A transformer total assembly process intelligent torque assembly system and process method

Abstract

The application belongs to the technical field of intelligent manufacturing of transformers, and particularly relates to an intelligent torque assembly system and process method for general assembly of transformers, which comprises the following steps: 1) according to the voltage grade of the transformer and the product type of the transformer, a three-dimensional process model of the transformer of different specifications and models is established, and a three-dimensional process library is formed; 2) the three-dimensional process model of the transformer is divided into modules for assembly, so as to serve as the overall sequence of assembly, the assembly sequence of each component of the transformer is obtained, and a two-dimensional process diagram of the corresponding component is obtained; 3) according to the structural characteristics of the transformer, a parameterized database is established according to the parameter information of the actual bolts of each type of structure, and the parameterized database is taken as a discrete unit library of the local sequence of assembly, so as to input the bolt parameter information after the two-dimensional process diagram of the corresponding component of the transformer is selected; 4) the three-dimensional process model of the transformer is divided into modules again, a process manufacturing model matched with the three-dimensional model of the transformer product is established, and the process manufacturing model is matched to the three-dimensional process diagram of the general assembly product of the transformer, so as to realize data mapping; and 5) a process flow is set in the intelligent torque assembly system, and the intelligent torque assembly system executes the corresponding process task flow.

Description

Technical Field

[0001] This invention belongs to the field of intelligent manufacturing technology for transformers, specifically an intelligent torque assembly system and process method for transformer assembly. Background Technology

[0002] The transformer assembly process utilizes bolted connections for accessory assembly. Accessories to be installed include oil conservators, coolers, radiators, outgoing line devices, riser seats, bushings, manholes, tank edges, and connecting pipes. All these accessories are installed using metal bolts for fastening. The tightening of these bolts directly determines the uniformity and rationality of the clamping force on the connected components. The uniformity of the clamping force and the scientific accuracy of the tightening torque directly affect the product's sealing performance. The product's sealing performance directly determines the transformer's safety and stability during operation. However, the current bolted assembly process in transformer assembly still suffers from the following problems: a lack of scientific methods in the tightening process, an inability to quantify and parameterize the bolt tightening process and its status, and a lack of traceability in the tightening status. Summary of the Invention

[0003] The purpose of this invention is to provide an intelligent torque assembly system and process method for transformer final assembly. It analyzes the installation characteristics from the perspective of transformer final assembly, dividing the transformer installation into modules. The work of each module does not interfere with or affect each other, and simultaneous installation is possible. Simultaneously, a final assembly database is established using the developed intelligent torque assembly system. The researched final assembly tightening process is loaded into the intelligent torque assembly system. Production is carried out using the intelligent torque assembly system. Following the system's scientific guidance, bolt tightening information is collected and fed back to the intelligent torque assembly system, completing closed-loop control of bolt assembly in the final assembly production process.

[0004] The technical solution adopted by the present invention to achieve the above objectives is: a process method for an intelligent torque assembly system in the transformer assembly process, comprising the following steps:

[0005] 1) Based on the voltage level and product type of the transformer, establish three-dimensional process models of transformers of different specifications and models to form a three-dimensional process library;

[0006] 2) Divide the three-dimensional process model of the transformer into modules for assembly, which serves as the overall assembly sequence. This yields the assembly sequence of each component of the transformer and corresponding two-dimensional process drawings of the parts.

[0007] 3) Based on the structural characteristics of the transformer, a parameterized database is established for each type of structure according to the parameter information of the actual bolts of the transformer. The parameterized database is used as a discretized unit library for the local sequence of assembly, so as to realize the input of bolt parameter information after selecting the two-dimensional process drawing of the corresponding parts of the transformer.

[0008] 4) The 3D process model of the transformer is divided into modules again to establish a process manufacturing model that matches the 3D model of the transformer product; and the process manufacturing model is matched to the 3D process drawing of the transformer assembly product to realize data mapping.

[0009] 5) Set the process flow in the intelligent torque assembly system, and the intelligent torque assembly system will execute the corresponding process task flow.

[0010] In step 1), the types of transformer products include: AC transformers, reactors, converter transformers, and special transformers;

[0011] The voltage levels of the transformers include: AC 110kV, AC 220kV, AC 330kV, AC 400kV, single-phase AC 500kV, three-phase AC 500kV, AC 750kV, AC 1000kV; 500kV reactors, 1000kV reactors; ±200kV converter transformers, ±400kV converter transformers, ±600kV converter transformers, ±800kV converter transformers, and ±1100kV converter transformers.

[0012] In step 2), the three-dimensional process model of the transformer is divided into modules for assembly, which serves as the overall assembly sequence, resulting in the assembly sequence of each component of the transformer, specifically:

[0013] The three-dimensional process model of the transformer is divided according to the main components of the overall transformer. The overall order is as follows: radiator module, bushing module, oil conservator module, and oil tank module, and the corresponding two-dimensional process drawings of the components are obtained.

