a function of the drive control section for controlling various drive motors (including the winding drive motor <NUM>) and a function of the data creation section for creating the winding data are realized by the one single controller <NUM>. However, the drive control section and the data creation section may be realized by separate hardware. The information of the rate of coverage may be displayed on a display of a computer that creates the winding data, or may be displayed on a display of a computer provided in the filament winding apparatus <NUM>.

Instead of the winding device <NUM> moving in the front-rear direction, the core material support devices <NUM> supporting the core material <NUM> may be moved in the front-rear direction. Accordingly, the winding device <NUM> is moved relative to the core material <NUM> in the Z direction, which can realize the substantially same motion as the above-described embodiment. Both of the winding device <NUM> and the core material support devices <NUM> may be moved in the front-rear direction.

The lifting frame <NUM> may be omitted, and then the winding unit <NUM> may be mounted so as not to be rotated relative to the main frame <NUM>. In this case, the winding unit <NUM> cannot be moved up and down and cannot face up and down. However, if the core material <NUM> is two-dimensionally curved, the fiber bundle F can be wound around the core material <NUM> without any problem. In this configuration, the position information is only the X coordinate value Xn and the Z coordinate value Zn, and the posture information is only the rotation angle θVn.

The main frame <NUM> may be configured so as not to be moved left and right and not to be rotated around the rotational axis A1. In this case, the fiber bundle F is wound around the core material <NUM> only with vertical motion and pitching motion of the winding unit <NUM>. Also in this configuration, the fiber bundle F can be wound around the core material <NUM> if the core material <NUM> is two-dimensionally curved. In this configuration, the position information is only the Y coordinate value Yn and the Z coordinate value Zn, and the posture information is only the pitching angle θHn.

In the above-described embodiment, in order to three-dimensionally change the posture of the winding unit <NUM> (the hoop winding part <NUM> or the helical winding section <NUM>), a mechanism that realizes left-right motion and rotation around the rotational axis A1 is provided in the base frame <NUM>. Such mechanism further includes a mechanism that realizes vertical motion and rotation around the pitching axis A2. However, the mechanism that realizes vertical motion and rotation around the pitching axis A2 may be provided in the base frame <NUM>. Such mechanism may further include the mechanism that realizes left-right motion and rotation around the rotational axis A1.

Claim 1:
A winding data creation method for a filament winding apparatus (<NUM>), the filament winding apparatus (<NUM>) including a rail (<NUM>) extending in a first direction, a winding part (<NUM>) that winds a fiber bundle (F) onto an outer peripheral surface of a core material (<NUM>), a winding drive motor (<NUM>) that drives the winding part (<NUM>) in rotation around a winding rotational axis (A3) along an axial direction of the core material (<NUM>), and a control section (<NUM>) that controls the winding drive motor (<NUM>), the winding data creation method being characterized by
an initial setting value input step (S101) of inputting an initial setting value including a length (L) in the first direction (Z) of the core material (<NUM>) in the first direction (Z);
a point setting step (S102) of setting a plurality of points (P1, P2,...) so as to divide the length of the core material (<NUM>) in the first direction (Z);
a winding angle setting step (S104) of setting a target winding angle that is an angle defined by an axial direction of the core material (<NUM>), and the fiber bundle (F) wound around the core material (<NUM>) between two of the plurality of points (P1, P2,...) adjacent to each other in the first direction (Z); and
a winding rotational speed calculation step (S106) of calculating, at least based on the initial setting value to be inputted and the target winding angle to be set, a target winding rotational speed of the winding drive motor (<NUM>) between the two points adjacent to each other, respectively.