WIRE STRAIGHTENING DEVICE AND METHOD FOR MANUFACTURING WIRE

Abstract

A wire straightening device, including a straightening unit that performs straightening on a wire running in a longitudinal direction, an upstream measuring unit that measures a state of the wire at an upstream position from the straightening unit, and a controller that controls an operation of the straightening unit based on a measurement result of the upstream measuring unit, wherein the straightening unit includes a plurality of straightening rollers that contact the wire and perform straightening on the wire, an actuator that presses the straightening rollers toward the wire, and a load adjustment unit that adjusts a roller load applied from the actuator to the straightening rollers, and wherein the controller determines an open resistance pattern, which is a pattern of change in a roller load when the plurality of straightening rollers is pushed back by the wire, based on the measurement result of the upstream measuring unit.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is based on Japanese patent application No. 2025-033845 filed on Mar. 4, 2025, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a wire straightening device for wires such as an electric wire and a metal wire, and to a method for manufacturing the wires.

BACKGROUND OF THE INVENTION

Patent Literature 1 discloses a wire straightening device that corrects a kink of an electric wire serving as a wire material.

The wire straightening device described in Patent Literature 1 comprises:

• • an outer diameter measurement unit that measures the outer diameter of the electric wire;
  • a straightening unit provided downstream from the outer diameter measurement unit and configured to perform straightening by passing the electric wire between rollers; and
  • a controller that controls the operation of the straightening unit.

The controller adjusts the roller spacing based on a measurement value of the outer diameter measurement unit, thereby attempting to reduce damage to the electric wire.

CITATION LIST

Patent Literature 1: Japanese Patent No. 6633822B

SUMMARY OF THE INVENTION

In the wire straightening device described in Patent Literature 1, the roller spacing is set relatively wide, for example, when the electric wire has a severe kink. However, from the viewpoint of straightening the electric wire, there is a limit to widening the roller spacing. Therefore, in case where an electric wire has a severe kink, the electric wire may strongly strike the rollers and may get scratched.

The present invention has been made in view of the aforementioned circumstances, and an object thereof is to provide a wire straightening device and a method for manufacturing wire that can prevent scratches on the wires.

In order to achieve the above object, the present invention provides a wire straightening device comprising:

• • a straightening unit that performs straightening on a wire which is running in a longitudinal direction;
  • an upstream measuring unit that measures a state of the wire at an upstream position from the straightening unit; and
  • a controller that controls the operation of the straightening unit based on a measurement result of the upstream measuring unit,
  • wherein the straightening unit includes:
  • a plurality of straightening rollers that contact the wire and perform straightening on the wire;
  • an actuator that presses the straightening rollers toward the wire; and
  • a load adjustment unit that adjusts a roller load applied from the actuator to the straightening rollers,
  • wherein the controller determines an open resistance pattern, which is a pattern of change in the roller load when the plurality of straightening rollers is pushed back by the wire, based on the measurement result of the upstream measuring unit.

In order to achieve the above object, the present invention also provides a method for manufacturing wire using a wire straightening device comprising:

• • a straightening unit that performs straightening on a wire which is running in a longitudinal direction;
  • an upstream measuring unit that measures a state of the wire at an upstream position from the straightening unit; and
  • a controller that controls the operation of the straightening unit based on a measurement result of the upstream measuring unit,
  • wherein the straightening unit includes:
  • a plurality of straightening rollers that contact the wire and perform straightening on the wire;
  • an actuator that presses the straightening rollers toward the wire; and
  • a load adjustment unit that adjusts a roller load applied from the actuator to the straightening rollers,
  • wherein the controller determines the open resistance pattern, which is a pattern of change in the roller load when the plurality of straightening rollers is pushed back by the wire, based on the measurement result of the upstream measuring unit.

Advantageous Effects of the Invention

According to the present invention, it is possible to provide a wire straightening device and a method for manufacturing wire that can prevent scratches on the wire.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram showing the configuration of a manufacturing equipment for an enameled wire in a first embodiment.

FIG. 2 is a diagram showing the configuration of a wire straightening device in the first embodiment.

FIG. 3 is a view of a first measuring unit as seen from a running direction of the wire in the first embodiment.

FIG. 4 is a functional block diagram of a controller in the first embodiment.

FIG. 5 is a graph showing multiple examples of open resistance patterns in the first embodiment.

FIG. 6 is a flowchart showing the operation of the controller in the first embodiment.

FIG. 7 is a diagram showing the configuration of a first straightening unit in a second embodiment.

FIG. 8 is a diagram showing the configuration of the first straightening unit in a third embodiment.

DETAILED DESCRIPTION OF THE INVENTION

First Embodiment

A first embodiment of the present invention will be described with reference to FIGS. 1 to 6. Note that the embodiment described below is presented as a preferable concrete example for carrying out the present invention, and some parts concretely illustrate various technically preferable matters. However, the technical scope of the present invention is not limited to this specific mode.

(Manufacturing Equipment 100 for Enameled Wire 102)

FIG. 1 is a diagram showing the configuration of a manufacturing equipment 100 for an enameled wire 102. In the present embodiment, an example will be described in which the wire straightening device 1 for a metal wire 101 (i.e., wire) is used as a part of the manufacturing equipment 100 for the enameled wire 102. First, the manufacturing equipment 100 for the enameled wire 102 will be described. Note that the use of the wire straightening device 1 is not limited to that as the manufacturing equipment 100 for the enameled wire 102.