[0014] In step 3), based on the structural characteristics of the transformer, a parameterized database is established for each type of structure according to the parameter information of the actual bolts of the transformer. Specifically:

[0015] Based on the structural characteristics of transformers, they are divided into: round flange structure and square flange structure; the parameter information of the actual bolts includes: the number of bolts and the bolt specification composition.

[0016] The number and specifications of bolts corresponding to the circular flange structure and the method flange structure, as well as the two-dimensional process drawings of the transformer main components, are combined to form a discretized unit library;

[0017] Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. Tighten the local bolts in the following order: first the middle, then the two sides, tighten symmetrically and adjacently, repeat 3 times, to ensure the uniformity of installation force on all sealing surfaces in the final assembly process and improve the installation quality.

[0018] Specifically, the tightening torque value for the bolts is set as follows:

[0019] a. Taking into account the compression of the sealing gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm;

[0020] b. Using the yield strength of the connected parts as the critical point, simulation calculations are performed to obtain the allowable torque values ​​under different corresponding transformer main component structures;

[0021] c. Based on the constraints of steps a and b, take the smaller value as the standard torque value.

[0022] The manufacturing process model includes: a process route template database and a process diagram template database.

[0023] Step 4) specifically includes:

[0024] 1-1) Set up process route templates according to the production process of transformer products to form a process route template database;

[0025] 1-2) Based on the transformer product structure and production process, process drawing templates are set up to form a process drawing template database;

[0026] 1-3) Map each product unit area in the process route template to the discretized unit in the process diagram template one by one;

[0027] 1-4) Store the process route template library and process diagram template database, along with their mapping relationships, into the database;

[0028] 1-5) Retrieve the corresponding process drawing template and process route template from the template database according to the product specifications and model, and send them to the torque workstation under the intelligent torque assembly system path.

[0029] The intelligent torque assembly system includes: an MES system, a torque workstation, and a field installation platform;

[0030] The MES system is used to create work order sheets and dispatch them to torque workstations, while also receiving completion sheets from the torque workstations.

[0031] The torque workstation is used to receive the process task order dispatched by the MES system, call the established process manufacturing model according to the process task order, assign the process step task, send the process step task to the field installation platform for execution, and receive and store the operation data fed back by the field installation platform.

[0032] The on-site installation platform is used to perform operations according to the process sequence and set torque values ​​based on the task data of the received torque workstation, and to send the operation data back to the torque workstation for storage.

[0033] The process flow is set in the intelligent torque assembly system, and the intelligent torque assembly system executes the corresponding process task flow, specifically as follows:

[0034] 2-1) The MES system creates a process task sheet based on the process name and dispatches the process task sheet to the corresponding torque workstation through the final assembly process workstation;

[0035] 2-2) The torque workstation decomposes the work order, retrieves the established process route template according to the needs of the work order, and assigns work steps.

[0036] 2-3) Follow the process manufacturing model to guide the operation. Dispatch the work steps to the on-site installation platform via Bluetooth device for execution. After the operation is completed, transmit the bolt tightening operation data back to the final assembly process workstation for processing and saving via the torque workstation.

[0037] 2-4) The final assembly process workstation sends the completion order information to the MES system to end the operation. The MES system then remotely transmits the information to the monitoring terminal via a Wi-Fi transmission module.

[0038] In step 2-2), the allocation of work steps specifically refers to:

[0039] (1) The torque workstation decomposes the process task sheet, selects the final assembly 3D drawing according to the product type and voltage level of the transformer, and generates the process task.

[0040] (2) Based on the process task, select the main transformer components in each module of the main transformer components that require tightening bolts;

[0041] (3) The operator retrieves the process diagram template from the process manufacturing model according to the actual structure of the product, selects the corresponding discretized unit according to the actual operation part, maps the process route with the process diagram data, and displays the three-dimensional process diagram on the torque workstation.

[0042] (4) Automatically match the process route template according to the selected transformer main components of each process to generate the process route of each step;

[0043] (5) Determine the overall assembly sequence of the transformer and the local sequence of tightening the bolts, and finally generate the bolt tightening sequence.

[0044] In step (5), the determination of the overall assembly sequence of the transformer and the local sequence of tightening the bolts, and finally the generation of the bolt tightening sequence, are as follows:

[0045] 3-1) Following the order of radiator module, bushing module, oil conservator module, and oil tank module, select the flange face according to the flange face required for each module, and input the number and specifications of bolts for each flange face;

[0046] 3-2) Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. Tighten the local bolts in the following order: first the middle, then the two sides, tighten symmetrically and adjacently, repeat 3 times to ensure uniform stress on all sealing surfaces during the final assembly process and improve the installation quality.

