WINDING DEVICE FOR WIRE BODY

Abstract

A winding device for a wire body, the winding device includes a bobbin configured to wind the wire body, a winding machine configured to rotate the bobbin, and a guide roller configured to guide the wire body to the bobbin. The bobbin is configured to reciprocate relative to the guide roller along an axial direction of the bobbin. The winding device includes a processor configured to calculate a winding diameter of the bobbin, based on a relative moving speed of the bobbin with respect to the guide roller, the number of rotations of the bobbin, and a winding speed of the wire body.

Claims

1. A winding device for a wire body, the winding device comprising: a bobbin configured to wind the wire body; a winding machine configured to rotate the bobbin; and a guide roller configured to guide the wire body to the bobbin, wherein the bobbin is configured to reciprocate relative to the guide roller along an axial direction of the bobbin, and the winding device includes a processor configured to calculate a winding diameter of the bobbin, based on a relative moving speed of the bobbin with respect to the guide roller, the number of rotations of the bobbin, and a winding speed of the wire body.

2. The winding device for a wire body according to claim 1, wherein the processor is configured to: acquire the number of rotations of the guide roller; and calculate the winding speed of the wire body, based on the number of rotations of the guide roller.

3. The winding device for a wire body according to claim 1, further comprising: a capstan disposed upstream of the guide roller in a traveling path of the wire body, the capstan being configured to control a traveling speed of the wire body, wherein the processor is configured to use, as the winding speed of the wire body, the traveling speed of the wire body on the capstan.

4. The winding device for a wire body according to claim 1, wherein the processor is configured to control a reversal position of a relative movement of the bobbin with respect to the guide roller, based on a newly calculated winding diameter and the winding diameter at an axial center of the bobbin.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0012] Exemplary embodiment(s) of the present invention will be described in detail based on the following figures, wherein:

[0013] FIG. 1 is a diagram illustrating an overall configuration of a winding device for a wire body according to an embodiment of the present disclosure;

[0014] FIG. 2 is a view of a winding bobbin illustrated in FIG. 1 as viewed from a direction of an arrow Y;

[0015] FIG. 3 is a block diagram illustrating a configuration of a processing device illustrated in FIG. 1; and

[0016] FIG. 4 is a diagram for illustrating a method of calculating a winding diameter of the winding bobbin by a calculation processing unit of the processing device illustrated in FIG. 3.

DESCRIPTION OF EMBODIMENTS

Description of Embodiment of the Present Disclosure

[0017] First, contents of an embodiment of the present disclosure will be listed and described.

[0018] A winding device for a wire body according to the present disclosure is

[0019] (1) a winding device for a wire body including: [0020] a bobbin configured to winding the wire body; [0021] a winding machine configured to rotate the bobbin; and [0022] a guide roller configured to guide the wire body to the bobbin, [0023] where the bobbin is configured to reciprocate relative to the guide roller along an axial direction of the bobbin, and [0024] the winding device includes a processor configured to calculate a winding diameter of the bobbin based on a relative moving speed of the bobbin with respect to the guide roller, the number of rotations of the bobbin, and a winding speed of the wire body.

[0025] As described above, by using the relative moving speed of the bobbin with respect to the guide roller, the number of rotations of the bobbin, and the winding speed of the wire body, the winding diameter of the bobbin during winding of the wire body can be calculated.

[0026] (2) In the winding device for a wire body according to (1), [0027] the processor may be configured to acquire the number of rotations of the guide roller, and calculate the winding speed of the wire body, based on the number of rotations of the guide roller.

[0028] For example, the line speed of the wire body on the guide roller can be calculated by multiplying the number of rotations of the guide roller by a length of the guide roller in a circumferential direction. In this way, since it is possible to calculate the line speed of the wire body on the guide roller, that is, the line speed of the wire body immediately before being wound onto the bobbin, it is possible to acquire the winding speed of the wire body more accurately.

