The present invention relates to a coil winding apparatus and a coil winding method.
Generally, there is a known heater element for an electronic cigarette that is formed by processing a wire rod made of a high resistivity alloy (for example, Nichrome, aldirom, constantan alloy, and so forth) into a predetermined shape (JP2016-507137A). With this heater element, a smoking effect is generated by atomizing a smoking liquid when energized. In order to atomize the smoking liquid efficiently, such a wire rod may be wound in a spiral manner around a core rod to be impregnated with the smoking liquid. According to such a heater element, the smoking liquid impregnated into the core rod may be efficiently atomized by the wire rod that is energized and heated.
Because the wire rod used to form the heater element made of the high resistivity alloy needs to be processed to a predetermined shape, the wire rod has a flexibility, but also, it is relatively rigid. Because the smoking liquid needs to be impregnated, the core rod is often formed into a string shape by binding heat resistive fibers such as glass fibers. The core rod having the string shape formed by binding such fibers is relatively soft. Therefore, in the manufacture of the heater element, the relatively rigid wire rod is wound around the relatively soft string-shaped core rod in a spiral manner. Thus, mechanization of manufacturing steps of the heater element is difficult, and in reality, many steps are performed by manual operations.
An object of the present invention is to provide a coil winding apparatus and a coil winding method that are capable of winding a relatively rigid wire rod around a relatively soft string-shaped core rod in a spiral manner.
According to an embodiment of the present invention, a coil winding apparatus includes: a core rod feeding unit configured to feed a string-shaped core rod from a core rod nozzle at a constant tension; a core rod drawing unit configured to draw out the core rod from the core rod nozzle against the tension by holding the core rod that has been fed from the core rod nozzle; a wire rod feeding unit configured to feed a wire rod towards the core rod that has been drawn out from the core rod nozzle, the wire rod being fed in a direction intersecting with a drawing direction of the core rod; a rotator into which the core rod nozzle is inserted, the rotator being capable of rotating about the core rod nozzle; a guide member provided on an end portion of the rotator with shift respect to a center of the rotator, the guide member being configured to clamp, with the core rod, the wire rod that has been fed from the wire rod feeding unit; and a rotating unit configured to rotate the rotator to rotate the guide member together with the rotator so as to revolve the wire rod around the core rod in a vicinity of the core rod nozzle.
According to another embodiment of the present invention, the coil winding is a winding method for winding the wire rod around the string-shaped core rod in a spiral manner, and in the coil winding method, the core rod is inserted through the core rod nozzle while applying a predetermined tension to the core rod, and the wire rod is revolved around the core rod in the vicinity of the core rod nozzle while drawing out the core rod from the core rod nozzle against the tension.
Next, a coil winding apparatus and a coil winding method according to an embodiment of the present invention will be described with reference to the drawings.
In the heater element of the electronic cigarette, if there is a gap between the wire rod 12 and the core rod 11 or if the core rod 11 is squeezed too much, a liquid is not supplied around the wire rod 12 sufficiently. As a result, there is a possibility that the wire rod 12 is burned. For such a reason, it is required to wind the wire rod 12 in moderate close contact without gaps around the core rod 11. Further, the string-shaped core rod 11 is soft and has an unstable diameter. When the diameter of the core rod 11 is varied, which has been formed by winding the wire rod 12 in moderate close contact without gaps around the core rod 11, is also varied. As the inner diameter of the spiral member is varied, a length of the wire rod 12 is also varied, and in turn, the electrical resistance is varied. Thus, it is important to control the inner diameter of the spiral member (an electrical resistance control). In the heater element of the electronic cigarette, the electrical resistance of the wire rod 12 is a factor that determines an amount and taste of a liquid smoke, and the electrical resistance control is extremely important.
According to the present embodiment, the relatively rigid wire rod 12 may be wound around the relatively soft string-shaped core rod 11 in a spiral manner. Further, according to the present embodiment, the wire rod 12 may be wound around the core rod 11 at the same inner diameter in a spiral manner without forming a gap between the core rod 11 and the wire rod 12.
