Patent ID: 12246373

DESCRIPTION OF EMBODIMENTS

First Embodiment

An embodiment of the present invention will now be described with reference to the drawings.FIG.1is a schematic plan view showing a configuration of a wire processing device1including a wire straightening device20according to the present embodiment.

The wire processing device1includes a reel3around which a wire2is wound, the wire straightening device20that straightens the curl of the wire2, a length measuring section4that measures the amount of feed (the length of feed) of the wire2, a feeding device5that feeds the wire2, a clamp6F that clamps a front end portion of the wire2fed by the feeding device5, a terminal crimper9F that crimps a terminal8at the front end portion of the wire2clamped by the clamp6F, a cutter device7, a clamp6R that clamps a rear end portion of the wire2downstream of the cutter device7, and a terminal crimper9R that crimps the terminal8at the rear end portion of the wire2clamped by the clamp6R.

Although not shown in the figures, the wire2is a so-called covered wire, which includes a core wire and a coating material surrounding the core wire. The core wire is made of a conductor such as a metal, and the coating material is made of an insulator such as a resin.

The cutter device7has a cutting blade7athat cuts the wire2, a strip blade7F for stripping off the coating material at the front end portion of the wire2clamped by the clamp6F, and a strip blade7R that strips off the coating material at the rear end portion of the wire2clamped by the clamp6R.

The feeding device5is a device that feeds the wire2in the longitudinal direction of the wire2. There is no particular limitation on the configuration of the feeding device5. In the present embodiment, the feeding device5includes left and right conveyor belts5A that sandwich the wire2therebetween, a pair of pulleys5B between which each conveyor belt5A is wound, and a conveyor motor5C linked to at least one pulley5B. When the conveyor motor5C is driven, a pulley5B linked to the conveyor motor5C is rotated, and the left and right conveyor belts5A circulate as shown by arrows in the figure. Therefore, the wire2sandwiched by the left and right conveyor belts5A is fed out forward (rightward inFIG.1). As will be described in detail later, during operation of the wire processing device1, the feeding device5repeats the operation of feeding the wire2and the operation of stopping the wire2. Note that in the present embodiment, the wire2is dispensed from the reel3as the feeding device5feeds the wire2forward. Note however that it is possible to separately provide another motor, or the like, that rotates the reel3so as to feed the wire2.

The wire processing device1includes a control device10for controlling the operation of the feeding device5, the wire straightening device20, the cutter device7, the terminal crimpers9F and9R, etc. The control device10is a computer including a CPU, a ROM, a RAM, etc. The control device10may be a dedicated computer for the wire processing device1or may be a general-purpose computer (e.g., a personal computer).

Next, the wire straightening device20will be described with reference toFIG.2.

The wire straightening device20is a device that straightens the curl of the wire2fed onto a straight feed path2A. The wire straightening device20includes a plurality of cylindrical guide members42arranged along the feed path2A so that the wire2can be easily guided onto the feed path2A.

The wire straightening device20includes a plurality of first straightening rollers25and a plurality of second straightening rollers23arranged along the feed path2A. One or both of the first straightening rollers25and the second straightening rollers23may be arranged parallel to the feed path2A or may be arranged non-parallel to the feed path2A. For example, one or both of the first straightening rollers25and the second straightening rollers23may be arranged so that the further downstream (rightward inFIG.2), the farther away they are from the delivery path2A. The wire straightening device20includes a first support member24supporting the first straightening rollers25and a second support member22supporting the second straightening rollers23. The second straightening rollers23are arranged on the opposite side of the first straightening rollers25with respect to the feed path2A. Here, the first straightening rollers25are arranged on the upper side of the feed path2A and the second straightening rollers23are arranged on the lower side of the feed path2A. Note however that the arrangement is not limited to this arranged as long as the first straightening rollers25and the second straightening rollers23are arranged on opposite sides from each other with the feed path2A therebetween. Other arrangements may be possible, for example, the first straightening rollers25may be arranged on the lower side of the feed path2A and the second straightening rollers23may be arranged on the upper side of the feed path2A. The first straightening rollers25may be arranged on the left side of the feed path2A and the second straightening rollers23may be arranged on the right side of the feed path2A.

The wire straightening device20includes a lift mechanism26that raises and lowers the first support members24. The lift mechanism26includes a motor26aand a ball screw26b. Here, the motor26ais a servo motor. The upper end portion of the ball screw26bis linked to the motor26a, and a lower end portion of the ball screw26bis engaged with a female thread portion (not shown) of the first support member24. When the motor26ais driven, the ball screw26brotates and the first support member24rises or lowers. When the first support member24lowers, the first straightening rollers25move closer to the second straightening rollers23. When the first support member24rises, the first straightening rollers25move away from the second straightening rollers23. The motor26ais an example of an actuator for moving the first support member24in a direction such that the first straightening rollers25move closer to the second straightening rollers23and in a direction such that the first straightening rollers25move away from the second straightening rollers23. Note however that such an actuator is not limited to the motor26a. The actuator may be an actuator of any other type such as an air cylinder.

