A magnetic core winding system and method

Abstract

The application provides a magnetic core winding system and method, comprising: a first acquisition module, configured to acquire a first winding radius of a tape on a winding system in real time; a second acquisition module, configured to acquire a second winding radius of the tape on a unwinding system in real time; a driving module, configured to adjust an angular velocity of the winding system, so that the winding system drives the unwinding system to unwind at a preset initial angular momentum; and a tension control module, provided with a calculation algorithm, wherein the calculation algorithm represents a rule of the change of the angular velocity of the winding system with the first winding radius and the second winding radius, and is configured to control the angular velocity of the winding system according to the first winding radius and the second winding radius. The application has the beneficial effects that the winding radii of the winding system and the unwinding system are monitored in real time, the angular velocity of the winding system is adjusted, the tension of the winding system is kept unchanged, and the crack phenomenon between the tapes is avoided; meanwhile, the tightness consistency of the magnetic core winding is good, and the difference distribution of the permeability performance of different parts of the magnetic core is more uniform.

Description

Technical Field

[0001] This invention relates to the field of magnetic core winding technology, and more particularly to a magnetic core winding system and method. Background Technology

[0002] Because the size of ultra-large magnetic cores is much larger than that of conventional magnetic cores, the winding of larger magnetic cores in existing technologies is usually achieved through manual control. This winding control is quite difficult, especially when the core diameter exceeds a certain value, such as 150mm. Uneven tension is prone to occur during the strip winding process, particularly the phenomenon of looseness on the inside and tightness on the outside, which leads to cracks between the strips. Furthermore, if the winding factor is too large (i.e., the winding is too tight), the stress release is insufficient, resulting in a decrease in the magnetic permeability of the strip. If the winding factor is too small (i.e., the winding is too loose), the effective cross-sectional area of ​​the magnetic circuit will decrease, which will also lead to a decrease in the magnetic permeability of the strip, resulting in a large difference in the magnetic permeability distribution in different parts of the magnetic core. Summary of the Invention

[0003] To address the above technical problems, this invention provides a magnetic core winding system and method suitable for ultra-large magnetic cores.

[0004] The technical problem solved by this invention can be achieved by the following technical solutions:

[0005] A magnetic core winding system, comprising:

[0006] A first acquisition module is used to acquire the first winding radius of the strip on the tape winding system in real time;

[0007] A second acquisition module is used to acquire the second winding radius of the strip on the unwinding system in real time;

[0008] A drive module is used to adjust the winding angular velocity of the winding system, so that the winding system drives the unwinding system to unwind the tape with a preset initial angular momentum through the tape.

[0009] A tension control module is connected to the first acquisition module, the second acquisition module, and the drive module. The tension control module has a pre-set calculation algorithm that characterizes the variation of the winding angular velocity of the winding system with the second winding radius and the first winding radius. The algorithm is used to control the drive module to drive the winding angular velocity of the winding system according to the first winding radius and the second winding radius.

[0010] Preferably, the calculation algorithm preset in the tension control module uses the following formula to obtain the tape winding angular velocity:

[0011] W1 = L0 * r t / ((M0R0 2 +ρπrt 4 hk)*r1);

[0012] Wherein, L0 represents the preset initial angular momentum of the tape feeding system; r t The second winding radius of the tape feeding system at time t is represented by M0; the mass of the tape feeding reel of the tape feeding system is represented by R0; the radius of the tape feeding reel of the tape feeding system is represented by ρ; the tape density is represented by h; the tape thickness is represented by k; the lamination factor is represented by k; the first winding radius of the tape feeding system at time t is represented by r1; and the winding angular velocity driving the tape feeding system is represented by W1.

[0013] Preferably, it further includes:

[0014] A storage unit is used to store a list of correspondences between the stacking coefficients and the preset initial angular momentum;

[0015] The driving module is connected to the storage unit and is used to obtain the stacking coefficients and determine the corresponding preset initial angular momentum from the correspondence list based on the obtained stacking coefficients.

