Transformer winding process intelligent monitoring method and system, and electronic equipment
Through the combination of dual-stroke switches and control modules, the wire position is detected in real time and dynamically adjusted, the problem of inaccurate wire position control in transformer winding is solved, the winding accuracy and efficiency are improved, the system stability is enhanced, and equipment loss and production costs are reduced.
Patent Information
- Application Number
- CN202510600896.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-05-12
- Publication Date
- 2025-08-12
AI Technical Summary
In the prior art, the wire position control during the transformer winding process is inaccurate, resulting in low winding accuracy, slow efficiency, risk of equipment damage, and lack of an effective abnormality detection mechanism.
The dual-stroke switch is used to detect the wire position in real time, and the control module drives the moving components to move in the axial direction of the winding device to ensure that the wire is axially perpendicular to the winding coil. Combined with the abnormality detection mechanism, determine whether the movement is abnormal, output a prompt signal and stop winding.
It significantly improves winding accuracy and efficiency, enhances system stability, reduces equipment losses and production costs, and has good scalability and intelligent upgrade capabilities.
Smart Images
Figure CN120473329A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of transformer winding process intelligent monitoring solution design, and in particular to a transformer winding process intelligent monitoring method and system, and electronic equipment. Background Art
[0002] Transformers are essential core equipment in power systems, and the quality of their winding directly impacts their performance and service life. Traditional transformer winding processes rely primarily on manual operation or semi-automated equipment, resulting in low winding accuracy, slow efficiency, and high labor costs. Wire position control is particularly critical during the winding process. Wire deviation and uneven tension during the winding process can lead to poor concentricity of the wound coil, increase the risk of inter-turn short circuits, and even damage the winding equipment or reduce the transformer's electrical performance.
[0003] Furthermore, the axial perpendicularity of the conductor to the coil during winding is a crucial factor affecting winding quality. Failure to maintain this perpendicularity not only results in uneven turns distribution, but also increases friction during the winding process, potentially leading to conductor breakage or damage to the winding apparatus. Therefore, developing an intelligent monitoring system capable of real-time monitoring of conductor position, dynamic adjustment of the winding path, and anomaly detection is crucial for improving transformer winding quality and efficiency.
[0004] The present invention provides an intelligent monitoring system and method for the transformer winding process. By introducing a double-stroke switch to detect the position of the conductor, combined with the dynamic adjustment of the mobile component and the abnormality detection mechanism, the problems of inaccurate conductor position control and insufficient abnormal situation handling in the prior art are solved, providing technical support for achieving efficient and accurate transformer winding.
[0005] Therefore, the existing technology needs to be further developed. Summary of the Invention
[0006] The purpose of the present invention is to overcome the above technical deficiencies and provide a method and system for intelligently monitoring the winding process of a transformer, as well as electronic equipment, to solve the problems existing in the prior art.
[0007] To achieve the above technical objectives, according to a first aspect of the present invention, the present invention provides an intelligent monitoring system for a transformer winding process, comprising: A wire-paying device, wherein the wire-paying device is provided with a moving component, a control module and a wire position detection device; The wire position detection device includes a travel switch, which is used to detect the winding position of the wire. The control module is controlled and connected to the movable component, and is used to control the movement of the movable component to drive the wire-releasing device to move. The control module is used to control the movement of the movable component according to the winding position of the wire during the winding process, so that the wire is always perpendicular to the axial direction of the coil to be wound set on the winding device during the winding process.
[0008] Specifically, the wire position detection device includes a first travel switch and a second travel switch, and the first travel switch and the second travel switch are respectively communicatively connected to the control module.
[0009] Specifically, when the wire hits the first travel switch during the winding process, the control module controls the moving component to move a preset distance to the right along the axis of the coil to be wound, thereby positioning the wire at the center position between the first travel switch and the second travel switch.
[0010] Specifically, when the wire hits the second travel switch during the winding process, the control module controls the moving component to move a preset distance to the left along the axis of the coil to be wound, thereby positioning the wire at the center between the first travel switch and the second travel switch.
