Noise standard reaching method based on production process control

Abstract

The invention relates to the technical field of iron core noise reduction, and discloses a noise standard reaching method based on production process control, which comprises the following steps: obtaining design parameters and a target noise value, and calculating a predicted noise value according to the design parameters; judging whether the predicted noise value is smaller than or equal to a target noise value, and if the predicted noise value is larger than the target noise value, determining a target adjustment amount according to the target noise value and the predicted noise value; a plurality of noise reduction means are matched from a preset second database according to the target adjustment amount to serve as adjustment means, and adjustment parameters corresponding to the matched adjustment means are determined according to the design parameters. According to the design parameters, control parameters of all working procedures in iron core production are determined from a preset first database, the corresponding working procedures are sequentially determined according to the matched adjustment means, the control parameters of the corresponding working procedures are replaced with the corresponding adjustment parameters, and then production process control is carried out according to the control parameters of all the working procedures.

Description

Technical Field

[0001] The invention relates to the technical field of core noise reduction, and in particular to a noise compliance method based on production process control. Background Art

[0002] As end users pay more attention to and have higher requirements for transformer noise, the noise limits of transformer noise, especially dry-type transformers, are getting lower and lower. Core noise is the main source of transformer noise, and controlling core noise is an important method of transformer noise control.

[0003] Due to the complexity of the core vibration noise mechanism and the immaturity of noise control measures, core manufacturers are currently unable to control core noise to meet standards. One of the reasons is that the key processes and key factors that affect noise in the core production process are not clearly identified, making it impossible to effectively control core noise.

[0004] The present invention provides a noise compliance method based on production process control, which helps to achieve noise process control. Summary of the invention

[0005] In view of the above-mentioned shortcomings of the prior art, an object of the present invention is to provide a noise compliance method based on production process control to solve one or more problems in the prior art.

[0006] To achieve the above object, the technical solution of the present invention is as follows: A noise compliance method based on production process control comprises the following steps: Obtain design parameters and target noise values, and calculate predicted noise values ​​according to the design parameters; Determine whether the predicted noise value is less than or equal to the target noise value, If the predicted noise value is less than or equal to the target noise value, the control parameters of each process in the iron core production are determined from a preset first database according to the design parameters, and the production process control is implemented according to the control parameters of each process; wherein the first database stores the control parameters of each process corresponding to the iron cores of different specifications; If the predicted noise value is greater than the target noise value, the target adjustment amount is determined according to the target noise value and the predicted noise value; According to the target adjustment amount, a plurality of noise reduction means are matched from a preset second database as adjustment means, wherein the second database stores a plurality of noise reduction means and a plurality of estimated noise reduction ranges, and different estimated noise reduction ranges correspond to different noise reduction combinations, and the noise reduction combination includes at least one noise reduction means; The adjustment parameters corresponding to the matched adjustment means are determined according to the design parameters.

[0007] According to the design parameters, the control parameters of each process in the core production are determined from the preset first database, and the corresponding process is determined in turn according to the matched adjustment means, and the control parameters of the corresponding process are replaced with the corresponding adjustment parameters, and then the production process control is implemented according to the control parameters of each process.

[0008] Furthermore, the second database includes a basic database and an additional database, wherein the basic database and the additional database both store a plurality of noise reduction means, noise reduction combinations formed by combining the noise reduction means, and estimated noise reduction ranges corresponding to the noise reduction combinations one by one; the noise reduction means in the basic database are defined as basic means, and the noise reduction means in the additional database are defined as additional means; The method of matching a plurality of noise reduction means from a preset second database according to the determined preset noise reduction range as adjustment means comprises the following steps: Determine whether the target adjustment amount is greater than the preset value, If it is not greater than, then select a number of basic means from the basic library as adjustment means according to the target adjustment amount; If it is greater, all specific basic means in the basic library will be used as adjustment means, and several additional means will be selected from the additional library as adjustment means according to the target adjustment amount.

[0009] Furthermore, the selecting of a plurality of additional means from an additional library as adjustment means according to the target adjustment amount comprises the following steps: Generates a corrected noise reduction value based on the target adjustment amount and the preset value. A corresponding noise reduction combination is matched from the additional library according to the modified noise reduction value, and the additional means in the matched noise reduction combination is used as the adjustment means.