[0016] Preferably, the tape winding system includes: a tape reel and a tape shaft, the tape shaft being disposed at the center of the tape reel, and the tape reel and the tape shaft being integrally formed.

[0017] Preferably, the first acquisition module includes a first winding radius sensor, which is disposed on the reel and extends from the winding shaft toward the edge of the reel.

[0018] Preferably, the tape reel is arranged horizontally.

[0019] Preferably, the tape feeding system includes: a tape feeding reel and a tape feeding shaft, wherein the tape feeding shaft is disposed at the center of the tape feeding reel, and the tape feeding reel and the tape feeding shaft are integrally formed.

[0020] Preferably, the second acquisition module includes a second winding radius sensor, which is disposed on the unwinding reel and extends from the unwinding shaft toward the edge of the unwinding reel.

[0021] Preferably, the tape reel is set horizontally.

[0022] The present invention also provides a magnetic core winding method, applied to the magnetic core winding system described above, comprising:

[0023] Adjust the winding angular velocity of the winding system so that the winding system drives the unwinding system to unwind the tape with a preset initial angular momentum through the tape.

[0024] The first winding radius of the strip on the winding system is collected in real time; at the same time, the second winding radius of the strip on the unwinding system is collected in real time.

[0025] The drive module controls the winding angular velocity of the winding system based on the first winding radius and the second winding radius.

[0026] The advantages or beneficial effects of the technical solution of this invention are as follows:

[0027] This invention adjusts the angular velocity of the tape winding system by real-time monitoring of the winding radius of the tape winding and unwinding systems. This ensures that the angular momentum of the unwinding system remains constant, thereby ensuring that the tension of the tape winding system remains constant. This results in a magnetic core with uniform tape tension, avoiding cracks between the tapes. At the same time, the good consistency of the core winding tension makes the difference in permeability performance in different parts of the core more uniform. Attached Figure Description

[0028] Figure 1 A structural block diagram of the magnetic core winding system in a preferred embodiment of the present invention;

[0029] Figure 2 This is a schematic diagram of the structure of a magnetic core winding system in a preferred embodiment of the present invention.

[0030] Figure 3 In a preferred embodiment of the present invention, a schematic diagram of obtaining the three magnetic core parts a, b, and c using the strip stripping method is shown.

[0031] Figure 4 In a preferred embodiment of the present invention, a comparative schematic diagram showing the permeability test results of the magnetic cores obtained by winding in Example 1 and Comparative Example 1 is provided.

[0032] Figure 5 In a preferred embodiment of the present invention, a comparative schematic diagram showing the permeability test results of the magnetic cores obtained by winding in Example 2 and Comparative Example 2 is provided.

[0033] Figure 6 This is a schematic flowchart of the magnetic core winding method in a preferred embodiment of the present invention. Detailed Implementation

[0034] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The present invention is not limited to this embodiment; other embodiments that conform to the spirit of the present invention may also fall within the scope of the present invention.

[0035] See Figure 1In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, a magnetic core winding system is provided, suitable for winding ultra-large magnetic cores, comprising:

[0036] A first acquisition module 1 is used to acquire the first winding radius of the strip on the tape system 100 in real time;

[0037] A second acquisition module 2 is used to acquire the second winding radius of the strip on the tape feeding system 200 in real time;

[0038] A drive module 3 is used to adjust the winding angular velocity of the winding system 100, so that the winding system 100 drives the unwinding system 200 to unwind the tape with a preset initial angular momentum.

[0039] A tension control module 4 is connected to the first acquisition module 1, the second acquisition module 2, and the drive module 3 respectively. The tension control module 4 has a pre-set calculation algorithm that characterizes the variation of the winding angular velocity of the winding system 100 with the second winding radius and the first winding radius. It is used to control the winding angular velocity of the winding system 100 driven by the drive module 3 according to the first winding radius and the second winding radius.

