An automatic transformer quality detection system

Abstract

The present invention is applicable to the field of electrical engineering technology, and provides an automated transformer quality detection system, the system comprising: a plurality of input detectors, a mid-section detector, an output controller, a detection pipeline, a voltage input device, a current detector, and a controller; each of the input detectors is connected to a transformer input terminal to count the transformers to be tested input to the detection pipeline; the detection pipeline comprises an input section and a detection section; the input section is located upstream of the detection pipeline, and is used to carry the transformer input by the transformer input terminal, and the detection section is located downstream of the detection pipeline, and is used to test the performance of the transformer to be tested; the controller determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector. This solution has a low overall cost and is suitable for providing accurate automated quality detection for high-speed and large-volume small transformer production lines.

Description

Technical Field

[0001] The invention belongs to the technical field of electrical engineering, and in particular relates to an automatic transformer quality detection system. Background Art

[0002] A transformer is an electrical device used to change the voltage level of alternating current. It converts the voltage between the input coil (called the primary coil) and the output coil (called the secondary coil) through the principle of electromagnetic induction, while keeping the electrical power basically unchanged. Transformers can be classified according to their rated capacity and rated voltage level. For example, according to the rated capacity, they can be divided into the following categories: small transformers, usually referring to transformers with a rated voltage of about 100 volts, used for household and small industrial purposes; medium-sized transformers, usually referring to transformers with a rated voltage of about 100 volts, used for industry and distribution networks; large transformers, used for large industries and power transmission, and their rated capacity can reach tens of kilovolt-amperes to hundreds of kilovolt-amperes or more.

[0003] Small transformers are widely used in various small electronic products, household appliances and various industrial modules, and the demand is very large. Therefore, for the small transformer production line, its output per unit time is very large. However, due to the production cost and output requirements, after the entire production process of the transformer is completed, it is often not possible to conduct a unified inspection of the quality of all transformers before leaving the factory. The existing mainstream method is to take samples in proportion from each batch and each production line for random inspection.

[0004] Therefore, it is difficult for existing transformer detection methods to strike a balance between maintaining a low detection cost and having a high detection speed. Summary of the invention

[0005] The purpose of the embodiments of the present application is to provide an automated transformer quality inspection system, aiming to solve the problem that existing transformer inspection methods are difficult to strike a balance between maintaining a low inspection cost and having a high inspection speed.

[0006] The embodiment of the present application is implemented as follows: an automated transformer quality detection system, the system comprising:

[0007] Several input detectors, mid-stage detectors, output controllers, detection pipelines, voltage input devices, current detectors and controllers;

[0008] Each of the input detectors is connected to a transformer delivery terminal for counting the transformers to be tested input to the detection pipeline;

[0009] The detection pipeline includes an input section and a detection section; the input section is located upstream of the detection pipeline and is used to carry the transformer input from the transformer transmission end; the detection section is located downstream of the detection pipeline and is used to test the performance of the transformer to be tested;

[0010] The output controller is located at the end of the detection section and is used to discharge the transformer to be tested from the detection pipeline;

[0011] The middle section detector is located upstream of the detection section and is used to control the output controller. Whenever the middle section detector detects that a transformer to be tested enters the detection section, the output controller is controlled to discharge a transformer to be tested, so that the number of transformers to be tested in the detection section remains constant;

[0012] The voltage input device is used to provide voltage input to the transformer to be tested in the detection section;

[0013] The current detector is used to detect the current output of the transformer to be tested in the detection section;

[0014] The controller is connected to the input detector, the middle section detector, the output controller, the voltage input device and the current detector, and determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector.

[0015] Preferably, the detection pipeline comprises a plurality of sliding rail grooves for connecting to respective terminals of the transformer to be tested and transporting the transformer to be tested from the upstream of the input section to the downstream of the detection section.