The manufacturing equipment 100 for the enameled wire 102 is a device that manufactures the enameled wire 102 by processing the metal wire 101. The state of the metal wire 101 gradually changes while it is processed by the manufacturing equipment 100, and the final state of the metal wire 101 is the enameled wire 102. The manufacturing equipment 100 for the enameled wire 102 comprises: a supply unit 11, the wire straightening device 1, a round wire drawing machine 12, a flat rolling mill 13, a first annealing furnace 14, a flat wire drawing machine 15, a second annealing furnace 16, a coating machine 17, a baking furnace 18, and a take-up machine 19.

The supply unit 11 includes a bobbin, a dancing wheel, etc. around which the metal wire 101 is wound. The metal wire 101 is pulled out from the supply unit 11, travels in the longitudinal direction of the metal wire 101 so as to sequentially go through the wire straightening device 1, the round wire drawing machine 12, the flat rolling mill 13, the first annealing furnace 14, the flat wire drawing machine 15, the second annealing furnace 16, the coating machine 17, and the baking furnace 18, and then is wound up by the take-up machine 19. Note that the metal wire 101 passes multiple times through the section including the coating machine 17 and the baking furnace 18.

The metal wire 101 is made of, for example, copper or a copper alloy. The shape of the cross-section orthogonal to the longitudinal direction of the metal wire 101 is circular until flat rolling is performed by the flat rolling mill 13. Hereinafter, when the cross-section of the metal wire 101 is mentioned, it means the cross-section orthogonal to the longitudinal direction of the metal wire 101, unless otherwise specified.

The wire straightening device 1 corrects the kink of the metal wire 101 and makes the metal wire 101 closer to a straight shape. Details of the wire straightening device 1 will be described later. The round wire drawing machine 12 performs drawing so that the metal wire 101 becomes a round wire having a desired diameter. The flat rolling mill 13 performs flat rolling on the metal wire 101. The first annealing furnace 14 anneals the metal wire 101. The flat wire drawing machine 15 performs drawing so that the cross-section of the metal wire 101 becomes a rectangle (specifically, a rectangular shape with rounded corners). The second annealing furnace 16 anneals the metal wire 101.

The coating machine 17 coats the surface of the metal wire 101 with enamel coating material, thereby forming a coating film of the enamel coating material of a predetermined thickness on the surface of the metal wire 101. The baking furnace 18 heats the metal wire 101 and performs baking to dry and harden the coating film formed on the surface of the metal wire 101. The coating of the enamel coating material by the coating machine 17 and the heating of the coating film by the baking furnace 18 are performed repeatedly. As a result, the enameled wire 102, which is the metal wire 101 having the enamel coating of the predetermined thickness, is obtained. The enameled wire 102 is wound up by the take-up machine 19.

(Wire Straightening Device 1)

FIG. 2 is a diagram showing the configuration of the wire straightening device 1. The wire straightening device 1 comprises an upstream measuring unit 21, a first straightening unit 31, a second straightening unit 32, a downstream measuring unit 22, and a controller 5. The upstream measuring unit 21, the first straightening unit 31, the second straightening unit 32, and the downstream measuring unit 22 are arranged in this order from the upstream side (for example, the left side in FIG. 2) in a running direction X of the metal wire 101. The upstream measuring unit 21 measures the state of the metal wire 101 at an upstream position from the first and second straightening units 31, 32. The first and second straightening units 31, 32 correct the kink of the metal wire 101 and make the metal wire 101 closer to a straight shape. The downstream measuring unit 22 measures the state of the metal wire 101 at a downstream position from the first and second straightening units 31, 32. The controller 5 controls the operations of the first and second straightening units 31, 32 based on the measurement results of the upstream measuring unit 21. The components of the wire straightening device 1 will be described below in detail.

The upstream measuring unit 21 is arranged at an upstream position from and adjacent to the first straightening unit 31 and measures the state of the metal wire 101 immediately before it is supplied to the first straightening unit 31. In the present embodiment, the upstream measuring unit 21 measures a displacement amount (change amount) (see symbol A in FIG. 3 described below) and a diameter (see symbol Φ in FIG. 3) of the metal wire 101 as the state of the metal wire 101.

The upstream measuring unit 21 has a first measuring unit 201 and a second measuring unit 202. The first and second measuring units 201, 202 have similar configurations, but are arranged in mutually different orientations.

FIG. 3 is a view of the first measuring unit 201 as seen from the running direction X of the metal wire 101. The first measuring unit 201 has a base portion 201a, an irradiation unit 201b, and a light-receiving unit 201d. The base portion 201a fixes the irradiation unit 201b and the light-receiving unit 201d in a mutually spaced-apart state. The first measuring unit 201 is installed such that the metal wire 101 passes between the irradiation unit 201b and the light-receiving unit 201d.

In the first measuring unit 201, the irradiation unit 201b and the light-receiving unit 201d are arranged at positions spaced apart from each other in a direction Y (for example, the left-right direction (horizontal direction) in FIG. 3) that is orthogonal to both the running direction X and a vertical direction Z. The irradiation unit 201b of the first measuring unit 201 includes an irradiation portion 201c having a light-emitting element such as an LED that emits parallel light L toward the light-receiving unit 201d in a direction parallel to the direction Y. The irradiation portion 201c of the upstream measuring unit 21 irradiates the parallel light L having a layered form within a predetermined range in the vertical direction Z.

The light-receiving unit 201d includes a light-receiving portion 201e that receives the parallel light L emitted from the irradiation portion 201c, and a processing unit 201f that processes the light-receiving result obtained by the light-receiving portion 201e. The light-receiving portion 201e includes a plurality of light-receiving elements such as photodiodes that receive the parallel light L at multiple positions.