[0047] 3-3) Set the tightening torque value for the bolts:

[0048] a. Taking into account the compression of the sealing gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm;

[0049] b. Using the yield strength of the connected parts as the critical point, simulation calculations are performed to obtain the allowable torque values ​​under different corresponding transformer main component structures;

[0050] c. Based on the constraints of steps a and b, take the smaller value as the standard torque value.

[0051] The present invention has the following beneficial effects and advantages:

[0052] 1. This invention sets the unit tightening sequence based on process research results, studying a tightening sequence from overall to local. According to the transformer assembly structure model, the overall product tightening sequence is determined as follows: radiator (cooler) module → bushing module → oil conservator module → oil tank module. The bolt assembly flange faces of each module are round or square. The local bolt tightening sequence is from the middle to the sides, symmetrically and adjacently tightened, repeated 3 times. This ensures uniform stress distribution on all sealing surfaces during the assembly process and improves installation quality.

[0053] 2. This invention categorizes products into major product types and voltage levels based on their characteristics. A proprietary manufacturing model for each process is established using process diagrams and routes, specifying the torque values ​​and sequence for each product. This creates a unique set of bolt tightening arrangements for each product. Based on the principle of these arrangements, a unique assembly model is established for each process, preventing incorrect tightening, omissions, and insufficient torque. Due to the uniqueness of the arrangements, if operators deviate from the corresponding torque values ​​and tightening sequence, the earliest possible result for the task will be deemed unqualified. Simultaneously, the intelligent torque assembly system applies scientifically sound sequences and torque values ​​during product manufacturing, playing a crucial role in ensuring the quality of product installation.

[0054] 3. This invention develops a torque workstation for the final assembly process and an interface with the on-site installation platform for use by the intelligent torque assembly system in the transformer final assembly process. When using the intelligent torque assembly system in the factory, a completion report is generated in real time and transmitted back to both the intelligent torque assembly system and the MES system upon completion. During on-site installation, a completion report is generated in offline mode and saved to the on-site installation platform. When connected to the internet, it is automatically transmitted back to the intelligent torque assembly system. This achieves closed-loop management of the final assembly process.

[0055] 4. This invention addresses the issue of inaccurate calculation by considering two aspects in calculating the tightening torque of the bolts on the final assembly sealing surface. The smaller of the two constraints is taken as the standard torque value. Attached Figure Description

[0056] Figure 1 This is a flowchart of a process method for an intelligent torque assembly system in the transformer assembly process according to the present invention.

[0057] Figure 2 This is a schematic diagram of the intelligent torque assembly system of the present invention;

[0058] Figure 3 This is a structural diagram of the manufacturing model for the overall assembly process of this invention;

[0059] Figure 4 This is a three-dimensional assembly view of the transformer of the present invention.

[0060] Among them, 1 is the oil storage tank module; 2 is the bushing module; 3 is the oil tank module; and 4 is the radiator module. Detailed Implementation

[0061] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments.

[0062] like Figure 1 The diagram shown is a flowchart of the method of the present invention. The present invention provides a process method for an intelligent torque assembly system in the transformer assembly process, which includes the following steps:

[0063] 1) Based on the voltage level and product type of the transformer, establish three-dimensional process models of transformers of different specifications and models to form a three-dimensional process library;

[0064] 2) Divide the three-dimensional process model of the transformer into modules for assembly, which serves as the overall assembly sequence. This yields the assembly sequence of each component of the transformer and corresponding two-dimensional process drawings of the parts.

[0065] 3) Based on the structural characteristics of the transformer, a parameterized database is established for each type of structure according to the parameter information of the actual bolts of the transformer. The parameterized database is used as a discretized unit library for the local sequence of assembly, so as to realize the input of bolt parameter information after selecting the two-dimensional process drawing of the corresponding parts of the transformer.

[0066] 4) The 3D process model of the transformer is divided into modules again to establish a process manufacturing model that matches the 3D model of the transformer product; and the process manufacturing model is matched to the 3D process drawing of the transformer assembly product to realize data mapping.

[0067] 5) Set the process flow in the intelligent torque assembly system, and the intelligent torque assembly system will execute the corresponding process task flow.

[0068] like Figure 3 The diagram shown is a construction diagram of the overall assembly manufacturing model of this invention. In this process method: First, in order to establish a three-dimensional process model, a three-dimensional process drawing library needs to be established. Transformers are generally divided according to voltage level and product type. Product types include AC transformers, reactors, converter transformers, and special transformers; voltage levels include AC 110kV, AC 220kV, AC 330kV, AC 400kV, AC 500kV (single-phase), AC 500kV (three-phase), AC 750kV, and AC 1000kV; reactors include 500kV and 1000kV; converter transformers include ±200kV, ±400kV, ±600kV, ±800kV, and ±1100kV. Three-dimensional assembly models of the above-mentioned transformer products of different specifications and models are established, and the three-dimensional models are divided into modules.

