A transformer coil automatic alignment, compaction and measurement device and process method

Abstract

The present invention relates to an automatic alignment, compaction, and measurement device for transformer coils, comprising a robotic arm placed on one side of a vertical winding machine, an alignment, compaction, and measurement device provided at the front end of the robotic arm, the robotic arm being located on a base, a robotic arm control box provided on one side of the robotic arm, a robotic arm teaching pendant provided above the robotic arm control box, and an operating control platform placed on the other side of the vertical winding machine. The alignment, compaction, and measurement device comprises a lifting device, an alignment device, a compaction device, and a measuring device, the alignment device, the compaction device, and the measuring device being mounted on the lifting device, and the lifting device being fixedly connected to the robotic arm. The present invention also relates to a method for automatic alignment, compaction, and measurement of transformer coils, utilizing the aforementioned automatic alignment, compaction, and measurement device for coils. The present invention implements the functions of automatic axial compaction of coils, automatic alignment of coils, high-precision dimensional measurement, alarm for out-of-tolerance measurement values, setting of hazardous areas, and safety protection.

Description

Technical Field

[0001] The present invention belongs to the technical field of transformer production and manufacturing, and specifically relates to an automated device and process method for automatically aligning and compacting wire cakes during the winding process of transformer coils and accurately measuring the inner and outer diameters and width dimensions of the wire cakes. Background Art

[0002] At present, during the winding process of transformer coils, it is necessary to effectively control the size of the coils to ensure that each coil is flat and tight, and to meet the process requirements related to coil production.

[0003] During the coil manufacturing process, it is necessary to control the radial flatness and tightness of the wire coils in order to reduce and eliminate the wire collapse and collapse caused by the "umbrella-shaped" structure of the wire coil with a high inner diameter side and a low outer diameter side when winding the coil. This leads to poor radial tightening of the wire coil, a large spacing between the upper and lower wire coils (i.e., axial direction), looseness and lack of tightness, resulting in the axial and radial dimensions of the wire coil being out of tolerance and the mechanical strength against short circuits being reduced. Currently, in the coil manufacturing process, one operator is required to be responsible for coil winding, and another operator is responsible for aligning the wire coils using a nylon hammer and nylon pads. The effect of manually aligning the wire coils is unstable, and the effect of eliminating the "umbrella-shaped" structure is poor. The actual effect is closely related to the state of the operator. The work content is simple and repetitive, with a certain degree of labor intensity, and the human resource benefits are not fully utilized.

[0004] During the coil production process, in addition to aligning and compacting the wire coils and controlling their flatness, it is also necessary to constantly monitor whether the inner and outer diameters (radial dimensions) of the coils conform to the design drawings and make corresponding adjustments. Therefore, during the coil winding process, the machine needs to be stopped multiple times to measure the radial dimensions of each wire coil during and after operation to conduct timely inspections of the coil dimensions. The inner diameter of the wire coil requires two operators to measure using a steel tape measure with an accuracy of 1mm. The actual measurement is of the polygonal dimensions formed by the coil struts, which has poor measurement accuracy compared to the inner diameter deviation requirement of ±3mm. The radial dimensions of the wire coil are measured by operators using a steel ruler at multiple points, resulting in low measurement efficiency and poor accuracy.

[0005] These two issues necessitate the deployment of two operators for coil winding, with both tasks being entirely manual. Measurements require machine downtime, resulting in low efficiency and suboptimal results. To address these issues, it is necessary to develop an automated device that can replace manual coil alignment, compaction, and measurement, thereby improving coil winding automation and product quality. Summary of the Invention

[0006] To address the above technical issues, the present invention provides a device and process method for automatically aligning, compacting, and measuring transformer coils. These devices, applied during the coil winding stage on a vertical winding machine, achieve automatic alignment and compaction of coils and measurement of inner and outer diameters. This automated device replaces manual alignment and compaction of coils, achieving a more uniform and stable alignment and compaction effect. The automated device measures the inner and outer diameters of coils in real time, eliminating the need to stop the machine for measurement and enabling efficient and accurate measurement. The technical solutions employed by the present invention are as follows:

[0007] A device for automatically aligning, compacting and measuring coils of transformer coils, comprising: a robotic arm placed on one side of a vertical winding machine, an aligning, compacting and measuring device provided at the front end of the robotic arm, the aligning, compacting and measuring device being used to measure the outer diameter of a paper tube, the inner diameter of a coil and the outer diameter of a coil, and to align and compact the coils; the robotic arm being located on a base and being used to drive the aligning, compacting and measuring device to a set position; a robotic arm control box being provided on one side of the robotic arm, a robotic arm teach pendant being provided above the robotic arm control box, the robotic arm control box and the robotic arm teach pendant being used for programming and controlling the movements of the robotic arm; an operation control platform being placed on the other side of the vertical winding machine and being used to input relevant technical parameters, receive collected data, calculate measurement results and control the movements of the aligning, compacting and measuring device; the aligning, compacting and measuring device comprising: a lifting device, an aligning device, a compacting device and a measuring device, the aligning device, the compacting device and the measuring device being installed on the lifting device, and the lifting device being fixedly connected to the robotic arm.