The coil winding apparatus 20 is provided with core rod feeding unit 21 that feeds the string-shaped core rod 11 made of a bundle of fibers from a core rod nozzle 22 at a constant tension. As shown in
The core rod tension device 24 is configured so as to be capable of applying the tension to the core rod 11 and pulling back the core rod 11. The core rod tension device 24 is provided with a casing 26 that is provided on a mounting 19 and a tension bar 27 that is provided on a side surface of the casing 26 in the X axis direction so as to extend along the side surface.
The core rod spool 23 is provided on the side surface of the casing 26 in the X axis direction. A feeding control motor 28 that rotates the core rod spool 23 to feed the core rod 11 is provided in the inside of the casing 26. A core rod guide pulley 29 is provided on a distal end of the tension bar 27. The core rod 11 is fed from the core rod spool 23 and guided to the core rod guide pulley 29, and thereby, the core rod 11 is wired from the core rod guide pulley 29 so as to be inserted through the core rod nozzle 22.
A turning shaft 27a that extends in the X axis direction is provided on a proximal end of the tension bar 27, and the tension bar 27 is configured so as to be able to turn about the turning shaft 27a. The turning angle of the turning shaft 27a is detected by a potentiometer 30 serving as turning angle detection means that is accommodated in the casing 26 and mounted to the turning shaft 27a. A detection output from the potentiometer 30 is input to a controller (not shown), and a control output from the controller is linked to the feeding control motor 28.
At a predetermined position between the turning shaft 27a of the tension bar 27 and the core rod guide pulley 29, a spring 31 that is an elastic member serving as biasing means is mounted at one end thereof via a mounting bracket 27b. The spring 31 biases the tension bar 27 towards the turning direction of the tension bar 27. The tension bar 27 receives an elastic force from the spring 31 correspondingly to the turning angle. Other end of the spring 31 is fixed to a moving member 32. The moving member 32 is screwed to a tension adjusting screw 33 and is configured such that the movement thereof can be adjusted in accordance with rotation of the tension adjusting screw 33. In other words, the position at which the other end of the spring 31 is fixed can be changed, and thereby, the tension of the core rod 11 that is applied by the tension bar 27 can be adjusted.
The controller (not shown) is configured so as to control the feeding control motor 28 such that the turning angle detected by the potentiometer 30 becomes a predetermined angle. Therefore, in the core rod tension device 24, the tension is applied to the core rod 11 by the spring 31 via the tension bar 27, and the core rod spool 23 is rotated such that the turning angle of the tension bar 27 becomes a predetermined angle, and thereby, the core rod 11 is fed at a predetermined amount. Thus, the tension of the core rod 11 is maintained at a predetermined level.
As shown in an enlarged view in
The coil winding apparatus 20 is provided with a rotator 37 into which the core rod nozzle 22 is inserted. The rotator 37 rotates about the core rod nozzle 22. Specifically, a second support pillar 38 erects on the mounting 19 so as to be separated away from the first support pillar 36 in the Y axis direction, and the rotator 37 having a cylindrical shape is provided on the second support pillar 38. The core rod nozzle 22 is inserted through the rotator 37 having the cylindrical shape. The rotator 37 is provided on the second support pillar 38 via a bearing 39 so as to be rotatable about the core rod nozzle 22.
The rotator 37 projects from the second support pillar 38 towards the first support pillar 36. A pulley 41 is fitted to a projecting end of the rotator 37. A motor 42 serving as a rotating means that rotates the rotator 37 is provided on the second support pillar 38. The motor 42 has a rotating shaft 42a that is in parallel with the rotator 37. In addition to the pulley 41, a pulley 43 is provided on the rotating shaft 42a of the motor 42. The motor 42 may be provided on the mounting 19.
A belt 44 is suspended between the pulley 41 of the rotator 37 and the pulley 43 on the rotating shaft 42a of the motor 42. As the motor 42 is driven, rotation of the rotating shaft 42a is transmitted to the rotator 37 via the belt 44, and the rotator 37 is rotated.