[0069] Then, the transformer is divided into modules for assembly. The modular assembly mode serves as the overall assembly sequence, such as... Figure 3 The figure shown is a schematic diagram of the assembly of the main components of the transformer of the present invention in three dimensions;

[0070] The final assembly process manufacturing model consists of a process route template library, a 3D process drawing library, and a discretized unit library. The 3D process drawing library is categorized by voltage level and product type. Product types include AC transformers, oil-immersed reactors, converter transformers, and special transformers. The discretized unit library is a 2D drawing library of transformer components, including cooler modules, oil storage tank modules, bushing modules, and oil tank modules. The bolt group module of the discretized unit for the final assembly process mainly consists of circular and rectangular flanges. Flange information primarily consists of the number and specifications of bolts. During work assignment, the final assembly 3D drawing is first selected based on the product type and voltage level to generate the process task. Then, the corresponding module is selected based on the components to be tightened, and the flange face is selected according to the flange face required for each module. The number and specifications of bolts are input for each flange face, and finally, the work step task is generated.

[0071] The overall structure is divided into a radiator (cooler) module, a bushing module, an oil conservator module, and an oil tank module. The radiator (cooler) module includes the cooler, connecting pipes, and a support frame.

[0072] The riser module includes a cable outlet, a riser, a sleeve, and a manhole; the oil tank module includes support legs, a manhole, and a connecting pipe; the oil tank module includes a tank edge and a manhole.

[0073] The two-dimensional process drawing of the final assembly section serves as the local assembly sequence. Based on the transformer's structural characteristics, it is divided into round flange structure and square flange structure. For each type of structure, a parametric database is established based on the actual number of bolts in the product. This parametric database allows the system to automatically display a two-dimensional process drawing with the actual number of bolts after selecting the two-dimensional process drawing and inputting bolt parameter information. This guides operators and inspectors to operate according to the local sequence. The overall sequence is the component display order of the product, specifically: radiator (cooler) module → bushing module → oil conservator module → oil tank module. The local sequence displays the actual bolt positions, specifying a sequence of tightening the middle bolts first, then the two sides, symmetrically and adjacently, repeating three times.

[0074] The 3D model is used in the intelligent torque assembly system to display the overall 3D model of the product on the process drawing interface. The modules are divided to enable the system to display the structure of the parts at different working positions in real time, so that operators and inspectors can quickly locate the parts that need to be installed.

[0075] In step 4), in order to develop the manufacturing process model, the three-dimensional process diagram of the transformer assembly is divided into modules. At the same time, a process route database matching the three-dimensional model of the transformer product is established. Through proprietary digital twin technology, the process route data is matched to the three-dimensional process diagram of the assembly product to achieve data mapping.

[0076] The process manufacturing model includes: a process route template database and a process diagram template database.

[0077] The specific method for implementing data mapping is as follows:

[0078] 1-1) Set up process route templates according to the production process of transformer products to form a process route template database;

[0079] 1-2) Based on the transformer product structure and production process, process drawing templates are set up to form a process drawing template database;

[0080] 1-3) Map each product unit area in the process route template to the discretized unit in the process diagram template one by one;

[0081] 1-4) Store the process route template library and process diagram template database, along with their mapping relationships, into the database;

[0082] 1-5) Retrieve the corresponding process drawing template and process route template from the template database according to the product specifications and model, and send them to the torque workstation under the intelligent torque assembly system path.

[0083] Finally, the final assembly module interface for the intelligent torque assembly system was developed and established under the torque workstation path. Simultaneously, an interface for the field installation platform and a data query interface were created. A remote field installation platform was established, built using the existing intelligent torque assembly system architecture. The platform added offline Bluetooth data transmission functionality and developed online remote data transmission capabilities. The aim was to enable normal installation even without a network connection. Once connected to the network, the system automatically transmits the completion report data from the field installation back to the intelligent torque assembly system within the factory for later review.

[0084] Based on research into bolt tightening processes, a digital torque management system was developed and introduced to achieve scientific tightening operations and guidance, embedding bolt tightening process requirements into the system. Based on this system, torque value information sent via the process route is transmitted to an intelligent wrench to guide employees in tightening according to standard torque. Simultaneously, the system sends process diagram information to a torque workstation, which displays the bolt tightening status on the process diagram in real time, prompting employees to tighten in the prescribed sequence.

[0085] The specific method is as follows:

[0086] Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. Tighten the local bolts in the following order: first the middle, then the two sides, tighten symmetrically and adjacently, repeat 3 times, to ensure the uniformity of installation force on all sealing surfaces in the final assembly process and improve the installation quality.

