Transformer winding machine convenient to adjust

Abstract

The invention discloses a winding machine of a transformer winding convenient to adjust, and relates to the technical field of transformer winding manufacturing, the winding machine comprises a main shaft, a winding displacement device, a control module and a rack, and the winding machine is characterized in that the control module comprises a real-time detection module and a double closed-loop control unit; and the real-time detection module is fixed on the rack, is positioned on the outer side of the winding layer of the main shaft, and is used for acquiring diameter change data of the winding layer in real time. According to the winding machine of the transformer winding convenient to adjust, diameter data of a winding layer is accurately obtained through the real-time detection module, real-time matching of the winding displacement speed and the rotating speed of the main shaft is ensured in combination with a dynamic synchronization mechanism of the double-closed-loop control unit, and the problems of wire turn gaps, lap winding and compactness fluctuation caused by parameter mismatching of a traditional winding machine are effectively solved. The distribution uniformity and consistency of the winding layers are improved, the dependence on artificial experience is avoided, and the electromagnetic performance and the insulation characteristic of the winding process of windings with different specifications meet the standard requirements.

Description

Technical Field

[0001] The invention relates to the technical field of transformer winding manufacturing, in particular to a transformer winding winding machine which is easy to adjust. Background Art

[0002] In traditional transformer winding processes, winding machines typically use manual or fixed-ratio adjustments to the lateral speed of the wire arrangement and the spindle rotation speed. While this method generally meets requirements for winding coils of a single specification, it exhibits significant drawbacks when handling windings of varying diameters. Since coil diameter directly affects the density of wire distribution on the bobbin, the matching relationship between wire arrangement speed and spindle speed must be readjusted when switching between larger and smaller diameter windings. However, existing equipment lacks a dynamic feedback mechanism, requiring operators to rely solely on experience-based preset parameters or manual fine-tuning, resulting in uneven wire distribution during the actual winding process. For example, if the spindle speed decreases due to an increase in coil diameter, without a simultaneous adjustment in the wire arrangement speed, the wire cannot be evenly laid along the bobbin axis, leading to gaps or overlaps between adjacent turns. This not only affects the mechanical strength of the coil but also degrades insulation performance due to localized electric field concentration. Furthermore, fixed-ratio speed regulation modes struggle to adapt to gradual changes in coil diameter. For example, during the winding process of a conical coil, the wire-winding speed must be continuously adjusted as the diameter changes. Traditional equipment, lacking a real-time coordination mechanism, often results in fluctuations in winding tightness. Variations in tightness between sections of the same coil directly impact the transformer's electromagnetic performance stability. While existing technologies attempt to improve winding quality by optimizing tension control or introducing automated modules, these improvements remain limited to single-parameter control and fail to overcome the bottleneck of dynamic coordination between the wire-winding device and the spindle's motion. Operators still must repeatedly search for matching parameters through trial and error, resulting in low efficiency and difficulty ensuring process consistency. Summary of the Invention

[0003] (1) Technical problems solved

[0004] In view of the shortcomings of the existing technology, the present invention provides a winding machine for transformer windings that is easy to adjust, which solves the problem of how to achieve dynamic synchronization and precise matching of the lateral movement speed of the wire arrangement device and the rotation speed of the main shaft.

[0005] (2) Technical solution

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: a winding machine for transformer windings that is easy to adjust, comprising a main shaft, a wire arrangement device, a control module and a frame;

[0007] The control module includes a real-time detection module and a dual closed-loop control unit;

[0008] The real-time detection module is fixed on the frame and located outside the spindle winding layer, and is used to collect diameter change data of the winding layer in real time;

[0009] The dual closed-loop control unit is electrically connected to the spindle drive motor and the servo motor of the wire arrangement device, and dynamically adjusts the lateral movement speed of the servo motor and the rotation speed of the spindle drive motor based on the diameter data output by the real-time detection module;

[0010] The lateral moving guide rail of the wire arranging device is arranged parallel to the axial direction of the main shaft, and the servo motor drives the wire arranging device to move along the guide rail through the ball screw.

