A transformer coil shape detection device

Abstract

The present invention provides a transformer coil shape detection device, including an entry roller, a coil DC resistance test device, a 3D shape detector, a placement platform, a manipulator, a coil outlet platform and a control system, wherein the placement platform is arranged at the outlet end of the entry roller, the coil DC resistance test device and the 3D shape detector are arranged in sequence in the area between the entry end and the outlet end of the entry roller, the coil outlet platform is arranged on the side of the placement platform away from the entry roller, and the manipulator is arranged between the placement platform and the coil outlet platform. The transformer coil shape detection device of the present invention integrates the functions of coil DC resistance testing, 3D shape detection and manipulator grasping, realizes the automation and efficiency of the coil production process, reduces the occurrence of human errors, reduces labor costs, improves the stability and reliability of the production process, and improves the overall efficiency of the production line.

Description

Technical Field

[0001] The embodiments of the present invention relate to the technical field of transformer coils, and in particular to a transformer coil shape detection device. Background Art

[0002] Regarding the selection and storage of transformer coils, currently after the winding operation is completed, the DC resistance of the transformer coils will be manually measured and the numbers will be recorded and placed in the assembly area. When the transformer needs to be assembled, it will be manually picked and lifted out for assembly. Due to the different specifications and sizes of the coils, storage requires personnel to register and enter them, and finding them is even more difficult, time-consuming and laborious. There is a risk of coils slipping and getting hurt during manual lifting. Summary of the invention

[0003] The embodiment of the present invention provides a transformer coil shape detection device, thereby solving the problem that the existing coil selection, storage and lifting are time-consuming and labor-intensive.

[0004] In order to solve the above-mentioned technical problems, the present invention is achieved as follows:

[0005] In a first aspect, an embodiment of the present invention provides a transformer coil shape detection device, comprising: an entrance roller, a coil DC resistance test device, a 3D shape detector, a placement platform, a manipulator, a coil outlet platform and a control system, wherein the placement platform is arranged at the outlet end of the entrance roller, the coil DC resistance test device and the 3D shape detector are arranged in sequence in the area between the entrance end and the outlet end of the entrance roller, the coil outlet platform is arranged on a side of the placement platform away from the entrance roller, and the manipulator is arranged between the placement platform and the coil outlet platform;

[0006] The control system controls the entrance roller to transfer the coil to be tested to the area where the coil DC resistance test equipment is located to measure the resistance information, and obtains the measured resistance information and the theoretical shape data corresponding to the resistance information, and transmits the theoretical shape data to the 3D shape detector, and controls the entrance roller to transfer the coil to be tested to the area where the 3D shape detector is located; the 3D shape detector performs shape contour detection on the coil to be tested to obtain measured shape data, calculates the shape size error between the measured shape data and the theoretical shape data, determines whether the coil to be tested is a qualified coil according to the shape size error, numbers the qualified coil and obtains the position information of the qualified coil on the placement platform, and sends the number and position information of the qualified coil to the manipulator; the manipulator grabs the qualified coil to the coil exit platform according to the number and position information of the qualified coil.

[0007] Optionally, the transformer coil shape detection equipment also includes: a truss, the truss includes two parallel rails, a crossbeam erected on the rails and a plurality of longitudinal beams for supporting the rails, the crossbeam can slide on the rails, the two parallel rails are arranged on opposite sides of the placement platform, and the manipulator is arranged on the crossbeam.

[0008] Optionally, the manipulator is provided with a 2D camera, and the 2D camera is used to photograph the coil to be grasped by the manipulator. The manipulator determines the position information of the coil to be grasped based on the image of the coil to be grasped taken by the 2D camera, and compares the determined position information with the position information sent by the 3D shape detector. If the determined position information is consistent with the position information sent by the 3D shape detector, the coil to be grasped is grasped.

[0009] Optionally, the transformer coil shape detection equipment further includes: an unqualified coil exit roller, wherein the unqualified coil exit roller is arranged at the exit end of the entry roller.