[0011] According to a second aspect of the present invention, there is provided a method for intelligently monitoring a transformer winding process, comprising: S100, after winding starts, controlling the winding motor to start working, and using the wire position detection device to detect the winding position of the wire; S200 , controlling the movement of the moving assembly according to the winding position of the wire, thereby ensuring that the wire is always perpendicular to the axial direction of the coil to be wound provided on the winding device during the winding process.
[0012] Specifically, controlling the movement of the moving assembly according to the winding position of the wire so that the wire is always perpendicular to the axial direction of the coil to be wound provided on the winding device during the winding process includes: When the wire hits the first travel switch during the winding process, the control module controls the moving component to move a preset distance to the right along the axial direction of the coil to be wound, so that the wire is located at the center position of the first travel switch and the second travel switch.
[0013] Specifically, controlling the movement of the moving assembly according to the winding position of the wire so that the wire is always perpendicular to the axial direction of the coil to be wound provided on the winding device during the winding process includes: When the wire hits the second travel switch during the winding process, the control module controls the moving component to move a preset distance to the left along the axial direction of the coil to be wound, so that the wire is located at the center position of the first travel switch and the second travel switch.
[0014] Specifically, the method further includes: When the wire hits any travel switch during the winding process, the positioning module arranged on the wire-releasing device is used to obtain the first position information of the current wire-releasing device. After a preset time has passed, the second position information of the current wire-releasing device is obtained. Based on the first position information and the second position information, it is judged whether the movement of the wire-releasing device is abnormal, and a prompt signal about the judgment result is output.
[0015] Specifically, the method further includes: Calculating an absolute value of an axial distance of the first position information and the second position information along the axial direction of the coil to be wound, and determining whether a difference between the absolute value of the axial distance of the coil to be wound and a preset distance is within a preset interval; If so, it is determined that the pay-off device is moving normally, and a prompt signal indicating that the pay-off device is moving normally is output; If not, it is determined that the pay-off device has not completed the movement, and a prompt signal about the abnormal movement of the pay-off device is output, and the winding motor is controlled to stop winding.
[0016] According to a third aspect of the present invention, there is provided an electronic device comprising: a memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the above-mentioned intelligent monitoring method for transformer winding process is implemented.
[0017] Beneficial effects: The present invention uses a dual-travel switch to detect the position of the wire in real time, and combines it with the control module to accurately control the moving component, which significantly improves the quality and efficiency of transformer winding. Its specific beneficial effects are reflected in the following aspects: 1. Improve winding accuracy By installing a first and second travel switch on the pay-off mechanism, the wire's winding position is monitored in real time. The control module then drives the moving assembly along the winding mechanism's axis, ensuring the wire remains perpendicular to the axial direction of the coil. This dynamic adjustment mechanism effectively prevents wire deviation or uneven tension, significantly improving the coil's concentricity and turn distribution uniformity, thereby enhancing the transformer's electrical performance.
[0018] 2. Enhance system stability This invention incorporates an anomaly detection mechanism into the winding process. When the wire strikes any travel switch, the positioning module records the initial position of the payout device and its position after a set time. By calculating the absolute value of the axial distance between the two along the coil to be wound and comparing it with a preset interval, it determines whether the movable assembly has completed adjustment. If an anomaly is detected, the system immediately stops winding and issues a warning signal. This mechanism effectively prevents winding failures caused by equipment malfunction or abnormal adjustments, enhancing the stability and reliability of the system.
[0019] 3. Improve production efficiency Traditional winding methods require manual monitoring and adjustment of wire position, which is not only inefficient but also prone to operational errors. This invention reduces manual intervention through automated monitoring and dynamic adjustment, significantly improving winding efficiency. Furthermore, the system can quickly respond to deviations in wire position, avoiding winding interruptions caused by adjustment delays, further improving production efficiency.
[0020] 4. Reduce equipment loss and production costs By adjusting the conductor position in real time, excessive friction between the conductor and the winding device, or conductor breakage, is avoided, reducing wear on the winding device and extending the equipment's service life. This also reduces scrap rates due to winding quality issues and lowers production costs.