[0011] Preferably, the real-time detection module includes a non-contact laser ranging unit and an encoder. The laser ranging units are symmetrically distributed on both sides of the main shaft, with their scanning direction aligned with the outer contour of the winding layer. The encoder is coaxially connected to the main shaft and is used to output a pulse signal indicating the main shaft rotation angle. During operation, the real-time detection module uses the non-contact laser ranging unit to scan the outer contour of the winding layer at multiple angles, obtain radial dimension data of the winding layer, and transmit it to the control center. The control center cross-validates the laser ranging data with the equivalent diameter converted from the encoder pulses. If the deviation between the two does not exceed a preset threshold, the wire traversing speed is controlled based on the laser data. Otherwise, the encoder data is switched to and a redundant calibration procedure is triggered. During the execution of the redundant calibration procedure, the control center pauses the main shaft drive motor, instructs the wire traversing device to retract to the end position of the previous winding, and reversely calculates the actual diameter of the winding layer based on the accumulated encoder pulse count. If the calculated result is consistent with the current encoder data, the abnormality flag is cleared and the winding process is resumed. If not, the control center is forced into manual maintenance mode and the device status is locked.

[0012] Preferably, the control module further comprises a control center, which receives the outer contour data of the winding layer scanned by the laser ranging unit and calculates the real-time winding diameter in combination with the pulse signal of the encoder;

[0013] When the diameter difference calculated by the laser ranging unit and the encoder exceeds a preset threshold, the control center corrects the real-time winding diameter based on the encoder data.

[0014] Preferably, the control center has a built-in dynamic transmission ratio algorithm module, which calculates the line speed in real time based on the following parameters, including:

[0015] Real-time winding diameter, spindle speed, wire diameter and layer winding coefficient;

[0016] The interlayer winding coefficient is dynamically corrected by matching a preset database according to the surface roughness of the wire.

[0017] Preferably, the dual closed-loop control unit comprises a main control loop and an auxiliary correction loop. The main control loop receives the wire-trapping speed command output by the dynamic transmission ratio algorithm module and controls the pulse frequency of the servo motor. The auxiliary correction loop is connected to a winding tension sensor located on the wire pulley of the wire-trapping device. When tension fluctuations exceeding a preset range are detected, the auxiliary correction loop sends a compensation signal to the main control loop to adjust the pulse frequency. The main control loop of the dual closed-loop control unit dynamically calculates the wire-trapping speed command based on the real-time winding diameter, wire diameter, and interlayer overlap coefficient, and converts the command into a pulse frequency signal for the servo motor. The auxiliary correction loop monitors the actual wire tension via the winding tension sensor and sends a compensation signal to the main control loop to adjust the pulse frequency when the tension exceeds a preset range. The commands of the main control loop and the auxiliary correction loop are time-aligned via a timestamp synchronization module to ensure that the matching error between the wire-trapping speed and the spindle speed is below a preset threshold. If a command transmission delay or servo motor response lag is detected, the synchronization module dynamically inserts a buffer queue and predicts the spindle angle change within a future time window to adjust the triggering timing of the wire-trapping speed command in real time.

[0018] Preferably, the main control loop and the auxiliary correction loop exchange data through a timestamp synchronization module, and the synchronization module ensures that the timing matching error between the wire speed instruction and the spindle speed is less than 5 milliseconds.

[0019] Preferably, the control center is also connected to an offline simulation verification unit, which pre-stores a winding dynamics model for simulating the matching relationship between the wire arrangement speed and the spindle speed under different wire specifications; a high-precision grating ruler is installed on the frame for real-time detection of the actual ratio of the wire arrangement displacement to the spindle rotation angle. If the deviation between the actual value and the simulation value exceeds 0.05mm / turn for three consecutive times, the control center triggers a shutdown and resets the parameters. The offline simulation verification unit pre-stores winding parameter models for different wire specifications, loads the corresponding model before the winding task starts, and generates a theoretical wire arrangement speed curve; during actual operation, the high-precision grating ruler and encoder collect the wire arrangement displacement and spindle angle data in real time, and the control center compares the actual ratio with the simulation model circle by circle. If the deviation exceeds the process standard for multiple consecutive circles, the system triggers the parameter reset program and recalibrates the zero position of the grating ruler and encoder; if the deviation is caused by mechanical wear, a maintenance warning is generated and the deviation trend data is recorded for manual analysis.

[0020] The control center incorporates a built-in thermal drift compensation model. When ambient temperature changes cause mechanical components to expand, the reference cable displacement is dynamically corrected based on temperature sensor data. In the event of sudden electromagnetic interference or clock signal anomalies, the synchronization module switches to a backup oscillator to maintain basic control functions while reducing the spindle speed to a safe threshold. After each task, the system generates a process report and enforces the calibration of key parameters. If key indicators continue to fall below standard, batch production is prohibited until the optimization process is complete.