[0029] (3) The winding device for a wire body according to (1) further includes [0030] a capstan disposed upstream of the guide roller in a traveling path of the wire body, the capstan being configured to control a traveling speed of the wire body, [0031] where the processor may be configured to use, as the winding speed of the wire body, the traveling speed of the wire body on the capstan.

[0032] Here, since the wire body traveling on the capstan is in close contact with the capstan by a capstan belt or the like, line vibration and the like are unlikely to occur. Therefore, with the above-described configuration, the winding speed of the wire body can be acquired more stably.

[0033] (4) In the winding device for a wire body according to any one of (1) to (3), [0034] the processor may be configured to control a reversal position of a relative movement of the bobbin with respect to the guide roller, based on a newly calculated winding diameter and the winding diameter at an axial center of the bobbin.

[0035] In the winding device for a wire body according to the present disclosure, as described above, the winding diameter of the bobbin can be calculated while the wire body is being wound, and therefore distribution of the winding diameter in the axial direction of the bobbin can be updated in real time. Therefore, based on the distribution of the winding diameter, it is possible to eliminate any protrusions or depressions in the wire body near the flange of the bobbin, and to perform control to make the winding diameter of the bobbin more uniform.

Details of Embodiment of the Present Disclosure

[0036] A specific example of a winding device for a wire body according to an embodiment of the present disclosure will be described below with reference to the drawings. However, the present invention is not limited to these examples, but is defined by the claims, and is intended to include all modifications within the meaning and scope of the claims. In addition, in each drawing used in the following description, the scale is appropriately changed so that each component can be made recognizable.

Overall Configuration of Winding Device

[0037] FIG. 1 is a diagram illustrating an overall configuration of a winding device 100 for a wire body according to the embodiment of the present disclosure. FIG. 2 is a view of a winding bobbin 20 illustrated in FIG. 1 as viewed from a direction of an arrow Y.

[0038] Here, the winding device 100 for an optical fiber 1, which is an example of a wire body, will be described. As illustrated in FIG. 1, the winding device 100 includes a supply section 10, a plurality of capstans 11, a plurality of dancer rollers 12, a plurality of guide rollers 13, a winding motor 14, a first detector 15, a traverse motor 16, a second detector 18, the winding bobbin 20, and a processing device 30.

[0039] In the winding device 100, the optical fiber 1 pulled out from the supply section 10 is wound around the winding bobbin 20 via the plurality of capstans 11, the plurality of dancer rollers 12, and the plurality of guide rollers 13 configured to guide the optical fiber 1 to the winding bobbin 20.

[0040] As illustrated in FIG. 2, the winding bobbin 20 has a body portion 21 having a cylindrical shape around which the optical fiber 1 is wound, and two flange portions 22A and 22B having a disk shape and provided on both ends of the body portion 21. The winding bobbin 20 is driven to rotate by the winding motor (winding machine) 14 illustrated in FIG. 1.

[0041] Referring back to FIG. 1, the first detector 15 connected to a rotating shaft of the winding motor 14 is configured to detect the number of rotations ft of the winding bobbin 20. When the first detector 15 detects the number of rotations ft of the winding bobbin 20, the first detector outputs data indicating the detected number of rotations ft to the processing device 30. The number of rotations ft of the winding bobbin 20 is controlled by the processing device 30, based on a vertical position of the dancer roller 12, for example, as described below.

[0042] In addition, the winding bobbin 20 is driven and moved by the traverse motor 16 controlled by the processing device 30. More specifically, as illustrated in FIG. 2, the winding bobbin 20 is configured to reciprocate along an axial direction of the winding bobbin 20 at a predetermined traverse speed (moving speed) Vtrv relative to the guide roller 13.

[0043] In addition, the traverse motor 16 illustrated in FIG. 1 may be connected to the guide roller 13 (hereinafter referred to as a guide roller 13A) located closest to the winding bobbin 20 in a traveling path of the optical fiber 1, instead of being connected to the winding bobbin 20. In this case, the guide roller 13A is driven by the traverse motor 16 to move along the axial direction of the winding bobbin 20 at a predetermined traverse speed Vtrv relative to the winding bobbin 20.