The processing unit 201f has, for example, a control area including a processor and a RAM (Random Access Memory) that serves as a calculation area during the processor operation, and a storage area that includes a ROM (Read Only Memory), a hard disk, and the like and stores programs executed by the processor. Note that a method to realize a function of the processing unit 201f is not limited to software-based implementation as long as the processing unit 201f is configured to be able to realize its functions. For example, at least a part of the functions of the processing unit 201f may be realized using hardware such as a logic circuit.

The processing unit 201f calculates a displacement amount A1 of the metal wire 101 in the vertical direction Z and a diameter φ of the metal wire 101 based on the light-receiving result of the light-receiving portion 201e. From the output results of the light-receiving portion 201e, the processing unit 201f outputs to the controller 5 a length in the vertical direction Z of a shadow region S created by the parallel light L being blocked by the metal wire 101 as the diameter φ of the metal wire 101. Also, the processing unit 201f outputs to the controller 5 the distance in the vertical direction Z between a central position C of the shadow region S and a reference position P as the displacement amount A1 of the metal wire 101. In addition, the reference position P is a center position of the metal wire 101 on the assumption that the metal wire 101 is straight.

The second measuring unit 202 has the same basic structure as the first measuring unit 201, but is arranged in an orientation rotated 90° about the reference position P relative to the first measuring unit 201. The second measuring unit 202 outputs to the controller 5 the displacement amount of the metal wire 101 in the horizontal direction and the diameter of the metal wire 101. As described later in details, the controller 5 geometrically calculates the displacement amount A, which is the distance from the reference position P to the center of the metal wire 101, based on the displacement amount A1 in the vertical direction Z output from the first measuring unit 201 and the displacement amount in the horizontal direction output from the second measuring unit 202. The metal wire 101 drawn from the supply unit 11 has a tendency to coil due to having been wound around the supply unit 11 and thus has a wavy shape; the larger the tendency to coil, the greater the displacement amount A of the metal wire 101. Moreover, because the diameter of the metal wire 101 may fluctuate depending on the position in the running direction X, the fluctuations in diameter are measured at the upstream measuring unit 21.

In addition, the configuration of the upstream measuring unit 21 is not limited to the configuration described above, but any device capable of measuring a predetermined state of the metal wire 101 may be used. For example, an image of the metal wire 101 may be captured, and the predetermined state of the metal wire 101 may be measured by analyzing the captured image.

As shown in FIG. 2, the first and second straightening units 31, 32 have similar configurations, but are arranged such that their orientations differ by 90° around the metal wire 101. In the present embodiment, the first straightening unit 31 straightens the metal wire 101 in the vertical direction Z, and the second straightening unit 32 straightens the metal wire 101 in a direction orthogonal to both the running direction X and the vertical direction Z.

Each of the first and second straightening units 31, 32 includes a first straightening roller row 301, a second straightening roller row 302, a first support member 303, a second support member 304, a stopper 305, a roller-load applying mechanism 306, and a roller spacing sensor 307.

The first straightening roller row 301 has a plurality of first straightening rollers 301a arranged in the running direction X on one side of the metal wire 101. The second straightening roller row 302 has a plurality of second straightening rollers 302a arranged in the running direction X on the side opposite to the first straightening roller row 301 with respect to the metal wire 101. The first straightening rollers 301a and the second straightening rollers 302a are arranged alternately in the running direction X of the metal wire 101.

The first support member 303 supports each of the plurality of first straightening rollers 301a. In the present embodiment, the first support member 303 integrally supports all of the first straightening rollers 301a. The first support member 303 is arranged on one side in the axial direction of the plurality of first straightening rollers 301a and supports the respective rotation shafts 301b of the plurality of first straightening rollers 301a.

The second support member 304 supports each of the plurality of second straightening rollers 302a. In the present embodiment, the second support member 304 integrally supports all of the second straightening rollers 302a. The second support member 304 is arranged on one side in the axial direction of the plurality of second straightening rollers 302a and supports the respective rotation shafts 302b of the plurality of second straightening rollers 302a.

The first support member 303 and the second support member 304 are configured to be movable relative to each other in an opening/closing direction D, which is a direction orthogonal to both the running direction X and the axial directions of the first and second straightening rollers 301a, 302a. In the present embodiment, each of the first support member 303 and the second support member 304 is configured to be movable in the opening/closing direction D relative to the metal wire 101. In the present embodiment, the opening/closing direction D of the first straightening unit 31 is the vertical direction Z, and the opening/closing direction D of the second straightening unit 32 is a direction orthogonal to both the running direction X and the vertical direction Z. In FIG. 2, the opening/closing direction D for each of the first and second straightening units 31, 32 is shown in the vicinity of the first and second straightening units 31, 32.

The stopper 305 regulates the spacing in the opening/closing direction D between the first support member 303 and the second support member 304 so that the spacing does not go below a predetermined minimum spacing. In other words, the stopper 305 regulates the spacing in the opening/closing direction D between the first straightening rollers 301a and the second straightening rollers 302a so that the spacing does not go below a predetermined minimum spacing. As one example, the stopper 305 is configured by a bolt that is screwed into the first support member 303 and has a tip protruding toward the second support member 304 from the first support member 303. The tip surface of the bolt abuts the second support member 304, thereby restricting the approach between the first support member 303 and the second support member 304. By changing the screw-in amount of the bolt into the first support member 303, the minimum spacing in the opening/closing direction D between the first support member 303 and the second support member 304 can be adjusted. Additionally, it is preferable that the minimum spacing be set to the outer diameter of the metal wire 101.