[0008] A method for automatically aligning, compacting, and measuring transformer coils, using the aforementioned automatic aligning, compacting, and measuring device, comprises the following steps:

[0009] Preparation stage: The automatic wire bun alignment, pressing and measuring device is installed in place, the relative position with the vertical winding machine is calibrated to meet the automatic alignment, pressing and measuring requirements, the initial parameters of the alignment, pressing and measuring device are set, the adjustable mold and paper tube are installed, and the automatic wire bun alignment, pressing and measuring device is simulated and debugged;

[0010] Test winding stage: During the first test winding, the coil is automatically aligned, pressed, and measured, and automatically extends to the upper part of the coil. The laser measurement is used to determine the position of the coil corresponding to the coil pad. The pressing device applies pressure according to the set pressure to apply constant axial pressure to the coil. The measuring device measures the coil data in real time, and the control platform calculates the measurement data, checks the umbrella structure and radial dimensions, and fine-tunes the pressing force and striking force values ​​according to the actual results.

[0011] During the formal coil winding stage, the alignment device automatically predicts the position of the coil oil channel pad according to the collected values ​​and calculation results of the measuring device, and strikes the pad position according to the set alignment pressure. The striking force is always evenly applied to the coil. At the same time, the clamping device applies axial pressure to the coil. The measuring device measures the winding coil and the formed coil in real time during the rotation of the coil. The coil data is calculated and displayed in real time through the operation control platform. When the coil measurement data is out of tolerance, an alarm is issued and an audible and visual prompt is given.

[0012] The main advantages of the present invention are as follows:

[0013] (1) Automatic axial pressing function of the coil. Two high-strength adjustable pressure rollers are configured at both ends of the alignment device. The pressure rollers are composed of multiple small pressure rollers, and the position of the pressure rollers can be adjusted according to the inner and outer diameters of the coil to ensure that the corresponding pressure rollers can rotate flexibly during pressing, and the pressing force is adjustable. Continuously and stably applying downward axial pressure has a good effect in reducing and eliminating the "umbrella-shaped" structure of the coil. This is a newly added function that does not exist during manual operation. In actual use, the pressure is continuously and stably, which is much better than the effect of eliminating the "umbrella-shaped" structure by manual operation, and the axial pressing effect during the coil winding process is significantly enhanced.

[0014] (2) Automatic wire cake alignment function. The alignment device accurately predicts the position of the wire cake oil channel pad based on the laser measurement value and algorithm judgment, and accurately strikes above the oil channel pad without hitting between the cakes and causing deformation of the wire cake. The striking head of the alignment device can move with the width of the wire cake, so that the striking point is always at the radial midpoint of the wire cake, and the force is evenly transmitted to the wire cake through the floating pressure plate. The striking frequency and striking force are adjustable. The alignment effect is good, reducing and eliminating the "umbrella-shaped" structure of the wire cake.

[0015] (3) High-precision dimensional measurement. It has both static and real-time detection functions. Measurement can be performed without stopping during winding, resulting in high efficiency and accuracy. The algorithm module calculates and fits circular curves, automatically removing the influence of rectangular struts, and achieving precise dimensional measurement.

[0016] (4) Alarm for measured value deviation. Automatically compare the measured data with the input drawing data and the deviation range, and issue an alarm in time if the data deviation is too large.

[0017] (5) Dangerous area setting and safety protection. Dangerous areas are marked with warning colors and protected by laser curtain lines. Automatic alarms are triggered when people approach, and the machine automatically shuts down when entering the dangerous area.

[0018] (6) Anti-collision safety device. Automatic avoidance, locking and positioning devices are used to avoid collision with the coil during operation, and automatic avoidance is provided in the event of an accidental collision. Electrical and mechanical anti-collision dual insurance is provided. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1This is a front view of the device for automatically aligning and measuring the inner and outer diameters of wire cakes according to the present invention.