[0087] Specifically, the tightening torque value for the bolts is set as follows:

[0088] a. Taking into account the compression of the sealing gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm;

[0089] b. Using the yield strength of the connected parts as the critical point, simulation calculations are performed to obtain the allowable torque values ​​under different corresponding transformer main component structures;

[0090] c. Based on the constraints of steps a and b, take the smaller value as the standard torque value.

[0091] After the operation is completed, the torque wrench transmits data such as the tightening sequence, tightening torque value, tightening angle, and tightening process to the torque management system. The torque management system compares the parameters to determine whether the tightening is qualified and archives the data, thereby completing the digital judgment and data archiving control of the bolt tightening process and ensuring full control of the tightening process of each bolt.

[0092] like Figure 2 The diagram shown is a schematic diagram of the intelligent torque assembly system. In this invention, the intelligent torque assembly system includes: a MES system, a torque workstation, and a field installation platform.

[0093] The MES system is used to create work order sheets and dispatch them to torque workstations, while also receiving completion sheets from the torque workstations.

[0094] The torque workstation is used to receive the process task order dispatched by the MES system, call the established process manufacturing model according to the process task order, assign the process step task, send the process step task to the field installation platform for execution, and receive and store the operation data fed back by the field installation platform.

[0095] The on-site installation platform is used to perform operations according to the process sequence and set torque values ​​based on the task data of the received torque workstation, and to send the operation data back to the torque workstation for storage.

[0096] Workstation operation procedure:

[0097] Factory operating procedures:

[0098] Log in to the torque assembly system and enter the torque workstation module. Go to the add process task interface, select the final assembly process, obtain the MES order, and create the process task. Then, assign the process task to the work step task and perform task allocation. After the task allocation is completed, you can start the operation.

[0099] On-site installation procedure:

[0100] Log in to the on-site installation platform and access the intelligent torque assembly system via Bluetooth. Follow the factory operating procedures; the process is the same as in the factory. After completion, the data is saved to the intelligent torque assembly system and uploaded to the on-site installation platform via Bluetooth. The on-site installation platform then remotely uploads the data to the factory system via WiFi.

[0101] The intelligent torque assembly system sets the process flow and executes the corresponding process tasks. The specific process methods are as follows:

[0102] 2-1) The MES system creates a process task sheet based on the process name and dispatches the process task sheet to the corresponding torque workstation through the final assembly process workstation;

[0103] 2-2) The torque workstation decomposes the work order, retrieves the established process route template according to the needs of the work order, and assigns work steps.

[0104] The specific steps for assigning tasks are as follows:

[0105] (1) The torque workstation decomposes the process task sheet, selects the final assembly 3D drawing according to the product type and voltage level of the transformer, and generates the process task.

[0106] (2) Based on the process task, select the main transformer components in each module of the main transformer components that require tightening bolts;

[0107] (3) The operator retrieves the process diagram template from the process manufacturing model according to the actual structure of the product, selects the corresponding discretized unit according to the actual operation part, maps the process route with the process diagram data, and displays the three-dimensional process diagram on the torque workstation.

[0108] (4) Automatically match the process route template according to the selected transformer main components of each process to generate the process route of each step;

[0109] (5) Determine the overall assembly sequence of the transformer and the local sequence of tightening the bolts, and finally generate the bolt tightening sequence;

[0110] (5-1) Following the order of radiator module, bushing module, oil tank module, and oil tank module, select the flange face according to the flange face required for each module, and input the number and specifications of bolts for each flange face;

[0111] (5-2) Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. The local bolt tightening sequence is as follows: first the middle and then the two sides, tighten symmetrically and adjacently, repeat 3 times, so as to ensure the uniformity of installation force on all sealing surfaces in the final assembly process and improve the installation quality.

[0112] (5-3) Set the tightening torque value for the bolts:

[0113] a. Taking into account the compression of the sealing gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm;

[0114] b. Using the yield strength of the connected parts as the critical point, simulation calculations are performed to obtain the allowable torque values ​​under different corresponding transformer main component structures;

[0115] c. Based on the constraints of steps a and b, take the smaller value as the standard torque value.

[0116] 2-3) Follow the process manufacturing model to guide the operation. Dispatch the work steps to the on-site installation platform via Bluetooth device for execution. After the operation is completed, transmit the bolt tightening operation data back to the final assembly process workstation for processing and saving via the torque workstation.

[0117] 2-4) The final assembly process workstation sends the completion order information to the MES system to end the operation. The MES system then remotely transmits the information to the monitoring terminal via a Wi-Fi transmission module.