As shown in
The core-rod-holding-device moving mechanism 52 illustrated in
In the present embodiment, the core rod holding device 51 is mounted to a rotating shaft 49a of the motor 49, the motor 49 is mounted to the housing 57d of the Y axis direction telescopic actuator 57 so as to be able to move the core rod holding device 51 in the Y axis direction, and the follower 57c of the Y axis direction telescopic actuator 57 is mounted to the follower 58c of the Z axis direction telescopic actuator 58 so as to be able to move, together with the Y axis direction telescopic actuator 57, the core rod holding device 51 in the Z axis direction. Further, the housing 58d of the Z axis direction telescopic actuator 58 is mounted to the follower 56c of the X axis direction telescopic actuator 56 so as to be able to move, together with the Y axis and Z axis direction telescopic actuators 57 and 58, the core rod holding device 51 in the X axis direction. The housing 56d of the X axis direction telescopic actuator 56 is fixed to the mounting 19 so as to extend in the X axis direction.
The servo motors 56a to 58a in the telescopic actuators 56 to 58 are connected to a controller (not shown), and they are controlled by the controller. In other words, with the telescopic actuators 56 to 58, as the servo motors 56a to 58a are driven by commands from the controller (not shown), the ball screws 56b to 58b are rotated, and thereby, the followers 56c to 58c screwed to the ball screws 56b to 58b are moved along the lengthwise direction of the housings 56d to 58d. As the followers 56c to 58c are moved, the core rod holding device 51 is moved in three axial directions.
The core rod holding device 51 with the pair of opening clamping blocks 51a and 51b is moved such that the core rod 11 projecting from a distal end of the core rod nozzle 22 is positioned between the pair of clamping blocks 51a and 51b, and thereafter, the pair of clamping blocks 51a and 51b are closed to hold the core rod 11 with the pair of clamping blocks 51a and 51b. In addition, by moving the core rod holding device 51 in the direction away from the core rod nozzle 22 while holding the core rod 11, the core rod 11 is drawn out from the core rod nozzle 22. As described above, the core rod drawing unit 50 is configured so as to hold the core rod 11 inserted into the core rod nozzle 22 and draw the core rod 11 out from the core rod nozzle 22.
A core rod clamping tool 53 is provided on the mounting 19. In the core rod clamping tool 53, the core rod 11 extending from the core rod tension device 24 to the core rod nozzle 22 is clamped by clamping blocks 53a at the vicinity of the first support pillar 36, thereby prohibiting the movement of the core rod 11 towards the core rod nozzle 22.
The core rod clamping tool 53 shown in
As shown in
The wire-rod-nozzle moving mechanism 62 is configured so as to be capable of moving a support plate 66 in the three axial directions with respect to the mounting 19. The wire-rod-nozzle moving mechanism 62 has the same structure with that of the above-described core-rod-holding-device moving mechanism 52. Specifically, the wire-rod-nozzle moving mechanism 62 is provided with an X axis direction telescopic actuator 63 that moves the support plate 66 in the X axis direction, a Z axis direction telescopic actuator 65 that moves, together with the X axis direction telescopic actuator 63, the support plate 66 in the Z axis direction, and a Y axis direction telescopic actuator 64 that moves, together with the X axis and the Z axis direction telescopic actuator 63 and 65, the support plate 66 in the Y axis direction.
The support plate 66 is mounted to a housing 63d of the X axis direction telescopic actuator 63. A follower 63c of the X axis direction telescopic actuator 63 is mounted to a follower 65c of the Z axis direction telescopic actuator 65. A housing 65d of the Z axis direction telescopic actuator 65 is mounted to a follower 64c of the Y axis direction telescopic actuator 64. A housing 64d of the Y axis direction telescopic actuator 64 is fixed to the mounting 19 so as to extend in the Y axis direction. Servo motors 63a to 65a in the telescopic actuators 63 to 65 are connected to a controller (not shown) that controls these components. The servo motors 63a to 65a respectively rotate ball screws 63b to 65b of the telescopic actuators 63 to 65.
The support plate 66 supports a fluid pressure cylinder 68. A main body portion 68b of the fluid pressure cylinder 68 is mounted to the support plate 66 such that an retracting rod 68a of the fluid pressure cylinder 68 extends in the X axis direction. A mounting plate 67 is mounted on a projecting end of the retracting rod 68a. The wire rod nozzle 61 is mounted on the mounting plate 67 so as to face towards the X axis direction.