[0044] Further, the second detector 18 configured to detect the number of rotations of the guide roller 13A is connected to the guide roller 13A. When the second detector 18 detects the number of rotations of the guide roller 13A, the second detector outputs data indicating the detected number of rotations to the processing device 30.

Configuration of Processing Device

(a) Calculation of Winding Diameter of Winding Bobbin

[0045] FIG. 3 is a block diagram illustrating a configuration of the processing device 30 illustrated in FIG. 1. As illustrated in FIG. 3, the processing device 30 includes an acquisition unit 31, a calculation processing unit 32, a storage unit 33, and a controller 34. The processing device 30 includes a central processing unit (CPU), a read only memory (ROM), a random access memory (RAM), a hard disk drive (HDD), and the like. The CPU may function as the acquisition unit 31, the calculation processing unit 32, the controller 34 and the like.

[0046] The acquisition unit 31 is configured to acquire various data from each of the first detector 15 and the second detector 18 illustrated in FIG. 1. More specifically, when the acquisition unit 31 acquires the data indicating the number of rotations ft of the winding bobbin 20 from the first detector 15, the acquisition unit 31 outputs the acquired data to the calculation processing unit 32. Furthermore, when the acquisition unit 31 acquires the data indicating the number of rotations of the guide roller 13A from the second detector 18, the acquisition unit 31 outputs the acquired data to the calculation processing unit 32.

[0047] When the calculation processing unit 32 receives the data indicating the number of rotations of the guide roller 13A from the acquisition unit 31, the calculation processing unit acquires a winding speed Vt of the optical fiber 1 on the guide roller 13A by using the number of rotations of the guide roller 13A and a diameter of the guide roller 13A that is stored in the storage unit 33 in advance.

[0048] Specifically, the calculation processing unit 32 is configured to calculate a line speed of the optical fiber 1 at the guide roller 13A by multiplying the number of rotations of the guide roller 13A by a circumferential length (=diameter of the guide roller 13) of the guide roller 13A. The calculation processing unit 32 then uses the calculated line speed as the winding speed Vt of the optical fiber 1 around the winding bobbin 20 in a calculation to be described below.

[0049] In this way, the calculation processing unit 32 calculates the line speed of the wire body at the guide roller 13A, that is, the line speed of the optical fiber 1 immediately before being wound onto the winding bobbin 20, thereby making it possible to more accurately acquire the winding speed Vt of the optical fiber 1.

[0050] In addition, the calculation processing unit 32 is configured to calculate a winding diameter D of the winding bobbin 20, based on the traverse speed Vtrv of the winding bobbin 20, the number of rotations ft of the winding bobbin 20 indicated by the data output from the first detector 15, and the winding speed Vt of the optical fiber 1.

[0051] FIG. 4 is a diagram for illustrating a method of calculating the winding diameter D of the winding bobbin 20 by the calculation processing unit 32 of the processing device 30 illustrated in FIG. 3. As illustrated in FIG. 4, the traverse speed Vtrv (m/s) of the winding bobbin 20, the number of rotations ft (s-1) of the winding bobbin 20, the winding speed Vt (m/s) of the optical fiber 1, and the winding diameter D (m) of the winding bobbin 20 satisfy a relationship of the following equation (1) according to Pythagoras' theorem of velocity.

[00001]$\begin{array}{cc}\left[\mathrm{Math}.1\right]& \\ {\left(\mathrm{Winding}\mathrm{speed}\right)}^2={\left(\mathrm{Winding}\mathrm{circumferential}\mathrm{speed}\right)}^2+{\left(\mathrm{Winding}\mathrm{longitudinal}\mathrm{speed}\right)}^2& \left(1\right)\end{array}$${\mathrm{Vt}}^2={\left(\mathrm{ft}D\right)}^2+{\mathrm{Vtrv}}^2$

The calculation processing unit 32 illustrated in FIG. 3 can calculate the winding diameter D of the winding bobbin 20 as illustrated in the following equation (2) by using the traverse speed Vtrv of the winding bobbin 20, the number of rotations ft of the winding bobbin 20, and the winding speed Vt of the optical fiber 1 based on the above equation (1).

