Automatic assembly line of transformer

Abstract

The invention relates to the technical field of transformer production, in particular to an automatic transformer assembly line which comprises a material incoming area, an automatic conveying subsystem and an intelligent dispatching subsystem. The material incoming area comprises a multifunctional three-dimensional goods shelf and a material recognition device. The material recognition device is used for recognizing the type, number and position information of materials, and the automatic conveying subsystem is used for conveying the materials from a material incoming area to a production line and comprises a conveying belt, an automatic guiding trolley, a suspension type crane and an annular rail car; the intelligent scheduling subsystem comprises a data processing module and a path planning module; the data processing module is used for receiving, processing and analyzing real-time data of the materials, and the real-time data of the materials comprises data uploaded by the material recognition device and production requirements of a production line; the path planning module is used for planning the conveying path of the materials from the material incoming area to the production line according to the real-time data of the materials. The technical scheme can improve the production efficiency and reduce the cost.

Description

Technical Field

[0001] The invention relates to the technical field of transformer production, and in particular to an automated transformer assembly line. Background Art

[0002] In the field of power equipment manufacturing, transformers are a vital component of the power system, and their manufacturing process involves multiple complex links, including material preparation, coil winding, assembly of various components, shaping and baking, body assembly, and final assembly. Traditional transformer production methods often rely on manual operation and simple mechanized equipment, which not only leads to low production efficiency, but also makes it difficult to ensure the consistency and traceability of product quality.

[0003] In recent years, with the rapid development of automation technology, more and more manufacturing companies have begun to explore the application of automation technology in the production process of transformers. However, most of the existing automated transformer production lines have problems such as unreasonable design and loose connection between various production links, resulting in a low degree of automation and limited improvement in production efficiency. Summary of the invention

[0004] The purpose of the present invention is to provide a transformer automation production line, which can improve production efficiency and reduce costs.

[0005] To achieve the above-mentioned purpose, the embodiment of the present disclosure provides a transformer automation production line, including a material incoming area, a winding area, an assembly area, a shaping and baking area, a body assembly area and a final assembly area, and each area is seamlessly connected with the automation equipment through a logistics path; The material incoming area includes a multifunctional vertical warehouse, which is used for automatic storage and retrieval of materials; The winding area is used for coil winding and is equipped with an automatic guided vehicle for coil transfer; The assembly area is used for the assembly of transformer components and is equipped with a suspension crane for lifting and assembly of heavy objects; The shaping and baking area is used to shape and bake the wound coils; The body assembly area is used for the body assembly of laminated core products; The general assembly area is used for drying the transformer body and oil filling, degassing and oil replenishment operations of the transformer. It is equipped with a circular rail car to realize the transportation of the transformer between different workstations.

[0006] Beneficial effects of the basic solution: This technical solution uses modular design to set up multiple relatively independent and closely connected transformer assembly line areas, making the production line scalable and able to flexibly adjust production scale and capacity according to market demand. At the same time, modular design can further improve the accuracy and traceability of production management and ensure product quality.

[0007] Through automated equipment such as the multi-functional automated storage and retrieval system in the material incoming area, the automated guided vehicle in the winding area, the overhead crane in the assembly area, and the surrounding rail vehicle in the general assembly area, the whole process from material storage and retrieval to product general assembly has been automated, significantly improving production efficiency and reducing labor costs. At the same time, seamless connection between various areas of the transformer production line is achieved through the logistics path and automated equipment, making the entire production process smoother and more efficient.

[0008] As an implementable preferred solution, the multi-functional automated storage and retrieval system is provided with an empty oil tank inlet, a static oil tank inlet, a return point for IBC pallets, an IBC pallet inlet, a static oil tank outlet, an empty oil tank outlet, an assembly material outlet, a stacked core outlet, a wound core body assembly material outlet, a temporary inlet, and a temporary outlet; the operation of the stacker is controlled by a PLC controller to achieve automated storage, retrieval, and transfer of oil tanks and pallets.

[0009] As an implementable preferred solution, the winding area includes a low-voltage winding area, a low-voltage foil winding area, an amorphous three-dimensional wound core area, a wire-foil integrated winding area, a high-voltage self-aligning wire winding area, and a coil transfer area; an automatic winding machine is also provided in the winding area, and is equipped with a tension control subsystem and a speed control subsystem.