In addition, the support plate 66 supports a proximal end nozzle 69 that is provided coaxially with the wire rod nozzle 61 and a wire rod clamping tool 71 that is provided in the vicinity of the proximal end nozzle 69. In the wire rod clamping tool 71, a pair of clamping blocks 71a clamp the wire rod 12 that has passed through the proximal end nozzle 69 towards the wire rod nozzle 61 so as to be releasable. Because a fluid pressure cylinder having the same structure as that of the core rod clamping tool 53 that clamps the core rod 11 is used for the wire rod clamping tool 71, detailed descriptions of the wire rod clamping tool 71 will be omitted.
As shown in
The cutter device 59 is lowered by the elevating cylinder 72, and thereby, cutter blades 59b are moved to cutting positions for cutting the wire rod 12 and the core rod 11. In addition, the cutter device 59 is lifted by the elevating cylinder 72, and thereby, the cutter blades 59b are moved to a stand-by position away from the wire rod 12 and the core rod 11. The cutter device 59 is rotated by the rotating cylinder 73 about the vertical axis, and thereby, the cutter device 59 is switched from a wire rod cutting orientation in which the cutter blades 59b pinch and cut the wire rod 12 to a core rod cutting orientation in which the cutter blades 59b pinch and cut the core rod 11 extending orthogonal to the wire rod 12.
As shown in
The wire rod tension device 75 in the present embodiment has substantially the same structure as the structure of the core rod tension device 24 (see
As shown in
In other words, in the wire rod tension device 75, the tension is applied to the wire rod 12 by the spring 81 via the tension bar 77. In addition, the wire rod spool 74 is rotated by controlling the feeding control motor 78 such that the tension bar 77 is oriented in a predetermined angle, in other words, such that the turning angle detected by the potentiometer 80 becomes a predetermined angle, and the wire rod 12 is fed at a predetermined amount. Thereby, the tension of the wire rod 12 is maintained at a predetermined level.
As shown in
As shown in
As shown in
A main body 92b of the fluid pressure cylinder 92 is mounted on the follower 91c of the telescopic actuator 91 such that an retracting shaft 92a of the fluid pressure cylinder 92 faces upwards. The receiving tool 93 is mounted on an upper end of the retracting shaft 92a of the fluid pressure cylinder 92. A recessed groove 93a capable of receiving the coil 8 (see
Next, a coil winding method of the present invention will be described.
In the coil winding method of the present invention, the wire rod 12 is wound around the string-shaped core rod 11 in a spiral manner. The coil winding method is characterized in that the core rod 11 is inserted through the core rod nozzle 22 while applying a predetermined tension to the core rod 11, and the wire rod 12 is revolved around the core rod 11 in the vicinity of the core rod nozzle 22 while drawing out the core rod 11 from the core rod nozzle 22 against a tensile force.
The coil winding method is performed on the above-described coil winding apparatus 20. In other words, as shown in
A procedure of the coil winding method will be described specifically. The core rod 11 and the wire rod 12 are first installed to the coil winding apparatus 20. As shown in
The core rod nozzle 22 in the present embodiment is a straight cylindrical member that has the inner diameter smaller than the outer diameter of the core rod 11 in the natural state. The core rod 11 is inserted through the core rod nozzle 22 in a state in which the core rod 11 is stretched such that the outer diameter thereof is reduced suitably. In this state, the core rod clamping tool 53 mounted on the mounting 19 is used to clamp the core rod 11, thereby prohibiting the movement of the core rod 11. Thus, even if the core rod 11 is pulled by the core rod tension device 24, the core rod 11 is prevented from been pulled back from the core rod nozzle 22.
As shown in
The wire rod nozzle 61 is mounted on the support plate 66 via the fluid pressure cylinder 68. The wire rod 12 is inserted through the wire rod nozzle 61 in a state in which the retracting rod 68a of the fluid pressure cylinder 68 is projected from the main body portion 68b. A projecting amount of the wire rod 12 from the wire rod nozzle 61 is set to a length required for allowing the core rod 11 and the wire rod 12 to intersect with each other. In this state, the wire rod clamping tool 71 provided on the support plate 66 is used to clamp the wire rod 12, thereby prohibiting the movement of the wire rod 12. Thus, even if the wire rod 12 is pulled by the wire rod tension device 75 towards the wire rod tension device 75, the wire rod 12 is prevented from been pulled back from the wire rod nozzle 61.