The roller-load applying mechanism 306 comprises an actuator 306a that presses the first straightening rollers 301a or the second straightening rollers 302a toward the metal wire 101, and a load adjustment unit 306g that adjusts the roller load, which is the force applied from the actuator 306a to the first straightening rollers 301a or the second straightening rollers 302a. When the metal wire 101 is being straightened, the roller load can be regarded as the load applied from the first straightening rollers 301a or the second straightening rollers 302a to the metal wire 101. In the present embodiment, the roller-load applying mechanism 306 is attached to each of the first and second support members 303, 304. In FIG. 2, only the actuator 306a of the roller-load applying mechanism 306 for the second straightening rollers 302a is illustrated for convenience.

The actuator 306a is capable of adjusting the roller load and is composed of, for example, an air cylinder, a hydraulic cylinder, or the like. In the present embodiment, a case where the actuator 306a is an air cylinder is described as one example.

The actuator 306a comprises a cylinder body 306b, a piston 306e, and a piston rod 306f. The cylinder body 306b is formed such that its interior constitutes a hollow space. The piston 306e partitions the space inside the cylinder body 306b into a first space 306c and a second space 306d, and moves in the axial direction of the piston rod 306f relative to the cylinder body 306b when air is supplied to/removed from the first and second spaces 306c, 306d. The piston rod 306f is disposed in the second space 306d, is formed long in the movement direction of the piston 306e, and moves integrally with the piston 306e. The end of the piston rod 306f opposite to the end connected to the piston 306e protrudes from the cylinder body 306b and presses the first support member 303 or the second support member 304 toward the metal wire 101 in the opening/closing direction D.

The load adjustment unit 306g comprises an air compressor 306i and a switching valve 306j, which are connected to the first and second spaces 306c, 306d through piping 306h. The air compressor 306i supplies compressed air of a constant pressure, for example. The compressed air supplied from the air compressor 306i is introduced through the piping 306h and the switching valve 306j into one of the first and second spaces 306c, 306d, while the air in the other of the first and second spaces 306c, 306d is discharged through the switching valve 306j. The switching valve 306j also functions as a regulator capable of adjusting the pressure of the air supplied into one of the first and second spaces 306c, 306d.

A first pressure sensor 306k is provided to the piping 306h between the first space 306c and the switching valve 306j, and a second pressure sensor 306l is provided to the piping 306h between the second space 306d and the switching valve 306j. The first pressure sensor 306k measures the pressure of the first space 306c, and the second pressure sensor 306l measures the pressure of the second space 306d. The measurement results of the first and second pressure sensors 306k and 306l are output to the controller 5, and the operation of the air compressor 306i and the switching valve 306j is controlled by the controller 5.

Note that the configuration of the load adjustment unit 306g is not limited to the above configuration, but any configuration may be adopted as long as the roller load can be adjusted. For example, when the actuator 306a is a hydraulic cylinder, a publicly known configuration capable of adjusting the roller load by the hydraulic cylinder may be adopted.

The roller spacing sensor 307 acquires the roller spacing related to the spacing in the opening/closing direction D between the first straightening rollers 301a and the second straightening rollers 302a. The roller spacing may be defined, for example, as a distance (spacing) in the opening/closing direction D between the first straightening rollers 301a and the second straightening rollers 302a. Alternatively, the roller spacing may be the information that indirectly determines the spacing in the opening/closing direction D between the first straightening rollers 301a and the second straightening rollers 302a, such as the spacing in the opening/closing direction D between the first support member 303 that moves integrally with the first straightening rollers 301a, and the second support member 304 that moves integrally with the second straightening rollers 302a, or the advance/retract amount of the piston rod 306f of each actuator 306a. The roller spacing sensor 307 may be, for example, a displacement sensor or the like. The measurement result of the roller spacing sensor 307 is output to the controller 5.

The downstream measuring unit 22 is arranged downstream from the second straightening unit 32 and measures the state of the metal wire 101 that has passed through the first and second straightening units 31, 32. The downstream measuring unit 22 measures the displacement amount and the diameter of the metal wire 101 as the state of the metal wire 101 that has passed through the second straightening unit 32. The measurement of the displacement amount and the diameter of the metal wire 101 by the downstream measuring unit 22 is performed in the same manner as by the upstream measuring unit 21. The measurement results of the downstream measuring unit 22 are output to the controller 5.

Although not illustrated, it is preferable to provide an evaluation unit that evaluates the enameled wire 102 obtained by processing the metal wire 101. The evaluation unit is, for example, an external appearance inspection device for the enameled wire 102. The external appearance inspection device analyzes an image capturing the enameled wire 102 and inspects the presence or absence of defects such as swelling of the enamel coating. In particular, in the process of forming the enamel coating, if a large scratch exists on the surface of the metal wire 101, swelling of the enamel coating film may occur. Therefore, it is desirable to avoid making scratches on the metal wire 101 while using the wire straightening device 1, etc. The external appearance inspection device outputs, for example, an external appearance score in which the external appearance state of the enameled wire 102 is scored according to a predetermined method. Note that the evaluation unit is not limited to an external appearance inspection device, and may be any device capable of evaluating information regarding characteristics required for the enameled wire 102 (for example, electrical insulation properties). The evaluation results obtained by the evaluation unit are output to the controller 5.

The controller 5 comprises, for example, a control area including a processor and a RAM (Random Access Memory) serving as an calculation area while the processor is in operation, and a storage area including a ROM (Read Only Memory), a hard disk, etc., which stores programs executed by the processor, Note that the controller 5 is not limited to software-based implementation as long as it is configured to realize its functions. For example, at least a part of the functions of the controller 5 may be realized using hardware such as a logic circuit.

FIG. 4 is a functional block diagram of the controller 5. The controller 5 comprises a storage unit 51, a data acquisition unit 52, an estimation unit 53, an actuator controller 54, and a learning unit 55.