When the first support member24is raised or lowered, the vertical spacing between the first straightening rollers25and the second straightening rollers23(hereinafter referred to as the roller spacing) changes. In the present embodiment, the roller spacing is defined by the distance rd in the vertical direction between the center of the first straightening rollers25and the center of the second straightening rollers23. Note however that there is no particular limitation on the definition of the roller spacing as long as it is a parameter that uniquely specifies the vertical positional relationship between the first straightening rollers25and the second straightening rollers23.

The wire straightening device20includes a roller spacing measuring section27that measures the roller spacing. The roller spacing measuring section27includes a sensor body27b, and a detection pin27aprotruding downward from the sensor body27b. The detection pin27ais displaceable with respect to the sensor body27band is in contact with the first support member24. When the first support member24is raised, the detection pin27ais pushed upward by the first support member24, thereby reducing the length of protrusion of the detection pin27afrom the sensor body27b. Conversely, when the first support member24is lowered, the length of protrusion of the detection pin27afrom the sensor body27bincreases. Therefore, by detecting the amount of displacement of the detection pin27a, it is possible to identify the position of the first support member24and to measure the roller spacing. In the present embodiment, a Hall IC linear displacement sensor (not shown) is provided inside the sensor body27b. The Hall IC linear displacement sensor detects the amount of displacement of the detection pin27a, thereby measuring the roller spacing.

The wire straightening device20also includes an outer diameter measuring section40that measures the outer diameter of the wire2(see reference sign D in the figure). The outer diameter measuring section40includes a fixed roller43, a movable roller44that is movable in the vertical direction, and a displacement sensor46that detects the position of the movable roller44in the vertical position. The wire2is sandwiched between the fixed roller43and the movable roller44. The movable roller44is displaceable in the vertical direction inside a long hole45and is biased toward the fixed roller43by a spring (not shown). The position of the movable roller44in the vertical direction is displaced according to the outer diameter of the wire2. Therefore, the displacement sensor46detects the position of the movable roller44in the vertical direction to measure the outer diameter of the wire2.

As shown inFIG.3, the wire straightening device20includes a change input device50that is operated by an operator. The change input device50is a device that is operated by the operator to change the roller spacing during operation of the wire processing device1. In the present embodiment, the change input device50includes an up button51that is pressed to increase the roller spacing and a down button52that is pressed to decrease the roller spacing. Note however that the change input device50described herein is merely an example. The change input device50is a device that can be used to input an instruction to increase the roller spacing and an instruction to decrease the roller spacing, and there is no limitation on the configuration thereof. The change input device50is not limited to a button-type input device, but may also be a dial-type input device, a touch panel-type input device, or any other type of an input device.

As shown inFIG.4, the wire straightening device20includes an indicator60that displays the degree of the change in roller spacing. In the present embodiment, the indicator60includes eight vertically-aligned lamps61to68. These eight lamps61to68display the amount of change in eight levels. Here, the larger the roller spacing, the greater the number of lamps that are lit. When the amount of change is zero, the lamps61to64in the lower half are lit, and the lamps65to68in the upper half are turned off. When the amount of change decreases below zero (i.e., a negative amount of change), the lamps61to64are turned off gradually one by one in the following order:64,63,62,61. Conversely, when the amount of change increases above zero, the lamps65to68are lit gradually one by one in the following order:65,66,67,68. Note however that the indicator60described herein is merely an example. There is no limitation on the configuration thereof as long as the indicator60can display the degree of the amount of change in roller spacing. The indicator60may be a meter-type indicator, an image display device, or any other form of an indicator.

FIG.5is a block diagram showing a controller28and units that are connected to controller28. The controller28is composed of a computer including a CPU, a ROM, a RAM, etc. Note that while the controller28of the wire straightening device20may be configured separately from the control device10of the wire processing device1, the control device10of the wire processing device1may serve also as the controller28of the wire straightening device20. As shown inFIG.5, the controller28includes an input port31A connected to the outer diameter measuring section40(specifically, the displacement sensor46of the outer diameter measuring section40), an outer diameter input section31that receives information of the outer diameter of the wire2from the outer diameter measuring section40, a memory section32, a roller spacing setting section33, an input port35A connected to the change input device50, a correction value setting section35that receives information of the amount of change in roller spacing from the change input device50, a motor drive control section36, an output port36A connected to a servo amplifier37, and an output port35B connected to the indicator60.

As shown inFIG.6, the wire straightening device20sandwiches the wire2by the first straightening rollers25and the second straightening rollers23to give an appropriate pressing force on the wire2, thereby straightening the curl. Here, the pressing force to be given to the wire2is determined based on the roller spacing. On the other hand, the pressing force to be given to the wire2varies if the outer diameter of the wire2is different even if the roller spacing is the same. That is, even if the roller spacing is the same, the pressing force decreases if the outer diameter of the wire2is smaller, and the pressing force increases if the outer diameter of the wire2is larger. Therefore, the roller spacing with which the pressing force is desirable differs for each outer diameter of the wire2. The desirable roller spacing can be determined for each outer diameter of the wire2by conducting preliminary tests or based on past experience. The memory section32stores the predetermined relationship between outer diameters of the wire and desirable roller spacings. In the present embodiment, the memory section32forms a “preset value obtaining device” for obtaining a predetermined preset value of the roller spacing for each type of wire.