[0118] Example 1:

[0119] A process method for an intelligent torque assembly system in the final assembly of a transformer, see [link to relevant documentation]. Figure 1 The following explanation uses the final assembly process of a 110kV structural product as an example:

[0120] 1. Research on the process flow of tightening bolts in transformer assembly:

[0121] In the transformer assembly process, the radiator (cooler) module, riser module, oil conservator module, and oil tank module can be installed simultaneously without interference. However, for ease of hoisting, the recommended assembly sequence is: radiator (cooler) module → bushing module → oil conservator module → oil tank module. The bolt flanges for each module should be round or square. The tightening sequence for local bolts is: first the middle, then the sides, symmetrically and adjacently tightened, repeated three times. This ensures uniform stress distribution on all sealing surfaces during assembly and improves installation quality.

[0122] 2. Study on bolt tightening torque values:

[0123] The study on the tightening torque value of the bolts on the final assembly sealing surface is based on two aspects: first, the compression of the sealing gasket to ensure that the gap between the flange faces of the connected parts is 0 to +5 mm; second, simulation calculations are performed using the yield strength of the connected parts as the critical point to obtain the allowable torque value under different module structures. The smaller value of the above two constraints is taken as the standard torque value.

[0124] 3. Develop manufacturing process models

[0125] Based on the above two fundamental research areas, in order to guide employees to operate according to the prescribed tightening sequence, a process manufacturing model was developed to map the process route to the process diagram data; based on the current intelligent torque assembly system technology, a process route template for the final assembly process was edited; a three-dimensional process diagram library was developed according to the modular path of the final assembly drawings; and the above process route template and process diagram library were combined into a process manufacturing model through data mapping technology, which was then embedded into the torque workstation of the intelligent torque assembly system for use in the transformer final assembly process.

[0126] The process manufacturing model is displayed as a screen on the intelligent torque assembly system, guiding operators and inspectors to perform installation according to the prescribed component sequence and torque values. The 3D process diagram shows the overall component working sequence, while the 2D process diagram shows the connection surface currently in operation. At the same time, the process manufacturing model also displays the torque value, tightening angle, and standard range of torque values ​​of the currently tightened bolts in real time.

[0127] The manufacturing process model displays components and bolts that are currently tightened as green (qualified) and red (unqualified); the next component to be installed and the next bolt to be tightened are yellow.

[0128] 4. Development of a torque workstation for the intelligent torque assembly system

[0129] In the intelligent torque assembly system, a final assembly workstation is opened under the torque workstation path. After entering the workstation, a settings interface pops up. The setting process is as follows: MES task order → product type → voltage level → module → 2D process drawing → 2D drawing parameterization setting → process manager → confirm completion of process task assignment.

[0130] The MES order refers to the process task information received by the intelligent torque assembly system from the MES system, including the task order number, product technical code, product model, product work number, and product process name. Product types include AC transformers, reactors, converter transformers, and special transformers. Voltage levels vary depending on the product. AC transformer voltage levels are 110kV, 220kV, 330kV, 400kV, 500kV (single-phase), 500kV (three-phase), 750kV, and 1000kV; reactor voltage levels are 500kV, 750kV, and 1000kV; and converter transformer voltage levels include ±200kV, ±400kV, ±600kV, ±800kV, and ±1100kV. Modules are divided into radiator (cooler) modules, bushing modules, oil conservator modules, and oil tank modules. Two-dimensional process drawings are divided into circular and square types. The two-dimensional parameterization settings include setting the number of flange connection faces for the module, the number of bolts on each flange face, and the torque value of each bolt. Typically, the bolt torque values ​​for the same flange face are the same. The process supervisor sets the operators for the process task. Finally, the completion confirmation system completes the assignment of the process task. Different modules can assign tasks separately or simultaneously, and the task supervisor can be set individually.

[0131] 5. Development of a remote management and control platform

[0132] To achieve remote control, an intelligent torque assembly system on-site installation platform and interface were developed, and a data interface was established to provide a two-way channel for information transmission. Based on the MES system, a data chain structure for the torque assembly system was built: a five-in-one system of "MES system + torque central system + torque workstation + wrench calibration system + terminal execution system". This system scientifically studies bolt tightening torque values ​​and tightening sequence, fundamentally solving a series of problems related to bolt fastening connections, such as tool management, production management, personnel management, and product quality, thereby achieving intelligent management.

[0133] 6. System usage process:

[0134] (1) Log in to the system → Enter the torque workstation interface → Assembly workstation → Pop up the task setting interface → Select and obtain the MES task order → Enter the process task interface to create process tasks and assign step tasks → Select the product type → Select the product voltage level → Select and add the step task model (here select the module to be worked on, and set the number of flange faces and the number of bolts on each flange face of the step task model) → Set the bolt specifications and standard torque values ​​for different flange faces → Set the upper and lower limits of the judgment torque value → Set the person in charge of each step task → Confirm the completion of task assignment → Click the assembly 3D process diagram display module to display the assembly process manufacturing model → Operation (receive the intelligent torque wrench and handheld device, and operate according to the instructions of the process manufacturing model) → After the operation is completed, the data is automatically uploaded to the intelligent torque assembly system → Automatically generate the completion report → Return to the MES system.

