JP4775904B2 - Winding machine - Google Patents

Description

  The present invention relates to a winding machine for manufacturing a coil, a transformer, a stator for a motor, a rotor, and the like (hereinafter, the coil itself and these various products having a coil are collectively referred to as a winding product). The present invention relates to a winding machine that can detect an insulation failure of a coil in a manufacturing process of a wire product.

2. Description of the Related Art Conventionally, various methods and apparatuses for detecting flaws and pinholes in enamel, which is an insulating film, are provided in a wound product having a coil made of enameled wire or the like.
For example, in Patent Document 1, a small electric machine such as a motor is installed in a container whose internal pressure is maintained at a predetermined value, and whether or not glow discharge is generated from the coil when a surge voltage is applied to the coil. In addition, a non-destructive insulation test method is disclosed in which coil winding unevenness and insulation failure caused by this are detected.

  Patent Document 2 discloses a specimen in which a coil constituting a stator or rotor of a low-voltage small motor is wound around an iron core, a corona measuring instrument for measuring corona discharge between the coil and the iron core in the specimen, A winding abnormality detection device is disclosed that includes a quality determination unit that determines quality of a coil winding state provided on the output side.

Japanese Patent Laying-Open No. 2004-361415 ([0022] to [0025], FIG. 1, FIG. 6, etc.) JP-A-3-246472 (second page, lower right column, line 11 to page 3, upper right column, first line, FIG. 1, etc.)

The conventional techniques described in Patent Documents 1 and 2 described above both detect the insulation failure of the coil using corona discharge, but both are intended for winding products for which coil winding has been completed. Yes.
For this reason, for example, even if there is an insulation failure at the coil winding start portion of the coil bobbin or the iron core, the insulation failure cannot be detected unless the winding product is manufactured, and early detection is impossible. Manufacturing equipment, energy, wasted time, and yields deteriorated.

In addition, when a withstand voltage test or an insulation test is performed by applying a high voltage between a coil and an iron core or a metal bobbin as the other electrode portion as in Patent Document 2, a defective portion of the coil due to an insulation failure is the above electrode. When it is at a position away from the part, it is difficult for the discharge to occur, so that it is difficult to detect the defective part. Furthermore, it is also difficult to detect a defective portion in a state before a one-turn short circuit due to a rare short circuit or a metal coil bobbin.
Needless to say, it is difficult to visually detect defects in the deep layers and inside of the coil when it is completed as a wound product. In addition, visual inspection has high accuracy in detecting defects due to variations among inspectors. I can't hope.

On the other hand, poor insulation in winding products is caused by scratches and pinholes inherent to the coil wire before being wound as a coil, or due to frictional force applied to the coil wire during operation of the winding machine. That is also possible.
Accordingly, the present invention has been made paying attention to the above-mentioned points, and the problem to be solved is to provide a winding machine that can detect an insulation failure of a coil wire material with high accuracy in a manufacturing process of a wound product. It is in.

In order to solve the above problem, the invention described in claim 1 is a winding machine for manufacturing a wound product by winding a coil wire around a member to be wound.
A wire supply unit that accommodates the coil wire ;
A conductive detection nozzle that is disposed in the middle of the path from one end of the coil wire rod of the wire rod supply portion to the wound member, and that passes through the coil wire rod that is supplied from the wire rod supply portion toward the wound member member,
A conductive winding nozzle that is disposed between the detection nozzle and the member to be wound and through which the coil wire passes;
Voltage application means for applying a voltage between the detection nozzle and the coil wire, and between the winding nozzle and the coil wire;
When a voltage is applied between the detection nozzle and the coil wire by the voltage applying means, a discharge is generated between the detection nozzle and the coil wire due to a defect in the insulating film of the coil wire passing through the vicinity of the detection nozzle. And when the voltage is applied between the winding nozzle and the coil wire by the voltage applying means, the winding nozzle is caused by a defect in the insulation film of the coil wire passing through the vicinity of the winding nozzle. And a discharge detecting means for detecting a discharge generated between the coil wire rod and the coil wire rod.

The invention described in claim 2 is the winding machine described in claim 1,
The discharge detection means detects a defect in the insulating coating by detecting a pulsed discharge current.

The invention described in claim 3 is the winding machine according to claim 1 or 2,
The voltage application unit and the discharge detection unit are provided in a single withstand voltage insulation meter for a withstand voltage / insulation test .