[0020] Figure 2-1 、 2-2 It is a front view and a three-dimensional view of the alignment device of the present invention.

[0021] Figure 3-1 、 3-2 3-3 is a three-dimensional view, a front view and a top view of the clamping device of an embodiment of the present invention.

[0022] Figure 4-1 、 4-2 It is a front view and a three-dimensional view of the lifting device of the present invention.

[0023] Figure 5-1 、 5-2 5-3 are three-view drawings of the measuring device of the present invention.

[0024] In the figure, 1 is a robotic arm, 2 is a robotic arm control box, 3 is a striking, pressing and measuring device, 4 is a safety grating, 5 is an operation control platform, 6 is a base, 7 is a mounting plate, 8 is a compression spring, 9 is a linear bearing, 10 is a retaining ring, 11 is a guide shaft, 12 is a striking plate, 13 is a stepping motor, 14 is a first linear guide rail, 15 is a synchronous belt, 16 is a three-axis cylinder mounting base, 17 is a striking roller, 18 is a fixing plate, 19 is a three-axis cylinder, 20 is a guide shaft connecting plate, 2 1 is the lower pressure wheel mounting plate, 22 is the pressure roller base plate, 23 is the cam bearing follower, 24 is the pressure roller mounting plate, 25 is the pressure roller, 26 is the detection base plate, 27 is the laser displacement sensor, 28 is the sensor bracket, 29 is the mounting column, 30 is the manipulator connecting plate, 31 is the cylinder, 32 is the cylinder mounting base, 33 is the second linear guide rail, 34 is the slider, 35 is the slider mounting plate, 36 is the buffer, 37 is the buffer mounting plate, 38 is the guide rail mounting plate, and 39 is the mounting connecting plate. DETAILED DESCRIPTION

[0025] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, but not all of the embodiments.

[0026] like Figure 1The figure shows a front view of the automatic coil alignment, compaction, and inner and outer diameter measurement device of the present invention. This device comprises a robotic arm 1 positioned on one side of a vertical winding machine. The robotic arm 1 is located on a base 6 and is used to drive an alignment, compaction, and measurement device 3 to a set position. A robotic arm control box 2 is located on one side of the robotic arm 1, and a robotic arm teach pendant is located above the robotic arm control box 2. The robotic arm control box 2 and the teach pendant are used to program and control the movements of the robotic arm 1. Safety light barriers 4 are located on either side of the robotic arm 1 for safety alarms. When an object enters the safety light barrier area, the device automatically shuts down. An operation control platform 5 is located on the other side of the vertical winding machine and is used to input relevant technical parameters, receive collected data, calculate measurement results, and control the automatic alignment, compaction, and measurement device 3. The alignment, compaction, and measurement device 3 is located at the front end of the robotic arm 1. It is used to measure the outer diameter of the paper tube, the inner diameter of the coil, and the outer diameter of the coil, as well as to compact and align the coil.

[0027] As a preferred embodiment, the robotic arm 1 is an LB series palletizing robot, model LBBD-2100-F-4. The operation control platform 5 comprises a control cabinet, a PLC control device, and a touch screen, equipped with emergency stop, pause, and start buttons. The PLC control device is located in the control cabinet and is a Siemens 6ES7214-1AG40-OXBO. The touch screen is a Siemens 6AV2123-2GB03-OAOX (a 7-inch Siemens human-machine interface). The data interaction between the PLC control device and the touch screen adopts Siemens' special protocol - S7 protocol for data interaction. The PLC and HMI can be connected through a network cable to realize real-time data interaction; the alignment, pressing and measuring device 3 belongs to a control sub-part under the control cabinet. The data collected and the control signals received by the alignment, pressing and measuring device 3 include IO signals, analog signals, and high-speed pulse signals. The control cabinet is connected to the alignment, pressing and measuring device 3 through multiple multi-core cables. The multi-core cables are connected to the solenoid valve, sensor, laser displacement sensor, and stepper drive motor of the alignment, pressing and measuring device 3. At the same time, the cables are finally connected to the terminals of the PLC control device on the control cabinet side.

[0028] The aligning, pressing and measuring device 3 includes: a lifting device, an aligning device, a pressing device and a measuring device. The aligning device, the pressing device and the measuring device are installed on the lifting device, and the lifting device is fixedly connected to the mechanical arm 1.