[0016] Preferably, the detection pipeline comprises a first rail groove, a second rail groove, a third rail groove and a fourth rail groove;

[0017] The first rail groove and the second rail groove are used to be connected to two terminals of the primary coil of the transformer to be tested, respectively, and the third rail groove and the fourth rail groove are used to be connected to two terminals of the secondary coil of the transformer to be tested, respectively;

[0018] The voltage input device includes a first voltage input terminal and a second voltage input terminal, which are respectively connected to the first groove and the second groove, and are used to form a potential difference between the first groove and the second groove.

[0019] Preferably, the transformers to be tested in the detection section are closely arranged close to each other.

[0020] Preferably, the third rail groove comprises N first groove segments of equal length and insulated from each other, and the fourth rail groove comprises N second groove segments of equal length and insulated from each other, and the first groove segments and the second groove segments are of equal length;

[0021] The first slot segment of the k+1th section is electrically connected to the second slot segment of the kth section, ;

[0022] The current detector comprises a first current measuring end and a second current measuring end, which are respectively connected to the first section first slot segment and the Nth section second slot segment, and are used to detect the current signal flowing through the current detector.

[0023] Preferably, the length of the first slot section satisfy:

[0024]

[0025]

[0026] in, is the length of the outer shell of the transformer to be tested near the secondary coil end, is the distance between the third rail groove and the fourth rail groove.

[0027] Preferably, the input detector and the middle section detector are both photoelectric switches.

[0028] Preferably, the peripheral circuit of the controller includes: a buzzer and a warning light. When the controller detects an abnormal transformer, the controller controls the buzzer and the warning light to sound an alarm.

[0029] Preferably, the peripheral circuit of the controller further includes:

[0030] The timer circuit is used to provide time information to the controller.

[0031] An automated transformer quality inspection system provided in an embodiment of the present application has the following outstanding advantages: through the inspection pipeline provided in the present application, a large number of transformers to be tested can be inspected simultaneously, the overall inspection speed is fast, the use is convenient, and the production cost of the inspection equipment is low, which is conducive to wide promotion; since the transformer to be tested can only be discharged from the assembly line after running for a period of time in the test section, the system can detect the continuous working ability of the transformer, avoiding the missed faults caused by the difficulty of traditional inspection to maintain the tutorial time; it can also obtain the inspection waveform to know the product quality of the transformer to be tested in the batch and time period, the inspection is more comprehensive and sufficient, and the yield rate is significantly improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 A structural block diagram of an automated transformer quality detection system provided in an embodiment of the present application;

[0033] Figure 2 A schematic diagram of a transformer provided in an embodiment of the present application;

[0034] Figure 3 A schematic diagram of a connection method between a transformer to be tested and a detection pipeline provided in an embodiment of the present application;

[0035] Figure 4 FIG. 4 is a block diagram of the internal structure of a computer device in one embodiment. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not intended to limit the present invention.

[0037] It is understood that the terms "first", "second", etc. used in this application may be used herein to describe various elements, but unless otherwise specified, these elements are not limited by these terms. These terms are only used to distinguish a first element from another element. For example, a first script may be referred to as a second script, and similarly, a second script may be referred to as a first script without departing from the scope of this application.

[0038] like Figure 1 As shown, in one embodiment, an automated transformer quality detection system is proposed, which may specifically include:

[0039] Several input detectors, mid-stage detectors, output controllers, detection pipelines, voltage input devices, current detectors and controllers;

[0040] Each of the input detectors is connected to a transformer delivery terminal for counting the transformers to be tested input to the detection pipeline;

[0041] The detection pipeline includes an input section and a detection section; the input section is located upstream of the detection pipeline and is used to carry the transformer input from the transformer input end; the detection section is located downstream of the detection pipeline and is used to test the performance of the transformer to be tested;

[0042] The output controller is located at the end of the detection section and is used to discharge the transformer to be tested from the detection pipeline;

[0043] The middle section detector is located upstream of the detection section and is used to control the output controller. Whenever the middle section detector detects that a transformer to be tested enters the detection section, the output controller is controlled to discharge a transformer to be tested, so that the number of transformers to be tested in the detection section remains constant;

[0044] The voltage input device is used to provide voltage input to the transformer to be tested in the detection section;

[0045] The current detector is used to detect the current output of the transformer to be tested in the detection section;

[0046] The controller is connected to the input detector, the middle section detector, the output controller, the voltage input device and the current detector, and determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector.