[0021] 5. Easy to integrate and expand The control module and anomaly detection mechanism of the present invention are based on a modular design, offering excellent scalability and seamless integration with existing winding equipment. Furthermore, the system supports software-based intelligent monitoring methods through memory and processors, laying the foundation for further intelligent upgrades.
[0022] In summary, the present invention can effectively improve winding accuracy, enhance system stability, improve production efficiency and reduce equipment loss through the combination of dual-stroke switches, dynamic adjustment mechanism and abnormality detection function, and has important technical value and promotion significance for the transformer winding industry. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Figure 1 This is a schematic diagram of the system composition of the intelligent monitoring system for transformer winding process provided in a specific embodiment of the present invention. Figure 2 1 is a flow chart of an intelligent monitoring method for a transformer winding process provided in a specific embodiment of the present invention; The following reference numerals are present in the above drawings: 1. Pay-off device; 2. Moving assembly; 3. Control module; 4. First travel switch; 5. Second travel switch; 6. Wire; 7. Winding device; 8. Coil to be wound; 9. Guide hole; 10. Positioning module; 11. Winding motor; 12. Mounting plate. DETAILED DESCRIPTION
[0024] In order to enable those skilled in the art to better understand the technical solution of the present invention, the technical solution of the present invention is clearly and completely described below in conjunction with the drawings of the present invention. Based on the embodiments in this application, other similar embodiments obtained by ordinary technicians in this field without making creative work should fall within the scope of protection of this application. In addition, the directional words mentioned in the following embodiments, such as "up", "down", "left", "right", etc., are only reference to the directions of the drawings. Therefore, the directional words used are used to illustrate rather than limit the invention.
[0025] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.
[0026] See also Figure 1 The present invention provides an intelligent monitoring system for transformer winding process, comprising: The wire-releasing device 1 is provided with a moving component 2, a control module 3 and a conductor position detection device.
[0027] Specifically, the wire-releasing device 1 is also provided with an auxiliary guide hole 9 and a mounting plate 12. The first travel switch 4 and the second travel switch 5 are both installed on the mounting plate 12. The wire passes through the auxiliary guide hole 9 and is hung on the mounting plate 12, and then the wire 6 is wound. The auxiliary guide hole 9 is used for auxiliary guidance during the winding of the wire, which further improves the reliability of the winding process of the present invention.
[0028] The wire position detection device includes a travel switch, which is used to detect the winding position of the wire 6. The control module 3 and the moving component 2 are controlled and connected, and are used to control the movement of the moving component 2 to drive the wire-releasing device 1 to move. The control module 3 is used to control the movement of the moving component 2 according to the winding position of the wire 6 during the winding process, so that the wire 6 is always perpendicular to the axial direction of the coil 8 to be wound set on the winding device 7 during the winding process.
[0029] Specifically, the wire position detection device includes a first travel switch 4 and a second travel switch 5 , and the first travel switch 4 and the second travel switch 5 are respectively connected to the control module 3 for communication.
[0030] Specifically, when the wire 6 hits the first travel switch 4 during the winding process, the control module 3 controls the moving component 2 to move a preset distance to the right along the axial direction of the coil 8 to be wound, so that the wire 6 is located at the center position of the first travel switch 4 and the second travel switch 5.
[0031] Specifically, when the wire 6 hits the second travel switch 5 during the winding process, the control module 3 controls the moving component 2 to move a preset distance to the left along the axial direction of the coil 8 to be wound, so that the wire 6 is located at the center position of the first travel switch 4 and the second travel switch 5.
[0032] In a preferred embodiment of the present invention, the hardware system provided by the present invention is further described: 1. Pay-off device 1 The bottom of the pay-off device is provided with a moving assembly 2 for axial movement along the winding device. The moving assembly 2 is an electrically controlled moving wheel. There are four electrically controlled moving wheels to improve the moving stability of the pay-off device.