[0010] Further, the design parameters include core design dimensions and thickness adjustment types, and the adjustment means include clamping force control and material selection control; The step of determining the adjustment parameters corresponding to the matched adjustment means according to the design parameters comprises the following steps: When the adjustment means is clamping force control, the adjustment parameters including clamping force, torque value, binding spacing and binding force are determined according to the core design size; When the adjustment means is material selection control, the adjustment parameters including material thickness and AMV value are determined according to the thickness adjustment type and the target adjustment amount.

[0011] Further, the thickness adjustment type includes allowing adjustment and prohibiting adjustment, and determining the adjustment parameters including material thickness and AMV value according to the thickness adjustment type includes the following steps: Determine whether the thickness adjustment type is allowed. If allowed, the material thickness is determined based on the corrected noise reduction value; If not allowed, the AWV value is determined based on the modified noise reduction value.

[0012] Further, the step of determining whether the thickness adjustment type is before adjustment is allowed comprises the following steps: Determine whether the preset material library has an AWV value corresponding to the material. If yes, then match the AWV value from the material library according to the target adjustment amount; if no, then determine whether the thickness adjustment type is allowed adjustment.

[0013] Furthermore, after matching the AWV value from the material library according to the target adjustment amount, it is determined whether the thickness adjustment type is adjustment allowed. If allowed, a thick plate is selected from the material corresponding to the matched AWV value.

[0014] Furthermore, before determining the control parameters of each process in the core production from the preset first database according to the design parameters, the following steps are included: Determine the key factors affecting the core noise based on the core vibration noise mechanism; Combine the existing production control parameters of the core and the allowable control parameters of the equipment to determine the control parameters of the key factors affecting the noise of the core; Track the abnormalities related to key factors of each process in the production line, and perform abnormal control to obtain test cores; Conduct noise tests on test cores to obtain control effectiveness; The key factors of noise and control parameters are modified according to the effectiveness of control to determine the control parameters of the key factors affecting the core noise, and the determined control parameters are stored in the first database.

[0015] Compared with the prior art, the beneficial technical effects of the present invention are as follows: when the predicted noise is greater than the target noise value, a suitable noise reduction combination and corresponding adjustment parameters are selected to replace the control parameters in the conventional production process, so that the actual core noise produced can meet the design requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A flowchart of a noise compliance method based on production process control provided by an embodiment of the present invention is shown. DETAILED DESCRIPTION

[0017] A noise compliance method based on production process control, see Figure 1 , including the following steps: S100: Obtain design parameters and target noise values, and calculate predicted noise values ​​according to the design parameters.

[0018] Design parameters include core parameters and test parameters.

[0019] The core parameters include core design size, core weight, thickness adjustment type, design magnetic flux density, excitation frequency, design number of turns and other parameters. Among them, the thickness adjustment type is based on the design requirements to determine whether the thickness of the silicon steel sheet is allowed to be adjusted. The thickness adjustment types include allowing adjustment and prohibiting adjustment.

[0020] The test parameters include noise test reference standards, test methods, noise test distance and other information.

[0021] According to the vibration noise mechanism of the core and the existing noise prediction formulas, a noise prediction formula containing the contribution weights of unknown parameters to the noise is preliminarily output.

[0022] Based on the above noise prediction formula, the core parameters related to the core and noise are collected in batches, and the noise at a distance of 1m from the core is tested in batches. The core parameters and the corresponding noise are fitted with the unknown parameters in the core noise prediction formula using a multi-factor regression analysis method, so that the key parameters are substituted into the fitting formula to obtain the predicted value of the noise 1m away from the core. The batch core noise test collects the deviation between the predicted core noise value and the measured noise, and the noise prediction formula is corrected according to the maximum deviation.

[0023] Finally, the necessary data in the design parameters are input into the revised noise prediction formula to calculate the predicted noise value.

[0024] S200: Determine whether the predicted noise value is less than or equal to the target noise value.

[0025] If the predicted noise value is less than or equal to the target noise value, control parameters of each process in the core production are determined from a preset first database according to the design parameters, and production process control is implemented according to the control parameters of each process.

