Automatic winding system and method for distribution transformer coils

Abstract

The present application relates to the field of transformer production and manufacturing, in particular to an automatic winding system and method for distribution transformer coils. The automatic winding system for distribution transformer coils comprises a control module, a visual recognition module for obtaining the outer dimensions and spatial positions of the coils and the cores, a three-dimensional scanning module for scanning the coils and the cores and modeling the coils and the cores, a path planning module for planning a moving path according to the spatial positions of the coils and the cores, and a winding module for grabbing the coils and winding them on the core columns of the cores according to the moving path under the control of the control module. The automatic winding system for distribution transformer coils can conveniently realize automatic winding and ensure the winding quality of the coils and the cores.

Description

Technical Field

[0001] This invention relates to the field of transformer manufacturing, and more specifically to an automatic assembly system and method for distribution transformer coils. Background Technology

[0002] With the acceleration of my country's digital transformation, the power industry is also continuously developing towards intelligence, high-end technology, and green practices. Smart factories have become a new trend in the development of power manufacturing enterprises, bringing huge market opportunities and development space to the power industry. The promotion of smart factories means that processes that previously relied excessively on manual labor will gradually be replaced by machines, and procedural and data-driven processes will gradually become the mainstream. Currently, manual and semi-automated operations are still prevalent in some processes of transformer manufacturing, seriously restricting the improvement of production efficiency and becoming a bottleneck restricting the capacity expansion of transformer factories. How to achieve automation and intelligence in key processes has become a research direction for the industry.

[0003] The coil assembly process for distribution transformers is highly manual, with a low level of automation, resulting in significant time and money wasted on logistics and product waiting. The coil assembly process involves operators using forklifts to transport the arranged high-voltage coils and their pallets to designated locations. Then, an overhead crane is used to lift the iron core to the designated position. Through the coordination of the crane and a lifting strap, the coil is lifted to a suitable height. One operator operates the crane remotely, moving it above the iron core, while another operator uses their experience to position the coil and iron core, working together to complete the coil assembly. This operation requires at least two people, and the entire process, from transport to assembly, requires manual intervention. It demands a high level of operator skill and precision, which is detrimental to ensuring the quality of transformer assembly.

[0004] Therefore, a new technical solution is needed in this field to solve the above problems. Summary of the Invention

[0005] To improve or solve the technical problem of high manual intervention and unreliable assembly quality in the coil assembly process of existing technologies, this invention provides an automatic assembly system for distribution transformer coils. The automatic assembly system for distribution transformer coils includes: a control module; a vision recognition module for acquiring the external dimensions and spatial position of the coil and the iron core; a 3D scanning module for scanning the coil and the iron core and modeling them; a path planning module for planning a movement path based on the spatial position of the coil and the iron core; and an assembly module that, under the control of the control module, grasps the coil according to the movement path and assembles it onto the core post of the iron core.

[0006] This invention relates to an automatic coil assembly system for distribution transformers, comprising a control module, a vision recognition module, a path planning module, a 3D scanning module, and an assembly module. The control module is connected to the vision recognition module, path planning module, 3D scanning module, and assembly module, and is used to control the actions of each module. The vision recognition module acquires the external dimensions and spatial position of the coil and the iron core; the path planning module plans the movement path of the coil; and the assembly module, based on the movement path, grasps the coil and assembles it onto the core post of the iron core, achieving automatic assembly. The 3D scanning module scans the coil and the iron core, thereby modeling them and obtaining a relatively complete and intuitive understanding of their external dimensions. Through the above configuration, this invention's automatic coil assembly system for distribution transformers can conveniently achieve automatic assembly, ensuring the quality of coil and iron core assembly.

[0007] In the preferred embodiment of the above-mentioned automatic assembly system for distribution transformer coils, an analysis module is further included. This analysis module analyzes the matching degree of the coil and the iron core based on their external dimensions and modeling. Through this setup, the analysis module automatically determines whether the iron core and the coil can be assembled based on their matching degree according to their external dimensions.

[0008] In the preferred embodiment of the above-described automatic assembly system for distribution transformer coils, the external dimensions of the coil include its surface quality, inner diameter, and outer diameter; the external dimensions of the core include the number, surface quality, and dimensions of the core posts. Through this setup, the surface quality of the core and coil is detected, thereby ensuring the quality of the transformer after assembly.