[0021] Preferably, the servo motor and ball screw of the wire arrangement device are rigidly connected via a coupling, and the ratio of the lead of the ball screw to the wire diameter ranges from 1:0.8 to 1:1.2. The servo motor of the wire arrangement device drives the ball screw to rotate via a rigid coupling, driving the wire arrangement device to move along a guide rail parallel to the main shaft axis. The lead of the ball screw is dynamically matched to the wire diameter. When the wire diameter changes, the system automatically adjusts the lead-to-diameter ratio to a preset range and verifies the wire arrangement displacement in real time using a high-precision grating ruler. If a single-turn displacement deviation exceeding the allowable error is detected, the system suspends winding and prompts the user to check the mechanical transmission components. If the deviation is caused by an incorrect wire diameter input, the winding dynamics model in the offline simulation verification unit is automatically called to regenerate the matching curve.

[0022] Preferably, the winding machine for transformer windings that is easy to adjust also includes a human-computer interaction interface, which integrates a parameter input module and a status display module; the parameter input module is used to set the wire diameter, interlayer winding coefficient and tension threshold; the status display module displays the matching ratio curve of the winding diameter, wire arrangement speed and spindle speed in real time. The human-computer interaction interface provides wire parameter input, real-time status display and abnormal diagnosis functions, including: after the operator selects the wire type, the system automatically matches the default parameters and limits the input range; during the winding process, the matching curve of the winding diameter, wire arrangement speed and spindle speed is dynamically displayed, and the abnormal section is highlighted and associated with the cause of the fault. In response to the winding requirements of gradual winding, the interface supports manual input of the diameter change rate and generates a prediction curve. The actual operation data is superimposed on the prediction curve in real time. If the deviation continues to expand, the winding is suspended and the parameter optimization prompt is given.

[0023] Preferably, the detection end of the winding tension sensor and the contact part of the wire are made of ceramic material, and the contact surface is provided with a V-shaped guide groove, the opening width of the guide groove is 1.2-1.5 times the diameter of the wire. The detection end of the winding tension sensor adopts a ceramic contact head, and the opening width of the V-shaped guide groove is automatically adjusted with the diameter of the wire to ensure bilateral contact; when the wire is detected to be offset or the guide groove is worn, the system fine-tunes the lateral position of the wire arrangement device to correct the path. For high-tension wire winding, the contact head has a built-in piezoelectric film sensor to monitor the pressure distribution, and if the pressure on one side is unbalanced, the servo motor compensation is triggered; for low-tension thin wires, the guide groove surface is coated with a friction-reducing coating and the clamping force is dynamically adjusted to prevent sliding. If the wire breaks or becomes loose, the infrared photoelectric sensor synchronously detects the existence of the wire and initiates the emergency shutdown and rewinding procedure.

[0024] (3) Beneficial effects

[0025] The present invention provides a winding machine for transformer windings that is easy to adjust. It has the following beneficial effects:

[0026] This easily adjustable transformer winding machine uses a real-time detection module to accurately acquire winding layer diameter data. Combined with a dynamic synchronization mechanism within a dual closed-loop control unit, this ensures real-time matching of wire speed and spindle speed, effectively eliminating the issues of turn gap, overlap, and tightness fluctuations caused by parameter mismatches in traditional winding machines. The synergy between a redundant calibration program and an offline simulation verification unit improves the uniformity and consistency of winding layer distribution, eliminating reliance on manual experience and ensuring standardized electromagnetic and insulation performance across windings of varying specifications. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 It is a schematic diagram of the overall framework of the present invention;

[0028] Figure 2 This is a control logic timing diagram of the present invention. DETAILED DESCRIPTION

[0029] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] See also Figure 1 and Figure 2 , the present invention provides a technical solution: a winding machine for transformer windings that is easy to adjust, comprising a main shaft, a wire arrangement device, a control module and a frame;

[0031] The control module includes a real-time detection module and a dual closed-loop control unit;

[0032] The real-time detection module is fixed on the frame and located outside the spindle winding layer. It is used to collect the diameter change data of the winding layer in real time. During the operation of the winding machine, the real-time detection module uses the non-contact laser ranging unit fixed on the frame to perform multi-angle scanning on the outer contour of the spindle winding layer and synchronously obtain the radial dimension data of the winding layer. When the diameter of the winding layer changes dynamically due to an increase in the number of coil turns or a change in the wire specifications, the laser ranging unit transmits the real-time collected diameter data to the control module.