[0010] Optionally, the 3D shape detector numbers the unqualified coils and obtains the position information of the unqualified coils on the placement platform, and sends the numbers and position information of the unqualified coils to the manipulator; the manipulator grabs the unqualified coils to the unqualified coil exit roller according to the numbers and position information of the unqualified coils.

[0011] Optionally, the 3D shape detector receives an order from a superior, which includes resistance information of a required coil group, where the coil group includes three-phase coils A, B, and C, determines position information of target A, B, and C three-phase coils that are the same or similar to the resistance information of the required coil group, and sends the position information of the target A, B, and C three-phase coils to the manipulator, and the manipulator grabs the target A, B, and C three-phase coils on the placement platform to the coil exit platform according to the position information of the target A, B, and C three-phase coils.

[0012] Optionally, the 3D shape detector determines the position information of the target three-phase coils A, B, and C that are the same or similar to the resistance information of the required coil group according to the following rules:

[0013] For products of the same model, select coils in the order of A, B, and C;

[0014] When there are multiple products of the same model, obtain the corresponding resistance information of all A, B, and C coils, according to P = I 2 R calculates the load loss value, P is power, I is current, and R is resistance. Select three coils A, B, and C according to the load loss value;

[0015] Check the resistance unevenness of the three coils A, B, and C. If (R max -R min ) / R 三相平均 < the preset value, the group is considered qualified, otherwise it is considered unqualified. max is the maximum resistance, R min is the minimum resistance, R 三相平均 is the average resistance of the three coils A, B, and C.

[0016] Optionally, when a grouping failure occurs, it is handled by controlling the lead length.

[0017] Optionally, the placement platform includes a plurality of sub-placement platforms arranged side by side.

[0018] Optionally, the 3D shape detector is provided with a display screen, and the display screen is used to display the 3D image display screen and set reference plane parameters.

[0019] The embodiments of the present invention have the following beneficial effects:

[0020] 1. The transformer coil shape detection equipment described in the present invention integrates functions such as coil DC resistance testing, 3D shape detection and robot grasping, realizes the automation and efficiency of the coil production process, reduces the occurrence of human errors, reduces labor costs, improves the stability and reliability of the production process, and improves the overall efficiency of the production line.

[0021] 2. The transformer coil shape detection device described in the present invention can perform high-precision measurement and detection of the resistance information and shape data of the coil through the combined use of the coil DC resistance test device and the 3D shape detector to ensure product quality.

[0022] 3. The transformer coil shape detection equipment described in the present invention can obtain the measured resistance information and shape data in real time, and judge whether the coil is qualified according to the shape size error, realize real-time feedback and control, ensure the control and management of product quality during the production process, and help prevent unqualified products from flowing into the next production link. BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings:

[0024] Figure 1 A schematic diagram of the structure of a transformer coil shape detection device provided by an embodiment of the present invention;

[0025] Figure 2 A schematic diagram of the structure of a 3D shape detector of a transformer coil shape detection device provided by an embodiment of the present invention;

[0026] Figure 3 A schematic diagram of an operation interface of a manipulator of a transformer coil shape detection device provided by an embodiment of the present invention;

[0027] Figure 4 A schematic diagram of selecting coils is shown on a display screen of a 3D shape detector of a transformer coil shape detection device provided by an embodiment of the present invention;

[0028] Figure 5 A schematic diagram showing the appearance of a detection coil on a display screen of a 3D appearance detector of a transformer coil appearance detection device provided by an embodiment of the present invention;

[0029] Figure 6 A schematic diagram of a 3D shape detector of a transformer coil shape detection device provided by an embodiment of the present invention showing a trigger for taking photos of the coil at multiple angles;

[0030] Figure 7 A display screen of a 3D shape detector of a transformer coil shape detection device provided in an embodiment of the present invention displays a schematic diagram of coil shape dimensions. DETAILED DESCRIPTION