The storage unit 51 stores data from various sensors as well as a learned model used by the estimation unit 53. The learned model takes the displacement amount and the diameter of the metal wire 101 obtained on the basis of the measurement results of the upstream measuring unit 21 as input parameters, and outputs the open resistance pattern, which is a pattern of change in roller load when a portion of the metal wire 101 where the state was measured at the upstream measuring unit 21, pushes back the first and second straightening rollers 301a, 302a. The open resistance pattern will be described below.

The learned model is generated by machine learning using the following as at least training data: the state of the metal wire 101 at an upstream position from the first straightening unit 31, the open resistance pattern, and the state of the metal wire 101 after passing through the second straightening unit 32. In addition, the training data may include other information such as evaluation results obtained from the evaluation unit described above.

Here, among the training data, the state of the metal wire 101 at an upstream position from the first straightening unit 31 is the displacement amount and the diameter of the metal wire 101 obtained based on the measurement results of the upstream measuring unit 21.

Next, the open resistance pattern among the training data will be described. For example, when a portion of the metal wire 101 having a relatively severe kink is supplied to the first straightening unit 31, the metal wire 101 resists the roller load so that the first and second straightening rollers 301a, 302a are pushed back in such a manner that they move away from each other in the opening/closing direction D. In such a case, the temporal change in resistance as the first and second straightening rollers 301a, 302a are pushed back, in other words, the open resistance pattern, is adjusted in various ways by changing over time air pressure of the first space 306c of the air cylinder serving as the actuator 306a by means of the load adjustment unit 306g.

FIG. 5 is a graph showing multiple examples of the open resistance patterns. In the present embodiment, the open resistance pattern is the correlation between the roller spacing and the roller load. FIG. 5 shows four examples of open resistance patterns according to this embodiment, but these are merely examples. In this embodiment, the open resistance pattern is such that the roller load increases as the roller spacing increases. In patterns a through c shown in FIG. 5, the degree of increase in roller load associated with the increase in roller spacing is reduced in that order. A pattern d is a pattern in which, when the roller spacing is relatively small, the degree of increase in roller load associated with an increase in roller spacing is small so that the roller spacing tends to open easily, while once the roller spacing opens to a certain extent, the degree of increase in roller load associated with an expansion of roller spacing becomes rapidly large.

Note that the open resistance pattern is not limited to the correlation between the roller spacing and the roller load, but it may be a pattern of temporal change in the roller load while the roller spacing is open. In other words, in the open resistance pattern according to this embodiment, the roller load is determined based on a value of the roller spacing, but not limited to this, the roller load may be determined based on elapsed time while the roller spacing is open.

Among the training data, the state of the metal wire 101 after passing through the second straightening unit 32 was the displacement amount of the metal wire 101 obtained based on the measurement results of the downstream measuring unit 22. Furthermore, the above-mentioned external appearance score of the enameled wire 102 obtained from the evaluation unit was also used as training data.

By performing machine learning using the training data as described above, a learned model representing the correlations in the training data can be obtained. As one example, when generating a learned model through reinforcement learning, a learned model can be generated by changing the open resistance pattern in various ways as an action in reinforcement learning, and using the state of the metal wire 101 after passing through the second straightening unit 32 as a reward in reinforcement learning. This makes it possible to generate a learned model that outputs the open resistance pattern in which a state of the metal wire 101 and a state of the enameled wire 102 are good after passing through the second straightening unit 32, when the state of the metal wire 101 at the upstream position from the first straightening unit 31 is input as a parameter. Note that the mechanism for generating the learned model is not limited to reinforcement learning, but other known mechanisms such as supervised learning or unsupervised learning may be adopted.

The data acquisition unit 52 receives data transmitted from the upstream measuring unit 21, the first pressure sensor 306k, the second pressure sensor 306l, the roller spacing sensor 307, the downstream measuring unit 22, and the evaluation unit, and stores the data in the storage unit 51. In this embodiment, the diameter of the metal wire 101 is input from each of the first and second measuring units 201, 202 of the upstream measuring unit 21, but, for example, an average value of these is determined as the diameter of the metal wire 101 and stored in the storage unit 51. The same applies to the downstream measuring unit 22. Furthermore, regarding the displacement amount of the metal wire 101 at the upstream position from the first straightening unit 31, the displacement amount A of the metal wire 101 at the upstream position from the first straightening unit 31 is geometrically calculated on the basis of the displacement amount A1 (see FIG. 3) of the metal wire 101 in the vertical direction Z obtained by the first measuring unit 201 and the displacement amount of the metal wire 101 in the horizontal direction obtained by the second measuring unit 202, and the calculated value is stored in the storage unit 51. The same applies to the displacement amount of the metal wire 101 at the downstream position from the second straightening unit 32.

The estimation unit 53 uses the learned model to output an appropriate open resistance pattern (for example, a pattern that maximizes a reward in reinforcement learning), using the displacement amount and the diameter of the metal wire 101 that are obtained based on the measurement results of the upstream measuring unit 21 as input parameters.

The actuator controller 54 controls the open resistance pattern in accordance with the output result of the estimation unit 53, when the first straightening rollers 301a and the second straightening rollers 302a are pushed back by the metal wire 101. The actuator controller 54 controls the open resistance pattern by adjusting the air pressure of the first space of the air cylinder serving as the actuator 306a by means of the load adjustment unit 306g.

The learning unit 55 performs additional learning based on the state of the metal wire 101 at the upstream position from the first straightening unit 31, the open resistance pattern, and the state of the metal wire 101 after passing through the second straightening unit 32, which are acquired when the enameled wire 102 is actually manufactured, and then updates the learned model.

(Operation of the Controller 5)

Next, the operation of the controller 5 will be described with reference to FIG. 6.

FIG. 6 is a flowchart showing the operation of the controller 5.