[0047] In the embodiment of the present application, since the output is often lower than the detection speed, a detection line can have multiple input terminals at the same time. For example, a line is connected to several production groups, and each production group's product output terminal is provided with a counter to count the output. In addition, when it is detected that there are too many products on the line, the input terminal can be controlled to stop inputting. The detection line can have driving and conveying capabilities, and can be Figure 2 The transformer shown is connected to the pipeline by means of a snap-in connection, a plug-in connection, etc. The detection section of the pipeline detects it. The current detector used in this embodiment is used to cooperate with the load to detect the operating capacity of the transformer under load, wherein the load can be adjusted based on the situation, for example, by using a resistor-capacitor circuit, etc. An abnormality in the current signal, such as too high, too low, abnormal peaks or troughs, oscillations, etc., can be considered as an abnormal transformer.

[0048] In this embodiment, the middle section detector can be located at the end of the detection section pipeline to count the number of transformers in the detection section. The output controller action can also be indirectly controlled by the controller. For example, whenever a transformer to be tested passes through, the last transformer to be tested in the detection pipeline is taken out of the pipeline. That is, the detection section can be a step-by-step detection, one enters and one exits, and the number of transformers in the detection section is generally maintained stable. This makes the time for each transformer to be tested the same, and within this time, the continuous working state capability of the transformer can be obtained. The output controller can discharge the transformer to be tested from the pipeline for controlling the switch door, the jacking device, etc., which is not limited here. The initial number of transformers to be tested in the detection section can be determined according to actual conditions. The advantage of maintaining a stable number is that the current value output in the detection section is also constant, which is convenient for unified standard detection and can simplify the detection circuit structure.

[0049] In this embodiment, the voltage input device and the current detector can detect the transformer by connecting the terminals to each other, setting a breadboard socket, and when the transformer moves to a specific position, the assembly line stops transmission, and uses a large number of voltage input terminals and current detection terminals to connect with all the transformers in the assembly line, and then perform detection.

[0050] As an embodiment of the present application, the outstanding advantages are: through the detection pipeline provided in the present application, a large number of transformers to be tested can be tested simultaneously, the overall detection speed is fast, the use is convenient, and the production cost of the detection equipment is low, which is conducive to wide promotion; since the transformer to be tested can only be discharged from the assembly line after running for a period of time in the test section, the system can detect the continuous working ability of the transformer, avoiding the failure omission caused by the difficulty of traditional detection to maintain the tutorial time; it is also possible to obtain the detection waveform to know the product quality of the transformer to be tested in the batch and time period, the detection is more comprehensive and sufficient, and the yield rate is significantly improved.

[0051] In a preferred embodiment, the detection pipeline comprises a plurality of sliding rails for connecting to respective terminals of the transformer to be tested and transporting the transformer to be tested from the upstream of the input section to the downstream of the detection section.

[0052] In this embodiment, if Figure 3 As shown, a schematic diagram of a pipeline is provided. Figure 3 The right-pointing arrow in the middle indicates the direction of movement of the assembly line. Figure 3 The middle rectangular frame is the transformer body or the transformer fixing seat, fixing frame, etc. For the convenience of detection, the assembly line is provided with four slots 1-1, 1-2, 2-1, and 2-2. In this embodiment, slots 1-1 and 1-2 are used to connect the primary side of the transformer, and 2-1 and 2-2 are used to connect the secondary side. The four terminals of the transformer are respectively plugged in. It can be understood that when the transformer has more or fewer terminals, the number of slots can be increased or decreased, and 4 are used as an example here. The transformer to be tested slides along the assembly line from upstream to downstream by pushing or pulling the assembly line.

[0053] In the embodiment of the present application, when using the present assembly line, the four terminals of the transformer can be manually or automatically snapped and plugged into the assembly line detection slot. Since the transformer is generally square and the relative positions of its several terminals are fixed after the entire production process is completed, it can be easily snapped into the inspection slot of the assembly line.