[0031] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] like Figure 1 and Figure 2 As shown, a transformer coil shape detection device comprises: an entrance roller 1, a coil DC resistance test device 2, a 3D shape detector 3, a placement platform 5, a manipulator 6, a coil outlet platform 7 and a control system, wherein the placement platform 5 is arranged at the outlet end of the entrance roller 1, the coil DC resistance test device 2 and the 3D shape detector 3 are arranged in sequence in the area between the entrance end and the outlet end of the entrance roller 1, the coil outlet platform 7 is arranged on a side of the placement platform 5 away from the entrance roller 1, and the manipulator 6 is arranged between the placement platform 5 and the coil outlet platform 7;

[0033] The control system controls the entrance roller 1 to transfer the coil to be tested to the area where the coil DC resistance test equipment 2 is located to measure the resistance information, and obtains the measured resistance information and the theoretical shape data corresponding to the resistance information, and transmits the theoretical shape data to the 3D shape detector 3, and controls the entrance roller 1 to transfer the coil to be tested to the area where the 3D shape detector 3 is located; the 3D shape detector 3 performs shape contour detection on the coil to be tested to obtain measured shape data, calculates the shape dimension error between the measured shape data and the theoretical shape data, and determines whether the coil to be tested is a qualified coil based on the shape dimension error. In this embodiment, the coil with a shape dimension error within ±1mm is the qualified coil, the qualified coil is numbered and the position information of the qualified coil on the placement platform 5 is obtained, and the number and position information of the qualified coil are sent to the manipulator 6; the manipulator 6 grabs the qualified coil to the coil exit platform 7 based on the number and position information of the qualified coil.

[0034] The transformer coil shape detection equipment described in the present invention integrates functions such as coil DC resistance testing, 3D shape detection and robot grasping, realizes the automation and efficiency of the coil production process, reduces the occurrence of human errors, reduces labor costs, improves the stability and reliability of the production process, and improves the overall efficiency of the production line; the transformer coil shape detection equipment described in the present invention can perform high-precision measurement and detection of the resistance information and shape data of the coil through the combined use of the coil DC resistance testing equipment and the 3D shape detector to ensure product quality; the transformer coil shape detection equipment described in the present invention can obtain the measured resistance information and shape data in real time, and judge whether the coil is qualified according to the shape size error, realize real-time feedback and control, ensure the control and management of product quality in the production process, and help prevent unqualified products from flowing into the next production link.

[0035] Optionally, the transformer coil shape detection device further includes: a truss, the truss includes two parallel tracks, a crossbeam mounted on the tracks, and a plurality of longitudinal beams for supporting the tracks, the crossbeam can slide on the tracks, the two parallel tracks are arranged on opposite sides of the placement platform 5, and the manipulator 6 is arranged on the crossbeam. The truss has a stable supporting capacity and can withstand the weight and force of the crossbeam and the manipulator 6 during operation and movement; the setting of the manipulator 6 realizes automated operation, improves production efficiency and detection accuracy, and reduces the need for manual operation.

[0036] Optional, such as Figure 3As shown, the manipulator 6 is provided with a 2D camera, and the 2D camera is used to photograph the coil to be grasped by the manipulator 6. The manipulator 6 determines the position information of the coil to be grasped based on the image of the coil to be grasped photographed by the 2D camera, and compares the determined position information with the position information sent by the 3D shape detector 3. If the determined position information is consistent with the position information sent by the 3D shape detector 3, the coil to be grasped is grasped. By photographing the coil to be grasped by the 2D camera, a clear image can be obtained, thereby accurately determining the position information of the coil to be grasped, and comparing the position information sent by the 3D shape detector 3 helps to ensure the accuracy and consistency of grasping.

[0037] Optionally, the transformer coil shape detection device further includes: an unqualified coil outlet roller 4, which is arranged at the outlet end of the inlet roller 1. It is possible to classify qualified products and unqualified products in the entire production process, ensure the control and management of product quality in the production process, and help prevent unqualified products from flowing into the next production link.