[0033] After receiving the diameter data, the dual closed-loop control unit in the control module first calculates the required lateral speed of the wire-winding mechanism using a preset dynamic transmission ratio algorithm, combined with the current spindle speed and wire diameter. This speed command is then converted into a pulse frequency signal for the servo motor. If a mismatch occurs between the winding speed and the spindle speed due to wire tension fluctuations or mechanical transmission errors during the winding process, an auxiliary correction loop triggers a speed compensation mechanism based on real-time feedback from the winding tension sensor. This mechanism reduces the winding speed to minimize wire stretch if the tension exceeds a preset upper limit, and increases it to prevent wire slack if the tension falls below a preset lower limit.

[0034] In addition, when the laser ranging unit experiences data jumps due to uneven winding layer surface or environmental interference, the system automatically compares the diameter value converted from the encoder pulse. If the deviation between the two exceeds the allowable threshold, the wire speed instruction is forcibly corrected based on the encoder data to ensure the reliability of the winding layer diameter calculation.

[0035] To meet the winding requirements of gradient winding or special-shaped winding, the system pre-loads the winding dynamics model of different wire specifications through the offline simulation verification unit, and continuously monitors the actual ratio of the wire displacement and the spindle rotation angle through a high-precision grating ruler during actual operation. If three consecutive deviations are detected outside the tolerance range, the system will automatically shut down and reset the control parameters to avoid consistency defects in mass production.

[0036] The dual closed-loop control unit is electrically connected to the spindle drive motor and the servo motor of the wire traversing device, and dynamically adjusts the lateral movement speed of the servo motor and the rotation speed of the spindle drive motor based on the diameter data output by the real-time detection module; the dual closed-loop control unit receives the winding layer diameter data in real time, and the main control loop first calculates the initial wire traversing speed instruction based on the current winding diameter and the preset wire specifications, and converts the instruction into a pulse frequency signal of the servo motor to drive the wire traversing device to move laterally; at the same time, the spindle drive motor runs according to the preset speed, and continuously feeds back the actual rotation angle through the encoder.

[0037] If the wire diameter suddenly changes during the winding process due to deviations in the wire diameter or uneven stacking of the winding layers, the main control loop updates the wire winding speed command in real time. This includes: if the winding diameter increases, the servo motor pulse frequency is proportionally reduced to slow the wire winding movement; if the winding diameter decreases, the pulse frequency is increased to speed up the winding. Simultaneously, the auxiliary correction loop monitors the actual wire tension via the winding tension sensor. If the tension value exceeds a preset upper limit, it is determined that the winding speed is too slow, causing the wire to be overstretched, and an acceleration signal is immediately sent to the main control loop to increase the servo motor speed. If the tension value falls below a preset lower limit, it is determined that the winding speed is too fast, causing the wire to be slack, and a deceleration signal is sent to reduce the servo motor speed.

[0038] When winding a tapered winding, the system dynamically adjusts the spindle drive motor's speed curve based on the continuous change in diameter data. This includes: if the diameter change rate exceeds a set threshold, the spindle speed is simultaneously reduced to match the gradient adjustment of the wire-laying speed, preventing winding gap accumulation due to speed inertia. If the laser ranging unit experiences abnormal data jumps due to reflections from the winding surface or mechanical vibration, the system automatically switches to the diameter value converted from encoder pulses and triggers an alarm on the human-machine interface. Closed-loop control resumes after manual confirmation.

[0039] In the event of sudden mechanical jams or load fluctuations, the main control loop uses real-time current feedback from the servo motor to determine the operating status. This includes: if the current value continuously exceeds the safe range, the spindle and wire arrangement device will be urgently stopped, and the winding diameter, speed, and tension data at the time of the fault will be recorded for subsequent analysis.

[0040] The lateral guide rails of the cable arrangement are arranged parallel to the main spindle axis, and the servo motor drives the cable arrangement along the guide rails via a ball screw. It should be further explained that, in the specific implementation, the lateral guide rails of the cable arrangement are fixed to both sides of the frame with bolts, and their extension direction remains parallel to the main spindle axis. During installation, a laser calibrator is used to check the parallelism error between the guide rails and the main spindle to ensure that the deviation does not exceed 0.1mm / m. The servo motor is rigidly connected to the ball screw via a coupling, and the ball screw nut seat is fixed to the base of the cable arrangement. When the servo motor receives pulse commands from the control module, it drives the ball screw to rotate and drives the cable arrangement to move linearly along the guide rails.

