A high-precision servo valve coil resistance and outer diameter calculation method

Abstract

The application discloses a kind of high-precision servo valve coil resistance and outer diameter calculation method, comprising the following steps: step 1: input design parameter;Step 2: preliminary winding parameter;Step 3: process parameter calculation;Step 4: coil resistance and winding after outer diameter calculation;Step 5: calculation result output;Step 6: compare result correction parameter, the present application is aimed at servo valve coil enameled wire wire diameter, the number of turns is many, ordinary calculation method precision difference cannot directly guide the design, manufacture etc. of coil, innovatively proposed considering the method of ellipse correction perimeter according to coil cross winding condition, in combination with the setting of layer height, filling coefficient and other detailed parameters, solve the problem that accurate resistance, coil winding diameter etc. cannot be obtained by traditional slot width coefficient calculation method.The calculation method realizes the automatic calculation by software program, and the test of enameled wire meter resistance, outer diameter and coil winding resistance and outer diameter verifies the accuracy of the calculation method.

Description

Technical Field

[0001] This invention relates to the technical field of servo valve coil design and manufacturing, and in particular to a high-precision method for calculating the resistance and outer diameter of servo valve coils. Background Technology

[0002] Electro-hydraulic servo valves are tiny, precision control components in electro-hydraulic servo control systems. They are widely used in aircraft flight control surfaces, nose wheel steering, electronic anti-skid brakes, radar servo systems, door retraction and extension, air intake adjustment, missile servo mechanisms, engine main fuel metering, main combustion pump servo mechanisms, guide vane and compressor angles, afterburner metering, tail nozzles, and vector nozzles.

[0003] In dual-nozzle baffle servo valves or jet deflector servo valves, the torque motor is the electromechanical conversion device. The torque motor generates a low-power electrical signal through a coil, which is converted into the deflection motion of the armature, driving the baffle or deflector plate to move. This outputs a differential pressure differential at the pre-stage, driving the next stage spool valve. Servo valve coils are characterized by their small size, high number of turns, and small enameled wire diameter. Therefore, many factors influence the resistance and outer diameter during coil winding. Currently, a single parameter, the filler coefficient, is often used for correction, which cannot fully simulate the actual state and introduces systematic deviations. Currently, the error between the calculated and measured values ​​of the servo valve coil outer diameter and resistance is approximately 5% for resistance and 1mm for outer diameter. Summary of the Invention

[0004] The purpose of this invention is to solve the above problems. This invention provides a high-precision method for calculating the resistance and outer diameter of a servo valve coil. In response to the phenomenon that small-diameter enameled wire is prone to crossing when winding servo valve coils, an innovative correction method is proposed. This method can eliminate the systematic error of the traditional slot width coefficient calculation method, improve the resistance calculation accuracy from 5% to 0.5%, and reduce the calculation error of the outer diameter after winding from 1mm to 0.1mm.

[0005] The technical solution of the present invention is as follows:

[0006] A method for calculating the resistance and outer diameter of a high-precision servo valve coil includes the following steps:

[0007] Step 1: Input design parameters;

[0008] Step 2: Initially determine the winding parameters;

[0009] Step 3: Calculate process parameters;

[0010] Step 4: Calculation of coil resistance and outer diameter after winding;

[0011] Step 5: Output the calculation results;

[0012] Step 6: Compare the results and adjust the parameters.

[0013] Furthermore, in step 1, the design parameters that need to be input include: coil bobbin width Lk, bobbin inner diameter dk, enameled wire outer diameter dw, meter resistance Rm, and number of turns N.

[0014] Furthermore, the coil bobbin width Lk and bobbin inner diameter dk are set according to the servo valve specifications; the enameled wire outer diameter dw and the resistance per meter Rm are obtained by measuring the enameled wire actually selected; the number of turns N is 1.5 times the number of turns required by the design.

[0015] Furthermore, in step 2, the initially determined winding parameters include: the initial number of close winding layers N0, the close winding layer filling coefficient K1, the close winding layer outer diameter increase rate Kw1, the axial length of the cross winding layer ellipse Lq, the cross winding layer filling coefficient K2, and the cross winding layer outer diameter increase rate Kw2.