In addition, the motor 42 serving as the rotating means is driven to rotate the rotator 37, and thereby, the guide member 86 provided on a tip end of the rotator 37 is positioned on an imaginary place that is in parallel with the core rod 11 and orthogonal to the feeding direction of the wire rod 12 (above the core rod 11 in
Next, as shown in
By releasing the core rod 11 from the state held by the core rod clamping tool 53 provided on the mounting 19, the feeding of the core rod 11 is allowed. By holding the core rod 11 that has been fed from the core rod nozzle 22 by the core rod drawing unit 50, even if the core rod 11 is pulled by the core rod tension device 24, the core rod 11 is prevented from been pulled back from the core rod nozzle 22.
Next, as shown in
Next, as shown in
Next, as shown in
Next, as shown in
Next, as shown in
While the core rod 11 is being drawn out, the guide member 86 is revolved around the core rod 11. The revolution of the guide member 86 is performed by rotating the rotator 37 by the motor 42 serving as the rotating means (
As the guide member 86 is revolved in the vicinity of the core rod nozzle 22, the distal-end side wire rod 12a passed through between the guide member 86 and the core rod 11 is continuously suspended on the guide member 86. As the guide member 86 on which the distal-end side wire rod 12a is suspended is further revolved around the core rod 11, the distal-end side wire rod 12a is continuously guided around the core rod 11 and is rubbed and placed onto the core rod 11. As a result, the distal-end side wire rod 12a is wound around the core rod 11.
The guide member 86 in the present embodiment is a pulley that is pivotably supported on an end portion of the rotator 37. Thus, the guide member 86 is rotated while the wire rod 12 is suspended and guides the distal-end side wire rod 12a. Therefore, it is possible to prevent occurrence of abrasion of the distal-end side wire rod 12a against the guide member 86 and to prevent occurrence of the surface damage of the wire rod 12 due to the abrasion. Because the wire rod 12 is wound while drawing out the core rod 11, the distal-end side wire rod 12a is wound around the core rod 11 that has been drawn out from the core rod nozzle 22 in a spiral manner.
In the above, the core rod nozzle 22 is a cylindrical member having the inner diameter that is smaller than the outer diameter of the core rod 11 in the natural state. Because the constant tension is applied to the core rod 11 by the core rod tension device 24 (
A proximal-end side wire rod 12b that extends from the wire rod nozzle 61 to the core rod 11 does not pass through between the core rod 11 and the guide member 86, and so, it does not come into contact with the guide member 86. As shown in
In the present embodiment, as the core rod 11 is drawn out, the wire rod nozzle 61 from which the wire rod 12 is fed is moved by the wire-rod-nozzle moving mechanism 62 (
As shown in
In the above, during the winding of the wire rod 12, the core rod 11 is drawn out from the distal end of the core rod nozzle 22 in a state in which the constant tension is applied to the core rod 11, and the outer diameter of the core rod 11 during the winding is smaller than the outer diameter of the core rod 11 in the natural state and is relatively uniform. Therefore, the wire rod 12 is wound around the core rod 11 having the smaller outer diameter and having little variation in the outer diameter in the lengthwise direction.
After the winding, as the core rod 11 that has been held is released by the core rod holding device 51, the tension applied to the core rod 11 is removed. As a result, the core rod 11 returns to the natural state without the tension, and as shown in
After the winding is completed, as shown in
The length of the wire rod 12 between the core rod 11 and the wire rod nozzle 61 is set to a length that is equal to a total of the length required for the leader of the coil 8 that is precedingly formed by winding the wire rod 12 around the core rod 11 in a spiral manner and the length of the wire rod 12 required for the subsequent winding. Thereafter, the wire rod 12 is held by the wire rod clamping tool 71 again, and thereby, the movement of the wire rod 12 is prohibited. In this state, the wire rod 12 is cut by lowering the cutter device 59 by the elevating cylinder 72 and moving it into the cutting position.