The roller spacing setting section33drives the motor26aso that a desirable roller spacing is achieved in accordance with the outer diameter of the wire2. When the outer diameter measuring section40measures the outer diameter of the wire2, the information of the outer diameter of the wire2is input to the outer diameter input section31. When the roller spacing setting section33obtains the information of the outer diameter of the wire2from the outer diameter input section31, the roller spacing setting section33reads out, from the memory section32, the preset value of desirable roller spacing in accordance with the outer diameter. Then, the roller spacing setting section33sends a command to the motor drive control section36so that the roller spacing becomes equal to the preset value. Then, the motor drive control section36controls the motor26athrough the servo amplifier37so that the roller spacing becomes equal to the preset value. Note that the preset values are retained without being overwritten during operation of the wire processing device1. In the present embodiment, the preset values stored in memory section32cannot be erased or changed. Note however that there is no particular limitation on this configuration. The preset values stored in memory section32may be erasable or changeable. Note that in the present embodiment, the roller spacing setting section33and the motor drive control section36form a “roller spacing automatic setting device” that drives the motor26aso that the roller spacing becomes equal to the preset values.

Information of the amount of change in roller spacing input to the change input device50is input to the correction value setting section35. For example, if the operator presses the up button51of the change input device50once, a command to increase the roller spacing by one step is input to the correction value setting section35. Conversely, if the operator presses the down button52of the change input device50once, a command to narrow the roller spacing by one step is input to the correction value setting section35. The correction amount of the roller spacing when the up button51and the down button52are pressed once is set in advance. For example, when the up button51is pressed once, the roller spacing is set to increase by 0.05 mm, and when the down button52is pressed once, the roller spacing is set to decrease by 0.05 mm The correction value setting section35sets the correction value of the roller spacing based on the number of times the up button51and the down button52are pressed. Then, the correction value setting section35sends the set correction value to the motor drive control section36. Upon receiving the correction value, the motor drive control section36controls the motor26ato change the roller spacing by an amount that corresponds to the correction value. Note that when the correction value is set by the correction value setting section35, information of the correction value is sent to the indicator60, and the indicator60turns on or turns off the lamps61to68in accordance with the amount of change in roller spacing. In the present embodiment, the correction value setting section35, the motor drive control section36and the motor26atogether form a “roller spacing change device”.

Although there is no particular limitation on the degree of the difference between the preset value of the roller spacing and the correction value, for example, the correction value may be −50% to +50%, −30% to +30%, −20% to +20%, −10% to +10%, or −5% to +5 of the preset value.

The wire straightening device20is configured as described above. Next, the operation of the wire processing device1will be described. The wire processing device1continuously produces the wire2of a predetermined length with terminals8crimped at opposite ends by repeating one cycle of operation as described below.

One cycle of operation begins with the terminal8crimped on the front end portion of the wire2and the front end portion of the wire2being positioned rearward (leftward inFIG.1) of the cutting blade7aof the cutter device7. From this state, first, the feeding device5feeds the wire2forward (rightward inFIG.1) by a predetermined length. Accordingly, the wire2is dispensed from the reel3. The wire2passes between the first straightening rollers25and the second straightening rollers23of the wire straightening device20and receives a pressing force from the first straightening rollers25and the second straightening rollers23, thereby straightening the curl (seeFIG.6).

When the wire2is fed forward by a predetermined length, the feeding device5stops feeding the wire2. When the feeding of the wire2is stopped, the clamp6F and the clamp6R clamp the wire2, and the cutting blade7aof the cutter device7cuts the wire2. As a result, the wire2is cut into a rear wire2clamped by the clamp6F and a front wire2clamped by the clamp6R.

Next, the clamp6F swivels leftward (upward inFIG.1) and guides the front end portion of the rear wire2to the strip blade7F. The clamp6R swivels to rightward (downward inFIG.1) to guide the rear end portion of the front wire2to the strip blade7R. The strip blade7F strips off the coating material at the front end portion of the wire2clamped by the clamp6F, and a strip blade7R strips off the coating material at the rear end portion of the wire2clamped by the clamp6R.