[0010] As an implementable preferred solution, the assembly area is provided with a core assembly station, an oil tank assembly station, and an oil conservator assembly, oil injection, and repair area; a material buffer area is also provided for temporarily storing the materials and components required for assembly.

[0011] As an implementable preferred solution, the shaping and baking area includes a coil shaping area, a coil baking area, and a press plate removal area; In the coil shaping area, a coil shaping ring rail vehicle is used for the transfer and shaping of coils; in the coil baking area, baking equipment is used for baking coils, and the baking equipment is equipped with a temperature control subsystem and a time control subsystem; the press plate removal area is used for removing the coil press plate after baking and performing subsequent assembly preparation work.

[0012] As an implementable preferred solution, in the coil baking area, automated baking equipment is used,配合 with the temperature control subsystem, to automatically adjust the baking temperature and time according to the coil material and baking requirements; through thermal imaging technology, the temperature change during the baking process is monitored in real time.

[0013] As an implementable preferred solution, the core body assembly area includes a stacked core product core body assembly area, a wound core body assembly area, and an amorphous planar core body assembly area; The stacked core product core body assembly area is used for the core body assembly of stacked core products, including a stacked core buffer area, a core sleeve insertion and iron insertion station, and a lead wire assembly station; The wound core body assembly area is used for the body assembly of wound core products, including the wound core body assembly station and the wound core body lead wire assembly station; The amorphous planar body assembly area is used for the body assembly of amorphous planar products, including the assembly of amorphous planar iron cores, amorphous planar insulating parts and clips.

[0014] As an implementable preferred solution, the general assembly area includes a body drying tank, an oil filling area, a steam removal tank and an oil replenishment area, and a test area; The instrument body drying tank is used for drying the instrument body, including the instrument body drying tank front area, the instrument body drying tank rear area and the instrument body drying tank; The oil filling area is used for oil filling of transformers, including the oil filling RGV1 and oil filling equipment. The oil filling equipment injects insulating oil into the transformer according to preset parameters. At the same time, the degassing equipment degasses the insulating oil to remove gas and impurities. After the oil filling and degassing are completed, the transformer enters the oil filling area for oil filling to ensure the stability of the internal oil level. Degassing tank and oil filling area are used for degassing and oil filling operations of transformers to ensure that there are no bubbles inside the transformer and that there is sufficient oil; Test area, used for transformer test operations.

[0015] As an implementable optimal solution, a path planning algorithm is used to dynamically calculate and generate the optimal transfer path by combining the actual layout of the coil transfer area, the distribution of obstacles, and the current and target position information of the automatic guided vehicle. The specific contents are as follows: Obtain a map of the coil transfer area and build an environmental model; use A * Algorithm as a path planning algorithm, A * The algorithm finds the shortest path from the starting point to the end point by maintaining an open list and a closed list and combining a heuristic function to guide the search direction; According to the current state of the automated guided vehicle and the path conditions, the weight of the heuristic function in the path search is dynamically adjusted to balance the path length and the driving cost; the initially planned path is smoothed.

[0016] As an implementable and optimal solution, the AGV continuously monitors environmental changes and updates the environmental model in real time during the transfer task. When it is detected that the environmental changes affect the validity of the current path, the re-planning process is immediately triggered. The AGV is equipped with obstacle avoidance sensors, which monitor the movement status of the AGV and changes in the surrounding environment in real time based on inertial navigation technology and sensor data fusion; When a potential collision risk is detected, the kinematic model is used to predict the collision time and location, evaluate the collision risk level, and combine the obstacle type, distance and speed information to decide whether to implement a graded obstacle avoidance strategy or emergency braking; When avoiding, for static obstacles, a detour path is directly planned; for dynamic obstacles, avoidance is performed in advance based on the predicted trajectory; during emergency braking, an electro-hydraulic composite braking system is used, combining electromagnets and hydraulic cylinders to achieve rapid response braking. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of a transformer automation assembly line architecture. DETAILED DESCRIPTION

[0018] In order to make the technical solution and advantages of the present application clearer, the technical solution of the present invention will be further described in detail below in conjunction with the accompanying drawings. It will be understood that the specific embodiments described herein are only partial embodiments of the present invention, which are only used to explain the present application, rather than to limit the present application. It should be noted that the technical features or combinations of technical features described in the following embodiments should not be considered isolated, and they can be combined with each other to achieve better technical effects. The same reference numerals appearing in the drawings of the following embodiments represent the same features or components, which can be applied to different embodiments.