Next, the orientation of the cutter device 59 is changed by the rotating cylinder 73, and the cutter device 59 is moved by the wire-rod-nozzle moving mechanism 62. By cutting the core rod 11 around which the wire rod 12 is wound in a spiral manner at a predetermined length, the coil 8 shown in
Once the core rod 11 is cut, the coil 8 shown in
In the above-mentioned embodiment, descriptions have been given on the core-rod-holding-device moving mechanism 52 and the wire-rod-nozzle moving mechanism 62 that are configured by combining the X axis, the Y axis, and the Z axis direction telescopic actuators. However, the structures of the core-rod-holding-device moving mechanism 52 and the wire-rod-nozzle moving mechanism 62 are not limited thereto, and other structures may also be employed as long as the core rod holding device 51, the wire rod nozzle 61, and so forth can be moved in the three axial directions with respect to the mounting 19.
In addition, in the above-mentioned embodiment, descriptions have been given on a case in which the tension bars 27 and 77 are tilted by the springs 31 and 81, respectively, and thereby, the tension is applied to the core rod 11 and the wire rod 12 by the core rod tension device 24 and the wire rod tension device 75, respectively. However, the structures of the core rod tension device 24 and the wire rod tension device 75 are not limited those described above, and other structures may also be employed. For example, the core rod tension device 24 and the wire rod tension device 75 may have structures in which the tension may be applied to the core rod 11 and/or the wire rod 12 by moving the core rod spool 23 and/or the wire rod spool 74 themselves/itself.
In addition, in the above-mentioned embodiment, a description has been given on a case in which the wire rod nozzle 61 is moved in the drawing direction of the core rod 11 at the same speed as the drawing speed when the wire rod 12 is wound. However, in a case in which the wire rod nozzle 61 feeding the wire rod 12 is sufficiently away from the core rod 11 and the tilting of the wire rod 12 caused along with the drawing of the core rod 11 may be allowed, the wire rod nozzle 61 may not necessarily be moved.
In addition, in the above-mentioned embodiment, a description has been given on a case in which the guide member 86 is the pulley that is pivotably supported on the end portion of the rotator 37. However, as long as the surface damage of the wire rod 12 due to the abrasion may be avoided, the guide member 86 may be a member that is not rotatable with respect to the rotator 37, for example, a pin shaped member in which a part coming into contact with the wire rod 12 has been polished in order to avoid the surface damage of the wire rod 12.
Furthermore, in the above-mentioned embodiment, a description has been given on a case in which the core rod 11 is drawn out in straight. However, if required, during the drawing of the core rod 11, it may be possible to draw out the core rod 11 while twisting it by rotating the core rod holding device 51 holding the core rod 11 by the motor 49. By drawing out the core rod 11 while twisting it, it is possible to further reinforce the core rod 11 around which the wire rod 12 is wound by being rubbed and placed thereonto, and at the same time, it is possible to further increase uniformity of the outer diameter. Therefore, it becomes possible to wind the wire rod 12 around the core rod 11 in a spiral manner so as to achieve more uniform inner diameter. In a case in which it is not required to twist the core rod 11, the motor 49 may not be installed.
The configurations, operations, and effects of the embodiments of the present invention will be collectively described below.
The coil winding apparatus is provided with: the core rod feeding unit configured to feed the string-shaped core rod from the core rod nozzle at the constant tension; the core rod drawing unit configured to draw out the core rod from the core rod nozzle against the tension by holding the core rod that has been fed from the core rod nozzle; the wire rod feeding unit configured to feed the wire rod towards the core rod that has been drawn out from the core rod nozzle in the direction intersecting therewith; the rotator into which the core rod nozzle is inserted, the rotator being capable of rotating about the core rod nozzle; the guide member provided on the end portion of the rotator with shift respect to the center of the rotator, the guide member being configured to clamp, with the core rod, the wire rod that has been fed from the wire rod feeding unit; and the rotating unit configured to rotate the rotator to rotate the guide member together with the rotator so as to revolve the wire rod around the core rod in the vicinity of the core rod nozzle.
The wire rod feeding unit is preferably provided with: the wire rod nozzle configured to feed the wire rod; the wire rod clamping tool configured to clamp the wire rod passing through the wire rod nozzle so as to be releasable; and an increasing/reducing unit configured to increase and reduce the gap between the wire rod nozzle and the wire rod clamping tool. The wire rod feeding unit may be further provided with the wire rod-nozzle moving mechanism configured to move at least the wire rod nozzle. The guide member is preferably the pulley pivotably supported on the end portion of the rotator, the guide member being configured such that the wire rod can be suspended.