[0040] Specifically, in this embodiment, firstly, the drive module 3 adjusts the winding angular velocity of the winding system 100 so that the winding system 100 drives the unwinding system 200 to unwind with a preset initial angular momentum. Then, the winding radius and unwinding radius of the winding system 100 and the unwinding system 200 are monitored in real time by the first acquisition module 1 and the second acquisition module 2. The tension control module 4 has a pre-set calculation algorithm, which further characterizes the change in angular velocity W1 of the winding system 100 with the second winding radius r. t Based on the variation of the first winding radius r1, the winding angular velocity of the winding system 100 can be automatically calculated according to the first and second winding radii. Then, the winding angular velocity is adjusted by the drive device 4 to ensure that the angular momentum of the unwinding system 200 remains constant, thereby ensuring that the tension of the winding system 100 remains constant. This results in a magnetic core with uniform winding tension, avoiding cracks between the strips. At the same time, the good consistency of the winding tension of the magnetic core makes the difference in the permeability performance of different parts of the magnetic core more uniform.

[0041] In a preferred embodiment, such as Figure 2 As shown, the tape reel system 100 includes a tape reel 101 and a tape reel shaft 102, with the tape reel shaft 102 located at the center of the tape reel 101.

[0042] In a preferred embodiment, the reel 101 and the winding shaft 102 are integrally formed, which can ensure that the magnetic core rotates synchronously with the winding shaft 102, so that no friction is generated during the winding process, thereby solving the problem of large cracks appearing in the magnetic core.

[0043] In a preferred embodiment, such as Figure 2 As shown, the first acquisition module 1 includes a first winding radius sensor 11, which is disposed on the reel 101 and extends from the winding shaft 102 toward the edge of the reel 101.

[0044] Specifically, in this embodiment, the first winding radius sensor 11 can be implemented using an optical fiber device. It monitors the size of the winding radius of the tape winding system based on the principle of transmitted light. That is, it emits light signals through a light emitter, receives light signals through a receiver, forms a protective light curtain, and determines the size of the radius based on the size of the light curtain.

[0045] In a preferred embodiment, the tape reel 101 is horizontally positioned.

[0046] Specifically, in this embodiment, the reel 101 is set horizontally, that is, a flat winding method is used to wind the ultra-large magnetic core, so as to overcome the influence of gravity on the ultra-large magnetic core and avoid gap problems.

[0047] The tape reel and unwinding reel are integrated with the chassis, and an optical fiber device is installed on the chassis.

[0048] In a preferred embodiment, the tape feeding system 200 includes a tape feeding reel 201 and a tape feeding shaft 202, with the tape feeding shaft 202 positioned at the center of the tape feeding reel 201.

[0049] In a preferred embodiment, the tape feeding disc 202 and the tape feeding shaft 201 are integrally formed.

[0050] Furthermore, the aforementioned winding shaft 102 is the driving shaft, and the unwinding shaft 202 is the driven shaft. Thus, the winding shaft 102 is driven and controlled, and then the winding shaft 102 drives the unwinding shaft 202 to unwind the tape through the tape, ensuring the consistency of the linear speed of the winding shaft 102 and the unwinding shaft 202.

[0051] In a preferred embodiment, the second acquisition module 2 includes a second winding radius sensor 21, which is disposed on the tape unwinding reel 201 and extends from the tape unwinding shaft 202 toward the edge of the tape unwinding reel 201.

[0052] Specifically, in this embodiment, the second winding radius sensor 21 can be implemented using an optical fiber device. It monitors the size of the winding radius of the tape feeding system based on the principle of transmitted light. That is, it emits light signals through a light emitter, receives light signals through a receiver, forms a protective light curtain, and determines the size of the radius based on the size of the light curtain.

[0053] In a preferred embodiment, the tape reel 202 is positioned horizontally.