[0029] like Figure 2-1 、 2-2The figure shows a front view and a perspective view of an embodiment of the present invention's straightening device. The straightening device is suspended above the wire cake and is used to straighten the wire cake, essentially eliminating the wire cake's umbrella-shaped structure. It includes a mounting plate 7, a compression spring 8, a linear bearing 9, a retaining ring 10, a guide shaft 11, a striking plate 12, a stepper motor 13, a first linear guide 14, a synchronous belt 15, a three-axis cylinder mounting base 16, a striking roller 17, a fixing plate 18, a three-axis cylinder 19, and a guide shaft connecting plate 20. The mounting plate 7 is a rectangular plate-like structure with a certain thickness. A pair of linear bearings 9 are symmetrically arranged in the middle position of the mounting plate 7. A guide shaft 11 is arranged in the linear bearing 9. The upper ends of the two guide shafts 11 are fixedly connected to the guide shaft connecting plate 20. The upper parts of the two guide shafts 11 are provided with compression springs 8 to provide buffering. The lower ends of the two guide shafts 11 are fixedly connected to the striking plate 12. The lower parts of the two guide shafts 11 are provided with retaining rings 10 for limiting position. The striking plate 12 is composed of a striking base plate and a striking contact plate. The striking contact plate is made of insulating material and contacts the wire coil when striking. A stepper motor 13 is fixedly mounted on a corner of the upper side of the mounting plate 7. The output shaft of the stepper motor 13 is connected to a synchronous belt 15. Two first linear guides 14 that cooperate with the stepper motor 13 are provided in the length direction of the upper side of the mounting plate 7. The first linear guides 14 are arranged parallel to the two guide shafts 11. A three-axis cylinder base 16 is mounted on the two first linear guides 14. The outer periphery of the three-axis cylinder base 16 is in contact with the synchronous belt 15. The synchronous belt 15 is controlled to rotate by the stepper motor 13, driving the three-axis cylinder base 16 to move horizontally on the two first linear guides 14. A three-axis cylinder 19 is mounted on the lower side of the three-axis cylinder base 16. A striking roller 17 is connected to the cylinder shaft of the three-axis cylinder 19 through a fixed plate 18. The striking roller 17 is located above the striking plate 12.

[0030] The alignment mechanism operates as follows: the triaxial cylinder base 16 moves horizontally on the two first linear guides 14, equivalent to the triaxial cylinder 19 moving along the lateral dimensions of the coil. The displacement of the triaxial cylinder 19 is automatically adjusted according to the lateral dimensions of the coil. During the coil winding process, when the coil stays rotate into position, the triaxial cylinder 19 controls the striking roller 17 to rapidly strike down, driving the striking contact plate of the striking plate 12 to strike the upper portion of the coil pad. The striking point is always centered in the lateral dimensions of the coil, ensuring uniform force applied to the coil. When the striking plate 12 strikes the coil, the coil undergoes lateral displacement due to the coil's rotation. The designed striking mechanism, a roller-type striking roller 17, eliminates this displacement by rolling. The impact force effectively overcomes inter-coil resistance, ensuring a tighter pressing force between the front and rear rollers, and essentially eliminating the coil's umbrella-like shape. The striking force can be selected and set on the operating control platform 5. The control system automatically adjusts the striking force accordingly to meet the striking force requirements for different wire specifications and coil structures.

[0031] like Figure 3-1 、3-2 3-3 shows a stereoscopic view, a front view and a top view of the pressing device of an embodiment of the present invention. The pressing device is used to press the wire cake after beating. The pressing device is composed of two sets of pressure roller structures. The pressure roller structure is a square frame structure as a whole. The pressure roller structures are respectively mounted on the edge positions of the length direction of the lower side surface of the mounting plate 7. The pressure roller structure and the striking plate 12 are parallel to each other. The pressure roller structure includes a lower pressure roller mounting plate 21, a pressure roller bottom plate 22, a cam bearing follower 23, a pressure roller mounting plate 24 and a pressure roller 25. The two ends of the pressure roller bottom plate 22 are fixedly connected to the pressure roller mounting plate 21 and the pressure roller mounting plate 24 respectively, and the pressure roller bottom plate 22 intersects the pressure roller mounting plate 21 and the pressure roller mounting plate 24 at right angles. Two sets of cam bearing followers 23 are fixedly mounted to the ends of the pressure roller mounting plate 21. A pressure roller 25 is fixedly mounted to the ends of the pressure roller mounting plate 24. The pressure roller 25 is parallel to the pressure roller base plate 22, and the end of the pressure roller 25 facing away from the pressure roller mounting plate 24 is in contact with the cam bearing followers 23. The two sets of cam bearing followers 23 serve as reverse support and position limiters for the pressure roller 25. The pressure roller 25 consists of multiple sets of rubber-coated rollers threaded onto a single pressure roller shaft. The pressure roller base plate 22 is bolted to the mounting plate 7, with its upper side contacting the lower side of the mounting plate 7. The clamping device works in conjunction with the aligning device to achieve the functions of aligning and compressing the bobbin.