[0038] Optional, such as Figure 4-7 As shown, the 3D shape detector 3 numbers the unqualified coils and obtains the position information of the unqualified coils on the placement platform 5, and sends the numbers and position information of the unqualified coils to the manipulator 6; the manipulator 6 grabs the unqualified coils to the unqualified coil exit roller 4 according to the numbers and position information of the unqualified coils. The 3D shape detector 3 can identify the unqualified coils in time and perform corresponding processing, reducing the risk of human error and the possibility of the unqualified products flowing into the downstream production links, which is conducive to improving the product qualification rate.

[0039] Optionally, the 3D shape detector 3 receives an order from a superior, the order includes the resistance information of the required coil group, the coil group includes three-phase coils A, B, and C, determines the position information of the target three-phase coils A, B, and C that are the same or similar to the resistance information of the required coil group, and sends the position information of the target three-phase coils A, B, and C to the manipulator 6. The manipulator 6 grabs the target three-phase coils A, B, and C on the placement platform 5 to the coil outlet platform 7 according to the position information of the target three-phase coils A, B, and C. The transformer coil shape detection equipment can identify and automatically grab the target three-phase coils A, B, and C to the coil outlet platform 7, ensuring the accuracy and consistency of production, reducing manpower input, and reducing unnecessary production waste and loss, which is conducive to the rational use and conservation of production resources.

[0040] Optionally, the 3D shape detector 3 determines the position information of the target three-phase coils A, B, and C that are the same or similar to the resistance information of the required coil group according to the following rules:

[0041] For products of the same model, select coils in the order of A, B, and C;

[0042] When there are multiple products of the same model, obtain the corresponding resistance information of all A, B, and C coils, according to P = I 2 R calculates the load loss value, P is power, I is current, and R is resistance. Select three coils A, B, and C according to the load loss value;

[0043] Check the resistance unevenness of the three coils A, B, and C. If R max -R min / R 三相平均 < the preset value, the group is considered qualified, otherwise it is considered unqualified. max is the maximum resistance, R min is the minimum resistance, R 三相平均 is the average resistance of the three coils A, B, and C. The preset value in this embodiment is 3%. Through strict selection and verification rules, the quality of the selected coils can be effectively controlled to ensure that the selected coils meet the specification requirements and reduce the possibility of human error.

[0044] Optionally, when a grouping failure occurs, it can be handled by controlling the lead length. Handling grouping failures through the lead process can effectively improve product quality and ensure that the final product meets the requirements. This helps to produce high-quality products and improve customer satisfaction.

[0045] Optionally, the placement platform 5 includes a plurality of sub-placement platforms arranged side by side. Different sub-placement platforms can operate independently and can be combined or split as needed to meet different needs and workflows; resources can be allocated to different sub-placement platforms according to different requirements and tasks to make resource utilization more efficient.

[0046] Optionally, the 3D shape detector 3 is provided with a display screen, which is used to display the 3D image display screen and set the reference plane parameters, including the line width, spacing, total length, etc. of the reference plane. By displaying the 3D image on the display screen, the operator can more intuitively understand the shape and characteristics of the detected object, which is helpful for accurate judgment and analysis; the display screen can be used to set the reference plane parameters, and the operator can adjust the parameters directly on the display screen, which simplifies the operation process and improves the convenience of operation.

[0047] The robot 6 grasping control description:

[0048] 1. The gripping control of the manipulator 6 is precise control of the five axes of X, Y, Z, R, and J, and the current position data is displayed in real time by the human-machine interface HMI. The control system sends the process model to the programmable logic controller PLC, and the PLC retrieves the process model and reads the process data. The process data includes the coil model, the actual photographing position of the coil, and the clamping position. Now, take the X-axis positioning as an example for analysis. The truss drive axis is driven by the X and Y axes. The actual position of the manipulator 6 is calculated by the encoder, and the actual position is compared with the target position. If the error value between the two is controlled within the range of 0.1mm, the equipment can operate normally.