[0054] In a preferred embodiment, the process of establishing the above calculation algorithm is as follows:

[0055] For a tape feeding system 200, the mass of the tape feeding reel is M0, the radius of the tape feeding reel is R0, and the initial angular momentum is set to L0. After a certain time t, the mass of the tape is m. t The second winding radius (i.e., the unwinding radius) is r. t The tape feeding angular velocity of the tape feeding system 200 is W. t .

[0056] Since the tape feeding system 200 always maintains a constant angular momentum, that is:

[0057] L0 = (M0 * R0) 2 + m t *r t 2 )*W t (1)

[0058] Furthermore, the calculation method for the above-mentioned material properties is as follows:

[0059] m t =ρ*π*r t 2 *h*k (2)

[0060] Where ρ represents the strip density; r t The second winding radius (i.e., the unwinding radius) is represented by h; the strip thickness is represented by k; the lamination factor is represented by m. t Indicates the quality of the strip.

[0061] We can obtain the following from formulas (1) and (2) above:

[0062] W t =L0 / (M0R0) 2 +ρπr t 4 hk) (3)

[0063] Formula (3) characterizes the tape release angular velocity W t With the second winding radius r t The patterns of change.

[0064] To ensure that the linear velocities are the same, the winding angular velocity and the unwinding angular velocity must satisfy the following relationship:

[0065] W t *r t =W1*r1 (4)

[0066] Among them, W t Indicates the angular velocity of the tape release; r t R1 represents the second winding radius (i.e., the unwinding radius); W1 represents the first winding radius; W1 represents the winding angular velocity.

[0067] We can obtain the following results using formulas (3) and (4) above:

[0068] W1 = L0 * r t / ((M0R0 2 +ρπr t 4 hk)*r1) (5)

[0069] Where L0 represents the preset initial angular momentum of the tape-laying system 200; r t The second winding radius of the tape feeding system 200 at time t is represented by M0; the mass of the tape feeding reel of the tape feeding system 200 is represented by R0; the radius of the tape feeding reel of the tape feeding system 200 is represented by ρ; the tape density is represented by h; the tape thickness is represented by k; the lamination factor is represented by k; the first winding radius of the tape winding system 100 at time t is represented by r1; and the winding angular velocity of the driving tape winding system 100 is represented by W1.

[0070] Since the initial angular momentum L0, the mass of the unwinding reel M0, the radius of the unwinding reel R0, the strip thickness h, and the lamination coefficient k are all known values, the above formula (5) characterizes the angular velocity W1 of the winding system 100 as a function of the second winding radius r. t Based on the variation of the first winding radius r1, the tension control module 4 can drive the winding shaft 102 based on the winding angular velocity calculated by the above formula (5), so that the tension remains constant, the core winding tightness is uniform, and no cracks appear between the strips; at the same time, the core winding tightness is relatively uniform, so that the difference in permeability performance of different parts of the ultra-large core is more uniform.

[0071] In a preferred embodiment, it further includes:

[0072] A storage unit is used to store a list of correspondences between stacking coefficients and preset initial angular momentum;

[0073] The drive module is connected to the storage unit to obtain the stacking coefficients and determine the corresponding preset initial angular momentum from the corresponding relationship list based on the obtained stacking coefficients.

[0074] Specifically, the smaller the lamination factor, the looser the core winding and the larger the gap between the strips; conversely, the larger the lamination factor, the tighter the core winding and the smaller the gap between the strips. The lamination factor is equal to the ratio of the actual weight of the core to its calculated weight. The actual weight of the core can be measured, and the calculated weight is the product of the strip density ρ and the strip volume V. In this embodiment, firstly, the lamination factor is determined, which is generally between 0.78 and 0.82. Then, the initial angular momentum L0 is determined according to the correspondence between the lamination factor F and the preset initial angular momentum L0 shown in Table 1 below.