[0016] Furthermore, K1=1 is set, and Kw1 is set so that the outer diameter of the tightly wound layer increases by dwx1=1.732dw. In the initial calculation, Lq=0 is set, that is, the effect of cross-winding is not considered for the time being.

[0017] Furthermore, step 3 specifically includes the following steps:

[0018] Step 3.1 Calculate the maximum number of layers k without considering the fill factor. max Maximum number of laps N max ;

[0019] Step 3.2 Calculate the initial close-wound outer diameter increment dwx1 and cross-wound outer diameter increment dwx2 based on Kw1 and Kw2; the initial close-wound outer diameter increment dwx1 and cross-wound outer diameter increment dwx2 are in the range of 1.732dw to 2dw.

[0020] Step 3.3 Calculate the number of turns per layer of the initial close-wound layer (nx1) and the number of turns per layer of the cross-wound layer (nx2) using the following formulas respectively; , .

[0021] Furthermore, step 4 specifically includes the following steps:

[0022] Step 4.1 Within the tightly wound layer, calculate the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx based on dwx1 and nx1;

[0023] Step 4.2 Within the cross-wound area, calculate the minor semi-axis a, major semi-axis b, and circumference Cw of the ellipse. Combined with dwx² and nx², calculate the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx; where, ; ; ;

[0024] Step 4.3 Calculate the coil resistance R, R = Rm × L.

[0025] Further, step 5 is to output the calculated resistance R-turns N curve and the outermost diameter Dwx-turns N curve.

[0026] Further, in step 6, the servo valve coil is produced based on the calculation results in step 4. The outer diameter of the coil after winding is measured. The measured value and the calculated value are compared. By correcting K2 and Kw2, the calculated value of the outer diameter Dwx after winding is made consistent with the measured value. Then, the Lq parameter is corrected so that the calculated value of the resistance R is consistent with the measured value. After repeated iterations, the deviation between the calculated value of the resistance and the measured value can be made no greater than 0.5%, and the error of the calculated value of the outer diameter after winding is no greater than 0.1mm.

[0027] Furthermore, it also includes step 7: reuse of winding parameters. Based on the designed coil winding parameters N0, K1, Kw1, Lq, K2, and Kw2, winding tests of enameled wire of different specifications can be conducted on coil frames of similar size.

[0028] Advantages and beneficial effects of the present invention:

[0029] 1. The coil winding process was simulated with high precision, compensating for the systematic errors introduced by cross-winding.

[0030] 2. Compensation coefficients were designed in three dimensions: coil layer height increment, resistance per layer, and fill factor per layer, which makes the calculation results extremely close to the measured values.

[0031] 3. By setting the winding parameters in the calculation process, the differences in coil winding caused by differences in process methods are simulated, and high-precision reuse can be obtained when the process method is stable.

[0032] 4. It can provide directional guidance for the coil manufacturing process, reducing the time required to verify coil resistance through testing. Attached Figure Description

[0033] Figure 1 This is a flowchart of the coil resistance calculation method;

[0034] Figure 2 It is the dense winding layer of the servo valve coil;

[0035] Figure 3 It is a servo valve coil with cross-wound layers;

[0036] Figure 4 This is a schematic diagram showing different outer diameter increments. Detailed Implementation

[0037] The present invention will be further illustrated below with reference to the accompanying drawings and specific embodiments. These embodiments are implemented based on the technical solutions of the present invention, and it should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention.

[0038] like Figure 1 As shown, this invention discloses a method for calculating the resistance and outer diameter of a high-precision servo valve coil;

[0039] The calculation method is designed for servo valve coils with small size (outer diameter no more than 30mm), thin enameled wire diameter (0.05mm~0.15mm), and many turns (800 turns~4000 turns). It takes into full account the factors that exist in the actual winding process of the coil and makes targeted corrections, improving the resistance calculation accuracy from 5% to 0.5% and reducing the calculation error of the outer diameter after winding from 1mm to 0.1mm.

[0040] The calculation method addresses the issue of interlacing of enameled wire in the actual winding process of servo valve coils, which leads to variations in layer height and fill factor. It innovatively proposes a correction method to address this problem.