As a step S1, the controller 5 acquires the displacement amount and the diameter of the metal wire 101 at the upstream position from the first straightening unit 31.

Next, as a step S2, the controller 5 outputs an appropriate open resistance pattern using the learned model, with the displacement amount and diameter of the metal wire 101 at the upstream position from the first straightening unit 31 as input parameters. The open resistance pattern may be common for the first straightening unit 31 and the second straightening unit 32, or may be different between the first straightening unit 31 and the second straightening unit 32.

After that, as a step S3, when the metal wire 101 is supplied to the first and second straightening units 31, 32, the controller 5 controls the load adjustment unit 306g so that the open resistance patterns of the first and second straightening units 31, 32 become the open resistance pattern obtained in the step S2.

Then, the controller 5 acquires the displacement amount and the external appearance score of the metal wire 101 at the downstream position from the second straightening unit 32, and stores them in the storage unit 51.

Finally, the controller 5 performs additional learning based on the newly added data and updates the learned model.

(Functions and Effects of the First Embodiment)

In the wire straightening device 1 of the present embodiment, the controller 5 determines an open resistance pattern, which is a pattern of change in roller load when the first straightening rollers 301a and the second straightening rollers 302a are pushed back by the wire (metal wire 101), based on the measurement results of the upstream measuring unit 21. That is, the manner in which resistance changes when the plurality of straightening rollers opens as they are pushed by the wire, is adjusted according to the state of the wire at the upstream position from the first straightening unit 31. Therefore, for example, when a portion of the wire having a severe kink passes through the first and second straightening rollers 301a, 302a, strong resistance generated by opening of the first and second straightening rollers 301a, 302a can be suppressed, thereby suppressing the occurrence of scratches on the wire.

Also, the controller 5 acquires an open resistance pattern with the measurement results of the upstream measuring unit 21 as input parameters, by using a learned model, in which the state of the wire at the upstream position from the first straightening unit 31, the open resistance pattern, and the state of the wire after passing through the second straightening unit 32 are learned by machine learning at least as training data, and controls the operation of the load adjustment unit 306g according to the acquired open resistance pattern. In this way, in the present embodiment, it becomes easier to suppress the occurrence of scratches when the wire is straightened, because the learned model which is generated using the open resistance pattern as training data is used.

In addition, the actuator 306a collectively applies the roller load to the plurality of straightening rollers constituting at least one of the first and second straightening roller rows 301, 302. Therefore, the configuration of the wire straightening device 1 becomes simple, which facilitates the control of the load adjustment unit 306g by the controller 5.

As described above, according to the present embodiment, it is possible to provide a wire straightening device and a method for manufacturing wire that can suppress the occurrence of scratches on the wire.

Second Embodiment

A second embodiment of the present invention will be described below with reference to FIG. 7. FIG. 7 is a diagram showing the configuration of the first straightening unit 31 in the present embodiment.

The present embodiment is an embodiment in which the configurations of the first and second straightening units 31, 32 are modified with respect to the first embodiment.

The first support member 303 has a first movable support portion 303a, which is capable of moving towards and away from the metal wire 101 during straightening of the metal wire 101, and a first fixed support portion 303b, which is incapable of moving towards and away from the metal wire 101. The first movable support portion 303a supports first control rollers 301c, which are among the first straightening rollers 301a including the most upstream one of the first straightening rollers 301a. The first fixed support portion 303b supports a first non-control roller 301d, which is among the first straightening rollers 301a other than the first control rollers 301c.

The second support member 304 has a second movable support portion 304a, which is capable of moving towards and away from the metal wire 101 during straightening of the metal wire 101, and a second fixed support portion 304b, which is incapable of moving towards and away from the metal wire 101. The second movable support portion 304a supports a second control roller 302c, which is among the second straightening rollers 302a including the most upstream one of the second straightening rollers 302a. The second fixed support portion 304b supports a second non-control roller 302d, which is among the second straightening rollers 302a other than the second control roller 302c.

A roller-load applying mechanism 306 is provided to each of the first movable support portion 303a of the first support member 303 and the second movable support portion 304a of the second support member 304. In FIG. 7, only the actuator 306a of the roller-load applying mechanism 306 is illustrated for convenience.

Furthermore, in the present embodiment, the roller spacing sensor 307 measures a roller spacing related to the interval in the opening/closing direction D between the first control roller 301c and the second control roller 302c.

Other configurations of the present embodiment are the same as those of the first embodiment. Also, among the reference numerals used in the second embodiment and subsequent embodiments, the ones used in the embodiment already mentioned represent the same components and the like as those in the embodiment already mentioned, unless otherwise specified.

(Functions and Effects of the Second Embodiment)

In the present embodiment, the plurality of first and second straightening rollers 301a, 302a comprise the first and second control rollers 301c, 302c to which the roller load to be applied is controlled by the load adjustment unit 306g, and the first and second non-control rollers 301d, 302d which are arranged at downstream positions from the first and second control rollers 301c, 302c and to which the roller load to be applied is not controlled by the load adjustment unit 306g. Therefore, when a portion of the wire (metal wire 101) having a severe kink is supplied to the first and second straightening units 31, 32, that portion firstly strikes the first and second control rollers 301c, 302c, which open relatively easily, thereby suppressing the occurrence of scratches on the wire. Also, since the non-control rollers located downstream are fixed immovably with respect to the wire, the wire is strongly straightened at the first and second non-control rollers 301d, 302d. As described above, according to the present embodiment, it is possible to achieve suppression of scratches on the wire while improving the straightening force.

In addition, the same functions and effects as those of the first embodiment are obtained.

Third Embodiment

A third embodiment of the present invention will be described below with reference to FIG. 8. FIG. 8 is a diagram showing the configuration of the first straightening unit 31 in the present embodiment.