[0019] In addition, unless otherwise defined, the technical terms or scientific terms used in the description of the present invention should have the common meanings understood by those skilled in the art in the art to which the present invention belongs.

[0020] The present invention is further described in detail below in conjunction with the accompanying drawings: Embodiment 1 Reference Figure 1 , a transformer automation production line, is used to produce 10kV and below oil-fired transformers and 35~110kV oil-fired transformers, including material incoming area, winding area, assembly area, shaping and baking area, body assembly area, and final assembly area. Each area is seamlessly connected with the automation equipment through the logistics path to ensure the smooth and efficient production process.

[0021] The material incoming area includes a multifunctional vertical warehouse and a material shelf warehouse. The multifunctional vertical warehouse is used for automatic storage and retrieval of materials. The operation of the stacker is controlled by a PLC controller to achieve accurate positioning and rapid storage and retrieval of materials. The multifunctional vertical warehouse is also equipped with an empty oil tank inlet, a static oil tank inlet, a Sichuan-shaped pallet return point, a Sichuan-shaped pallet inlet, a static oil tank outlet, an empty oil tank outlet, an assembly material outlet, a stacked core outlet, a rolled core body assembly material outlet, a temporary inlet and a temporary outlet, etc., for the storage and retrieval of oil tanks and the return of pallets. The automatic control system is used to realize the automatic storage and transfer of oil tanks and pallets. The material shelf warehouse is used to store coils, insulators, iron cores and other materials.

[0022] The winding area includes low-voltage winding area, low-voltage foil winding area, amorphous three-dimensional coil core winding area, wire-foil integrated winding area, high-voltage self-arranging winding area, coil transfer area, etc. This area is equipped with automatic winding machines and AGV (automatic guided vehicles). The automatic winding machine is used for coil winding and can perform precise winding according to preset parameters. The winding machine is equipped with a tension control subsystem and a speed control subsystem to ensure the winding quality and efficiency of the coil. AGV is used to transfer coils in the coil transfer area to improve transfer efficiency and accuracy.

[0023] The assembly area is used for the assembly of transformer cores, oil tanks and other components. This area is equipped with core assembly stations, oil tank assembly stations, and oil storage cabinet assembly, oil filling, and repair areas to meet the assembly needs of various transformer components.

[0024] During the assembly process, automated assembly equipment and tools are used for precise assembly, such as the use of KBK (suspension crane) for lifting and assembly of heavy objects to improve assembly efficiency and safety. At the same time, this area also has a material buffer area for temporary storage of materials and parts required for assembly to ensure the smooth progress of assembly work.

[0025] The shaping and baking area includes the coil shaping area, the coil baking area, the pressure plate removal area, the coil buffer area after baking, the coil buffer area after pressing, the coil buffer area after pressure plate removal, etc., which are used to shape and bake the wound coils to improve the performance and stability of the coils.

[0026] The coil shaping area uses coil shaping RGV (ring track vehicle) to transport and shape the coils to ensure the shaping accuracy and consistency of the coils. The coil baking area uses baking equipment to bake the coils. The baking equipment includes a temperature control subsystem and a time control subsystem to improve the quality and performance of the coils. The pressure plate removal area is used to remove the coil pressure plate after baking and to carry out subsequent assembly preparations.

[0027] The coil baking area is used for baking the coils. It uses automated baking equipment and a temperature control subsystem to automatically adjust the baking temperature and time according to the coil material and baking requirements to achieve uniform baking of the coils. At the same time, thermal imaging technology is introduced to monitor the temperature changes during the baking process in real time to ensure baking quality and safety.

[0028] The post-baking coil buffer area is used to store the baked coils to facilitate the subsequent pressure plate removal operation.

[0029] The coil buffer area after pressing is used to store the coils after pressing. The wire flow direction in this area is counterclockwise, which is convenient for the caching and transportation of the coils.

[0030] The coil buffer area after the pressure plate is removed is used to store the coil after the pressure plate is removed, which is convenient for subsequent device body assembly operations.