[0026] The first database stores control parameters of each process corresponding to cores of different specifications. Among them, the process is divided into key processes and ordinary processes according to whether the process will affect the core noise. The control parameters of ordinary processes are generally specified by national standards, industry standards or enterprise standards, while the control parameters corresponding to key processes generally need to be formulated according to the core. Compared with ordinary processes, the control parameters corresponding to special processes are undoubtedly more special. Therefore, the process referred to in this embodiment specifically refers to the key process, and the control parameters described mainly refer to the control parameters corresponding to the key process.

[0027] In one embodiment, the method for obtaining the control parameters stored in the first database comprises the following steps: S001. Determine the key factors affecting the core noise based on the core vibration noise mechanism.

[0028] S002. Determine the control parameters of the key factors affecting the noise of the core by combining the existing production control parameters of the core and the allowable control parameters of the equipment.

[0029] S003. Track the anomalies related to key factors in each process of the production line and perform abnormal control to obtain test cores.

[0030] S004. Perform noise test on the test core to obtain the effectiveness of control.

[0031] S005. Correct the key factors and control parameters of the noise according to the effectiveness of the control to determine the control parameters of the key factors affecting the core noise.

[0032] S006. Store all determined control parameters in the first database to provide assistance for subsequent noise control in the production process.

[0033] Among them, according to the vibration mechanism of the vibration system, the factors affecting the core vibration include: excitation force, excitation frequency, mass of the vibration system, equivalent elastic modulus, damping of the vibration system, resonant frequency of the structure, and core structure. According to these influencing factors, further determining the quantifiable data is the key factor. For example, the key factors corresponding to the influencing factor excitation force include magnetic density, and the key factors corresponding to the influencing factor core structure include core window height and center distance.

[0034] To judge whether the process affects the noise is to judge whether the process will affect the value of the key factor. Accordingly, in order to stabilize the core noise (reduce the error between the actual noise and the predicted noise), it is necessary to stabilize the value of the key factor, and the means to make the key factor within a smaller value range is the control parameter. Different key factors have different control parameters. Since the control parameters are implemented in a certain process, a corresponding relationship will be established between the key factor and the process.

[0035] The control parameters preliminarily designed are verified through steps S003 and S004. If the control effectiveness is high, the control parameters, the corresponding process and the corresponding key factors are stored together in the first database. If the control effectiveness is weak, the control parameters are modified and the verification steps are repeated.

[0036] S300: If the predicted noise value is greater than the target noise value, determine a target adjustment amount according to the target noise value and the predicted noise value.

[0037] Generally, the default predicted noise value is greater than the target noise value, which means that the noise of the produced core needs to be reduced through process control. Therefore, the target adjustment amount is obtained by subtracting the target noise value from the predicted noise value to clarify the noise value that needs to be reduced.

[0038] The production process control of core noise includes two aspects: one is the process control of key factors that affect noise in each production process, such as the need to control the flatness and burrs of a single silicon steel sheet in the longitudinal and transverse shearing processes, the need to control the flatness of the silicon steel sheet in the sheet sorting process, and the need to control the tightening sequence of the screws in the assembly process; the second is the process control of key factors in noise reduction measures.

[0039] If the target adjustment amount is negative or equal to zero, only the key factors in the production process need to be controlled to ensure that the noise meets the standard. This belongs to the control of the stability of the noise level in batch core production.

[0040] If the target adjustment is a positive number, it is necessary to control the key factors in the production process and the key factors in the noise reduction measures to ensure that the noise meets the standard. This is when the current manufacturing control level can no longer meet the existing noise requirements, and special noise reduction measures are taken to reduce noise.

[0041] Noise reduction measures include material selection control noise reduction measures and clamping force control noise reduction measures.

[0042] Among them, the key factors for material selection to control noise reduction measures are the magnetostrictive properties and thickness of the material, and the key factors for clamping force to control noise reduction are the size and uniformity of the clamping force.

[0043] The subsequent steps in this embodiment introduce how to achieve the noise reduction target by controlling the key factors in the noise reduction measures when the target adjustment amount is a positive number.

[0044] S400, matching a plurality of noise reduction means from a preset second database according to the target adjustment amount as adjustment means.