[00002]$\begin{array}{cc}\left[\mathrm{Math}.2\right]& \\ D=\frac{\mathrm{Vt}}{\mathrm{ft}}\sqrt{1-{\left(\frac{\mathrm{Vtrv}}{\mathrm{Vt}}\right)}^2}& \left(2\right)\end{array}$

(b) Modification Example of Method for Acquiring Winding Speed of Optical Fiber

[0052] The calculation processing unit 32 in the processing device 30 is not limited to a configuration configured to calculate the line speed of the optical fiber 1 on the guide roller 13A as the winding speed Vt of the optical fiber 1 used to calculate the winding diameter D.

[0053] For example, the calculation processing unit 32 may calculate a line speed VL of the optical fiber 1 controlled by the capstan 11 (see FIG. 1) arranged upstream of the guide roller 13, and use the calculated line speed VL as the winding speed Vt of the optical fiber 1 to calculate the winding diameter D.

[0054] Specifically, the capstan 11 (hereinafter referred to as a capstan 11A) located most downstream among the plurality of capstans 11 is connected to a detector (not illustrated) configured to detect the number of rotations of the capstan 11A. When the detector detects the number of rotations of the capstan 11A, the detector outputs data indicating the detected number of rotations to the processing device 30.

[0055] When the acquisition unit 31 in the processing device 30 acquires the data indicating the number of rotations of the capstan 11A, the acquisition unit 31 outputs the acquired data to the calculation processing unit 32.

[0056] When the calculation processing unit 32 receives the data indicating the number of rotations of the capstan 11A from the acquisition unit 31, the calculation processing unit calculates the line speed of the optical fiber 1 traveling around the capstan 11A by multiplying the number of rotations of the capstan 11A by a circumferential length (=diameter of the capstan 11A) of the capstan 11A. The calculation processing unit 32 can use the calculated line speed as the winding speed Vt of the optical fiber 1 around the winding bobbin 20 to calculate the winding diameter D.

[0057] Here, when the traveling speed of the optical fiber 1 on the guide roller 13 is used as the winding speed Vt of the optical fiber 1, there is a possibility that the optical fiber 1 may come off the bottom of a groove of the guide roller 13 due to line vibration of the optical fiber 1 or the like. In such a case, it is not possible to acquire an accurate winding speed Vt of the optical fiber 1.

[0058] In contrast, the optical fiber 1 traveling on the capstan 11 is in close contact with the capstan 11 by a capstan belt (not illustrated) or the like, so that line vibration and the like are unlikely to occur. Therefore, by calculating the line speed VL of the optical fiber 1 traveling on the capstan 11 as described above, the winding speed Vt of the optical fiber 1 can be acquired more stably.

[0059] In addition, as illustrated in FIG. 1, when the dancer roller 12 is provided between the capstan 11A and the guide roller 13, the line speed VL of the optical fiber 1 traveling on the capstan 11A may change downstream of the dancer roller 12. Therefore, a method of using the line speed VL of the optical fiber 1 traveling on the capstan 11A in calculating the winding speed Vt is more effective when the dancer roller 12 is not provided between the capstan 11A and the guide roller 13.

(c) Control by Processing Device

(c-1) Control of Number of Rotations of Winding Bobbin (Dancer Control)

[0060] Referring again to FIGS. 1 and 3, the vertical position of the dancer roller 12A, which is located furthest downstream among the plurality of dancer rollers 12, is detected by a sensor (not illustrated), and data indicating the detected position of the dancer roller 12A is transmitted to the processing device 30. When the acquisition unit 31 in the processing device 30 acquires the data, the acquisition unit outputs the acquired data to the controller 34. Then, the controller 34 is configured to control the number of rotations ft of the winding bobbin 20, based on the vertical position of the dancer roller 12A indicated by the data.