[0054] It is understandable that the contacts of the transformer can be slidably arranged in the elastic sliding groove in a snap-fit ​​manner, and the material hardness of the sliding groove should be higher than the material hardness of the transformer contacts to reduce contact wear.

[0055] In a preferred embodiment, the inspection pipeline includes a first rail groove and a second rail groove;

[0056] The first rail groove and the second rail groove are used to be connected to two terminals of the primary coil of the transformer to be tested, respectively, and the third rail groove and the fourth rail groove are used to be connected to two terminals of the secondary coil of the transformer to be tested, respectively;

[0057] The voltage input device includes a first voltage input terminal and a second voltage input terminal, which are respectively connected to the first groove and the second groove, and are used to form a potential difference between the first groove and the second groove.

[0058] In this embodiment, in order to further reduce the cost, preferably, all transformers to be tested use a common voltage input terminal for testing, and there is no need to arrange a large number of voltage input contact terminals to supply power to each transformer separately. That is, the voltage provided in the track is used as the voltage source, and there is no need to equip each transformer with a separate voltage input terminal. Due to the presence of the middle section detector, the number of transformers to be tested in the detection section is kept constant, which is convenient for detection.

[0059] Through the setting method of this embodiment, the system only needs to measure the total current output. When the current detector detects an abnormal output, it is determined that a faulty transformer has occurred. The fault generally occurs when the first transformer to be tested in the detection section is input, such as a circuit breaker. If there is no fault after the first transformer is detected, it may be a fault of other transformers in the detection section. The reason may be abnormal current after temperature rise caused by poor contact of the solder joint, short circuit of the winding, etc. Therefore, the abnormal situation can be roughly judged based on the waveform of the output current. In addition, the stability factor of this batch of transformers can be obtained based on the difference between the waveform of the output current and the standard current. This setting further reduces the production and use costs of the system.

[0060] In a preferred embodiment, if Figure 3 As shown, the transformers to be tested in the detection section are closely arranged close to each other.

[0061] In the embodiment of the present application, in order to increase the detection capacity of the assembly line, the transformers to be tested are arranged closely to each other.

[0062] In a preferred embodiment, the detection pipeline includes a third rail groove and a fourth rail groove;

[0063] The third chute includes N first chute segments of equal length and insulated from each other, and the fourth chute includes N second chute segments of equal length and insulated from each other, and the first chute segments and the second chute segments are of equal length;

[0064] The first slot segment of the k+1th section is electrically connected to the second slot segment of the kth section, ;

[0065] The current detector comprises a first current measuring end and a second current measuring end, which are respectively connected to the first section first slot segment and the Nth section second slot segment, and are used to detect the current signal flowing through the current detector.

[0066] In the embodiment of the present application, in order to further reduce the production cost of the equipment, avoid the hardware cost required for measuring the current of each transformer individually, and reduce the complexity of the measuring equipment, a multi-segment track design is adopted. Figure 3 As shown, there are several discontinuities in track 2-1 and track 2-2, and several sub-slots, i.e. slot segments, are formed through the discontinuities. The upper and lower slot segments are arranged from one side to the other side, and are the upper slot segment of the first section, the upper slot segment of the second end, and so on. The same is true for the lower slot segment. The purpose of the setting is: when the transformer slides in the track, the secondary side of a transformer connects the upper and lower corresponding slot segments to form an induced voltage source. Since the k+1th upper slot segment and the kth lower slot segment are electrically connected, several adjacent transformers in the chute are connected in series with each other, so that the current detector only needs to detect the total current under the overall load to obtain whether all transformers are normal. This significantly improves the detection speed. The detection structure is simplified, and there is no need to set up a large number of separate current sensors, which reduces costs.

[0067] It can be understood that the connection mode of each first section, first slot section and second slot section and the relative position of the upper and lower parts can be determined based on the specific form and actual connection relationship of the transformer. Here, only a basic four-terminal transformer detection method is given, but the first slot section and the second slot section should be of equal length. The value of K is from 1 to N. When the position of the terminal changes relatively, the length of the first slot section should also change relatively.