[0009] In the preferred embodiment of the above-mentioned automatic assembly system for distribution transformer coils, a memory storage module is further included. This memory storage module stores the external dimensions, modeling, and matching degree of the coil and the core. Through this configuration, the arrangement of the memory module avoids the analysis module from re-analyzing already analyzed cores and coils, saving the analysis module's computational resources and time.

[0010] In the preferred embodiment of the above-mentioned automatic assembly system for distribution transformer coils, the visual recognition module includes an optical camera and an infrared light source for supplementing the optical camera. Through this arrangement, the infrared light source enables the optical camera to acquire information unaffected even when the lighting in the work area is off, thus giving the visual recognition module the characteristic of 24-hour uninterrupted, unattended operation, making it more suitable for darkrooms.

[0011] In the preferred embodiment of the above-described automated assembly system for distribution transformer coils, the assembly module includes a four-axis robot and a gripping structure mounted on the four-axis robot. With this configuration, the gripping structure is used to grip the coils; the four-axis robot is used to drive the gripping structure to move.

[0012] In the preferred embodiment of the above-mentioned automatic coil mounting system for distribution transformers, the four-axis robot includes a first axis, a second axis rotatably connected to the first axis, a third axis rotatably connected to the second axis, and a fourth axis rotatably connected to the third axis; the gripping structure is installed at the end of the fourth axis away from the third axis; the fourth axis is an automatic lifting axis. With the above configuration, the position and angle of the coil can be adjusted relatively easily, thereby facilitating the mounting of the coil onto the core post of the iron core.

[0013] In the preferred embodiment of the above-described automatic assembly system for distribution transformer coils, the gripping structure includes a gripping frame connected to the four-axis robot, two grippers mounted on the gripping frame and arranged opposite each other, a ball screw that drives the two grippers closer to or further apart, and a locking cylinder arranged between the two grippers. Through this arrangement, the ball screw drives the two grippers closer to or further apart to accommodate the coil size; the locking cylinder locks the two grippers after they have gripped the coil, preventing the coil from falling.

[0014] To address the aforementioned technical problems, this invention also discloses an automatic assembly method for distribution transformer coils. This automatic assembly method is used in any of the aforementioned automatic assembly systems for distribution transformer coils. The automatic assembly method includes: controlling a vision recognition module to acquire the external dimensions and spatial positions of the coil and the iron core; controlling a 3D scanning module to scan the coil and the iron core and model them; controlling a path planning module to plan a movement path based on the spatial positions of the coil and the iron core; and controlling an assembly module, under the control of the control module, to grasp the coil according to the movement path and assemble it onto the core post of the iron core. Through the above configuration, this invention's automatic assembly method for distribution transformer coils can conveniently achieve automatic assembly, ensuring the quality of the coil and iron core assembly.

[0015] In the preferred embodiment of the above-described automatic assembly method for distribution transformer coils, after the control vision recognition module acquires the external dimensions and spatial position of the coil and the core, the control analysis module analyzes the degree of matching between the coil and the core based on their external dimensions. Through this setup, the analysis module automatically determines whether the core and coil can be assembled based on the degree of matching between their external dimensions. Attached Figure Description

[0016] The preferred embodiments of the present invention are described below with reference to the accompanying drawings, in which:

[0017] Figure 1 This is a schematic diagram of an embodiment of the automatic assembly system for distribution transformer coils according to the present invention.

[0018] Figure 2 This is a schematic diagram of the assembly module in the automatic assembly system for distribution transformer coils of the present invention.

[0019] Figure 3 This is a simplified motion diagram of the assembly module in the automatic assembly system for distribution transformer coils of the present invention.

[0020] Figure 4 This is a schematic diagram of the gripping structure in the automatic assembly system for distribution transformer coils of the present invention.

[0021] Figure 5 This is a schematic diagram of the automatic assembly method for distribution transformer coils according to the present invention.