[0045] The second database includes a basic database and an additional database, and both the basic database and the additional database store a plurality of noise reduction means, a noise reduction combination formed by combining the plurality of noise reduction means, and an estimated noise reduction range corresponding to the noise reduction combination.

[0046] The noise reduction methods stored in the basic library are more stable than those stored in the additional library. Therefore, when selecting noise reduction methods, it is preferred to select them from the basic library. The additional library is used to supplement the noise reduction solutions when facing higher noise reduction requirements.

[0047] The noise reduction combination includes at least one noise reduction scheme. Taking into account the different difficulties of different noise reduction schemes and certain differences in implementation, the noise reduction combination is not formed by enumerating all noise reduction schemes, but rather the combination that can improve the noise reduction effect is determined as the noise reduction combination based on actual experiments.

[0048] The estimated noise reduction range is formed based on the noise reduction results after a large number of actual tests corresponding to the noise reduction combination.

[0049] In this embodiment, since the clamping force has a more stable control on noise reduction, the noise reduction means stored in the basic library are noise reduction means related to the clamping force, and the noise reduction means stored in the additional library are noise reduction means related to material selection. The noise reduction means in the basic library are defined as the basic means, and the noise reduction means in the additional library are defined as the additional means.

[0050] The basic means include the clamping force control of the core column, the clamping force control of the upper yoke and the clamping force control of the lower yoke. The noise reduction combinations formed are: 1. Clamping force control of the upper yoke or lower yoke; 2. Clamping force control of the upper yoke and core column; 3. Clamping force control of the upper and lower yokes and core column. The estimated noise reduction ranges corresponding to these three noise reduction teams are 0dB-1dB, 1dB-3dB, and 3dB-5dB respectively.

[0051] Additional measures include thickness control and AWV value control, and the corresponding noise reduction combinations are 1. selection control; 2. AWV value control; the corresponding estimated noise reduction range is 0dB-2dB.

[0052] Specifically, matching a plurality of noise reduction means from a preset second database according to the determined preset noise reduction range as adjustment means includes the following steps: S410: Determine whether the target adjustment amount is greater than a preset value.

[0053] S420: If it is not greater than, select several basic means from the basic library as adjustment means according to the target adjustment amount.

[0054] S430: If it is greater than, all specific basic means in the basic library are used as adjustment means, and a number of additional means are selected from the additional library as adjustment means according to the target adjustment amount.

[0055] The preset value is the maximum noise reduction amount set according to the estimated noise reduction range in the basic library. In this embodiment, the preset value is 5dB.

[0056] Selecting several basic means from the basic library according to the target adjustment amount first matches the estimated noise reduction range in the basic library into which the target adjustment amount falls, and all the basic means in the noise reduction combination corresponding to the matched estimated noise reduction range will be selected.

[0057] The specific basic means are all the noise reduction means in the noise reduction combination corresponding to the estimated noise reduction range with the largest upper limit.

[0058] In this embodiment, the specific basic means include stem clamping force control, upper yoke clamping force control and lower yoke clamping force control.

[0059] According to the target adjustment amount, several additional means are selected from the additional library as adjustment means. Since additional means are added on the basis of specific basic means, it is necessary to coordinate the noise reduction amount that can be generated by the basic means and the additional means, so it is necessary to regenerate a suitable noise reduction range first. Specifically, the following steps are included: S431, generating a modified noise reduction value according to the target adjustment amount and the preset value.

[0060] S432: Match a corresponding noise reduction combination from the additional library according to the modified noise reduction value, and use the additional means in the matched noise reduction combination as the adjustment means.

[0061] The corrected noise reduction value is obtained by subtracting the preset value from the target adjustment amount.

[0062] S500: Determine adjustment parameters corresponding to the matched adjustment means according to the design parameters.

[0063] In this embodiment, when the adjustment means is clamping force control, the adjustment parameters including clamping force, torque value, binding spacing and binding force are determined according to the core design size.

[0064] When the adjustment means is material selection control, the adjustment parameters including material thickness and AMV value are determined according to the thickness adjustment type and the target adjustment amount.

[0065] Wherein, determining the adjustment parameters including material thickness and AMV value according to the thickness adjustment type includes the following steps: S510: Determine whether the thickness adjustment type is adjustment allowed.