[0061] More specifically, when the dancer roller 12A moves upward, the controller 34 determines that the number of rotations ft of the winding bobbin 20 is fast, and controls the number of rotations ft of the winding bobbin 20 to be reduced. On the other hand, when the dancer roller 12A moves downward, the controller 34 determines that the number of rotations ft of the winding bobbin 20 is slow, and controls the number of rotations ft of the winding bobbin 20 to be increased.

[0062] In this way, by controlling (hereinafter referred to as dancer control) the number of rotations ft of the winding bobbin 20 based on changes in the vertical position of the dancer roller 12A, the number of rotations ft of the winding bobbin 20 can be appropriately controlled.

(c-2) Control of Reversal Position of Winding Bobbin

[0063] The controller 34 is further configured to control a reversal position of relative movement of the winding bobbin 20 with respect to the guide roller 13A based on the winding diameter D of the winding bobbin 20 calculated by the calculation processing unit 32 so that the winding diameter D is uniform throughout the entirety of the body portion 21 of the winding bobbin 20.

[0064] In other words, the controller 34 is configured to control the reversal position so that the winding diameter D near the flange portions 22A and 22B of the winding bobbin 20 matches the winding diameter D at a position away from the flange portions 22A and 22B on the body portion 21 at an axial center of the winding bobbin 20. Specifically, the controller 34 is configured to control the reversal position so that the winding diameter D near the flange portions 22A and 22B of the winding bobbin 20 matches the winding diameter D at an axial center of the winding bobbin 20.

[0065] For example, the calculation processing unit 32 is configured to constantly calculate the winding diameter D of the winding bobbin 20, thereby updating distribution of the winding diameter D in real time. Then, the calculation processing unit 32 is configured to acquire, based on the distribution of the winding diameter D, a value obtained by performing an averaging process on a winding diameter D(x) in a predetermined range including a vicinity of the axial center of the body portion 21, as the winding diameter D at the center of the body portion 21, which is a target value Dr of the winding diameter.

[0066] As described above, the calculation processing unit 32 can update the distribution of the winding diameter D in real time, and therefore can update the target value Dr of the winding diameter during a period in which the optical fiber 1 is wound within the above-described specified range. Then, the calculation processing unit 32 is configured to periodically output the latest winding diameter D (hereinafter referred to as the current winding diameter D) and the updated target value Dr to the controller 34.

[0067] When the controller 34 acquires the current winding diameter D and the target value Dr, the controller determines the reversal position of the winding bobbin 20 based on the current winding diameter D and the target value Dr. For example, when the current winding diameter D is smaller than the target value Dr, the controller 34 determines the reversal position so that the reversal position is closer to the flange portion 22A or the flange portion 22B. On the other hand, when the current winding diameter D is larger than the target value Dr, the controller 34 determines the reversal position so that the reversal position is closer to the center of the body portion 21.

[0068] Furthermore, the controller 34 may perform control so that the winding diameter D approaches the target value Dr even closer, based on the current winding diameter D and the target value Dr, as illustrated in equation (3).

[0069] Specifically, as illustrated in FIG. 2, a point located outside the flange portion 22B in the axial direction of the winding bobbin 20 is set as a reference position. A distance from the reference position to the reversal position of the winding bobbin 20 is defined as L (m). The controller 34 may be configured to determine the reversal position of the winding bobbin 20 so that the distance L is proportional to a sum of a difference D (=DrD) between the current winding diameter D (m) and the target value Dr (m), a value obtained by integrating the difference D with respect to time (s) and dividing it by integral time Ti (s), and a value obtained by differentiating the difference D with respect to the time (s) and multiplying it by differential time Td (s). In equation (3), L (m) is an amount of change in L, and k1 (dimensionless) is a coefficient.