[0022] List of reference numerals in the attached diagram: 1. Control module; 2. Vision recognition module; 3. 3D scanning module; 4. Path planning module; 5. Assembly module; 51. Four-axis robot; 511. First axis; 512. Second axis; 513. Third axis; 514. Fourth axis; 52. Gripping structure; 521. Gripping frame; 522. Gripper; 523. Ball screw; 524. Locking cylinder; 6. Analysis module; 7. Memory storage module. Detailed Implementation

[0023] Preferred embodiments of the present invention will now be described with reference to the accompanying drawings. Those skilled in the art should understand that these embodiments are merely illustrative of the technical principles of the present invention and are not intended to limit the scope of protection of the present invention.

[0024] It should be noted that in the description of this invention, terms such as "upper," "lower," "left," "right," "inner," and "outer," indicating directional or positional relationships, are based on the directional or positional relationships shown in the accompanying drawings. These are merely for ease of description and do not indicate or imply that the device or element must have a specific orientation, or be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0025] Furthermore, it should be noted that, in the description of this invention, unless otherwise explicitly specified and limited, the terms "installation," "setting," and "connection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection, an indirect connection through an intermediate medium, or a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0026] To improve or solve the technical problems of high manual intervention and unreliable assembly quality in the coil assembly process of existing technologies, this invention provides an automatic assembly system for distribution transformer coils. This automatic assembly system for distribution transformer coils includes: a control module 1; a vision recognition module 2, which acquires the external dimensions and spatial position of the coil and core; a 3D scanning module 3, which scans the coil and core and models them; a path planning module 4, which plans a movement path based on the spatial position of the coil and core; and an assembly module 5, which, under the control of the control module 1, grasps the coil according to the movement path and assembles it onto the core post of the core.

[0027] Figure 1 This is a schematic diagram of an embodiment of the automatic assembly system for distribution transformer coils according to the present invention. In one or more embodiments, the automatic assembly system for distribution transformer coils according to the present invention includes a control module 1, a vision recognition module 2, a 3D scanning module 3, a path planning module 4, an analysis module 6, an assembly module 5, and a memory storage module 7. The control module 1 is connected to each module and is used to control the operation of each module.

[0028] See also Figure 1The visual recognition module 2 acquires the external dimensions and spatial position of the coil and iron core. Specifically, the visual recognition module 2 includes an optical camera and an infrared light source to supplement the optical camera. Multiple optical cameras are provided, including low-speed and high-speed cameras. The low-speed cameras acquire the external dimensions and spatial position of the coil and iron core, while the high-speed cameras acquire the movement trajectory of the coil and the assembly trajectory of the coil and iron core, thus ensuring assembly quality. The external dimensions of the coil include the surface quality, inner diameter, and outer diameter; the external dimensions of the iron core include the number of core posts, surface quality, and dimensions. The visual recognition module 2 is connected to the control module 1 and can transmit the above information to the control module 1. Specifically, through the optical cameras, the visual recognition module 2 can perform functions such as point detection, line detection, hole detection, circle detection, contour detection, and flatness detection. Furthermore, the visual recognition module 2 has a built-in image import and memory module, which can import reference images and memorize autonomous detection images, providing a basis and standard for the detection process. Furthermore, the visual recognition module 2 uses a built-in visual positioning module to spatially locate the dimensions and center point of the coil and iron core. Furthermore, the visual recognition module 2 has a built-in QR code scanning module, which can scan and recognize barcodes and QR codes on the coil and iron core to confirm product information. For example, it can scan the QR code on the iron core to identify the phase sequence of the core column.

[0029] See also Figure 1The 3D scanning module 3 scans the coil and iron core and models them. The 3D scanning module 3 is connected to the control module 1 and can send the modeled coil and iron core to the control module 1. Furthermore, the analysis module 6 is connected to the control module 1 and can analyze the matching degree of the coil and iron core based on their external dimensions and the modeled coil and iron core. It is understood that deviations exist in the manufacturing of both the iron core and the coil. When both the core post and the coil have an upward deviation, the coil can be fitted onto the core post; when the core post has an upward deviation and the coil has a downward deviation, the coil cannot be fitted onto the core post. The analysis module 6 analyzes whether the iron core and coil have upward or downward deviations based on their external dimensions and the model, and whether they can be fitted together. Furthermore, the automatic fitting system of this invention also includes an automatic matching module, which can match the coil and iron core. For example, when ten transformers need to be fitted simultaneously, the automatic matching module can allocate the coil to a suitable iron core based on the analysis structure of the analysis module 6. Furthermore, when only one or two transformers need to be assembled, and the coil and iron core do not match, the analysis module 6 sends an alarm message to the control module 1. Furthermore, the memory storage module 7 stores the external dimensions, modeling, and matching degree of the iron core and coil, avoiding remodeling and analysis of iron cores and coils with the same external dimensions. Furthermore, the path planning module 4 is connected to the control module 1, and can obtain the spatial position of the coil and iron core from the control module 1 to plan the movement path.