[0031] The device body assembly area includes the stacked core product body assembly area, the wound core body assembly area and the amorphous flat body assembly area. The stacked core product body assembly area is used for the assembly of the stacked core product body, including the stacked core buffer area, the sleeve iron insertion station, the lead wire assembly station, etc. The stacked core is transported from the stacked core buffer area to the sleeve iron insertion station through an automated conveyor line for body assembly. The wound core body assembly area is used for the assembly of the wound core product body, including the wound core body assembly station, the wound core body lead assembly station, etc. The wound core body is transported from the wound core body buffer station to the assembly station through an automated conveyor line for body assembly and lead wire assembly. The amorphous flat body assembly area is used for the assembly of the amorphous flat product body, including the assembly of amorphous flat cores, amorphous flat insulation parts and clamps. The amorphous flat body is transferred from the coil shaping workshop to the device body assembly area through an automated conveyor line for body assembly.

[0032] The general assembly area includes the body drying tank, oil filling area, degassing tank, oil replenishing area, test area, etc. The body drying tank is used for drying the body, including the front area of ​​the body drying tank, the rear area of ​​the body drying tank and the body drying tank. The body is transported from the body assembly area to the front area of ​​the drying tank through an automated conveyor line for drying. The oil filling area is used for oil filling of the transformer, including the oil filling RGV1 and the oil filling equipment. The oil filling equipment injects insulating oil into the transformer according to preset parameters. At the same time, the degassing equipment degasses the insulating oil to remove gas and impurities. After the oil filling and degassing are completed, the transformer enters the oil replenishing area for oil replenishment to ensure the stability of the internal oil level. The oil filling RGV uses an automated track system to realize the rapid transportation of the transformer between different workstations. The degassing tank and the oil replenishing area are used for degassing and oil replenishing operations of the transformer to ensure that there are no bubbles and sufficient oil inside the transformer. The test area is used for transformer test operations, including electrical tests, insulation tests, etc.

[0033] Embodiment 2 When traditional AGVs operate in complex and ever-changing coil transfer areas, they often face problems such as unreasonable path selection, long transfer time, high energy consumption, and safety hazards.

[0034] The technical feature that distinguishes this embodiment from the above-mentioned embodiments is that a path planning algorithm is used in combination with the actual layout of the coil transfer area, the obstacle distribution, and the current position and target position information of the AGV to dynamically calculate and generate the optimal transfer path.

[0035] Obtain a map of the coil transit area, including path width, intersection location, obstacle location and other information, convert the information into a data format recognizable by the algorithm, and build an environmental model.

[0036] Use A * Algorithm as a path planning algorithm, A * The algorithm finds the shortest path from the starting point to the end point by maintaining an open list (including nodes to be evaluated) and a closed list (including evaluated nodes) and combining a heuristic function to guide the search direction.

[0037] In the process of shortest path planning, the weight of the heuristic function in the path search is dynamically adjusted according to the current state of the AGV (such as power, load) and the path condition (such as congestion level) to balance the path length and driving cost. At the same time, the initially planned path is smoothed to reduce unnecessary sharp turns and frequent starts and stops, and improve the feasibility and reliability of the path.

[0038] During the AGV's transfer mission, it continuously monitors environmental changes (such as new obstacles, road repairs, etc.) and updates the environmental model in real time. When it detects that environmental changes affect the effectiveness of the current path, it immediately triggers the replanning process to ensure that the AGV always travels along the optimal path.

[0039] AGV is equipped with obstacle avoidance sensors, which monitor the movement status of AGV and changes in the surrounding environment in real time based on inertial navigation technology and sensor data fusion. When a potential collision risk is detected, the kinematic model is used to predict the collision time and location, evaluate the collision risk level, and combine the obstacle type, distance and speed information to decide whether to implement a graded obstacle avoidance strategy or emergency braking.

[0040] When avoiding, for static obstacles, a detour path is directly planned; for dynamic obstacles, avoidance is performed in advance based on the predicted trajectory.

[0041] In case of emergency braking, an electro-hydraulic composite braking system is used, combining electromagnets and hydraulic cylinders to achieve fast-response braking. When the pre-collision detection module issues a braking command, the electromagnet quickly acts to activate the hydraulic cylinder to generate sufficient braking force, causing the AGV to slow down to a stop in a very short time.