[00003]$\begin{array}{cc}\left[\mathrm{Math}.3\right]& \\ L=k1\left(D+\frac{1}{\mathrm{Ti}}\mathrm{Ddt}+\mathrm{Td}\frac{dD}{\mathrm{dt}}\right)& \left(3\right)\end{array}$

[0070] Further, the controller 34 is configured to output a control signal to the traverse motor 16 illustrated in FIG. 1 so that a moving direction of the winding bobbin 20 is reversed at the determined reversal position. As a result, the winding bobbin 20 reverses its moving direction at the reversal position determined by the controller 34. As a result, the newly calculated winding diameter D approaches the target value Dr.

[0071] In addition, in the case where the guide roller 13A reciprocates relative to the winding bobbin 20 instead of the winding bobbin 20, the controller 34 similarly determines the reversal position of the moving direction of the guide roller 13A by the method described above. Then, the controller 34 is configured to output a control signal to the traverse motor 16 configured to control the drive of the guide roller 13A so that the moving direction of the guide roller 13A is reversed at a determined determination position.

[0072] As described above, in the winding method described in JP2011-63381A, the traverse reversal position is controlled after the number of winding layers wound around the bobbin has increased, so it takes time for the winding diameter around the bobbin to change, and it is not easy to make the winding diameter around the bobbin uniform.

[0073] In addition, it is possible to control the reversal position of the relative movement of the winding bobbin 20 with respect to the guide roller 13A, based on the change in the vertical position of the dancer roller 12A. Specifically, when the dancer roller 12A moves upward, it is determined that the winding diameter D of the optical fiber 1 on the winding bobbin 20 has increased, and the reversal position is controlled to move away from the flange portion 22A or the flange portion 22B. On the other hand, when the dancer roller 12A moves downward, it is determined that the winding diameter D of the optical fiber 1 on the winding bobbin 20 has become smaller, and the reversal position is controlled to approach the flange portion 22A or the flange portion 22B.

[0074] However, when controlling the reversal position by such a method, it may take time before the winding diameter D of the winding bobbin 20 is affected, as in the winding method described in JP2011-63381A. Furthermore, when such control is performed at high speed, even when a bulge or dent occurs in the optical fiber 1 on the winding bobbin 20, the position of the dancer roller 12A does not change, and it may be difficult to make the winding diameter D of the optical fiber 1 on the winding bobbin 20 uniform.

[0075] In contrast, in the winding device 100 for the optical fiber 1 according to the present disclosure, as described above, the winding diameter D of the winding bobbin 20 can be calculated during winding of the optical fiber 1 by using the relative traverse speed Vtrv of the winding bobbin 20 with respect to the guide roller 13A, the number of rotations ft of the winding bobbin 20, and the winding speed Vt of the optical fiber 1.

[0076] Therefore, the distribution of the winding diameter D can be updated in real time. Based on this distribution of the winding diameter D, the reversal position of the relative movement of the guide roller 13A with respect to the winding bobbin 20 can be more appropriately controlled, so that the optical fiber 1 can be uniformly wound around the winding bobbin 20.

[0077] In addition, since the parameters for stabilizing the winding state of the winding bobbin 20 can be acquired quickly, the position of the dancer roller 12A is stabilized, and the winding tension of the optical fiber 1 can be stabilized.

[0078] In the above embodiment, the winding device 100 for the optical fiber 1 is described as an example of a winding device for a wire body according to the present disclosure, but the winding device for a wire body according to the present disclosure may be used for a wire body other than the optical fiber 1.

[0079] Although the present invention is described in detail and with reference to specific embodiment, it will be apparent to those skilled in the art that various changes and modifications can be made therein without departing from the spirit and scope of the present invention. Furthermore, the numbers, positions, shapes, and the like of the components described above are not limited to the above embodiment, and may be changed to any number, position, shape, and the like that is suitable for implementing the present invention.