[0075] Furthermore, after obtaining the initial angular momentum L0, the speed of the winding shaft is adjusted to control the speed of the unwinding shaft. The process is completed when the angular momentum reaches the set initial angular momentum L0 range. This process takes a short time and can generally be achieved within 30 seconds.

[0076] Table 1 shows the correspondence between the stacking coefficient F and the preset initial angular momentum L0.

[0077] 0.78 1.8-2.0 0.79 2.0-2.2 0.80 2.2-2.4 0.81 2.4-2.6 0.82 2.6-2.8

[0078] The aforementioned strip material can preferably be an amorphous or nanocrystalline strip material, or other existing strip materials can also be used.

[0079] This invention also provides a magnetic core winding method, applied to the magnetic core winding system described above, such as... Figure 6 As shown, it includes:

[0080] Adjust the winding angular velocity of the winding system 100 so that the winding system 100 drives the unwinding system 200 to unwind the tape with a preset initial angular momentum through the tape.

[0081] The first winding radius of the strip on the winding system 100 is collected in real time; at the same time, the second winding radius of the strip on the unwinding system 200 is collected in real time.

[0082] The drive module controls the winding angular velocity of the winding system 100 based on the first winding radius and the second winding radius.

[0083] The following two specific embodiments are provided to further illustrate or explain this technical solution:

[0084] Example 1

[0085] A nanocrystalline ribbon with a width of 30 mm was selected and wound into a 400*230*30 magnetic core. The initial angular momentum L0 of the tape feeding system 200 was set to 2.0 kg*m. 2 / s, according to the formula: W1=L0*r t / ((M0R0 2 +ρπr t4 hk)*r1) Set the calculation algorithm program.

[0086] The magnetic cores were wound using the magnetic core winding method described in this invention, and the tension was controlled based on the above calculation algorithm. A total of 18 magnetic cores were wound to obtain the test samples.

[0087] Comparative Example 1

[0088] Compared to Example 1, Comparative Example 1 involved direct winding without tension control, maintaining a constant speed, and obtaining 18 400*230*30 magnetic cores as a control sample.

[0089] The test sample obtained from winding in Example 1 and the control sample from Comparative Example 1 were placed in the same heat treatment furnace for heat treatment, and the soft magnetic properties of the magnetic cores were tested. For each magnetic core, such as Figure 3 As shown, the three magnetic core parts a, b, and c were obtained using the strip stripping method, and their permeability test results are as follows. Figure 4 As shown.

[0090] pass Figure 4 It can be seen that, compared with the control sample, the magnetic permeability distribution in different parts of the test sample is more uniform, because the winding tightness of the test sample is very consistent.

[0091] Example 2

[0092] A 20mm wide nanocrystalline ribbon was selected and wound into a 450*280*20mm magnetic core. The initial angular momentum L0 of the tape feeding system 200 was set to 2.3kg*m. 2 / s, according to the formula: W1=L0*r t / ((M0R0 2 +ρπr t 4 hk)*r1) Set the calculation algorithm program.

[0093] The magnetic cores were wound using the magnetic core winding method described in this invention, and the tension was controlled based on the above calculation algorithm. A total of 18 magnetic cores were wound to obtain the test samples.

[0094] Comparative Example 2

[0095] Compared to Example 2, Comparative Example 2 involved direct winding without tension control, maintaining a constant speed, and obtaining 18 400*230*30 magnetic cores as a control sample.

[0096] The test sample obtained from winding in Example 2 and the control sample from Comparative Example 2 were placed in the same heat treatment furnace for heat treatment, and the soft magnetic properties of the magnetic cores were tested. For each magnetic core, three parts, a, b, and c, were obtained using the strip stripping method, and their permeability test results are as follows. Figure 5 As shown.

[0097] pass Figure 5 It can be seen that, compared with the control sample, the magnetic permeability distribution in different parts of the test sample is more uniform, because the winding tightness of the test sample is very consistent.