[0030] Figure 2 This is a schematic diagram of the assembly module in the automatic assembly system for distribution transformer coils of the present invention. Figure 3 This is a simplified motion diagram of the assembly module in the automatic assembly system for distribution transformer coils of the present invention. Figure 4 This is a schematic diagram of the gripping structure in the automatic assembly system for distribution transformer coils of the present invention. Figure 2 , Figure 3 and Figure 4As shown, the assembly module 5 is connected to the control module 1 and, under the control of the control module 1, can grasp the coil according to the movement path and mount it onto the core post of the iron core. Specifically, the assembly module 5 includes a four-axis robot 51 and a grasping structure 52 mounted on the four-axis robot 51. The four-axis robot 51 includes a first axis 511, a second axis 512 rotatably connected to the first axis 511, a third axis 513 rotatably connected to the second axis 512, and a fourth axis 514 rotatably connected to the third axis 513. The end of the first axis 511 away from the second axis 512 is suitable for fixing to the mounting frame and is rotatably connected to the mounting frame. The fourth axis 514 is an automatic lifting axis, capable of driving the grasping structure 52 to rise and fall. Furthermore, the gripping structure 52 includes a gripping frame 521 connected to the four-axis robot 51, two grippers 522 mounted on the gripping frame 521 and arranged opposite each other, a ball screw 523 that drives the two grippers 522 to move closer or further apart, and a locking cylinder 524 arranged between the two grippers 522. The ball screw 523 is a bidirectional screw. Before gripping the coil, the gripping structure 52 adjusts the two grippers 522 to a suitable opening size according to the outer dimensions of the scanned coil using the ball screw 523. When the gripping structure 52 moves to the coil, it adjusts the grippers 522 via the ball screw 523 to grip the coil, and simultaneously, the locking cylinder 524 actuates to lock the two grippers 522, preventing the coil from slipping during transport. The control module 1 obtains the outer diameter, inner diameter, and core dimensions of the coil through the vision recognition module 2 and the 3D scanning module 3. It then selects the coil that matches the core through the analysis module 6 and the automatic matching module. The path planning module 4 plans the path, and the control module 1 controls the assembly module 5 to automatically lift the coil above the core and slowly lower it onto the core column to complete the coil assembly. After the coil assembly is completed, the transfer vehicle moves it to the next process.

[0031] Figure 5 This is a schematic diagram of the automatic assembly method for distribution transformer coils according to the present invention. Figure 1 and Figure 5 As shown, in order to improve or solve the technical problem of high manual involvement and unreliable assembly quality in the coil assembly process of existing technologies, this invention also provides an automatic assembly method for distribution transformer coils. This automatic assembly method includes:

[0032] Step S1: Control the visual recognition module 2 to obtain the external dimensions and spatial position of the coil and iron core;

[0033] Step S2: Control the 3D scanning module 3 to scan the coil and iron core, and model the coil and iron core;

[0034] Step S3: The control path planning module 4 plans the movement path according to the spatial position of the coil and the iron core;

[0035] Step S4: Under the control of the control module 1, the control module 5 picks up the coil according to the movement path and puts it on the core post of the iron core.

[0036] Furthermore, after step S1, a control analysis module 6 is included to analyze the matching degree of the coil and the iron core based on their external dimensions.

[0037] When assembling the coil and iron core:

[0038] The assembly line transports the iron cores and coils that need to be assembled to the assembly station;

[0039] The visual recognition module 2 detects and identifies the external dimensions of the iron core and coil, determines the external dimensions and spatial position of the coil and iron core, and transmits the data to the control module 1.