[0041] The calculation method divides the coil into closely wound layers and cross-wound layers, and sets different fill coefficients and layer height coefficients;

[0042] The calculation method sets different methods for calculating the circumference of the enameled wire for closely wound layers and cross-wound layers. In response to the cross-wound phenomenon, an elliptical circumference correction method is innovatively proposed, which fundamentally compensates for the systematic deviation in the calculation of coil resistance and outer diameter after winding caused by the traditional calculation method that only considers the filling coefficient.

[0043] The calculation method can set parameters for different coil bobbin and enameled wire parameters, combined with winding test results, such as the number of close winding layers, different filling coefficients and layer height coefficients for close winding layers and cross winding layers, and the parameters of the minor semi-axis of the ellipse of the cross winding layers. Since there is no correlation between the parameters and the winding process of the coil is strictly simulated, it can be guaranteed that there is a set of parameters that make the calculated results of the coil resistance and the outer diameter after winding the same as the measured values.

[0044] The calculation method, specifically the calculation process flow is as follows: Figure 1 As shown, the steps are as follows:

[0045] Step 1: Input design parameters

[0046] Servo valve coils are generally designed based on a coil frame. The coil frame width Lk and inner diameter dk parameters input at this stage are basic parameters and will not be modified in subsequent parameter iterations. This calculation method simplifies the enameled wire parameters affecting coil resistance and the calculated outer diameter after winding to two: the outer diameter dw and the resistance per meter Rm. To improve calculation accuracy, dw and Rm parameters need to be input after actual measurement. During the programming of this calculation method, a database of dw and Rm parameters was established based on the corresponding dimensions and resistivity in GB / T6109.1 "Enameled Round Winding Wire Part 1: General Provisions," which can be called at any time when high calculation accuracy is not required. When inputting design parameters, the number of turns N can be set to 1.5 times the required number of turns. The program will eventually plot a turns-resistance curve, from which the ideal result can be read.

[0047] Step 2: Initial determination of winding parameters

[0048] Based on the actual winding situation, set the initial number of close winding layers N0, the close winding layer filling coefficient K1, the close winding layer outer diameter increase rate Kw1, the axial length of the cross-winding layer ellipse Lq, the cross-winding layer filling coefficient K2, and the cross-winding layer outer diameter increase rate Kw2. Generally, K1=1 is set, and Kw1 is set so that the increase in the close winding layer outer diameter dwx1=1.732dw. For the initial calculation, Lq=0 is set, meaning the influence of cross-winding is not considered for the time being.

[0049] Step 3: Calculation of process parameters

[0050] Since the exact number of layers cannot be determined yet, we will first estimate the maximum number of layers k without considering the fill factor. max Maximum number of laps N max , as input for subsequent program calculations;

[0051] Calculate the initial close-wound outer diameter increment dwx1 and cross-wound outer diameter increment dwx2 based on Kw1 and Kw2 (according to geometric relationships, such as...). Figure 4 The outer diameter increment ranges from 1.732 dw to 2 dw.

[0052] Calculate the number of turns per layer in the initial tightly wound layer. , ;

[0053] Step 4: Calculation of coil resistance and outer diameter after winding

[0054] Within the tightly wound layer, calculate the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx based on dwx1 and nx1;

[0055] Within the cross-wrap layer range, the minor semi-axis of the ellipse ; ;according to The formula is used to calculate the circumference of the ellipse. Based on dwx2 and nx2, the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx are calculated.

[0056] Calculate the resistance R = Rm * L;

[0057] Step 4: Output the calculation results

[0058] Output the resistance R-turns N curve and the outermost diameter Dwx-turns N curve;

[0059] Step 5: Compare the results and adjust the parameters.

[0060] At this point, based on the actual number of turns and the measured outer diameter of the coil after winding, K2 and Kw2 can be corrected to make the calculated value of the outer diameter Dwx after winding correspond to the measured value. Then, the Lq parameter can be corrected to make the calculated value of the resistance R correspond to the measured value. After repeated iterations, the deviation between the calculated value of the resistance and the measured value can be made to be no more than 0.5%, and the error of the calculated value of the outer diameter after winding can be no more than 0.1mm.