[0033] 2. Mobile Component 2 The moving assembly is driven by a high-precision stepper motor. The step angle of the stepper motor is preferably set to 1.8° to ensure accurate movement. The moving assembly's speed is preferably set to 10-20 mm / s. Too fast a speed may cause adjustment lag, while too slow a speed will reduce production efficiency.
[0034] 3. Control module 3 The control module uses a programmable logic controller (PLC) with a built-in PID control algorithm. This algorithm rapidly calculates the target position of the mobile component based on signals from the travel switch and dynamically adjusts it. The control module and mobile component communicate via the CAN bus, with a latency of less than 10 milliseconds.
[0035] 4. Wire position detection device The position detection device includes a first travel switch 4 and a second travel switch 5, mounted on either side of the winding coil, with initial positions preferably -10 mm and +10 mm from the winding center axis, respectively. The trigger stroke of the travel switch is set to 0.5 mm, enabling rapid detection of wire contact.
[0036] 5. Positioning module 10 The positioning module uses a high-precision GPS module with a positioning accuracy of preferably ±1 mm, which can record the position information of the line-laying device in real time. The positioning module and the control module transmit data via a wireless communication module, preferably ZigBee, in the present invention.
[0037] It is understandable that the present invention significantly improves the quality and efficiency of transformer winding by detecting the wire position in real time through the dual-travel switch and combining it with the precise control of the moving component by the control module. Its specific beneficial effects are reflected in the following aspects: 1. Improve winding accuracy By installing a first and second travel switch on the pay-off mechanism, the wire's winding position is monitored in real time. The control module then drives the moving assembly along the winding mechanism's axis, ensuring the wire remains perpendicular to the axial direction of the coil. This dynamic adjustment mechanism effectively prevents wire deviation or uneven tension, significantly improving the coil's concentricity and turn distribution uniformity, thereby enhancing the transformer's electrical performance.
[0038] 2. Enhance system stability The present invention incorporates an anomaly detection mechanism into the winding process. When the wire strikes any travel switch, the positioning module records the initial position of the payout device and its position after a set time. By calculating the absolute value of the axial distance between the two along the coil 8 to be wound and comparing it with a preset interval, it determines whether the movable assembly has completed adjustment. If an anomaly is detected, the system immediately stops winding and issues a warning signal. This mechanism effectively prevents winding failures caused by equipment failure or abnormal adjustments, enhancing the stability and reliability of the system.
[0039] 3. Improve production efficiency Traditional winding methods require manual monitoring and adjustment of wire position, which is not only inefficient but also prone to operational errors. This invention reduces manual intervention through automated monitoring and dynamic adjustment, significantly improving winding efficiency. Furthermore, the system can quickly respond to deviations in wire position, avoiding winding interruptions caused by adjustment delays, further improving production efficiency.
[0040] 4. Reduce equipment loss and production costs By adjusting the conductor position in real time, excessive friction between the conductor and the winding device, or conductor breakage, is avoided, reducing wear on the winding device and extending the equipment's service life. This also reduces scrap rates due to winding quality issues and lowers production costs.
[0041] 5. Easy to integrate and expand The control module and anomaly detection mechanism of the present invention are based on a modular design, offering excellent scalability and seamless integration with existing winding equipment. Furthermore, the system supports software-based intelligent monitoring methods through memory and processors, laying the foundation for further intelligent upgrades.
[0042] In summary, the present invention can effectively improve winding accuracy, enhance system stability, improve production efficiency and reduce equipment loss through the combination of dual-stroke switches, dynamic adjustment mechanism and abnormality detection function, and has important technical value and promotion significance for the transformer winding industry.
[0043] See also Figure 2 The present invention provides another embodiment, which provides a method for intelligently monitoring a transformer winding process. The method comprises: S100 , after the winding starts, the winding motor 11 is controlled to start working, and the winding position of the wire 6 is detected by the wire position detection device.
[0044] It should be noted that, before step S100 , the preset distance, preset time, and preset interval are pre-set in the control module 3 .
[0045] It can be understood that the specific values of the preset distance, preset time, and preset interval can be set by the user of the present invention according to actual conditions and machine size. The present invention is not limited here, as long as it is applicable to the intelligent monitoring method of the transformer winding process proposed in the present invention.