[0040] The 3D scanning module 3 scans the coil and iron core, models the coil and iron core, and transmits the model to the control module 1.

[0041] The control analysis module 6 analyzes the matching degree of the coil and the iron core based on their external dimensions, and issues an alarm signal when the coil and the iron core cannot be fitted together.

[0042] When the coil and iron core can be assembled, the control path planning module 4 plans the movement path;

[0043] The control module 5 grabs the coil according to the movement path, scans the QR code on the iron core to obtain the phase sequence of the core column on the iron core, and sequentially sets the coil on the three-phase core column;

[0044] The control memory storage module 7 stores the external dimensions, modeling, and matching degree of the coil and the iron core, avoiding the remodeling and analysis of iron cores and coils with the same external dimensions;

[0045] Once the coil assembly is complete, the transfer vehicle moves it to the next process.

[0046] The technical solution of the present invention has been described above with reference to the preferred embodiments shown in the accompanying drawings. However, it will be readily understood by those skilled in the art that the scope of protection of the present invention is obviously not limited to these specific embodiments. Without departing from the principles of the present invention, those skilled in the art can make equivalent changes or substitutions to the relevant technical features, and the technical solutions after such changes or substitutions will all fall within the scope of protection of the present invention.

Claims

1. An automatic assembly system for distribution transformer coils, characterized in that, include: Control module (1); The visual recognition module (2) acquires the external dimensions and spatial position of the coil and the iron core; The three-dimensional scanning module (3) scans the coil and the iron core and models the coil and the iron core; The path planning module (4) plans the movement path according to the spatial position of the coil and the iron core; The assembly module (5), under the control of the control module (1), grasps the coil according to the movement path and mounts it onto the core post of the iron core. The assembly module (5) includes a four-axis robot (51) and a grasping structure (52) mounted on the four-axis robot (51). The four-axis robot (51) includes a first axis (511), a second axis (512) rotatably connected to the first axis (511), a third axis (513) rotatably connected to the second axis (512), and a third axis (513) rotatably connected to the third axis (513). The fourth axis (514) is installed at the end of the fourth axis (514) away from the third axis (513). The fourth axis (514) is an automatic lifting axis. The gripping structure (52) includes a gripping frame (521) connected to the four-axis robot (51), two grippers (522) mounted on the gripping frame (521) and arranged opposite to each other, a ball screw (523) that drives the two grippers (522) to move closer or further away from each other, and a locking cylinder (524) arranged between the two grippers (522).

2. The automatic assembly system for distribution transformer coils according to claim 1, characterized in that, It also includes an analysis module (6), which analyzes the matching degree of the coil and the iron core based on the external dimensions of the coil and the iron core and the modeling of the coil and the iron core.

3. The automatic assembly system for distribution transformer coils according to claim 2, characterized in that, The external dimensions of the coil include the surface mass, inner diameter, and outer diameter of the coil; the external dimensions of the iron core include the number, surface mass, and size of the core posts.

4. The automatic assembly system for distribution transformer coils according to claim 2, characterized in that, It also includes a memory storage module (7), which stores the external dimensions, modeling, and matching degree of the coil and the iron core.

5. The automatic assembly system for distribution transformer coils according to claim 1, characterized in that, The visual recognition module (2) includes an optical camera and an infrared light source for supplementing light to the optical camera.

6. An automatic assembly method for distribution transformer coils, characterized in that, An automatic assembly system for distribution transformer coils as described in any one of claims 1-5; the automatic assembly method comprising: The visual recognition module (2) is controlled to obtain the external dimensions and spatial position of the coil and the iron core; The three-dimensional scanning module (3) is controlled to scan the coil and the iron core, and to model the coil and the iron core; The control path planning module (4) plans the movement path according to the spatial position of the coil and the iron core; Under the control of the control module (1), the control assembly module (5) grabs the coil according to the moving path and mounts it on the core post of the iron core.

7. The automatic assembly method for distribution transformer coils according to claim 6, characterized in that, After the control vision recognition module (2) acquires the external dimensions and spatial position of the coil and the iron core, the control analysis module (6) analyzes the matching degree of the coil and the iron core based on their external dimensions.

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