[0032] The working process of the clamping device is as follows: Since the inner and outer wires rotate at different speeds when the coil is rotating, the present invention has designed two sets of pressure roller mechanisms to form a certain degree of angle and multiple sets of rubber-coated rollers to form a pressure roller 25 structure to match the rotating circular coil. The downward pressure of the pressure roller 25 comes from the lifting device and is transmitted to the pressure roller 25 through the mounting plate 7. The clamping force can be selected and set on the operating control platform 5. The control system automatically adjusts the clamping force according to the setting to meet the clamping force requirements of wires of different specifications and coils of different structures. In order to make the clamping device cooperate with the beating device, the normal height of the striking plate 12 is less than the height of the pressure roller 25.

[0033] like Figure 4-1 、 4-2The figure shows the main view and stereoscopic view of the lifting device of an embodiment of the present invention. The lifting device is used to control the position of the alignment, pressing and measuring device 3 and apply downward pressure to the pressure roller 25, and includes a manipulator connecting plate 30, a cylinder 31, a cylinder mounting base 32, a second linear guide 33, a slider 34, a slider mounting plate 35, a buffer 36, a buffer mounting plate 37, a guide rail mounting plate 38 and a mounting connecting plate 39. The slider mounting plate 35 and the mounting connecting plate 39 together constitute the alignment, pressing and measuring device mounting frame, and the guide rail mounting plate 38 and the manipulator connecting plate 30 together constitute the manipulator mounting frame. The manipulator mounting frame is a rigid bracket connected to the manipulator arm 1, and the manipulator connecting plate 30 is fixedly connected to the manipulator arm 1 by bolt connection; the manipulator connecting plate 30 is fixedly connected to the edge position of the guide rail mounting plate 38 to form a right-angle structure, and the connection is by bolt connection. Two sets of mutually parallel second linear guides 33 are mounted on the side of the guide rail mounting plate 38 of the manipulator mounting frame, away from the manipulator connecting plate 30. These are bolted together. Sliders 34 are mounted on the second linear guides 33 and can slide up and down. Sliders 34 are fixedly connected to slider mounting plates 35 and bolted together. The manipulator mounting frame is connected to the alignment, pressing, and measuring device mounting frame via sliders 34. A cylinder mounting base 32 and a cylinder 31 are mounted on the upper portion of the guide rail mounting plate 38. A buffer 36 and a buffer mounting plate 37 are mounted on the lower portion of the slider mounting plate 35. The cylinder shaft of the cylinder 31 is connected to the buffer 36, which is then connected to the buffer 36 and the buffer mounting plate 37. This allows the alignment, pressing, and measuring device to slide up and down along the second linear guides 33, pressing the two sets of roller structures onto the bobbin and applying a certain amount of pressure, while simultaneously suspending the striking plate 12 at a certain height above the bobbin. The mounting plate 7 is connected to the two mounting connecting plates 39 and the slider mounting plate 35 respectively, and the connection method is bolt connection.

[0034] like Figure 5-1 、 5-2, 5-3 are three views of the measuring device of an embodiment of the present invention. The measuring device is used to measure the outer diameter of the paper tube, the inner diameter of the coil and the outer diameter of the coil, and includes a detection base plate 26, a laser displacement sensor 27, a sensor bracket 28, and a mounting column 29. The measuring device is installed on the back of the guide rail mounting plate 38 (the front is installed with a second linear guide 33) through the detection base plate 26. The detection base plate 26 is an I-shaped structure as a whole, including: short beams and long beams parallel to each other and connecting beams that intersect the short beams and long beams at right angles. One side of the short beam is fixedly connected to the back of the guide rail mounting plate 38, and the connection method is bolt connection. The detection base plate 26 intersects the guide rail mounting plate 38 at right angles. Reinforcing ribs are installed between the upper side of the short beam and the connecting beam of the detection base plate 26 and the back of the guide rail mounting plate 38, and the connection method is Bolted together, three mounting posts 29 are evenly fixedly mounted on the lower side of the long beam of the detection base plate 26. The mounting posts 29 intersect the long beam of the detection base plate 26 at right angles. The sensor bracket 28 is mounted on the mounting posts 29. The sensor bracket 28 intersects the mounting posts 29 at right angles. The laser displacement sensor 27 is mounted at the end of the sensor bracket 28, close to the short beam of the detection base plate 26. Utilizing these three laser displacement sensors 27, the control system employs a data fitting algorithm to calculate and measure the outer diameter of the paper tube, the inner diameter of the coil, and the outer diameter of the coil. The specific calculation method is based on existing technology, with automatic measurement and calculation achieved through programming. The height of the sensor bracket 28 and the position of the laser displacement sensor 27 are manually adjusted in advance.