[0046] Preferably, the present invention sets the preset distance to 20 mm, the preset time to 2 seconds, and the preset interval to [-2 mm, 2 mm]. These preferred values were obtained by the present invention's technicians through extensive testing and are capable of effectively implementing the transformer winding process intelligent monitoring method proposed in the present invention, further improving the reliability and usability of the present invention.
[0047] S200 , controlling the movement of the moving assembly 2 according to the winding position of the wire 6 , thereby ensuring that the wire 6 is always perpendicular to the axial direction of the coil 8 to be wound provided on the winding device 7 during the winding process.
[0048] Specifically, the controlling of the movement of the moving assembly 2 according to the winding position of the wire 6 so that the wire 6 is always perpendicular to the axial direction of the coil 8 to be wound provided on the winding device 7 during the winding process includes: When the wire 6 hits the first travel switch 4 during the winding process, the control module 3 controls the moving component 2 to move a preset distance to the right along the axial direction of the coil 8 to be wound, so that the wire 6 is located at the center position of the first travel switch 4 and the second travel switch 5.
[0049] Specifically, the controlling of the movement of the moving assembly 2 according to the winding position of the wire 6 so that the wire 6 is always perpendicular to the axial direction of the coil 8 to be wound provided on the winding device 7 during the winding process includes: When the wire 6 hits the second travel switch 5 during the winding process, the control module 3 controls the moving component 2 to move a preset distance to the left along the axial direction of the coil 8 to be wound, so that the wire 6 is located at the center position of the first travel switch 4 and the second travel switch 5.
[0050] Specifically, the method further includes: When the wire hits any travel switch during the winding process, the positioning module 10 provided on the pay-off device 1 is used to obtain the first position information of the current pay-off device 1. After a preset time has passed, the second position information of the current pay-off device 1 is obtained. Based on the first position information and the second position information, it is determined whether the movement of the pay-off device 1 is abnormal, and a prompt signal regarding the judgment result is output.
[0051] Specifically, the method further includes: Calculating the absolute value of the axial distance of the first position information and the second position information along the axial direction of the coil to be wound 8, and determining whether the difference between the absolute value of the axial distance along the axial direction of the coil to be wound 8 and a preset distance is within a preset range; If so, it is determined that the pay-off device 1 moves normally, and a prompt signal indicating that the pay-off device 1 moves normally is output; If not, it is determined that the pay-off device 1 has not completed the movement, and a prompt signal regarding the abnormal movement of the pay-off device 1 is output, and the winding motor 11 is controlled to stop winding.
[0052] The workflow of the present invention is further described below: 1. Initialization phase The winding motor 11 and the moving assembly are initialized, and the first preset distance is set to a preferred value of 20 mm. The first travel switch and the second travel switch are set to initial positions of -10 mm and +10 mm, respectively.
[0053] 2. Winding stage After winding begins, the control module monitors the status of the travel switches in real time. When the wire hits the first travel switch, the control module drives the moving assembly 20 mm to the right. When the wire hits the second travel switch, the control module drives the moving assembly 20 mm to the left, ensuring that the wire remains centered between the first and second travel switches.
[0054] 3. Anomaly Detection Phase When the wire hits any travel switch, the positioning module records the initial position of the pay-off device and its position two seconds later, and calculates the absolute value of the axial distance between the two along the axial direction of the coil 8 to be wound. If the difference between the absolute value of the axial distance along the axial direction of the coil 8 to be wound is within the preferred range of ±2 mm, the movable assembly is considered to be adjusted normally; otherwise, it is considered abnormal, and the system will issue a warning signal and stop winding.
[0055] 4. End of operation After winding is completed, the system records the operating status and generates a winding quality report, including parameters such as winding accuracy and number of abnormalities, providing data support for equipment maintenance and optimization.
[0056] Specifically, the technical parameters of the present invention are preferably described as follows: Stepper motor step angle: 1.8°, taking into account both accuracy and cost.
[0057] Moving speed: 15 mm / s, balancing efficiency and responsiveness.