The clamp6F swings further leftward and guides the front end portion of the rear wire2to the terminal crimper9F (see the virtual line inFIG.1). The clamp6R swings further rightward and guides the rear end portion of the front wire2to the terminal crimper9R (see the virtual line inFIG.1). Then, the terminal crimper9F crimps the terminal8onto the front end portion of the wire2clamped by the clamp6F. The terminal crimper9R crimps the terminal8onto the rear end portion of the wire2clamped by the clamp6R. As a result, the wire2clamped by clamp6R becomes the wire2of a predetermined length with terminals8crimped at opposite ends. When clamp6R releases its grasp, the wire2is collected in a tray (not shown). On the other hand, the clamp6F swivels rightward (downward inFIG.1) and returns to the position in front of the cutting blade7aof the cutter device7. Then, the clamp6F releases its grasp on the wire2. Thus, one cycle of operation ends.

The wire processing device1successively produces the wires2of a predetermined length with terminals8crimped at opposite ends by repeating the cycle operation described above. During operation of the wire processing device1, the feeding device5successively dispenses the wire2from the reel3by repeating the operation of feeding the wire2and the operation of stopping the feed.

During operation of the wire processing device1(i.e., while the feeding device5is repeating the operation of feeding the wire2and the operation of stopping the feed), the wire2is dispensed in the order from the portion wound on the outer portion of the reel3to the portion wound on the inner portion. However, the portion wound on the inner portion of the reel3is more curved than the portion wound on the outer portion of the reel3. Therefore, during operation of the wire processing device1, the degree of the curl of the wire2supplied to the wire straightening device20is not constant and changes gradually.

The hardness of the wire2varies depending on environmental conditions such as temperature and humidity. For example, when the wire processing device1is operated twice without replacing the reel3, some time may elapse between the first operation and the second operation. In such a case, the environmental conditions may change between the first operation and the second operation, and the hardness of the wire2may vary. After using a part of the wire2wound on the reel3, the reel3may be replaced, and after elapse of a certain amount of time, the reel3may be reinstalled and the remaining wire2wound on the reel3may be used. In such a case, even if the wire2is wound on the same reel3, the environmental conditions may change and the hardness of the wire2may vary. Even wires2of the same type may have different hardnesses depending on the condition of storage before use. However, if the hardness of the wire2varies, the desirable pressing force varies, and the desirable roller spacing varies.

Therefore, the roller spacing (preset value) that is uniformly set in advance in accordance with the outer diameter of the wire2is not always the desirable roller spacing. By setting a desirable roller spacing in advance in accordance with the outer diameter of the wire2and setting the roller spacing to the preset value before starting operation of the wire processing device1, the curl of the wire2can be generally desirably straightened after the start of operation. However, if the roller spacing can be adjusted appropriately in accordance with the condition of the wire2during operation of the wire processing device1, it is possible to further precisely straighten the curl of the wire2.

In view of this, in the present embodiment, the operator adjusts the roller spacing by operating the change input device50while watching the condition of the wire2(e.g., the track of the wire2) downstream of the wire straightening device20during operation of the wire processing device1.

The operator presses the down button52of the change input device50, for example, if the pressing force on the wire2is inferred to be small based on the condition of the wire2. Then, the correction value setting section35sets a negative correction value, and the motor drive control section36controls the motor26ato move the first support member24down one step. As a result, the roller spacing is reduced by one step and the pressing force that the wire2receives from the first straightening rollers25and the second straightening rollers23is increased by one step. Then, the number of lamps of the indicator60that are lit is reduced by one, and the operator can easily recognize that the roller spacing has been reduced by one step.

Conversely, if it is inferred from the condition of the wire2that the pressing force on the wire2is large, the operator presses the up button51of the change input device50. Then, the correction value setting section35sets a positive correction value, and the motor drive control section36controls the motor26ato move the first support member24up one step. As a result, the roller spacing is increased by one step and the pressing force that the wire2receives from the first straightening rollers25and the second straightening rollers23is reduced by one step. Then, the number of lamps of the indicator60that are lit increases by one, and the operator can easily recognize that the roller spacing has been increased by one step.

FIG.7is a flow chart of the wire straightening method using the wire straightening device20. A wire straightening method according to the present embodiment will now be described with reference toFIG.7. First, in step S1, the outer diameter of the wire2is measured by the outer diameter measuring section40. Next, in step S2, the roller spacing is set by reading out, from the memory section32, a preset value of the roller spacing in accordance with the outer diameter of the wire2. Then, in step S3, the motor26ais driven so that the roller spacing becomes equal to the preset value. This automatically sets the roller spacing to the preset value.

After the automatic setting of the roller spacing ends, the operation of the wire processing device1is started (step S4). That is, the operation of the feeding device5, the cutter device7and the terminal crimpers9F and9R is started. In step S5, it is determined whether or not the processing of a predetermined number of wires2has been completed. In the present embodiment, the determination in step S5is made by the control device10. If the number of the wires2that have been processed is less than the predetermined number, the process proceeds to step S6.

In step S6, the operator visually checks the condition of the wire2to determine if the wire2is being straightened desirably. If the straightening is desirable, there is no need to change the roller spacing and the process returns to step S5. On the other hand, if it is determined by the operator that the straightening is not desirable, the operator makes a correction input by operating the change input device50(step S7). Specifically, the operator presses the up button51or the down button52of the change input device50. Then, a correction value is set in accordance with the amount of operation by the operator (step S8), and the motor26ais driven so that the roller spacing is changed by an amount in accordance with the correction value (step S9). When the roller spacing is changed, the process returns to step S5to repeat the process of step S5and subsequent steps.