[0068] In a preferred embodiment, the length of the first slot segment satisfy:

[0069]

[0070]

[0071] in, is the length of the outer shell of the transformer to be tested near the secondary coil end, is the distance between the third rail groove and the fourth rail groove.

[0072] In the embodiment of the present application, the first slot segment and the second slot segment are equal in length, and the transformer is rectangular. At this time, when the transformers are closely arranged, the specific geometric relationship is as follows: Figure 3 As shown. It is understandable that here The length of the shell of the transformer to be tested near the secondary coil end is only an example, and may also be the side length of the bracket of the plug-in transformer or the fixed transformer.

[0073] In a preferred embodiment, the input detector and the middle section detector are both photoelectric switches.

[0074] In an embodiment of the present application, the input detector and the middle section detector may be a pressure contact switch, a photoelectric counter, etc. Preferably, a photoelectric switch is selected to reduce costs. After each transformer to be tested passes through the photoelectric switch, the photoelectric switch fluctuates between high and low levels, and then the controller performs a count.

[0075] In a preferred embodiment, the peripheral circuit of the controller includes: a buzzer and a warning light. When the controller detects an abnormal transformer, the controller controls the buzzer and the warning light to sound an alarm.

[0076] In the embodiment of the present application, the controller may use an audible and visual alarm to give an alarm when an abnormality occurs. The abnormality may refer to a large abnormal fluctuation in the current measurement value, a current value that is too high or too low, etc.

[0077] In a preferred embodiment, the peripheral circuit of the controller further includes: a timer circuit for providing time information to the control circuit.

[0078] In an embodiment of the present application, a timer circuit can be used for timing, for example, by using a single-chip microcomputer or a quartz oscillation circuit. Since it takes a certain amount of time for the transformer to be tested to enter the detection section, or for the transformer to be tested to be discharged from the detection section, the number of transformers in the detection section changes during this time, so this time period is not used as a criterion for abnormal judgment. A counter circuit can be used, and a time threshold can be set using a controller. When the abnormal time of the current signal is measured to be higher than the threshold time, an alarm is issued. It is understandable that the residence time of each new transformer entering the detection section should be greater than the threshold time to avoid false alarms.

[0079] In the embodiment of the present application, the controller may be a PLC control device, a single chip microcomputer or a computer device, etc., which is not limited here.

[0080] Figure 4 The internal structure diagram of a computer device in one embodiment is shown. The computer device may specifically be Figure 1 Controller in. Figure 4As shown, the computer device includes a processor, a memory, a network interface, an input device and a display screen connected via a system bus. Among them, the memory includes a non-volatile storage medium and an internal memory. The non-volatile storage medium of the computer device stores an operating system and may also store a computer program, which, when executed by the processor, enables the processor to implement the control method described in the embodiment of the present application. The internal memory may also store a computer program, which, when executed by the processor, enables the processor to execute the control method. The display screen of the computer device may be a liquid crystal display or an electronic ink display, and the input device of the computer device may be a touch layer covering the display screen, or a button, trackball or touchpad provided on the housing of the computer device, or an external keyboard, touchpad or mouse, etc.

[0081] Those skilled in the art will understand that Figure 4 The structure shown in the figure is only a block diagram of a part of the structure related to the solution of the present application, and does not constitute a limitation on the computer device to which the solution of the present application is applied. The specific computer device may include more or fewer components than those shown in the figure, or combine certain components, or have a different arrangement of components.

[0082] It should be understood that, although each step in the flow chart of each embodiment of the present application is shown in sequence according to the indication of the arrow, these steps are not necessarily performed in sequence according to the order indicated by the arrow. Unless there is clear explanation in this article, the execution of these steps does not have strict order restriction, and these steps can be performed in other orders. Moreover, at least a portion of the steps in each embodiment may include a plurality of sub-steps or a plurality of stages, and these sub-steps or stages are not necessarily performed at the same time, but can be performed at different times, and the execution order of these sub-steps or stages is not necessarily performed in sequence, but can be performed in turn or alternately with at least a portion of other steps or sub-steps or stages of other steps.