[0058] Preset distance: 20 mm, ensuring sufficient wire adjustment range.
[0059] Preset range: ±2 mm to avoid misjudgment due to measurement error.
[0060] Through the above-mentioned design and parameter optimization, the present invention can achieve high-precision monitoring and dynamic adjustment of the transformer winding process, significantly improving the winding quality and system stability.
[0061] It should be noted that the present invention significantly improves the quality and efficiency of transformer winding by detecting the wire position in real time through a dual-travel switch and combining it with the precise control of the moving assembly by the control module. The specific beneficial effects are reflected in the following aspects: 1. Improve winding accuracy By installing a first and second travel switch on the pay-off mechanism, the wire's winding position is monitored in real time. The control module then drives the moving assembly along the winding mechanism's axis, ensuring the wire remains perpendicular to the axial direction of the coil. This dynamic adjustment mechanism effectively prevents wire deviation or uneven tension, significantly improving the coil's concentricity and turn distribution uniformity, thereby enhancing the transformer's electrical performance.
[0062] 2. Enhance system stability The present invention incorporates an anomaly detection mechanism into the winding process. When the wire strikes any travel switch, the positioning module records the initial position of the payout device and its position after a set time. By calculating the absolute value of the axial distance between the two along the coil 8 to be wound and comparing it with a preset interval, it determines whether the movable assembly has completed adjustment. If an anomaly is detected, the system immediately stops winding and issues a warning signal. This mechanism effectively prevents winding failures caused by equipment failure or abnormal adjustments, enhancing the stability and reliability of the system.
[0063] 3. Improve production efficiency Traditional winding methods require manual monitoring and adjustment of wire position, which is not only inefficient but also prone to operational errors. This invention reduces manual intervention through automated monitoring and dynamic adjustment, significantly improving winding efficiency. Furthermore, the system can quickly respond to deviations in wire position, avoiding winding interruptions caused by adjustment delays, further improving production efficiency.
[0064] 4. Reduce equipment loss and production costs By adjusting the conductor position in real time, excessive friction between the conductor and the winding device, or conductor breakage, is avoided, reducing wear on the winding device and extending the equipment's service life. This also reduces scrap rates due to winding quality issues and lowers production costs.
[0065] 5. Easy to integrate and expand The control module and anomaly detection mechanism of the present invention are based on a modular design, offering excellent scalability and seamless integration with existing winding equipment. Furthermore, the system supports software-based intelligent monitoring methods through memory and processors, laying the foundation for further intelligent upgrades.
[0066] In summary, the present invention can effectively improve winding accuracy, enhance system stability, improve production efficiency and reduce equipment loss through the combination of dual-stroke switches, dynamic adjustment mechanism and abnormality detection function, and has important technical value and promotion significance for the transformer winding industry.
[0067] In a preferred embodiment, the present application further provides an electronic device, comprising: A memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the method for intelligent monitoring of the transformer winding process is implemented. The computer device can be broadly defined as a server, a terminal, or any other electronic device with the necessary computing and / or processing capabilities. In one embodiment, the computer device may include a processor, a memory, a network interface, a communication interface, etc. connected via a system bus. The processor of the computer device can be used to provide the necessary computing, processing, and / or control capabilities. The memory of the computer device may include a non-volatile storage medium and an internal memory. An operating system, a computer program, etc. may be stored in or on the non-volatile storage medium. The internal memory can provide an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The network interface and the communication interface of the computer device can be used to connect to and communicate with external devices via a network. When the computer program is executed by the processor, the steps of the method of the present invention are performed.
[0068] The present invention can be implemented as a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, causes the steps of the method of an embodiment of the present invention to be performed. In one embodiment, the computer program is distributed on a plurality of computer devices or processors coupled to a network so that the computer program is stored, accessed, and executed in a distributed manner by one or more computer devices or processors. A single method step / operation, or two or more method steps / operations, can be performed by a single computer device or processor or by two or more computer devices or processors. One or more method steps / operations can be performed by one or more computer devices or processors, and one or more other method steps / operations can be performed by one or more other computer devices or processors. One or more computer devices or processors can perform a single method step / operation, or perform two or more method steps / operations.