According to the present invention, it is possible to detect the presence or absence of a defect due to a scratch or a pinhole in the coil wire manufacturing process and the position of the defect in the production process of the wound product, and the occurrence of defective products due to oversight of these defects, Waste of manufacturing equipment, energy, time, etc. can be prevented in advance. In particular, since it is possible to detect a defect inherent in a coil wire material as a material of a wound product or a defect generated in a manufacturing process, it is extremely useful for quality control.
In addition, it is based on the principle of detecting the discharge between the electrode part and the single-wire coil wire passing through the vicinity of the electrode part, not the method of detecting the discharge due to the insulation failure in the state of the winding product. A defect present at any position of the coil wire can be detected reliably, continuously and with high accuracy.
Furthermore, since it can be realized simply by connecting and wiring a testing machine such as a pressure-resistant insulation meter to a conventional winding machine, it has the effect of being extremely economical.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic configuration diagram of a winding machine according to this embodiment. In FIG. 1, reference numeral 10 denotes a winding machine body, and a coil bobbin 12 is attached to a spindle 11 coupled to a motor (not shown). The winding product may be a transformer, a stator for a motor, a rotor, or the like that winds a coil wire around an iron core as a member to be wound.

A traverse mechanism 13 for moving the coil wire 21 three-dimensionally is provided on the upper part of the winding machine body 10 in order to wind the coil wire 21 used for manufacturing the wound product around a predetermined position of the coil bobbin 12. Yes. A tension unit 14 for applying a predetermined tension to the coil wire 21 is disposed above the traverse mechanism 13.
Here, the coil wire 21 is a wire in which a conductive wire such as copper is covered with an insulating film such as enamel.

  On the other hand, 20 is a wire rod supply unit, and a coil spool 22 around which a coil wire rod 21 is wound is accommodated in the wire rod supply unit 20. The coil wire 21 is drawn obliquely upward from an outlet 23 provided at the upper center of the wire supply unit 20. Further, the winding start end portion 24 of the coil wire 21 around the coil spool 22 is connected to one measurement terminal 42 of the pressure-resistant insulation meter 40 via the measurement lead wire 41.

The coil wire 21 drawn from the outlet 23 of the wire supply unit 20 is guided to the nozzle unit 30 through the tension unit 14.
The structure of the nozzle part 30 will be described below with reference to FIG.

In FIG. 2, reference numeral 31 denotes a substantially U-shaped nozzle holder, and a detection nozzle 33 made of a conductive material is attached to the upper support 32 and a winding nozzle 35 made of a conductive material is attached to the lower support 34. ing. The detection nozzle 33 and the winding nozzle 35 function as a guide member for the coil wire 21 and also function as an electrode unit.
Both nozzles 33 and 35 are arranged on the same axis, and the coil wire 21 penetrates them from the tension unit 14 toward the coil bobbin 12.

Here, in the vicinity of the outlet of the winding nozzle 35, the coil wire 21 wound around the coil bobbin 12 is forced to bend (change the angle) over a wide range. Therefore, in order to prevent damage to the coil wire 21, The inner diameter is set to about 3 times (at least twice or more) the thickness of the coil wire 21.
On the other hand, the detection nozzle 33 has an inner diameter (for example, a detection nozzle) substantially matched to the thickness of the coil wire 21 in order to detect a defect existing in the insulating film of the coil wire 21 with high accuracy by the discharge detection principle described later. In the case where 1000 [V] is applied between the coil 33 and the coil wire 21, the coil wire 21 is set to have a thickness of about +0.1 [mm].

As shown in FIG. 1, the detection nozzle 33 and the winding nozzle 35 are collectively connected to a measurement lead wire 44, and this measurement lead wire 44 is connected to the other measurement terminal 43 of the pressure-resistant insulation meter 40. It is connected.
The withstand voltage tester 40 outputs an AC or DC high voltage (shown as having an AC power supply 45 for the sake of convenience) from the measurement terminals 42 and 43 to provide a withstand voltage test or insulation test at the measurement location. In this embodiment, the insulation failure between the coil wire 21 to which the high voltage is applied and the detection nozzle 33 and the gap between the coil wire 21 and the winding nozzle 35 are used. It has a function of detecting a pulsed discharge current generated when there is an insulation failure, that is, when there is a defect such as a scratch or a pinhole in the insulating film of the coil wire 21.
That is, the withstand voltage insulator 40 functions as a voltage applying means and a discharge detecting means, and the apparatus configuration can be simplified by providing these functions in the single withstand voltage insulator 40.

  In order to use the winding machine configured as described above, the pressure insulator 10 is used to drive the spindle 11 and wind the coil wire 21 from the coil spool 22 to the coil bobbin 12 side. An AC voltage or a DC voltage of 100 [V] to 2000 [V] is applied between the winding start end 24 of the coil wire 21 and the detection nozzle 33 and winding nozzle 35, as described below. Whether or not a discharge current is generated is observed by a pressure-resistant insulation meter 40.