[0042] Embodiment 3 The technical feature that distinguishes this embodiment from the above-mentioned embodiment is that the running path of the assembly area is planned, and the specific contents are as follows: The assembly area is abstracted into a two-dimensional plane or three-dimensional space, in which the KBK track, material storage point, assembly station, etc. are used as nodes, and the connection relationship between the nodes is used as the path according to the assembly task and material requirements.

[0043] The running path of KBK is represented as an individual gene sequence, and each gene represents a node or a connection relationship between nodes.

[0044] A set of paths are randomly generated as individuals to initialize the population.

[0045] The fitness value of each individual in the population is calculated according to the fitness function. The fitness function formula is as follows:

[0046]

[0047]

[0048]

[0049] in, represents the path length; Indicates the time cost, Indicates the movement speed of KBK; represents the obstacle avoidance penalty, Indicates the number of obstacles encountered on the path, represents the fixed penalty value for each obstacle, , and They are the weight coefficients of path length, time cost and obstacle avoidance penalty respectively; and is a very small positive number used to avoid zero denominator.

[0050] Roulette wheel selection is used to select excellent individuals from the population as parents.

[0051] The selected parent individuals are subjected to a crossover operation, that is, part of the gene sequence is exchanged to generate new individuals, which increases the diversity of the population and helps to search for a better solution.

[0052] Perform mutation operations on newly generated individuals, that is, change the values ​​of certain genes with a certain probability, so as to further increase the diversity of the population and avoid local optimal solutions.

[0053] Use newly generated offspring individuals to replace some of the old individuals in the population to form a new population; repeat operations such as selection, crossover and mutation until the termination condition is met.

[0054] Whether the algorithm has converged is determined by observing whether the fitness values ​​of individuals in the population tend to be stable; if the algorithm has converged, the optimal or approximately optimal KBK operation path can be obtained. In addition, it should be noted that the optimized path should be more in line with the requirements and constraints of the actual assembly task.

[0055] The above contents are only embodiments of the present invention. The common sense such as the known specific structures and characteristics in the scheme is not described in detail here. The ordinary technicians in the relevant field know all the common technical knowledge in the technical field to which the invention belongs before the application date or the priority date, can obtain all the existing technologies in the field, and have the ability to apply the conventional experimental means before that date. The ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the enlightenment given by this application. Some typical known structures or known methods should not become obstacles for the ordinary technicians in the relevant field to implement this application. It should be pointed out that for the technicians in this field, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, which will not affect the effect of the implementation of the present invention and the practicality of the patent. The protection scope required by this application shall be based on the content of its claims, and the specific implementation methods and other records in the specification can be used to explain the content of the claims.

Claims

1. A transformer automation production line, characterized by: It includes the material incoming area, winding area, assembly area, shaping and baking area, body assembly area and final assembly area. Each area is seamlessly connected through logistics paths and automated equipment. The material incoming area includes a multifunctional vertical warehouse, which is used for automatic storage and retrieval of materials; The winding area is used for coil winding and is equipped with an automatic guided vehicle for coil transfer; The assembly area is used for the assembly of transformer components and is equipped with a suspension crane for lifting and assembly of heavy objects; The shaping and baking area is used to shape and bake the wound coils; The body assembly area is used for the body assembly of laminated core products; The general assembly area is used for drying the transformer body and oil filling, degassing and oil replenishment operations of the transformer. It is equipped with a circular rail car to realize the transportation of the transformer between different workstations.

2. The transformer automation production line according to claim 1, characterized in that: The multifunctional vertical warehouse is provided with an empty oil tank inlet, a stationary oil tank inlet, a C-shaped pallet return point, a C-shaped pallet inlet, a stationary oil tank outlet, an empty oil tank outlet, an assembly material outlet, a stacked iron core outlet, a rolled iron core body assembly material outlet, a temporary inlet and a temporary outlet; the operation of the stacker is controlled by a PLC controller to realize the automatic storage, retrieval and transportation of oil tanks and pallets.