[0069] It will be understood by those skilled in the art that the method steps of the present invention can be performed by instructing relevant hardware such as a computer device or a processor through a computer program, and the computer program can be stored in a non-transitory computer-readable storage medium, and when the computer program is executed, the steps of the present invention are performed. Depending on the circumstances, any reference to memory, storage, database or other media in this document may include non-volatile and / or volatile memory. Examples of non-volatile memory include read-only memory ROM, programmable ROMPROM, electrically programmable ROMEPROM, electrically erasable programmable ROMEEPROM, flash memory, magnetic tape, floppy disk, magneto-optical data storage device, optical data storage device, hard disk, solid-state disk, etc. Examples of volatile memory include random access memory RAM, external cache memory, etc.
[0070] It is understandable that the present invention significantly improves the quality and efficiency of transformer winding by detecting the wire position in real time through the dual-travel switch and combining it with the precise control of the moving component by the control module. Its specific beneficial effects are reflected in the following aspects: 1. Improve winding accuracy By installing a first and second travel switch on the pay-off mechanism, the wire's winding position is monitored in real time. The control module then drives the moving assembly along the winding mechanism's axis, ensuring the wire remains perpendicular to the axial direction of the coil. This dynamic adjustment mechanism effectively prevents wire deviation or uneven tension, significantly improving the coil's concentricity and turn distribution uniformity, thereby enhancing the transformer's electrical performance.
[0071] 2. Enhance system stability The present invention introduces an abnormality detection mechanism during the winding process. When the wire hits any travel switch, the positioning module records the initial position of the pay-off device and the position information after a set time. By calculating the absolute value of the axial distance of the two along the coil (8) to be wound and comparing it with the preset interval, it is determined whether the moving component has completed the adjustment. If an abnormality is detected, the system will immediately stop the winding and issue a prompt signal. This mechanism effectively avoids winding failures caused by equipment failure or abnormal adjustment, and enhances the stability and reliability of the system.
[0072] 3. Improve production efficiency Traditional winding methods require manual monitoring and adjustment of wire position, which is not only inefficient but also prone to operational errors. This invention reduces manual intervention through automated monitoring and dynamic adjustment, significantly improving winding efficiency. Furthermore, the system can quickly respond to deviations in wire position, avoiding winding interruptions caused by adjustment delays, further improving production efficiency.
[0073] 4. Reduce equipment loss and production costs By adjusting the conductor position in real time, excessive friction between the conductor and the winding device, or conductor breakage, is avoided, reducing wear on the winding device and extending the equipment's service life. This also reduces scrap rates due to winding quality issues and lowers production costs.
[0074] 5. Easy to integrate and expand The control module and anomaly detection mechanism of the present invention are based on a modular design, offering excellent scalability and seamless integration with existing winding equipment. Furthermore, the system supports software-based intelligent monitoring methods through memory and processors, laying the foundation for further intelligent upgrades.
[0075] In summary, the present invention can effectively improve winding accuracy, enhance system stability, improve production efficiency and reduce equipment loss through the combination of dual-stroke switches, dynamic adjustment mechanism and abnormality detection function, and has important technical value and promotion significance for the transformer winding industry.
[0076] The various technical features described above can be combined arbitrarily. Although not all possible combinations of these technical features are described, any combination of these technical features should be considered to be covered by this specification as long as such combination does not conflict.
[0077] The specific embodiments of the present invention described above do not limit the scope of protection of the present invention. Any other corresponding changes and modifications made based on the technical concept of the present invention should be included in the scope of protection of the claims of the present invention.
Claims
1. An intelligent monitoring system for transformer winding process, characterized in that: The system comprises: A wire-releasing device (1), wherein the wire-releasing device (1) is provided with a moving component (2), a control module (3) and a wire position detection device; The wire position detection device includes a travel switch, which is used to detect the winding position of the wire (6). The control module (3) and the moving component (2) are controlled and connected, and are used to control the movement of the moving component (2) to drive the wire-releasing device (1) to move. The control module (3) is used to control the movement of the moving component (2) according to the winding position of the wire (6) during the winding process, so that the wire (6) is always perpendicular to the axial direction of the coil (8) to be wound provided on the winding device (7) during the winding process.