[0035] A method for automatically aligning, compacting, and measuring transformer coils, using the aforementioned automatic aligning, compacting, and measuring device, specifically includes the following steps:

[0036] (1) Install the automatic coil pressing and measuring device in place and calibrate the relative position with the vertical winding machine. Adjust the position of the device so that the laser emitted by the inner and outer diameter laser displacement sensor of the device is aligned with the axis of the vertical winding machine, and then fix the device.

[0037] (2) According to the coil drawing, set the wire size, coil height, coil inner and outer diameter dimensions and deviation requirements, select the impact force of the wire cake alignment device and the clamping force parameters of the clamping device, and turn on the safety protection grating.

[0038] (3) Guide the installation of the adjustable die. Install the adjustable die, automatically measure the coaxiality between the winding die axis and the vertical winding machine axis and the flatness of the support seat, and guide the adjustment of the axis position and flatness to meet the winding requirements.

[0039] (4) Guide the installation of the paper tube. Put the paper tube onto the adjustable die. The operator uses an electric wrench to control the expansion of the adjustable die and slowly tighten the paper tube. The paper tube diameter is automatically measured in real time. When the set value is reached, a signal is sent to stop the expansion of the adjustable die. The robotic arm automatically rises and falls, measuring at least three diameters: top, middle, and bottom. The diameter tolerance and the deviation values ​​at different positions are checked to meet the technical requirements. An alarm is issued if the tolerance is exceeded.

[0040] (5) Simulation debugging. Debug the striking position, automatic lifting, automatic avoidance, automatic measurement of inner and outer diameters and amplitude dimensions, etc., and check with the drawing requirements.

[0041] (6) Try to wind the first coil. When the coil starts to wind the first coil, press the start button of the coil automatic alignment and measurement device to turn on the machine, and the device will automatically take position.

[0042] (7) The automatic alignment, pressing and measurement of the wire coil automatically extends to the upper part of the wire coil, and is judged by laser measurement. The alignment device moves down and hits the coil pad corresponding to the wire coil position.

[0043] (8) The clamping device applies pressure according to the set pressure, applying constant axial pressure to the wire cake.

[0044] (9) The wire cake inner and outer diameter measuring device starts to measure the inner and outer diameter dimension data of the wire cake through the laser displacement sensor, and displays the real-time inner and outer diameter and width dimension values ​​on the screen.

[0045] (10) Check the umbrella structure and radial dimensions, and fine-tune the compression force and striking force values ​​according to the actual results.

[0046] (11) Formal winding. During the coil winding process, the coils are automatically aligned and pressed and the measuring device operates automatically.

[0047] The coil cake alignment device automatically predicts the position of the coil oil channel pad based on the laser measurement value and PLC algorithm calculation. According to the set alignment pressure, when the coil rotates to the coil pad position, the floating striking plate automatically falls at high speed to strike the pad position.

[0048] (12) As the coil is wound, the striking point of the alignment device moves from the inside to the outside as the width of the coil increases, so that the striking force is always evenly applied to the coil.

[0049] (13) The coil measuring device measures and compares the winding coil and the formed coil in real time during the coil rotation process, with a measurement every 10ms. The inner and outer diameter fitting curves are calculated through the PLC algorithm module, and the display screen displays the inner and outer diameter and width dimension data in real time.

[0050] (14) When the coil measurement data is out of tolerance, the display screen will alarm and provide sound and light prompts.

[0051] (15) After the coil is wound, the coil is automatically aligned and pressed, and the measuring device automatically stops. The inner and outer diameters of the coil are measured statically, and automatically compared and analyzed with the running measurement data, the previous coil data and the drawing data. If there is a deviation, an alarm is issued to prompt the operator to analyze the cause and make adjustments.

[0052] (16) After the measurement is completed, the striking plate of the alignment device automatically retracts to its initial position, and a working cycle ends.

[0053] (17) When the next line of cake is wound, the striking plate of the beating device automatically extends and repeats to enter the next working cycle.