The present embodiment is an embodiment in which the configurations of the first and second straightening units 31, 32 are modified with respect to the first embodiment.

The first support members 303 exist in the same number as a number of the first straightening rollers 301a, and the plurality of first straightening rollers 301a is supported by different first support members 303 respectively. Similarly, the second support members 304 exist in the same number as a number of the second straightening rollers 302a, and the plurality of second straightening rollers 302a is supported by different second support members 304 respectively. Each of the plurality of first support members 303 and each of the plurality of second support members 304 is configured to be capable of moving towards and away from the metal wire 101 in the opening/closing direction D.

The roller-load applying mechanism 306 is attached individually to each of the plurality of first support members 303 and each of the plurality of second support members 304. In FIG. 8, only the actuator 306a of the roller-load applying mechanism 306 is illustrated for convenience. The controller is configured to be able to individually control each of the plurality of roller-load applying mechanisms 306.

Furthermore, in the present embodiment, the roller spacing sensor 307 acquires a roller spacing related to the interval in the opening/closing direction D between the metal wire 101 and each of the first and second straightening rollers 301a, 302a.

In the present embodiment, the learned model stored in the storage unit 51 of the controller 5 is generated by machine learning the training data including pattern sets that are combinations of open resistance patterns for each of the plurality of roller-load applying mechanisms 306, and the roller spacings of each of the first and second straightening rollers 301a, 302a. As an example of the pattern set, a combination may be adopted such that the degree of increase in roller load accompanying the widening of roller spacing becomes greater the further downstream the roller-load applying mechanism 306 is located. With this configuration, the first and second straightening rollers 301a, 302a located upstream easily open when straightening a portion of the metal wire 101 having a severe kink, thereby suppressing scratches on the metal wire 101, while the first and second straightening rollers 301a, 302a located downstream become difficult to open, thereby enabling straightening even for portions having a severe kink.

Then, using the learned model, the controller 5 outputs an appropriate open resistance pattern for each of the plurality of roller-load applying mechanisms 306 with the displacement amount and the diameter of the metal wire 101 obtained based on the measurement results of the upstream measuring unit 21 as input parameters. The controller 5 controls the roller loads of the first and second straightening rollers 301a, 302a respectively according to the respective open resistance patterns of the plurality of roller-load applying mechanisms 306 that have been output.

Other configurations of the present embodiment are the same as those of the first embodiment.

Also, among the reference numerals used in the third embodiment and subsequent embodiments, the ones used in the embodiments already mentioned represent the same components and the like as those in the embodiments already mentioned, unless otherwise specified.

(Function and Effects of the Third Embodiment)

In the present embodiment, a plurality of the actuators 306a that individually applies roller loads to each of the plurality of first and second straightening rollers 301a, 302a, and a plurality of the load adjustment units 306g that individually adjusts the roller loads applied by the plurality of actuators 306a, are provided. Therefore, the roller loads applied to the wire (metal wire 101) can be flexibly changed, and it is possible to suppress the occurrence of scratches on the wire and improve the ability to straighten wire.

In addition, the same functions and effects as those of the first embodiment are achieved.

[Modified Example]

Next, modified examples that can be adopted with respect to the aforementioned embodiments will be described.

In the first to third embodiments, examples were shown in which the open resistance pattern is determined using the learned model generated by machine learning, but the invention is not limited thereto. For example, in the first and second embodiments, the controller may store a correspondence relation between the displacement amount of the metal wire 101 at the upstream position from the first straightening unit 31 and the open resistance pattern, such that as the displacement amount of the metal wire 101 at the upstream position from the first straightening unit 31 increases, the resistance decreases when the first straightening rollers 301a and the second straightening rollers 302a open (move away from each other), and thus, may control the load adjustment unit 306g on the basis of the correspondence relation. Furthermore, in the third embodiment, the configuration may be such that the degree of increase in roller load accompanying the widening of the roller spacing becomes larger the further downstream the first and second straightening rollers 301a, 302a are located, and also such that a change in the degree of increase in roller load accompanying the widening of the roller spacing increases as the displacement amount of the metal wire 101 at the upstream position from the first straightening unit 31 increases.

Additionally, in the first to third embodiments, examples were shown in which the metal wire 101 having a circular cross-section is straightened by the wire straightening device 1, but the invention is not limited thereto. For example, the wire straightening device 1 may straighten a flat wire having a rectangular cross-section. In this case, the straightening unit can straighten the metal wire 101 only in its thickness direction.

(Summary of the Embodiments)

Next, the technical concept understood from the embodiments described above will be described with reference to the reference numerals used in the embodiments. However, the reference numerals in the description below shall not limit the constituent elements in the claims to the specific components shown in the embodiments.