2. The intelligent monitoring system for transformer winding process according to claim 1, characterized in that: The wire position detection device comprises a first travel switch (4) and a second travel switch (5), wherein the first travel switch (4) and the second travel switch (5) are respectively communicatively connected to the control module (3).
3. The intelligent monitoring system for transformer winding process according to claim 2, characterized in that: When the wire (6) hits the first travel switch (4) during the winding process, the control module (3) controls the moving component (2) to move a preset distance to the right along the axial direction of the coil (8) to be wound, thereby positioning the wire (6) at the center of the first travel switch (4) and the second travel switch (5).
4. The intelligent monitoring system for transformer winding process according to claim 2, characterized in that: When the wire (6) hits the second travel switch (5) during the winding process, the control module (3) controls the moving component (2) to move a preset distance to the left along the axial direction of the coil (8) to be wound, thereby positioning the wire (6) at the center of the first travel switch (4) and the second travel switch (5).
5. A method for intelligent monitoring of transformer winding process, characterized in that: The method comprises: S100, after winding starts, controlling the winding motor (11) to start working, and using the wire position detection device to detect the winding position of the wire (6); S200, controlling the movement of the moving assembly (2) according to the winding position of the wire (6), thereby ensuring that the wire (6) is always perpendicular to the axial direction of the coil (8) to be wound provided on the winding device (7) during the winding process.
6. The intelligent monitoring method for transformer winding process according to claim 5, characterized in that: The method of controlling the movement of the moving component (2) according to the winding position of the wire (6) so as to ensure that the wire (6) is always perpendicular to the axial direction of the coil (8) to be wound provided on the winding device (7) during the winding process comprises: When the wire (6) hits the first travel switch (4) during the winding process, the control module (3) controls the moving component (2) to move a preset distance to the right along the axial direction of the coil (8) to be wound, thereby positioning the wire (6) at the center of the first travel switch (4) and the second travel switch (5).
7. The intelligent monitoring method for transformer winding process according to claim 5, characterized in that: The method of controlling the movement of the moving component (2) according to the winding position of the wire (6) so as to ensure that the wire (6) is always perpendicular to the axial direction of the coil (8) to be wound provided on the winding device (7) during the winding process comprises: When the wire (6) hits the second travel switch (5) during the winding process, the control module (3) controls the moving component (2) to move a preset distance to the left along the axial direction of the coil (8) to be wound, thereby positioning the wire (6) at the center of the first travel switch (4) and the second travel switch (5).
8. The intelligent monitoring method for transformer winding process according to claim 6 or 7, characterized in that: The method further comprises: When the wire hits any travel switch during the winding process, a positioning module (10) provided on the pay-off device (1) is used to obtain first position information of the current pay-off device (1). After a preset time has passed, second position information of the current pay-off device (1) is obtained. Whether the movement of the pay-off device (1) is abnormal is determined based on the first position information and the second position information, and a prompt signal related to the determination result is output.
9. The intelligent monitoring method for transformer winding process according to claim 8, characterized in that: The method further comprises: Calculating the absolute value of the axial distance of the coil to be wound (8) along the first position information and the second position information, and determining whether the difference between the absolute value of the axial distance of the coil to be wound (8) and a preset distance is within a preset interval; If so, it is determined that the pay-off device (1) moves normally, and a prompt signal indicating that the pay-off device (1) moves normally is output; If not, it is determined that the pay-off device (1) has not completed the movement, and a prompt signal about the abnormal movement of the pay-off device (1) is output, and the winding motor (11) is controlled to stop winding.
10. An electronic device, characterized in that: include: Memory; and a processor, wherein the memory stores computer-readable instructions, and when the computer-readable instructions are executed by the processor, the intelligent monitoring method for the transformer winding process according to any one of claims 5 to 9 is implemented.