Adaptive controlled high precision winding for columnar parts

The diversification and miniaturization of electric products have been rapidly advancing. In coil winding for electric parts, technologies that flexibly adapt to changes of wire diameter and that make denser wire coils are required. We developed an innovative winding system for columnar parts, such as solenoids, and experimentally proved its effectiveness. This system has a CCD line sensor to measure the diameter of the wire and the winding angle. It also has a carriage and rotating motor that are rate-controlled on the basis of this data. The pitch per rotation of the carriage is controlled in correspondence with the wire diameter measured just before winding. A target winding angle that will not cause back winding and gaps between the wire coils was experimentally determined, and the system controlled the winding angle to be the target angle during winding. We made an experimental device and verified the effect of the winding system. The results showed that the pitch per rotation of the carriage automatically adapted to changes in the wire diameter and the winding angle remained at the target angle plusmn6%. The experimental device with this system achieved complete contact winding for wires with diameters of 80 - 130 mum. This winding system is expected to be used for producing various high precision wound columnar parts.