[0135] (2) The on-site installation process is the same as described above, except that you enter the on-site installation workstation. The other operations are the same. The operating platform is the on-site installation platform, which has offline data transmission function. After the on-site installation is completed, it will automatically upload to the intelligent torque assembly system remotely when there is a network connection. The remote transmission will automatically generate a completion report and save it to the system for later review.

[0136] 7. Flange faces of the final assembly module that require tightening:

[0137] (1) Fastening sequence of oil tank module: support leg and oil tank connection flange → manhole flange → air pipe flange;

[0138] (2) Fastening sequence of the sleeve module: riser seat and oil tank connection flange → sleeve flange → manhole flange;

[0139] (3) Radiator (cooler) fastening sequence: support leg and oil tank flange → connecting pipe 1 and support leg flange → connecting pipe 2 and oil tank flange → connecting pipe 1 and connecting pipe 2 flange → radiator and butterfly valve flange.

[0140] (4) Fastening sequence of oil tank module: The fastening of the tank edge and manhole can be carried out simultaneously or separately during the fastening of the oil tank module. In principle, they should be carried out simultaneously to reduce the time the tank body is exposed to air.

[0141] This invention analyzes the installation characteristics from the perspective of transformer final assembly. Transformer installation is divided into modules, with each module operating independently and allowing for simultaneous installation. A developed intelligent torque assembly system is used to establish a final assembly database. The researched final assembly tightening process is loaded into the intelligent torque assembly system. Production is carried out using the intelligent torque assembly system, which collects and feeds back bolt tightening information according to its scientific guidance, completing closed-loop control of bolt assembly in the final assembly production process. Furthermore, a remote offline intelligent torque assembly system suitable for transformer on-site installation has been developed, allowing for comprehensive control of the entire transformer installation process. This system features intelligence, information technology, and integrated assembly capabilities.

[0142] The above description is merely an embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, extensions, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

Claims

1. A process method for an intelligent torque assembly system in the final assembly of a transformer, characterized in that, Includes the following steps: Step 1) Based on the voltage level and product type of the transformer, establish three-dimensional process models of transformers of different specifications and models to form a three-dimensional process library; Step 2) Divide the three-dimensional process model of the transformer into modules for assembly, which serves as the overall assembly sequence. This yields the assembly sequence of each component of the transformer and corresponding two-dimensional process drawings of the parts. In step 2), the three-dimensional process model of the transformer is divided into modules for assembly, which serves as the overall assembly sequence, resulting in the assembly sequence of each component of the transformer. Specifically: The three-dimensional process model of the transformer is divided according to the main components of the overall transformer. The overall order is as follows: radiator module, bushing module, oil conservator module, and oil tank module, and the corresponding two-dimensional process drawings of the components are obtained. Step 3) Based on the structural characteristics of the transformer, a parameterized database is established for each type of structure according to the parameter information of the actual bolts of the transformer. The parameterized database is used as a discretized unit library for the local sequence of assembly, so as to realize the input of bolt parameter information after selecting the two-dimensional process drawing of the corresponding parts of the transformer. In step 3), based on the structural characteristics of the transformer, a parameterized database is established for each type of structure according to the parameter information of the actual bolts of the transformer. Specifically: Based on the structural characteristics of transformers, they are divided into: round flange structure and square flange structure; the parameter information of the actual bolts includes: bolt quantity and bolt specifications; The number and specifications of bolts corresponding to the circular flange structure and the method flange structure, as well as the two-dimensional process drawings of the transformer main components, are combined to form a discretized unit library; Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. Tighten the local bolts in the following order: first the middle, then the two sides, tighten symmetrically and adjacently, repeat 3 times, to ensure the uniformity of installation force on all sealing surfaces in the final assembly process and improve the installation quality. Specifically, the tightening torque value for the bolts is set as follows: a. Taking into account the compression of the sealing gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm; b. Using the yield strength of the connected parts as the critical point, simulation calculations are performed to obtain the allowable torque values ​​under different corresponding transformer main component structures; c. Based on the constraints of steps a and b, take the smaller value as the standard torque value; Step 4) Divide the 3D process model of the transformer into modules again, establish a process manufacturing model that matches the 3D model of the transformer product; and match the process manufacturing model to the 3D process drawing of the transformer assembly product to achieve data mapping; Step 1-1) Set up process route templates according to the production process of transformer products to form a process route template database; Steps 1-2) Set up process drawing templates according to the transformer product structure and production process to form a process drawing template database; Steps 1-3) Map each product unit area in the process route template to the discretized unit in the process diagram template one-to-one; Steps 1-4) Store the process route template library, process diagram template database, and mapping relationships into the database; Steps 1-5) Retrieve the corresponding process drawing template and process route template from the template database according to the product specifications and model, and send them to the torque workstation under the intelligent torque assembly system path; Step 5) Set the process flow in the intelligent torque assembly system, and the intelligent torque assembly system executes the corresponding process task flow.