[0083] Those skilled in the art can understand that all or part of the processes in the above-mentioned embodiment methods can be completed by instructing the relevant hardware through a computer program, and the program can be stored in a non-volatile computer-readable storage medium. When the program is executed, it can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application may include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. As an illustration and not limitation, RAM is available in many forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link (Synchlink) DRAM (SLDRAM), memory bus (Rambus) direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM).

[0084] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0085] The above-mentioned embodiments only express several implementation methods of the present application, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the present application. It should be pointed out that, for a person of ordinary skill in the art, several variations and improvements can be made without departing from the concept of the present application, and these all belong to the protection scope of the present application. Therefore, the protection scope of the present application shall be subject to the attached claims.

Claims

1. An automated transformer quality inspection system, characterized in that: The system comprises: Several input detectors, mid-stage detectors, output controllers, detection pipelines, voltage input devices, current detectors and controllers; Each of the input detectors is connected to a transformer delivery terminal for counting the transformers to be tested input to the detection pipeline; The detection pipeline includes an input section and a detection section; the input section is located upstream of the detection pipeline and is used to carry the transformer input from the transformer transmission end; the detection section is located downstream of the detection pipeline and is used to test the performance of the transformer to be tested; The output controller is located at the end of the detection section and is used to discharge the transformer to be tested from the detection pipeline; The middle section detector is located upstream of the detection section and is used to control the output controller. Whenever the middle section detector detects that a transformer to be tested enters the detection section, the output controller is controlled to discharge a transformer to be tested, so that the number of transformers to be tested in the detection section remains constant; The voltage input device is used to provide voltage input to the transformer to be tested in the detection section; The current detector is used to detect the current output of the transformer to be tested in the detection section; The controller is connected to the input detector, the middle section detector, the output controller, the voltage input device and the current detector, and determines whether there is an abnormal transformer in the detection section based on the current signal output by the current detector; The detection pipeline includes a first rail groove, a second rail groove, a third rail groove and a fourth rail groove; The first rail groove and the second rail groove are used to be connected to two terminals of the primary coil of the transformer to be tested, respectively, and the third rail groove and the fourth rail groove are used to be connected to two terminals of the secondary coil of the transformer to be tested, respectively; The voltage input device comprises a first voltage input terminal and a second voltage input terminal, which are respectively connected to the first track groove and the second track groove, and are used to form a potential difference between the first track groove and the second track groove; The transformers to be tested in the detection section are arranged closely to each other; The third rail groove comprises N first groove segments of equal length and insulated from each other, and the fourth rail groove comprises N second groove segments of equal length and insulated from each other, and the first groove segments and the second groove segments are of equal length; The first slot segment of the k+1th section is electrically connected to the second slot segment of the kth section, ; The current detector comprises a first current measuring end and a second current measuring end, which are respectively connected to the first slot segment of the first section and the second slot segment of the Nth section, and are used to detect the current signal flowing through the current detector; The length of the first slot section satisfy: in, is the length of the outer shell of the transformer to be tested near the secondary coil end, is the distance between the third rail groove and the fourth rail groove.

2. An automated transformer quality detection system according to claim 1, characterized in that: The detection pipeline comprises a plurality of sliding rail grooves, which are used to be connected to the respective terminals of the transformer to be tested and to transport the transformer to be tested from the upstream of the input section to the downstream of the detection section.

3. The automatic transformer quality detection system according to claim 1 is characterized in that: The input detector and the middle section detector are both photoelectric switches.

4. The automatic transformer quality detection system according to claim 1 is characterized in that: The peripheral circuit of the controller includes: a buzzer and a warning light. When the controller detects an abnormal transformer, the controller controls the buzzer and the warning light to sound an alarm.

5. An automated transformer quality detection system according to claim 4, characterized in that: The peripheral circuit of the controller also includes: The timer circuit is used to provide time information to the controller.

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