3. The transformer automation production line according to claim 1, characterized in that: The winding area includes a low-voltage winding area, a low-voltage foil winding area, an amorphous three-dimensional wound core winding area, a wire-foil integrated winding area, a high-voltage self-arranging wire winding area and a coil transfer area; the winding area is also provided with an automatic winding machine, and is equipped with a tension control subsystem and a speed control subsystem.

4. The transformer automation production line according to claim 1, characterized in that: The assembly area is provided with an iron core assembly station, an oil tank assembly station, and an oil storage cabinet assembly, oil filling, and rework area; it is also provided with a material buffer area for temporarily storing materials and parts required for assembly.

5. The transformer automation production line according to claim 1, characterized in that: The shaping and baking area includes a coil shaping area, a coil baking area and a pressure plate removal area; The coil shaping area uses a coil shaping circular rail car to transport and shape the coils; the coil baking area uses baking equipment to bake the coils, and the baking equipment is equipped with a temperature control subsystem and a time control subsystem; the pressure plate removal area is used to remove the coil pressure plate after baking and carry out subsequent assembly preparations.

6. The transformer automation production line according to claim 5, characterized in that: The coil baking area adopts automatic baking equipment and cooperates with the temperature control subsystem to automatically adjust the baking temperature and time according to the material and baking requirements of the coil; and uses thermal imaging technology to monitor the temperature changes during the baking process in real time.

7. The transformer automation production line according to claim 1, characterized in that: The device body assembly area includes the stacked core product body assembly area, the rolled core body assembly area and the amorphous plane body assembly area; The body assembly area of ​​the laminated core product is used for the body assembly of the laminated core product, including the laminated core buffer area, the sleeve iron insertion station, and the lead wire assembly station; The wound core body assembly area is used for the body assembly of wound core products, including the wound core body assembly station and the wound core body lead wire assembly station; The amorphous planar body assembly area is used for the body assembly of amorphous planar products, including the assembly of amorphous planar iron cores, amorphous planar insulating parts and clips.

8. The transformer automation production line according to claim 1, characterized in that: The general assembly area includes the body drying tank, oil filling area, steam removal tank and oil replenishment area, and test area; The instrument body drying tank is used for drying the instrument body, including the instrument body drying tank front area, the instrument body drying tank rear area and the instrument body drying tank; The oil filling area is used for oil filling of transformers, including the oil filling RGV1 and oil filling equipment. The oil filling equipment injects insulating oil into the transformer according to preset parameters. At the same time, the degassing equipment degasses the insulating oil to remove gas and impurities. After the oil filling and degassing are completed, the transformer enters the oil filling area for oil filling to ensure the stability of the internal oil level. Degassing tank and oil filling area are used for degassing and oil filling operations of transformers to ensure that there are no bubbles inside the transformer and the oil is sufficient; Test area, used for transformer test operations.

9. The transformer automation production line according to claim 3, characterized in that: The path planning algorithm is used to dynamically calculate and generate the optimal transfer path by combining the actual layout of the coil transfer area, the distribution of obstacles, and the current and target position information of the automatic guided vehicle. The specific contents are as follows: Obtain a map of the coil transfer area and build an environmental model; use A * Algorithm as a path planning algorithm, A * The algorithm finds the shortest path from the starting point to the end point by maintaining an open list and a closed list and combining a heuristic function to guide the search direction; According to the current state of the AGV and the path conditions, the weight of the heuristic function in the path search is dynamically adjusted to balance the path length and driving cost; Smooth the initially planned path.

10. The transformer automation production line according to claim 9, characterized in that: When the AGV is performing the transfer task, it continuously monitors environmental changes and updates the environmental model in real time. When it detects that environmental changes affect the effectiveness of the current path, it immediately triggers the re-planning process. The AGV is equipped with obstacle avoidance sensors, which monitor the movement status of the AGV and changes in the surrounding environment in real time based on inertial navigation technology and sensor data fusion; When a potential collision risk is detected, the kinematic model is used to predict the collision time and location, evaluate the collision risk level, and combine the obstacle type, distance and speed information to decide whether to implement a graded obstacle avoidance strategy or emergency braking; When avoiding static obstacles, the system directly plans a detour path. For dynamic obstacles, avoidance is performed in advance based on the predicted trajectory; during emergency braking, an electro-hydraulic composite braking system is used, combining electromagnets and hydraulic cylinders to achieve fast-response braking.

Images