[0049] 2. Measuring linear displacement: If the encoder is used to measure linear displacement, the relationship between the number of pulses and length can be calculated by the following formula: Number of pulses = principle resolution x measurement length / maximum measurement range, where principle resolution refers to the number of pulses per unit length; maximum measurement range refers to the maximum displacement value that the encoder can measure.

[0050] 3. Determine the pulses per millimeter: When measuring the length through the encoder, the accuracy is 0.1 mm, and 10 pulses correspond to 0.1 mm. Then, by dividing the total number of pulses measured by 10, the number of millimeters can be obtained to achieve precise positioning of the robot.

[0051] For ease of description, spatially relative terms such as "above", "above", "on the upper surface of", "above", etc. may be used here to describe the spatial positional relationship between a device or feature and other devices or features as shown in the figure. It should be understood that spatially relative terms are intended to include different orientations of the device in use or operation in addition to the orientation described in the figure. For example, if the device in the accompanying drawings is inverted, the device described as "above other devices or structures" or "above other devices or structures" will be positioned as "below other devices or structures" or "below other devices or structures". Thus, the exemplary term "above" can include both "above" and "below". The device can also be positioned in other different ways (rotated 90 degrees or in other orientations), and the spatially relative descriptions used here are interpreted accordingly.

[0052] It should be noted that the terms used herein are only for describing specific embodiments and are not intended to limit the exemplary embodiments according to the present application. As used herein, unless the context clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should be understood that when the terms "comprise" and / or "include" are used in this specification, it indicates the presence of features, steps, operations, devices, components and / or combinations thereof.

[0053] It should be noted that the terms "first", "second", etc. in the specification and claims of the present application and the above-mentioned drawings are used to distinguish similar objects, and are not necessarily used to describe a specific order or sequence. It should be understood that the data used in this way can be interchangeable where appropriate, so that the embodiments of the present application described herein can be implemented in an order other than those illustrated or described herein, for example. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions, for example, a process, method, system, product or device comprising a series of steps or units is not necessarily limited to those steps or units clearly listed, but may include other steps or units that are not clearly listed or inherent to these processes, methods, products or devices. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood in specific circumstances.

[0054] Through the description of the above implementation methods, those skilled in the art can clearly understand that the above-mentioned embodiment methods can be implemented by means of software plus a necessary general hardware platform, and of course by hardware, but in many cases the former is a better implementation method. Based on such an understanding, the technical solution of the present invention, or the part that contributes to the prior art, can be embodied in the form of a software product, which is stored in a storage medium (such as ROM / RAM, magnetic disk, optical disk), and includes a number of instructions for enabling a terminal (which can be a mobile phone, computer, server, air conditioner or network equipment, etc.) to execute the methods described in each embodiment of the present invention.

[0055] The embodiments of the present invention are described above in conjunction with the accompanying drawings, but the present invention is not limited to the above-mentioned specific implementation modes, which are merely illustrative rather than restrictive. Under the guidance of the present invention, ordinary technicians in this field can also make many forms without departing from the scope of protection of the present invention and the claims, all of which are within the protection of the present invention.