[0041] When winding wires of varying diameters, the system dynamically adjusts the ball screw's lead to match the wire diameter. This includes: If the wire diameter increases, the servo motor speed is reduced to minimize displacement per turn; if the wire diameter decreases, the speed is increased to maximize displacement, ensuring even distribution of the wire along the bobbin's axial direction. When winding large-diameter windings increases the load on the wire-traversing mechanism, the servo motor monitors its output torque in real time. If the current exceeds a preset safety threshold, the overload protection function automatically triggers, halting spindle operation and prompting a check of the mechanical fit between the guide rail and the screw.

[0042] To address the frequent start-stop requirements of high-density windings, a backlash compensation mechanism is implemented between the ball screw and the guide rail. This mechanism involves pre-applying a reverse pulse to the servo motor during the reversal of the wire-traversing mechanism, eliminating transmission backlash and preventing misalignment of the wire turns due to mechanical backlash. If changes in ambient temperature cause the guide rail to expand and deform due to thermal expansion, the system detects this expansion using a displacement sensor mounted at the rail's end and dynamically adjusts the servo motor's pulse equivalent to compensate for the wire-traversing position error caused by this deformation. When continuous speed changes are required for winding conical windings, the ball screw's acceleration curve is synchronized with the spindle speed change rate. If a sudden acceleration change is detected that causes the servo motor's tracking error to exceed 2%, a smooth transition algorithm is automatically inserted to prevent vibration in the wire-traversing mechanism due to inertial shock.

[0043] In addition, the guide rail surface is coated with a wear-resistant ceramic coating and an automatic lubrication module is installed to regularly inject grease according to the cumulative movement distance of the wire arrangement device. If the friction resistance sensor detects that the resistance value increases by more than 20%, an abnormal alarm is triggered and the winding process is forcibly interrupted.

[0044] The real-time detection module includes a non-contact laser ranging unit and an encoder. The laser ranging units are symmetrically located on either side of the spindle, with their scanning direction aligned with the outer contour of the winding layer. The encoder is coaxially connected to the spindle and is used to output a pulse signal indicating the spindle's rotation angle. It should be further explained that, in the specific implementation, the non-contact laser ranging unit of the real-time detection module is mounted on adjustable brackets on either side of the spindle. Its scanning beam is aligned with the outer contour of the winding layer at a 45-degree angle. By alternately emitting two intersecting laser beams, the circumferential surface of the winding layer is covered, avoiding measurement blind spots caused by gaps in the wire or localized depressions. When the diameter of the winding layer changes, the laser ranging unit calculates the radial dimensions of the winding layer in real time using the principle of triangulation and transmits the data to the control center at a millisecond frequency. The encoder is rigidly connected to the rear end of the spindle via a flange. Its internal grating disk rotates synchronously with the spindle, outputting a fixed number of pulse signals per revolution to convert the actual spindle speed and rotation angle. When reflective materials such as enameled copper wire are present on the surface of the winding layer, the laser ranging unit automatically switches to low-reflectivity mode, compensating for signal attenuation by reducing laser intensity and increasing receiver sensitivity. If the winding layer is made of matte material such as paper-wrapped wire, it switches to high-resolution mode to improve contour scanning accuracy.

[0045] During continuous winding, if the laser ranging unit's data jumps abnormally beyond a preset threshold due to interference from environmental dust or oil, the system automatically switches to equivalent diameter data converted from encoder pulses and triggers a cleaning alarm on the human-machine interface. If the encoder pulse signal is intermittently lost due to mechanical vibration, historical winding diameter trend data is interpolated for compensation, while the spindle speed is reduced to below the safe threshold until the signal recovers. The laser ranging unit's scanning frequency is dynamically adjusted for windings of different wire diameters, including increasing to 2000 scans per second for fine wire winding to capture minute diameter changes, and reducing to 500 scans per second for thicker wire winding to reduce the data processing load.

[0046] The encoder features a dual-channel redundant design. If the primary channel signal fails, the backup channel immediately takes over the pulse output and marks the faulty channel number in the control center. A maintenance report is automatically generated after winding is completed. If the deviation between the laser ranging unit and the encoder data persists beyond the tolerance range and cannot be corrected through self-calibration, the system is forced into a shutdown protection state, locking the current winding parameters and displaying a fault diagnosis interface for manual intervention.