When it is determined in step S5that a predetermined number of wires have been processed, the operation of the wire processing device1is terminated (step S10). That is, the operation of the feeding device5, the cutter device7and the terminal crimpers9F and9R is terminated. Thereafter, the correction value set in the correction value setting section35is erased (step S11), and the operation of the wire straightening device20is terminated.

As described above, according to the present embodiment, the roller spacing can be changed through operation by the operator during operation of the wire processing device1. Therefore, after the roller spacing is automatically set to a preset value in accordance with the outer diameter of the wire2, the roller spacing can be fine-tuned based on how the wire2is being straightened. Therefore, even if the desirable roller spacing varies due to changes in environmental conditions, etc., the wire2can be straightened at the desirable roller spacing. Therefore, according to the present embodiment, the curl of the wire2can be precisely corrected.

Now, during operation of the wire processing device1, the feeding device5repeats the operation of feeding the wire2and the operation of stopping the feed. The motor drive control section36, which receives a command from the correction value setting section35, may drive the motor26awhen the wire2is being fed, but when the wire2is moving, a load is applied to the motor26athrough the first straightening rollers25, the first support member24and the ball screw26b. Therefore, smooth operation of the motor26amay be hindered. In view of this, the correction value setting section35and the motor drive control section36may wait for the wire2to stop before driving the motor26aif the operator operates the change input device50when the wire2is being fed. That is, the correction value setting section35and the motor drive control section36may be configured to change the roller spacing while the feeding device5stops feeding the wire2. This allows the motor26ato be driven smoothly and the roller spacing to be adjusted in a stable manner.

In the present embodiment, the same motor26ais used for the actuator that automatically sets the roller spacing before operation of the wire processing device1and the actuator that changes the roller spacing based on the operation by the operator during operation of the wire processing device1. Compared to the case where those actuators are provided separately, the number of actuators can be reduced, and the wire straightening device20can be made smaller and less expensive.

In the present embodiment, the wire straightening device20includes the change input device50that can be operated by the operator during operation of the wire processing device1. By using this change input device50, the operator can easily adjust the roller spacing while seeing the condition of the wire2during operation of the wire processing device1.

In the present embodiment, the wire straightening device20also includes the indicator60that displays the degree of the correction value of the roller spacing during operation of the wire processing device1. By seeing this indicator60, the operator can easily grasp the amount of change in roller spacing during operation of the wire processing device1.

Now, the correction value that is set during operation of the wire processing device1is merely a value that temporarily became optimal for that operation, and should be changed as necessary in accordance with subsequent changes in environmental conditions. According to the present embodiment, after the operation of the wire processing device1ends (step S10), the correction value setting section35deletes the correction value that is set during that operation (step S11). Therefore, before the start of the next operation of the wire processing device1, the roller spacing is automatically set to the preset value stored in the memory section32. Therefore, the next operation can be started with a roller spacing that is generally considered desirable (i.e., the preset value), and the wire2can be straightened more desirably from immediately after the start of operation. Since the deviation between the preset value and the optimal value of the roller spacing is normally small, the subsequent adjustment of the roller spacing can be performed quickly and smoothly. Note that the deletion of the correction value does not necessarily need to be performed immediately after the end of operation of the wire processing device1, but may be performed before the start of the next operation. For example, in the flow chart ofFIG.7, step S11may be performed before step S1.

However, the embodiment described above is merely an example, and the correction value does not necessarily have to be deleted. The controller28may be configured to retain the set correction value after the operation of the wire processing device1ends. For example, the controller28may store the correction value in a memory (not shown) after the operation of the wire processing device1ends. The stored correction value may, for example, be referred to by the operator as reference data for the next operation. Before the start of the next operation, the operator may be allowed to select between the preset value and a value that is obtained by adding a correction value to the preset value (i.e., the roller spacing at the end of the previous operation). Such as when environmental conditions have not changed much between the end of operation of the wire processing device1and the start of the next operation, the operator may wish to start the next operation with the roller spacing at the end of the previous operation. In such cases, the amount of time required to adjust the roller spacing can be reduced by selecting the value obtained by adding a correction value to the preset value.

Although the preset value is retained during operation of the wire processing device1, it is possible to update the preset value after the end of operation. For example, when the operation of the wire processing device1ends, the controller28may overwrite the preset value stored in the memory section32and re-set the preset value to a value that is obtained by adding a correction value to the preset value.

In the present embodiment, the indicator60includes eight lamps61to68and is configured to display the degree of the correction value in eight levels. However, there is no particular limitation on the form of display of the indicator60. The indicator60is not limited to an indicator that displays the degree of the correction value stepwise. The indicator60may be configured to display the correction value itself (i.e., a numerical value).