The coil winding method, for winding the wire rod around the string-shaped core rod in a spiral manner, is characterized in that the core rod is inserted through the core rod nozzle while applying a predetermined tension to the core rod, and the wire rod is revolved around the core rod in the vicinity of the core rod nozzle while drawing out the core rod from the core rod nozzle against the tension.
It is preferable that: the wire rod be fed from the direction orthogonal to the core rod drawn out from the core rod nozzle; the wire rod be clamped by the guide member with the core rod in the vicinity of the core rod nozzle; and the guide member be rotated about the core rod, thereby the distal-end side wire rod be continuously suspended on the guide member and the distal-end side wire rod be continuously revolved around the core rod, the distal-end side wire rod being a part of the wire rod extending beyond the guide member. It is preferable that: the core rod nozzle be rotatably inserted into the rotator, and the guide member be provided on the drawing-side end portion of the rotator with shift respect to the center of the rotator; and the rotation of the guide member about the core rod be performed by rotating the rotator on which the guide member is provided.
It is preferable that: the proximal-end side wire rod be moved in the drawing direction of the core rod at substantially the same speed as the drawing speed of the core rod while drawing out the core rod from the core rod nozzle, the proximal-end side wire rod being a part of the wire rod not approaching the guide member.
With the coil winding apparatus and the coil winding method of the present embodiment, because the guide member is revolved in the vicinity of the core rod nozzle while drawing out the core rod from the core rod nozzle, the distal-end side wire rod passing through the gap between the guide member and the core rod is continuously suspended on the guide member, and the distal-end side wire rod is continuously guided to and wound around the core rod by the revolving guide member.
In the above, because the constant tension is applied to the core rod, the core rod is drawn out against the tension. Although the core rod is relatively soft, on a drawing end portion of the core rod nozzle, the core rod is prevented from being bent drastically. Therefore, in the vicinity of the drawing end portion of the core rod nozzle, by winding the wire rod around the core rod that has been drawn out, it becomes possible to wind the relatively rigid wire rod around the relatively soft core rod in a spiral manner.
When the wire rod is wound around the core rod, the core rod is drawn out from the distal end of the core rod nozzle in a state in which the constant tension is applied to the core rod. The outer diameter of the core rod during the winding of the wire rod is smaller than the outer diameter in the natural state, and so, the outer diameter of the core rod becomes relatively uniform. Thus, the wire rod is wound around the core rod having the smaller outer diameter and with little variation in the outer diameter in the lengthwise direction.
After the winding, when the tension applied to the core rod is released, the stretched core rod returns to the natural state to which the tension is not applied, and then, the outer diameter of the core rod is increased. Therefore, the wire rod, which is wound around the outer circumference of the core rod in a spiral manner in a state in which the outer diameter is small, comes into suitably close contact with the outer circumferential surface of the core rod the outer diameter has been increased, and a state in which the wire rod is wound around the core rod in a spiral manner with the constant inner diameter is achieved.
Although the embodiments of the present invention have been described in the above, the above-mentioned embodiments merely illustrate a part of application examples of the present invention, and the technical scope of the present invention is not intended to be limited to the specific configurations of the above-described embodiments.
This application claims priority based on Japanese Patent Application No. 2019-49389 filed with the Japan Patent Office on Mar. 18, 2019, the entire contents of which are incorporated into this specification by reference.
Number | Date | Country | Kind |
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2019-049389 | Mar 2019 | JP | national |
Filing Document | Filing Date | Country | Kind |
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PCT/JP2020/010067 | 3/9/2020 | WO |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2020/189381 | 9/24/2020 | WO | A |
Number | Date | Country |
---|---|---|
102024559 | Apr 2011 | CN |
102592822 | Jul 2012 | CN |
102592822 | Jul 2012 | CN |
108420111 | Aug 2018 | CN |
824516 | Dec 1959 | GB |
2016-507137 | Mar 2016 | JP |
WO-2016095101 | Jun 2016 | WO |
Number | Date | Country | |
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20210178453 A1 | Jun 2021 | US |