[0061] Step 6: Reusing winding parameters

[0062] Based on the experimental results and this calculation method, the coil winding parameters N0, K1, Kw1, Lq, K2, and Kw2 were obtained. Under the same winding process and the same enameled wire specifications, the calculation results can be reused with high precision when the coil frame size is finely adjusted. To ensure the convenience of coil design, winding experiments with different specifications of enameled wire can be conducted on coil frames of similar dimensions to obtain the corresponding winding parameters. A corresponding database can then be established to meet the design requirements of different numbers of turns and enameled wire specifications.

[0063] It should be noted that the high accuracy of this calculation method depends on the stability of the coil winding process parameters. This is generally achieved by setting a program on an automatic winding machine, and a stable coil winding process is obtained by controlling parameters such as winding tension, winding speed, and wire laying speed.

[0064] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several improvements without departing from the principle of the present invention, and these improvements should also be considered within the scope of protection of the present invention.

Claims

1. A method for calculating the resistance and outer diameter of a high-precision servo valve coil, characterized in that, Includes the following steps: Step 1: Input design parameters, including: coil frame width Lk, frame inner diameter dk, enameled wire outer diameter dw, resistance per meter Rm, and number of turns N; the coil frame width Lk and frame inner diameter dk are set according to the servo valve specifications; the enameled wire outer diameter dw and resistance per meter Rm are obtained by measurement based on the actual enameled wire selected; the number of turns N is 1.5 times the number of turns required by the design. Step 2: Initially determine the winding parameters, including: initial number of close winding layers N0, close winding layer filling coefficient K1, close winding layer outer diameter increase rate Kw1, cross-winding layer ellipse axial length Lq, cross-winding layer filling coefficient K2, and cross-winding layer outer diameter increase rate Kw2; set K1=1, set Kw1 so that the close winding layer outer diameter increase dwx1=1.732dw, and set Lq=0 for the first calculation, that is, the cross-winding effect is not considered for the time being; Step 3: Process parameter calculation, including the following steps: Step 3.1 Calculate the maximum number of layers k without considering the fill factor. max Maximum number of laps N max ; Step 3.2 Calculate the initial close-wound outer diameter increment dwx1 and cross-wound outer diameter increment dwx2 based on Kw1 and Kw2; the initial close-wound outer diameter increment dwx1 and cross-wound outer diameter increment dwx2 are in the range of 1.732dw to 2dw. Step 3.3 Calculate the number of turns per layer of the initial close-wound layer (nx1) and the number of turns per layer of the cross-wound layer (nx2) using the following formulas respectively; ; Step 4: Calculation of coil resistance and outer diameter after winding, including the following steps: Step 4.1 Within the tightly wound layer, calculate the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx based on dwx1 and nx1; Step 4.2 Within the cross-wound area, calculate the minor semi-axis a, major semi-axis b, and circumference Cw of the ellipse. Combined with dwx² and nx², calculate the total length L of the enameled wire corresponding to different numbers of turns and the corresponding outermost diameter Dwx; where, ; ; ; Step 4.3 Calculate the coil resistance R, R = Rm × L; Step 5: Output the calculation results, namely the calculated resistance R-number of turns N curve and the outermost diameter Dwx-number of turns N curve; Step 6: Compare the results and correct the parameters. Based on the results calculated in Step 4, produce the servo valve coil and measure the outer diameter of the coil after winding. Compare the measured value with the calculated value. By correcting K2 and Kw2, first make the calculated value of the outer diameter Dwx after winding consistent with the measured value. Then, correct the Lq parameter to make the calculated value of the resistance R consistent with the measured value. Through repeated iterations, the deviation between the calculated value of the resistance and the measured value can be made no greater than 0.5%, and the error of the calculated value of the outer diameter after winding no greater than 0.1mm.

2. The method for calculating the resistance and outer diameter of a high-precision servo valve coil according to claim 1, characterized in that, It also includes step 7: reuse of winding parameters. Based on the designed coil winding parameters N0, K1, Kw1, Lq, K2, Kw2, winding tests of enameled wire of different specifications can be carried out on coil frames of similar size.

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