[0066] S520: If permitted, determine the material thickness according to the corrected noise reduction value.

[0067] S530: If not allowed, determine the AWV value according to the modified noise reduction value.

[0068] For the AWV value of silicon steel sheets in the free state when designing magnetic flux density, it is 80-100 dB(A). Silicon steel sheets are divided into two grades according to the AWV value, where the AWV value is 80-90 dB(A) for grade A and the AWV value is 90-100 dB(A) for grade B. When the corrected noise reduction value is between 1dB-2dB, select Class A silicon steel sheets. When the corrected noise reduction value is less than or equal to 1dB(A), select Class B silicon steel sheets.

[0069] The thickness range of silicon steel sheets in material noise reduction is easily controlled within the range of 0.2-0.27mm. When the corrected noise reduction value is between 1dB-2dB, select 0.27mm silicon steel sheets. When the corrected noise reduction value is equal to 1dB, select 0.23mm silicon steel sheets. When the corrected noise reduction value is less than 1dB, select 0.2mm silicon steel sheets. And on the basis of selecting the material thickness, you can also select silicon steel sheets with lower AWV values.

[0070] Considering that the material thickness may be different when the AWV value is the same, the material can be further screened. Therefore, after matching the AWV value from the material library according to the target adjustment amount, determine whether the thickness adjustment type is allowed. If allowed, select the thickest plate from the material corresponding to the matched AWV value.

[0071] When the AWV values ​​are consistent, thicker plates are preferred because thicker plates are less likely to bend during the production process and are less likely to generate new stress, thereby reducing the impact on noise.

[0072] In addition, since the AWV value can only be obtained by testing the material, and the testing of the AWV value takes time and material resources, the newly stored material may not have the AWV value tested. Therefore, before step S510, the following steps are also included: S501, determining whether there are AWV values ​​corresponding to the materials in the preset material library.

[0073] S502: If yes, match the AWV value from the material library according to the target adjustment amount.

[0074] S503: If not, determine whether the thickness adjustment type is adjustment allowed.

[0075] From the above steps, it can be seen that when the corresponding AWV value of the inventory material has been detected, the material is selected based on the AWV value first. Of course, the thickness of the selected material needs to be selected according to the design requirements. When the newly stored material has not yet been tested for the AWV value, the thickness adjustment type will be further determined. If the thickness adjustment type is not allowed to be adjusted, it is necessary to notify the staff to first test the AWV value of the material and enter the test results into the preset material library.

[0076] S600, determine the control parameters of each process in the core production from the preset first database according to the design parameters, determine the corresponding process according to the matched adjustment means in turn, replace the control parameters of the corresponding process with the corresponding adjustment parameters, and then implement production process control according to the control parameters of each process.

[0077] In order to effectively control noise, the adjustment parameters need to be more accurate than the control parameters in the same process. For example, in the production of 1600kVA cores, if the control parameters corresponding to the upper and lower yoke torques are adjusted in the assembly process, the error range between the measured noise and the predicted noise of the produced core is generally -5dB to +15dB. If the adjustment parameters are used instead of the control parameters in the assembly process, the error range is generally -5dB to +5dB.

[0078] 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.

[0079] The above-mentioned embodiments only express several implementation methods of the present invention, and the descriptions thereof are relatively specific and detailed, but they cannot be understood as limiting the scope of the invention patent. It should be pointed out that, for ordinary technicians in this field, several variations and improvements can be made without departing from the concept of the present invention, and these all belong to the protection scope of the present invention. Therefore, the protection scope of the patent of the present invention shall be subject to the attached claims.