Second Embodiment

The wire straightening device20according to the first embodiment is configured to adjust the roller spacing by utilizing the motor26athat automatically sets the roller spacing. However, the motor26afor automatically setting the roller spacing and the actuator for adjusting the roller spacing may be separate. The wire straightening device20according to the second embodiment includes an actuator for adjusting the roller spacing separately from the motor26afor setting the roller spacing.

As shown inFIG.8, the wire straightening device20according to the second embodiment includes a lift mechanism126that raises and lowers the second support member22. The lift mechanism126includes a motor126aand a ball screw126b. The lower end portion of the ball screw126bis linked to the motor126a, and the upper end portion of the ball screw126bengages with a female thread portion (not shown) of the second support member22. When the motor126ais driven, the ball screw126brotates and the second support member22rises or lowers. When the second support member22rises, the second straightening rollers23move closer to the first straightening rollers25, and when the first support member24lowers, the second straightening rollers23move away from the first straightening rollers25. The motor26ais an example of another actuator for moving the second support member22in a direction such that the second straightening rollers23move closer to the first straightening rollers25and in a direction such that the second straightening rollers23move away from the first straightening rollers25.

As shown inFIG.9, in the second embodiment, the controller28is connected to motor26avia the servo amplifier37and to the motor126avia a servo amplifier137. The controller28includes an output port136A connected to the servo amplifier137. The controller28also includes a motor drive control section136for controlling the motor126ain addition to the motor drive control section36for controlling the motor26a. The motor drive control section136controls the motor126abased on the correction value that is set by the correction value setting section35. In the present embodiment, the correction value setting section35, the motor drive control section136and the motor126atogether form a “roller spacing changing device”.

Otherwise, the configuration is similar to the first embodiment, and therefore the description will be omitted.

Also in the present embodiment, the outer diameter measuring section40measures the outer diameter of the wire2, and the roller spacing setting section33reads, from the memory section32, the preset value of the roller spacing in accordance with the outer diameter of the wire2, and drives the motor26aso that the roller spacing becomes equal to the preset value. As a result, the roller spacing is automatically set to the preset value before the start of operation of the wire processing device1. On the other hand, when the operator operates the change input device50, the correction value setting section35sets the correction value, and the motor drive control section136controls the motor126abased on the correction value to change the roller spacing.

Also in the present embodiment, the operator can change the roller spacing in accordance with the condition of the wire2during operation of the wire processing device1. Therefore, after the roller spacing is automatically set to a preset value in accordance with the outer diameter of the wire2, the roller spacing can be adjusted during operation of the wire processing device1so that the wire2is corrected more appropriately.

Thus, it is possible to precisely straighten the curl of the wire2.

The actuator for adjusting the roller spacing is not limited to the motor126a. Although not shown in the figures, the actuator for adjusting the roller spacing may be a hydraulic cylinder such as an air cylinder, or any other type of an actuator.

Third Embodiment

The wire straightening device20according to the first embodiment and the second embodiment used an actuator to change the roller spacing. However, it is not always necessary to use an actuator to change the roller spacing. The wire straightening device20according to the third embodiment changes the roller spacing by a manual operation.

As shown inFIG.10, the third embodiment includes a rotary knob126clinked to the ball screw126binstead of the motor126aof the lift mechanism126of the wire straightening device20according to the second embodiment. In the third embodiment, unlike the second embodiment, the change input device50and the indicator60are absent. The controller28does not include the correction value setting section35. In the present embodiment, the “roller spacing changing device” for changing the roller spacing is composed of the rotary knob126cand the ball screw126b.

When the rotary knob126cis turned in one direction (e.g., clockwise as viewed from below), the second support member22rises and the second straightening rollers23move closer to the first straightening rollers25. This reduces the roller spacing. When the rotary knob126cis rotated in the opposite direction (e.g., counterclockwise as viewed from below), the second support member22lowers and the second straightening rollers23move away from the first straightening rollers25. This increases the roller spacing. The ball screw126bforms a “moving mechanism” that moves the second support member22, by the operator manually operating the rotary knob126c, in a direction such that the first straightening rollers25move closer to the second straightening rollers23and in a direction such that the first straightening rollers25move away from the second straightening rollers23.

Otherwise, the configuration is similar to the second embodiment, and therefore the description will be omitted.

Also in the present embodiment, the outer diameter measuring section40measures the outer diameter of the wire2, and the roller spacing setting section33reads, from the memory section32, the preset value of the roller spacing in accordance with the outer diameter of the wire2, and drives the motor26aso that the roller spacing becomes equal to the preset value. The roller spacing is automatically set to the preset value before the start of operation of the wire processing device1. On the other hand, in the present embodiment, the roller spacing is manually changed by the operator operating the rotary knob126cduring operation of the wire processing device1.

In the present embodiment, the operator can also change the roller spacing during operation of the wire processing device1. Therefore, after the roller spacing is automatically set to a preset value according to the outer diameter of the wire2, the roller spacing can be adjusted according to the condition of the wire2. Thus, it is possible to precisely straighten the curl of the wire2.