That is, FIG. 3 shows that when an AC voltage is applied by the pressure-resistant insulation meter 40, the coil wire 21 and the coil wire 21 due to defects (scratches, pinholes, etc.) existing in the insulating film of the coil wire 21 that passes through the inside of the detection nozzle 33, for example. It is a figure for demonstrating the discharge current waveform generate | occur | produced between the detection nozzles.
FIG. 4 is a schematic diagram for explaining defects in the insulating film, in which 21a indicates a conductive wire, 21b indicates an insulating film made of enamel, and 21c indicates defects such as scratches and pinholes.

In FIG. 3, a substantially sinusoidal waveform A is a minute leakage current, and this leakage current exists constantly even in a state where there is no defect 21c. A waveform B is a discharge current waveform composed of a plurality of pulses flowing through the defect 21c, and has a period of about 10 [μs], for example.
In the present embodiment, the discharge current waveform B is detected by the pressure-resistant insulation meter 40, and the insulation film 21b has a defect 21c, that is, the insulation failure of the coil wire 21 is detected.

The electrical detection of the discharge current waveform B in FIG. 3 can be easily realized by a method of passing the entire waveform of FIG. 3 through a high-pass filter and performing threshold processing by a comparator.
In addition, if the defect 21c exists over a wide range and the inner peripheral surface of the detection nozzle 33 is in direct contact with the outer peripheral surface of the conducting wire 21a and a current flows, it cannot be said that it is a discharge current in a strict sense. Since the discharge phenomenon occurs prior to this, the defect 21c can be detected by detecting this discharge current with the withstand voltage insulator 40.

As described above, in this embodiment, basically, a discharge current between the detection nozzle 33 and the coil wire 21 is detected to detect an insulation failure of the coil wire 21.
However, the winding nozzle 35 is the final outlet of the coil wire 21, and there is a risk of damaging the insulating coating 21 b even in the winding nozzle 35. That is, in order to make the detection accuracy in the manufacturing process as high as possible, it is ideal that the insulation failure of the coil wire 21 can be detected at a position as close as possible to the coil bobbin 12.
Therefore, as shown in FIGS. 1 and 2, if the measurement lead wire 44 is also connected to the winding nozzle 35 and a predetermined voltage is applied between the winding nozzle 35 and the coil wire 21, the detection is performed. Similarly to the nozzle 33 side, the insulation failure of the coil wire 21 can be detected also on the winding nozzle 35 side, and the detection accuracy, the winding product, and the reliability of the winding machine can be further improved.

  In the above-described embodiment, the configuration of the winding machine main body 10 is not particularly limited. In short, any coil wire material may be supplied from a nozzle in order to manufacture a wound product. There is no restriction on the number and the like.

1 is a schematic configuration diagram of a winding machine according to an embodiment of the present invention. It is explanatory drawing of the nozzle part in FIG. It is explanatory drawing of a discharge current waveform. It is a schematic diagram for demonstrating the defect of an insulating film.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10: Winding machine main body 11: Spindle 12: Coil bobbin 13: Traverse mechanism 14: Tension unit 20: Wire rod supply part 21: Coil wire rod 21a: Conductive wire 21b: Insulation film 21c: Defect 22: Coil spool 23: Pull-out port 24: Winding Start end 30: Nozzle part 31: Nozzle holder 32: Upper support 33: Detection nozzle 34: Lower support 35: Winding nozzle 40: Pressure insulation meter 41, 44: Measurement lead wire 42, 43: Measurement terminal 45: AC source

Claims (3)

In a winding machine that manufactures a wound product by winding a coil wire around a wound member,
A wire supply unit that accommodates the coil wire ;
A conductive detection nozzle that is disposed in the middle of the path from one end of the coil wire rod of the wire rod supply portion to the wound member, and that passes through the coil wire rod that is supplied from the wire rod supply portion toward the wound member member,
A conductive winding nozzle that is disposed between the detection nozzle and the member to be wound and through which the coil wire passes;
Voltage application means for applying a voltage between the detection nozzle and the coil wire, and between the winding nozzle and the coil wire;
When a voltage is applied between the detection nozzle and the coil wire by the voltage applying means, a discharge is generated between the detection nozzle and the coil wire due to a defect in the insulating film of the coil wire passing through the vicinity of the detection nozzle. And when the voltage is applied between the winding nozzle and the coil wire by the voltage applying means, the winding nozzle is caused by a defect in the insulation film of the coil wire passing through the vicinity of the winding nozzle. Discharge detecting means for detecting discharge generated between the coil wire and the coil wire;
A winding machine characterized by comprising: In the winding machine according to claim 1,
The winding machine characterized in that the discharge detection means detects a pulse-like discharge current to detect a defect in the insulation coating. In the winding machine according to claim 1 or 2,
A winding machine characterized in that the voltage applying means and the discharge detecting means are provided in a single withstand voltage / insulation tester for a withstand voltage / insulation test .

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