Claims

1. A transformer coil shape detection device, characterized in that: include: An entrance roller conveyor (1), a coil DC resistance test device (2), a 3D shape detector (3), a placement platform (5), a manipulator (6), a coil exit platform (7) and a control system, wherein the placement platform (5) is arranged at the exit end of the entrance roller conveyor (1), the coil DC resistance test device (2) and the 3D shape detector (3) are arranged in sequence in the area between the entrance end and the exit end of the entrance roller conveyor (1), the coil exit platform (7) is arranged on a side of the placement platform (5) away from the entrance roller conveyor (1), and the manipulator (6) is arranged between the placement platform (5) and the coil exit platform (7); The control system controls the entrance roller (1) to transfer the coil to be tested to the area where the coil DC resistance test device (2) is located to measure the resistance information, obtain the measured resistance information and the theoretical shape data corresponding to the resistance information, and transmit the theoretical shape data to the 3D shape detector (3); and controls the entrance roller (1) to transfer the coil to be tested to the area where the 3D shape detector (3) is located; the 3D shape detector (3) performs shape contour detection on the coil to be tested to obtain measured shape data, calculates the shape size error between the measured shape data and the theoretical shape data, determines whether the coil to be tested is a qualified coil based on the shape size error, numbers the qualified coil and obtains the position information of the qualified coil on the placement platform (5), and sends the number and position information of the qualified coil to the manipulator (6); the manipulator (6) grabs the qualified coil to the coil exit platform (7) based on the number and position information of the qualified coil; The 3D shape detector (3) receives an order from a superior, the order includes resistance information of a required coil group, the coil group includes three-phase coils A, B, and C, determines position information of target three-phase coils A, B, and C that are the same or similar to the resistance information of the required coil group, and sends the position information of the target three-phase coils A, B, and C to the manipulator (6). The manipulator (6) grabs the target three-phase coils A, B, and C on the placement platform (5) to the coil exit platform (7) according to the position information of the target three-phase coils A, B, and C; The 3D shape detector (3) determines the position information of the target three-phase coils A, B, and C that are the same or similar to the resistance information of the required coil group according to the following rules: For products of the same model, select coils in the order of A, B, and C; When there are multiple products of the same model, obtain the corresponding resistance information of all A, B, and C coils, according to P=I 2 R calculates the load loss value, P is power, I is current, and R is resistance. Select three coils A, B, and C according to the load loss value; Check the resistance unevenness of the three coils A, B, and C. If (R max -R min ) / R 三相平均 < the preset value, the group is considered qualified, otherwise it is considered unqualified. max is the maximum resistance, R min is the minimum resistance, R 三相平均 is the average resistance of the three coils A, B, and C.

2. The transformer coil shape detection device according to claim 1, characterized in that: Also includes: A truss, the truss comprising two parallel tracks, a crossbeam mounted on the tracks, and a plurality of longitudinal beams for supporting the tracks, the crossbeam being able to slide on the tracks, the two parallel tracks being arranged on opposite sides of the placement platform (5), and the manipulator (6) being arranged on the crossbeam.

3. The transformer coil shape detection device according to claim 2, characterized in that: The manipulator (6) is provided with a 2D camera, and the 2D camera is used to photograph the coil to be grasped by the manipulator (6). The manipulator (6) determines the position information of the coil to be grasped based on the image of the coil to be grasped photographed by the 2D camera, and compares the determined position information with the position information sent by the 3D shape detector (3). If the determined position information is consistent with the position information sent by the 3D shape detector (3), the coil to be grasped is grasped.

4. The transformer coil shape detection device according to claim 1, characterized in that: Also includes: An unqualified coil outlet roller conveyor (4), wherein the unqualified coil outlet roller conveyor (4) is arranged at an outlet end of the inlet roller conveyor (1).

5. The transformer coil shape detection device according to claim 4, characterized in that: The 3D shape detector (3) numbers the unqualified coils and obtains the position information of the unqualified coils on the placement platform (5), and sends the numbers and position information of the unqualified coils to the manipulator (6); the manipulator (6) grabs the unqualified coils to the unqualified coil exit roller (4) according to the numbers and position information of the unqualified coils.

6. The transformer coil shape detection device according to claim 1, characterized in that: When grouping fails, it is handled by controlling the lead length.

7. The transformer coil shape detection device according to claim 1, characterized in that: The placement platform (5) comprises a plurality of sub-placement platforms arranged side by side.

8. The transformer coil shape detection device according to claim 1, characterized in that: The 3D shape detector (3) is provided with a display screen, and the display screen is used to display a 3D image display screen and set reference plane parameters.

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