Note that the rotary knob126cis an example of an operator for manually operating the lift mechanism126, but the operator is not limited to the rotary knob126c. Operators of other forms may also be used.

While the indicator60is absent in the present embodiment, it is of course possible to provide the indicator60. For example, a displacement sensor may be provided on the rotary knob126c, and the displacement sensor and the indicator60may be connected to each other. In this case, the displacement sensor detects the amount of operation of the rotary knob and sends a signal regarding the amount of operation to the indicator60. The indicator60receives the signal and displays the degree of the amount of operation. The indicator may also include an analog dial-type indicator (not shown), with which the display value changes in accordance with the amount of rotary operation of the rotary knob126c.

Fourth Embodiment

The wire straightening device20according to the first embodiment and the second embodiment includes the change input device50and the indicator60, but an input device and a display device for computers may be used instead of the change input device50and the indicator60, respectively. As shown inFIG.11, the wire straightening device20according to the fourth embodiment uses an input device28A and a display device28B for computers instead of the change input device50and the indicator60of the first embodiment. Note that the input device28A and the display device28B for computers may be used instead of the change input device50and the indicator60of the second embodiment.

There is no particular limitation on the specific configuration of the input device28A, and a keyboard, a mouse, a touch panel, or the like, may suitably be used, for example. There is no particular limitation on the specific configuration of the display device28B, and a liquid crystal display, or the like, may suitably be used, for example. In the present embodiment, a part of the image displayed on the display device28B includes a roller spacing display image29as shown inFIG.12. This roller spacing display image29includes a preset value display section29athat displays the preset value of the roller spacing and a correction value display section29bthat displays the correction value of the roller spacing. On the right side of the correction value display section29b, an up button icon (hereinafter referred to simply as the “up button”)29uand a down button icon (hereinafter referred to simply as the “down button”)29dare displayed.

Otherwise, the configuration is similar to the first embodiment, and therefore the description will be omitted.

Also in the present embodiment, the outer diameter measuring section40measures the outer diameter of the wire2, and the roller spacing setting section33reads, from the memory section32, the preset value of the roller spacing in accordance with the outer diameter of the wire2, and drives the motor26aso that the roller spacing becomes equal to the preset value. The roller spacing is automatically set to the preset value before the start of operation of the wire processing device1. The preset value of the roller spacing is displayed on the preset value display section29a. In the example shown inFIG.12, the preset value of the roller spacing is displayed as “2.01 mm”.

The operator changes the roller spacing using the input device28A while seeing the condition of the wire2during operation of wire processing device1. For example, each time the operator clicks on the up button29uof the roller spacing display image29using a mouse, the correction value of the roller spacing increases by one unit (herein, 0.01 mm), and each time the operator clicks on the down button29d, the correction value of the roller spacing decreases by one unit. For example, in order to increase the roller spacing by 0.05 mm, the operator clicks on the up button29ufive times. For example, if the preset value is 2.01 mm and the correction value is 0.05 mm, the roller spacing is adjusted to 2.01 mm+0.05 mm=2.06 mm Note that the preset value is retained during operation of the wire processing device1, and the value displayed on the preset value display section29aremains unchanged. When the operator clicks the up button29uor the down button29d, the numerical value displayed in the correction value display section29bchanges, but the numerical value displayed in the preset value display section29aremains unchanged.

In the present embodiment, the operator can still change the roller spacing during operation of the wire processing device1. Therefore, after the roller spacing is automatically set to the preset value in accordance with the outer diameter of the wire2, the roller spacing can be adjusted according to the condition of the wire2. Thus, it is possible to precisely straighten the curl of the wire2.

Also in the present embodiment, as in the first embodiment, the correction values may be erased after the end of operation of the wire processing device1or before the start of the next operation. The correction value may be retained after the end of operation of the wire processing device1. The preset value may be updated so that the updated preset value is obtained by adding the correction value to the preset value.

While the embodiment described above is configured so that the operator inputs the correction value, the configuration may be such that the operator inputs the roller spacing instead of the correction value. For example, the example described above may be configured so that the operator inputs the roller spacing “2.06 mm”, instead of inputting the correction value “0.05 mm”. Note that even in such a case, the preset value “2.01 mm” is retained during operation of the wire processing device1.

Fifth Embodiment

The controller28of the wire straightening device20of the embodiment described above includes the memory section32that stores the predetermined relationship between the outer diameter of the wire and the desirable roller spacing. The memory section32is an example of a “preset value obtaining device” for obtaining the preset value of the roller spacing predetermined for each type of wire. However, the preset value obtaining device is not limited to the memory section32provided in the controller28. A memory section that stores the predetermined relationship between the outer diameter of the wire and the desirable roller spacing may be provided outside of the controller28, and the controller28may include an obtaining section that obtains the roller spacing by communicating with the external memory section.