Claims

1. A transformer coil automatic alignment, compaction and measurement device, characterized in that: include: A robotic arm (1) is placed on one side of a vertical winding machine, and a aligning, pressing and measuring device (3) is provided at the front end of the robotic arm (1), and the aligning, pressing and measuring device (3) is used to measure the outer diameter of a paper tube, the inner diameter of a coil and the outer diameter of a coil, and to align and press the coil; the robotic arm (1) is located on a base (6), and is used to drive the aligning, pressing and measuring device (3) to a set position; a robotic arm control box (2) is provided on one side of the robotic arm (1), and a robotic arm teaching device is provided above the robotic arm control box (2), and the robotic arm control box (2) and the robotic arm teaching device are used for programming and controlling the movement of the robotic arm (1); an operation control platform (5) is placed on the other side of the vertical winding machine, and is used to input relevant technical parameters, receive collected data, calculate measurement results and control the movement of the aligning, pressing and measuring device (3); The aligning, pressing and measuring device (3) comprises: a lifting device, an aligning device, a pressing device and a measuring device, wherein the aligning device, the pressing device and the measuring device are mounted on the lifting device, and the lifting device is fixedly connected to the mechanical arm (1); Safety gratings (4) are respectively provided on both sides of the mechanical arm (1) for safety alarm; the mechanical arm (1) uses an LB series handling and stacking robot; the operation control platform (5) is composed of a control cabinet, a PLC control device and a touch screen; the PLC control device is provided in the control cabinet, and the PLC control device and the touch screen realize real-time data interaction; the control cabinet is connected to the alignment, pressing and measuring device (3) through a plurality of multi-core cables, and the control cabinet side is connected to the terminal of the PLC control device; The aligning device is suspended above the wire cake and is used for aligning the wire cake, and comprises a mounting plate (7), a compression spring (8), a linear bearing (9), a retaining ring (10), a guide shaft (11), a striking plate (12), a stepping motor (13), a first linear guide rail (14), a synchronous belt (15), a three-axis cylinder mounting base (16), a striking roller (17), a fixing plate (18), a three-axis cylinder (19) and a guide shaft connecting plate (20); The mounting plate (7) is a rectangular plate structure with a certain thickness. A pair of linear bearings (9) are symmetrically arranged in the middle position of the mounting plate (7). A guide shaft (11) is arranged in the linear bearing (9). The upper ends of the two guide shafts (11) are fixedly connected to the guide shaft connecting plate (20). The upper parts of the two guide shafts (11) are covered with compression springs (8). The lower ends of the two guide shafts (11) are fixedly connected to the striking plate (12). The lower parts of the two guide shafts (11) are covered with retaining rings (10). A stepper motor (13) is fixedly installed at one corner of the upper side of the mounting plate (7). The output shaft of the stepper motor (13) is connected to the synchronous The belt (15) is provided with two first linear guide rails (14) matched with the stepping motor (13) in the length direction of the upper side surface of the mounting plate (7), and the first linear guide rails (14) are arranged in parallel with the two guide shafts (11); the three-axis cylinder base (16) is installed on the two first linear guide rails (14), the outer periphery of the three-axis cylinder base (16) is in contact with the synchronous belt (15), the three-axis cylinder (19) is installed on the lower side surface of the three-axis cylinder base (16), the striking roller (17) is connected to the cylinder shaft of the three-axis cylinder (19) through the fixing plate (18), and the striking roller (17) is located above the striking plate (12).

2. The automatic alignment, compaction and measurement device for transformer coils according to claim 1, characterized in that: The pressing device is used to press the wire cake after beating. The pressing device is composed of two sets of pressing roller structures. The pressing roller structure is a square frame structure as a whole. The pressing roller structures are respectively installed at the edge positions of the length direction of the lower side surface of the mounting plate (7). The pressing roller structure and the striking plate (12) are parallel to each other. The pressing roller structure includes a lower pressing wheel mounting plate (21), a pressing roller bottom plate (22), a cam bearing follower (23), a pressing roller mounting plate (24) and a pressing roller (25).

3. The automatic alignment, compaction and measurement device for transformer coils according to claim 2, characterized in that: The two ends of the pressure roller base plate (22) are respectively fixedly connected to the pressure roller mounting plate (21) and the pressure roller mounting plate (24). The pressure roller base plate (22) intersects the pressure roller mounting plate (21) and the pressure roller mounting plate (24) perpendicularly. Two sets of cam bearing followers (23) are fixedly installed at the end of the pressure roller mounting plate (21). The end of the pressure roller mounting plate (24) is fixedly installed with a pressure roller (25). The pressure roller (25) is parallel to the pressure roller base plate (22). One end of the pressure roller (25) away from the pressure roller mounting plate (24) is in contact with the cam bearing follower (23). The pressure roller (25) is composed of multiple groups of rubber-coated rollers passing on a pressure roller shaft.