2. The process method of the intelligent torque assembly system for transformer assembly according to claim 1, characterized in that, In step 1), the types of transformer products include: AC transformers, reactors, converter transformers, and special transformers; The voltage levels of the transformers include: AC 110kV, AC 220kV, AC 330kV, AC 400kV, single-phase AC 500kV, three-phase AC 500kV, AC 750kV, AC 1000kV; 500kV reactors, 1000kV reactors; ±200kV converter transformers, ±400kV converter transformers, ±600kV converter transformers, ±800kV converter transformers, and ±1100kV converter transformers.

3. The process method of the intelligent torque assembly system for transformer assembly according to claim 1, characterized in that, The manufacturing process model includes: a process route template database and a process diagram template database.

4. The process method of the intelligent torque assembly system for transformer assembly according to claim 1, characterized in that, The intelligent torque assembly system includes: an MES system, a torque workstation, and a field installation platform; The MES system is used to create work order sheets and dispatch them to torque workstations, while also receiving completion sheets from the torque workstations. The torque workstation is used to receive the process task order dispatched by the MES system, call the established process manufacturing model according to the process task order, assign the process step task, send the process step task to the field installation platform for execution, and receive and store the operation data fed back by the field installation platform. The on-site installation platform is used to perform operations according to the process sequence and set torque values ​​based on the task data of the received torque workstation, and to send the operation data back to the torque workstation for storage.

5. The process method of the intelligent torque assembly system for transformer assembly according to claim 1, characterized in that, The process flow is set in the intelligent torque assembly system, and the intelligent torque assembly system executes the corresponding process task flow, specifically as follows: Step 2-1) The MES system creates a process task sheet based on the process name and dispatches the process task sheet to the corresponding torque workstation through the final assembly process workstation; Step 2-2) The torque workstation decomposes the process task sheet, retrieves the established process route template according to the needs of the process task sheet, and assigns the process steps. Steps 2-3) Follow the process manufacturing model to operate, dispatch the work steps to the on-site installation platform via Bluetooth device for execution, and after the operation is completed, transmit the bolt tightening operation data back to the final assembly process workstation for processing and saving via the torque workstation; Steps 2-4) The final assembly workstation sends the completion order information to the MES system to end the operation. The MES system then remotely transmits the information to the monitoring terminal via a Wi-Fi transmission module.

6. The process method of the intelligent torque assembly system for transformer assembly according to claim 5, characterized in that, In step 2-2), the allocation of work steps specifically refers to: Step (1) The torque workstation decomposes the process task sheet, selects the final assembly 3D drawing according to the product type and voltage level of the transformer, and generates the process task. Step (2) Based on the process task, select the main transformer components in each module of the main transformer components that require tightening bolts; Step (3) The operator retrieves the process diagram template from the process manufacturing model according to the actual structure of the product, selects the corresponding discretization unit according to the actual operation part, maps the process route with the process diagram data, and displays the three-dimensional process diagram on the torque workstation. Step (4) Automatically match the process route template according to the selected transformer main components for each process to generate the process route for each step; Step (5) determines the overall assembly sequence of the transformer and the local sequence of tightening the bolts, and finally generates the bolt tightening sequence.

7. The process method of the intelligent torque assembly system for transformer assembly according to claim 6, characterized in that, In step (5), the determination of the overall assembly sequence of the transformer and the local sequence of tightening the bolts, and the final generation of the bolt tightening sequence, are as follows: Step 3-1) Following the order of radiator module, bushing module, oil conservator module, and oil tank module, select the flange face according to the flange face required for each module, and input the number and specifications of bolts for each flange face; Step 3-2) Determine whether the bolt assembly flange face of each corresponding transformer main component is round or square. Tighten the local bolts in the following order: first the middle, then the two sides, tighten symmetrically and adjacently, repeat 3 times to ensure uniform stress on all sealing surfaces during the final assembly process and improve the installation quality. Step 3-3) Set the tightening torque value for the bolts: Step a) Taking into account the compression of the gasket, ensure that the gap between the flange faces of the connected parts is 0 to +5 mm; Step b) Use the yield strength of the connected parts as the critical point to perform simulation calculations and obtain the allowable torque values ​​under different corresponding transformer main component structures; Step c) Based on the constraints of steps a) and b), take the smaller value as the standard torque value.

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