• • [1] A wire straightening device 1 for a wire 101, comprising: straightening units 31, 32 that perform straightening on a wire 101 which is running in the longitudinal direction;
    • an upstream measuring unit 21 that measures the state of the wire 101 at an upstream position of the straightening units 31, 32; and
    • a controller 5 that controls the operation of the straightening units 31, 32 based on the measurement results of the upstream measuring unit 21;
    • wherein the straightening units 31, 32 comprise:
    • a plurality of straightening rollers 301a, 302a that contact the wire 101 and perform straightening on the wire 101;
    • an actuator 306a that presses the straightening rollers 301a, 302a toward the wire 101; and
    • a load adjustment unit 306g that adjusts a roller load applied from the actuator 306a to the straightening rollers 301a, 302a; and
    • wherein the controller 5 determines an open resistance pattern which is a pattern of change in roller load when the plurality of straightening rollers 301a, 302a are pushed back by the wire 101, based on the measurement results of the upstream measuring unit 21.
  • [2] The wire straightening device 1 for the wire 101 according to [1],
    • wherein the controller 5 acquires the open resistance pattern with the measurement results of the upstream measuring unit 21 as input parameters, using a learned model, in which the state of the wire 101 at the upstream position of the straightening units 31, 32, the open resistance pattern, and the state of the wire 101 after passing through the straightening units 31, 32 are learned by machine learning as at least training data, and controls the operation of the load adjustment unit 306g in accordance with the acquired open resistance pattern.
  • [3] The wire straightening device 1 for the wire 101 according to [1] or [2],
    • wherein the plurality of straightening rollers 301a, 302a constitute straightening roller rows 301, 302 having the plurality of straightening rollers 301a, 302a arranged respectively on both sides of the wire 101 along the running direction X of the wire 101, and
    • wherein the actuator 306a collectively applies the roller load to the plurality of straightening rollers 301a, 302a constituting at least one of the straightening roller rows 301, 302.
  • [4] The wire straightening device 1 for the wire 101 according to [1] or [2], wherein the plurality of straightening rollers 301a, 302a comprise control rollers 301c, 302c whose roller loads are controlled by the load adjustment unit 306g, and non-control rollers 301d, 302d that are arranged at downstream positions of the control rollers 301c, 302c and whose roller loads are not controlled by the load adjustment unit 306g.
  • [5] The wire straightening device 1 for the wire 101 according to [1] or [2], comprising:
    • a plurality of actuators 306a that individually applies roller loads to each of the plurality of straightening rollers 301a, 302a; and
    • the plurality of load adjustment units 306g that individually adjusts the roller loads applied by the plurality of actuators 306a.
  • [6] A manufacturing method for a wire 102 using a wire straightening device 1 for a wire 101; comprising:
    • straightening units 31, 32 that perform straightening on the wire 101 running in the longitudinal direction;
    • an upstream measuring unit 21 that measures the state of the wire 101 at an upstream position from the straightening units 31, 32; and
    • a controller 5 that controls the operation of the straightening units 31, 32 based on the measurement results of the upstream measuring unit 21,
    • wherein the straightening units 31, 32 comprise:
    • a plurality of straightening rollers 301a, 302a that contact the wire 101 and perform straightening on the wire 101;
    • an actuator 306a that presses the straightening rollers 301a, 302a toward the wire 101; and
    • a load adjustment unit 306g that adjusts the roller load applied from the actuator 306a to the straightening rollers 301a, 302a, and
    • wherein the controller 5 determines an open resistance pattern which is a pattern of change in roller load when the plurality of straightening rollers 301a, 302a is pushed back by the wire 101, based on the measurement results of the upstream measuring unit 21.

(Additional Note)

That is all for the description of the embodiments of the present invention, but the embodiments described above do not limit the invention according to the scope of claims. Also, it should be noted that not all combinations of the features described in the embodiments are essential means for solving the problems of the invention. Moreover, the present invention can be implemented with appropriate modifications without departing from the scope and spirit of the invention.

Claims

1. A wire straightening device, comprising:

a straightening unit that performs straightening on a wire running in a longitudinal direction;

an upstream measuring unit that measures a state of the wire at an upstream position from the straightening unit; and

a controller that controls an operation of the straightening unit based on a measurement result of the upstream measuring unit,

wherein the straightening unit comprises:

a plurality of straightening rollers that contact the wire and perform straightening on the wire;

an actuator that presses the straightening rollers toward the wire; and

a load adjustment unit that adjusts a roller load applied from the actuator to the straightening rollers; and

wherein the controller determines an open resistance pattern, which is a pattern of change in a roller load when the plurality of straightening rollers is pushed back by the wire, based on the measurement result of the upstream measuring unit.

2. The wire straightening device according to claim 1,

wherein the controller acquires the open resistance pattern with the measurement result of the upstream measuring unit as input parameters, using a learned model, in which a state of the wire at an upstream position of the straightening unit, the open resistance pattern, and a state of the wire after passing through the straightening unit are learned by machine learning as at least training data; and controls an operation of the load adjustment unit in accordance with the acquired open resistance pattern.

3. The wire straightening device according to claim 1,

wherein the plurality of straightening rollers has a straightening roller row composed of the plurality of straightening rollers arranged along the running direction of the wire on both sides of the wire, and

wherein the actuator collectively applies the roller load to the plurality of straightening rollers constituting at least one of the straightening roller rows.

4. The wire straightening device according to claim 1,

wherein the plurality of straightening rollers includes control rollers whose roller loads are controlled by the load adjustment unit, and non-control rollers that are arranged at a downstream position from the control rollers and whose roller loads are not controlled by the load adjustment unit.

5. The wire straightening device according to claim 1, comprising:

a plurality of the actuators that individually applies the roller load to each of the plurality of straightening rollers; and

a plurality of the load adjustment units that individually adjusts the roller load applied by the plurality of the actuators.

6. A method for manufacturing a wire using a wire straightening device, comprising:

a straightening unit that performs straightening on the wire running in a longitudinal direction;

an upstream measuring unit that measures a state of the wire at an upstream position from the straightening unit; and

a controller that controls an operation of the straightening unit based on measurement results of the upstream measuring unit;

wherein the straightening unit comprises:

a plurality of straightening rollers that contact the wire and perform straightening on the wire;

an actuator that presses the straightening rollers toward the wire; and

a load adjustment unit that adjusts a roller load applied from the actuator to the straightening rollers; and

wherein the controller determines an open resistance pattern, which is a pattern of change in the roller load when the plurality of straightening rollers is pushed back by the wire, based on the measurement results of the upstream measuring unit.