4. The automatic alignment, compaction and measurement device for transformer coils according to claim 1, characterized in that: The lifting device is used to control the position of the alignment, pressing and measuring device (3) and apply downward pressure to the pressure roller (25), and includes a manipulator connecting plate (30), a cylinder (31), a cylinder mounting base (32), a second linear guide rail (33), a slider (34), a slider mounting plate (35), a buffer (36), a buffer mounting plate (37), a guide rail mounting plate (38) and a mounting connecting plate (39).

5. The automatic alignment, compaction and measurement device for transformer coils according to claim 4, characterized in that: The manipulator connecting plate (30) is fixedly connected to the manipulator arm (1). The manipulator connecting plate (30) is fixedly connected to the edge position of the guide rail mounting plate (38) to form a right-angle structure. Two sets of second linear guide rails (33) parallel to each other are installed in the length direction of the side of the guide rail mounting plate (38) away from the manipulator connecting plate (30). The slider (34) is mounted on the second linear guide rail (33). The slider (34) is fixedly connected to the slider mounting plate (35). The upper part of the guide rail mounting plate (38) is equipped with a cylinder mounting base (32) and a cylinder (31). The lower part of the slider mounting plate (35) is equipped with a buffer (36) and a buffer mounting plate (37). The cylinder shaft of the cylinder (31) is connected to the buffer (36). The mounting plate (7) is respectively connected to the two mounting connecting plates (39) and the slider mounting plate (35).

6. The automatic alignment, compaction and measurement device for transformer coils according to claim 1, characterized in that: The measuring device is used to measure the outer diameter of a paper tube, the inner diameter of a coil and the outer diameter of a coil, and comprises a detection base plate (26), a laser displacement sensor (27), a sensor bracket (28) and a mounting column (29). The measuring device is mounted on the back of a guide rail mounting plate (38) through the detection base plate (26). The detection base plate (26) is an I-shaped structure as a whole, comprising: a short beam and a long beam parallel to each other and a connecting beam perpendicularly intersecting the short beam and the long beam. One side of the short beam is fixedly connected to the back of the guide rail mounting plate (38). The detection base plate (26) and the guide rail mounting plate (38) are perpendicularly intersected. A reinforcing rib is installed between the short beam and the upper side of the connecting beam of the detection base plate (26) and the back side of the guide rail mounting plate (38). Three mounting columns (29) are evenly fixedly installed on the lower side of the long beam of the detection base plate (26). The mounting columns (29) intersect the long beam of the detection base plate (26) vertically. The sensor bracket (28) is installed on the mounting columns (29). The sensor bracket (28) intersects the mounting columns (29) vertically. The laser displacement sensor (27) is installed at the end of the sensor bracket (28). The laser displacement sensor (27) is close to the short beam of the detection base plate (26).

7. A method for automatically aligning, pressing and measuring transformer coils, characterized in that: The automatic alignment, compaction and measurement device for transformer coils as claimed in claim 1 comprises the following steps: Preparation stage: The automatic wire bun alignment, pressing and measuring device is installed in place, the relative position with the vertical winding machine is calibrated to meet the automatic alignment, pressing and measuring requirements, the initial parameters of the alignment, pressing and measuring device are set, the adjustable mold and paper tube are installed, and the automatic wire bun alignment, pressing and measuring device is simulated and debugged; Test winding stage: During the first test winding, the coil is automatically aligned, pressed, and measured, and automatically extends to the upper part of the coil. The laser measurement is used to determine the position of the coil corresponding to the coil pad. The pressing device applies pressure according to the set pressure to apply constant axial pressure to the coil. The measuring device measures the coil data in real time, and the control platform calculates the measurement data, checks the umbrella structure and radial dimensions, and fine-tunes the pressing force and striking force values ​​according to the actual results. During the formal coil winding stage, the alignment device automatically predicts the position of the coil oil channel pad according to the collected values ​​and calculation results of the measuring device, and strikes the pad position according to the set alignment pressure. The striking force is always evenly applied to the coil. At the same time, the clamping device applies axial pressure to the coil. The measuring device measures the winding coil and the formed coil in real time during the rotation of the coil. The coil data is calculated and displayed in real time through the operation control platform. When the coil measurement data is out of tolerance, an alarm is issued and an audible and visual prompt is given.

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