Claims

1. A noise compliance method based on production process control, characterized in that: The following steps are involved: Obtain design parameters and target noise values, and calculate predicted noise values ​​according to the design parameters; Determine whether the predicted noise value is less than or equal to the target noise value, If the predicted noise value is less than or equal to the target noise value, the control parameters of each process in the iron core production are determined from a preset first database according to the design parameters, and the production process control is implemented according to the control parameters of each process; wherein the first database stores the control parameters of each process corresponding to the iron cores of different specifications; If the predicted noise value is greater than the target noise value, the target adjustment amount is determined according to the target noise value and the predicted noise value; According to the target adjustment amount, a plurality of noise reduction means are matched from a preset second database as adjustment means, wherein the second database stores a plurality of noise reduction means and a plurality of estimated noise reduction ranges, and different estimated noise reduction ranges correspond to different noise reduction combinations, and the noise reduction combination includes at least one noise reduction means; Determine the adjustment parameters corresponding to the matched adjustment means according to the design parameters; According to the design parameters, the control parameters of each process in the core production are determined from the preset first database, and the corresponding processes are determined in turn according to the matched adjustment means, and the control parameters of the corresponding processes are replaced with the corresponding adjustment parameters, and then the production process control is implemented according to the control parameters of each process.

2. A noise compliance method based on production process control as claimed in claim 1, characterized in that: The second database includes a basic database and an additional database, wherein the basic database and the additional database both store a plurality of noise reduction means, noise reduction combinations formed by combining the noise reduction means, and estimated noise reduction ranges corresponding to the noise reduction combinations one by one; Define the noise reduction means in the basic library as basic means, and the noise reduction means in the additional library as additional means; The method of matching a plurality of noise reduction means from a preset second database according to the determined preset noise reduction range as adjustment means comprises the following steps: Determine whether the target adjustment amount is greater than the preset value, If it is not greater than, then select a number of basic means from the basic library as adjustment means according to the target adjustment amount; If it is greater, all specific basic means in the basic library will be used as adjustment means, and several additional means will be selected from the additional library as adjustment means according to the target adjustment amount.

3. A noise compliance method based on production process control as claimed in claim 2, characterized in that: The step of selecting a plurality of additional means from an additional library as adjustment means according to the target adjustment amount comprises the following steps: Generates a corrected noise reduction value based on the target adjustment amount and the preset value. A corresponding noise reduction combination is matched from the additional library according to the modified noise reduction value, and the additional means in the matched noise reduction combination is used as the adjustment means.

4. A noise compliance method based on production process control as claimed in claim 3, characterized in that: The design parameters include core design dimensions and thickness adjustment types, and the adjustment means include clamping force control and material selection control; The step of determining the adjustment parameters corresponding to the matched adjustment means according to the design parameters comprises the following steps: When the adjustment means is clamping force control, the adjustment parameters including clamping force, torque value, binding spacing and binding force are determined according to the core design size; When the adjustment means is material selection control, the adjustment parameters including material thickness and AMV value are determined according to the thickness adjustment type and the target adjustment amount.

5. A noise compliance method based on production process control as claimed in claim 4, characterized in that: The thickness adjustment type includes allowing adjustment and prohibiting adjustment. The step of determining adjustment parameters including material thickness and AMV value according to the thickness adjustment type includes the following steps: Determine whether the thickness adjustment type is allowed. If allowed, the material thickness is determined based on the corrected noise reduction value; If not allowed, the AWV value is determined based on the modified noise reduction value.

6. A noise compliance method based on production process control as claimed in claim 5, characterized in that: The step of judging whether the thickness adjustment type is before allowing adjustment comprises the following steps: Determine whether the preset material library has an AWV value corresponding to the material. If yes, then match the AWV value from the material library according to the target adjustment amount; if no, then determine whether the thickness adjustment type is allowed adjustment.

7. A noise compliance method based on production process control as claimed in claim 6, characterized in that: After matching the AWV value from the material library according to the target adjustment amount, it is determined whether the thickness adjustment type is adjustment allowed. If allowed, a thick plate is selected from the material corresponding to the matched AWV value.

8. The noise compliance method based on production process control as claimed in claim 1, characterized in that: Before determining the control parameters of each process in the core production from the preset first database according to the design parameters, the following steps are included: Determine the key factors affecting the core noise based on the core vibration noise mechanism; Combine the existing production control parameters of the core and the allowable control parameters of the equipment to determine the control parameters of the key factors affecting the noise of the core; Track the abnormalities related to key factors of each process in the production line, and perform abnormal control to obtain test cores; Conduct noise tests on test cores to obtain control effectiveness; The key factors of noise and control parameters are modified according to the effectiveness of control to determine the control parameters of the key factors affecting the core noise, and the determined control parameters are stored in the first database.

Images