As shown inFIG.13, the wire straightening device20of the fifth embodiment includes an obtaining section132connected to the Internet70via an input port132A instead of the memory section32of the first embodiment. The obtaining section132is communicably connected through the Internet70to a server71which stores the predetermined relationship between the outer diameter of the wire and the desirable roller spacing. Otherwise, the configuration is similar to the first embodiment, and therefore the description will be omitted. In the present embodiment, the obtaining section132forms the “preset value obtaining device”. Note that the server71may be a single server or may be formed by multiple servers connected by a network. The server71may be a so-called cloud server.

In the present embodiment, when the outer diameter of the wire2is input to the outer diameter input section31, the obtaining section132reads the preset value of the roller spacing in accordance with the outer diameter of the wire2from the server71through the Internet70. Then, the roller spacing setting section33obtains the preset value of the roller spacing from the obtaining section132and sends a command to the motor drive control section36so that the roller spacing becomes equal to the preset value. The motor drive control section36controls the motor26aso that the roller spacing is set to the preset value. Thereafter, the roller spacing is adjusted in the same manner as in the first embodiment.

Also in the present embodiment, similar effects to those of the first embodiment can be obtained. According to the present embodiment, the preset value of the roller spacing can be changed as necessary by updating the information on the server71. Even when a new type of wire is used, it is only needed to add the roller spacing information for that wire to the server71. By simply adding or updating information stored in the server71, the obtaining section132can obtain the preset value of the roller spacing desirable for the new type of wire.

Alternative Embodiment

While some embodiments of the present invention have been described above, these embodiments are merely examples. Various other embodiments are possible. Next, examples of alternative embodiments will be briefly described.

The wire straightening device20according to the embodiments described above includes the outer diameter measuring section40that measures the outer diameter of the wire2. However, the outer diameter measuring section40is not always necessary. For example, the wire straightening device20may be configured so that the outer diameter of the wire2is input by an operator. For example, as shown inFIG.14, the outer diameter input section31of the controller28may be connected to an input device55operated by the operator. Note that there is no particular limitation on the form of the input device55, and the input device55may be a push button, a dial, a touch panel or a keyboard, for example. One or both of the input device55and the change input device50may be a portable terminal (e.g., a tablet PC, a smartphone) carried by the operator, etc. Note that the portable terminal may be communicably connected to the controller28via Bluetooth (registered trademark), or the like, or it may be communicably connected to the controller28via the Internet. The controller28may include another memory section (not shown) that stores the relationship between the wire2and the outer diameter of the wire2, and may be configured so that when the operator inputs information that identifies the wire2(e.g., the product number) to the input device55, the outer diameter input section31obtains the outer diameter in accordance with that wire2.

While the preset value of the roller spacing is determined based on the outer diameter of the wire2in the embodiments described above, it may be determined based on the outer diameter and other information. For example, since the hardness of the wire2differs depending on the material of the coating material, the preset value of the roller spacing may be determined based on the outer diameter of the wire2and the material of the coating material. The specific method for setting the preset value of the roller spacing is not limited to this as long as the preset value of the roller spacing is set for each type of wire.

During operation of the wire processing device1, the roller spacing is adjusted based on the condition of the wire2, but there is no particular limitation on the method for checking the condition of the wire2. The condition of the wire2may be visually checked directly by the operator. Alternatively, the condition of the wire2may be captured by a camera and the image captured by the camera may be displayed on a display. In this case, the operator can check the condition of the wire2by seeing the image on the display.

The wire straightening device20according to the embodiments described above includes the roller spacing measuring section27having the sensor body27band the detection pin27a(seeFIG.2, etc.). However, there is no particular limitation on the specific configuration of the roller spacing measuring section as long as the roller spacing measuring section is capable of measuring the roller spacing. The roller spacing measuring section may be configured to detect the rotational position of the motor26abased on the encoder value of the motor26a, which is a servo motor, so as to obtain the roller spacing based on the rotational position.

In the embodiments described above, the motor26ais configured to move only the first support member24, between the first support member24and the second support member22. However, the motor26amay be configured to move both of the first support member24and the second support member22.

The embodiments described above may be combined as appropriate. For example, in the first embodiment, the input device28A of the fourth embodiment may be used instead of the change input device50. The obtaining section132of the fifth embodiment may be applied to the second to fourth embodiments.

The process performed by the wire processing device1is not limited to cutting the wire2, stripping off the coating material, and crimping terminals onto the wire2. The wire processing device1may also perform other processes. The wire processing device1may be a device that performs at least one of cutting the wire2, stripping off the coating material of the wire2, and crimping terminals onto wires2, or it may be a device that performs other processes. There is no particular limitation on the processes performed by the wire processing device1.

REFERENCE SIGNS LIST

1Wire processing device2Wire2A Feed path20Wire straightening device22Second support member23Second straightening roller24First support member25First straightening roller26aMotor (actuator)28Controller (computer)32Memory section (preset value obtaining device)35Correction value setting section36Motor drive control section (drive control section)