the wound wires to the spatial area of the core.
Fig. 1 and Fig. 2 show front and rear views of the laminated core around which the
wires are wound with the ideal winding method having good wire alignment degree.
The wires are wound across each other as shown in Fig. 2, which is essential to
achieve good wire alignment degree.
Also, the better the alignment degree, the higher space factor achieved.
4. Development of New Type Inner Wire Winding Machine
4.1 Features of the Wire Winding Machine
In the inner type wire winding machine that is developed for the "P3" and "P5" AC
servo motors, the nozzle has a box-shaped movement (linear forward + rotation in
forward direction + linear backward + rotation in reverse direction), and a linear
motion/rotary motor (AC servo motor) is used as the power source of these motions.
The linear motion/rotary motor (AC servo motor) can control both the linear motion
and rotation as desired. The linear and rotary motions of the nozzle can be
controlled as desired while winding the wires with the linear motion/rotary motor,
and the deflection angle and stroke of the nozzle can be changed at will in the new
wire winding machine.
The new type inner wire winding machine has the following features:
(1) Highly-aligned wire winding is achieved by changing the nozzle stroke during
winding.
(2) Operation and setup performance are improved; the deflection and stroke of the
nozzle, as well as model switchover, can be done by single touch panel operations.
(3) Ideal crossover of wires is achieved by the linear motion stepping motor and
servo controlled indexes.
(4) The simple mechanism generates good linear motion.
(5) The winding time of the nozzle triplet is shorter,improving productivity (200%
better than conventional equivalent).
Fig. 3 New type inner wire winding machine
4.2 Linear Motion/Rotary Motor
The linear motion/rotary motor as shown in
Fig. 4 is the main part of the "P6" and
"P8" AC servo motors. This AC servo motor has two pairs of stator and rotor in one
housing that are controlled by independent encoders.
The linear motion/rotary motor has two hollow shafts as shown
Fig. 5. The spline
nuts and ball screws are attached to each hollow shaft. Rotation of the front rotor
revolves the output shaft (spline shaft), while rotation of the rear rotor revolves the
ball screw nut. At this moment, rotation of the ball screw is withheld, and its
rotation is converted to linear motion that is then transmitted to the output shaft.
With this structure, the dual-axes drive of rotation and linear motion is achieved.
The linear motion/rotary motor shown in Fig. 5 has the maximum stroke of 250 mm
with linear motion of thrust force of about 2.6 kN (rated). The resolution per pulse is
0.036
in the rotary direction and 0.002 mm in the linear motion.
4.3 Linear Motion Stepping Motor
The linear motion stepping motor is developed on the basis of the "89 steps,
five-phase" series stepping motor. It has a ball screw spline inside the hollow motor
shaft as shown in
Fig. 6. The nuts of the ball screw spline include the ball screw nut
in the front and the spline nut in the rear. Rotation of rotor is caught by the spline
and the shaft moves in the linear motion with the stroke of 200 mm. The linear
motion stepping motor that is used in the wire winding machine develops thrust
force of about 2.5 kN with the resolution of 0.016 mm/p.
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