[0098] The advantages or beneficial effects of the above technical solution are as follows: This invention adjusts the angular velocity of the tape winding system based on the winding radius of the tape winding system and the tape unwinding system obtained by real-time monitoring, so as to ensure that the angular momentum of the tape unwinding system remains constant, thereby ensuring that the tension of the tape winding system remains constant, thus obtaining a magnetic core with uniform tape tension and avoiding cracks between the tapes; at the same time, the uniformity of the core winding tension makes the difference in permeability performance in different parts of the core more uniform, providing a solid foundation for the manufacture of high-precision devices.

[0099] The above description is merely a preferred embodiment of the present invention and does not limit the implementation and protection scope of the present invention. Those skilled in the art should realize that any equivalent substitutions and obvious changes made using the content of this specification and illustrations should be included within the protection scope of the present invention.

Claims

1. A magnetic core winding system, characterized in that, include: A first acquisition module is used to acquire the first winding radius of the strip on the tape winding system in real time; A second acquisition module is used to acquire the second winding radius of the strip on the unwinding system in real time; A drive module is used to adjust the winding angular velocity of the winding system, so that the winding system drives the unwinding system to unwind the tape with a preset initial angular momentum through the tape. A tension control module is connected to the first acquisition module, the second acquisition module, and the drive module respectively. The tension control module has a pre-set calculation algorithm, which characterizes the law of the change of the winding angular velocity of the winding system with the second winding radius and the first winding radius. It is used to control the drive module to drive the winding angular velocity of the winding system according to the first winding radius and the second winding radius. The preset calculation algorithm in the tension control module uses the following formula to obtain the tape winding angular velocity: W1=L0*r t / ((M0R0 2 +ρπr t 4 hk)*r1); Wherein, L0 represents the preset initial angular momentum of the tape feeding system; r t M0 represents the second winding radius of the tape feeding system at time t; R0 represents the mass of the tape feeding reel of the tape feeding system; ρ represents the tape density; h represents the tape thickness; k represents the lamination factor; r1 represents the first winding radius of the tape feeding system at time t; W1 represents the tape winding angular velocity driving the tape feeding system. Also includes: A storage unit is used to store a list of correspondences between the stacking coefficients and the preset initial angular momentum; The driving module is connected to the storage unit and is used to obtain the stacking coefficients and determine the corresponding preset initial angular momentum from the correspondence list based on the obtained stacking coefficients.

2. The magnetic core winding system according to claim 1, characterized in that, The tape winding system includes a tape reel and a tape shaft, wherein the tape shaft is located at the center of the tape reel, and the tape reel and the tape shaft are integrally formed.

3. The magnetic core winding system according to claim 2, characterized in that, The first acquisition module includes a first winding radius sensor, which is disposed on the reel and extends from the winding shaft toward the edge of the reel.

4. The magnetic core winding system according to claim 3, characterized in that, The tape reel is set horizontally.

5. The magnetic core winding system according to claim 1, characterized in that, The tape feeding system includes a tape feeding reel and a tape feeding shaft, wherein the tape feeding shaft is located at the center of the tape feeding reel, and the tape feeding reel and the tape feeding shaft are integrally formed.

6. The magnetic core winding system according to claim 5, characterized in that, The second acquisition module includes a second winding radius sensor, which is disposed on the tape unwinding reel and extends from the tape unwinding shaft toward the edge of the tape unwinding reel.

7. The magnetic core winding system according to claim 5, characterized in that, The tape reel is set horizontally.

8. A method for winding a magnetic core, characterized in that, Applied to the magnetic core winding system as described in any one of claims 1-7, comprising: Adjust the winding angular velocity of the winding system so that the winding system drives the unwinding system to unwind the tape with a preset initial angular momentum through the tape. The first winding radius of the strip on the winding system is collected in real time; at the same time, the second winding radius of the strip on the unwinding system is collected in real time. The drive module controls the winding angular velocity of the winding system based on the first winding radius and the second winding radius.

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