[0047] The control module also includes a control center, which receives the outer contour data of the winding layer scanned by the laser ranging unit and calculates the real-time winding diameter in combination with the pulse signal of the encoder; when the diameter difference calculated by the laser ranging unit and the encoder exceeds a preset threshold, the control center corrects the real-time winding diameter based on the encoder data. It should be further explained that, in the specific implementation process, the control center receives real-time winding layer outer contour data scanned by the laser ranging unit and the spindle rotation pulse signal output by the encoder. It first averages the multiple angular radial dimensions collected by the laser ranging unit and converts them into an equivalent circumference based on the number of pulses per spindle rotation. The winding diameter values from these two sources are then simultaneously calculated based on the geometric relationship between circumference and diameter. If the deviation between the laser ranging data and the encoder-converted diameter does not exceed a preset threshold of ±0.3mm, the laser ranging data is preferentially used as the real-time diameter input to maintain high-precision dynamic response. If the deviation exceeds the threshold, it is determined that the laser ranging unit is subject to environmental interference or the winding layer surface is abnormal. The system immediately switches to the diameter value converted from the encoder pulses and triggers a redundant calibration procedure, including: the control center pauses the spindle drive motor, instructs the wire arrangement device to retract to the end position of the previous winding, and re-verifies the actual winding layer diameter using the accumulated encoder pulse count. If the verification result is consistent with the encoder data, the abnormal flag of the laser ranging unit is cleared and operation is resumed. Otherwise, the system is forced to enter manual maintenance mode.

[0048] For winding scenarios involving high-reflectivity wires such as silver-plated copper wire, the control center automatically reduces the scanning frequency of the laser ranging unit and adds a data filtering algorithm to eliminate spot reflection noise; when winding matte wires such as cotton-covered wire, the laser power is increased and the multi-point scanning mode is enabled to ensure the integrity of the contour data. During high-speed winding, if the encoder pulse signal is frequency saturated due to instantaneous acceleration of the spindle, the control center dynamically adjusts the data sampling period and uses an interpolation algorithm to compensate for the diameter change within the pulse interval to avoid wire speed lags due to data processing delays. When the redundant calibration program is triggered three times in a row and the diameter data deviation is still not eliminated, the system automatically switches to the preset safe winding mode, including: estimating the winding diameter based on the wire diameter and the initial number of layers, and adjusting the wire speed at a fixed ratio. At the same time, the accuracy degradation warning is highlighted on the human-machine interface until manual intervention is required to repair the detection module.

[0049] The control center has a built-in dynamic transmission ratio algorithm module, which calculates the wire arrangement speed in real time based on the following parameters: real-time winding diameter, spindle speed, wire diameter, and interlayer overlap coefficient. The interlayer overlap coefficient is dynamically corrected by matching a preset database based on the surface roughness of the wire. It should be further explained that in the specific implementation process, the dynamic transmission ratio algorithm module dynamically adjusts the wire arrangement speed based on the ratio of the real-time winding diameter to the wire diameter. This includes: when the winding diameter gradually increases due to the increase in the number of coil layers, the algorithm proportionally reduces the lateral movement speed of the wire arrangement device to ensure that the displacement of each turn of wire along the axial direction of the bobbin is constant; if it is detected that the wire diameter deviates from the preset value due to batch differences or production errors, the interlayer overlap coefficient is recalculated based on the actual measurement value and the corresponding surface roughness correction factor is matched through the preset database. For example, when the wire surface is a highly smooth enameled wire, a low overlap coefficient is used to reduce the gap between the turns; when the wire is a rough paper-wrapped wire, the overlap coefficient is increased to avoid extrusion and deformation between the wire layers.

[0050] During the winding process, if the system detects a deviation of more than ±5% between the input wire diameter and the actual measured value for three consecutive times, a parameter anomaly alarm is automatically triggered and the wire speed command is frozen until manual confirmation and correction is made. If a winding layer experiences a localized dent due to a sudden external force, the algorithm analyzes the sudden gradient of the diameter data and determines it is an abnormal disturbance rather than an actual diameter change. It temporarily locks the wire speed and initiates a self-check of the winding layer's surface flatness. To meet the requirements of gradually changing windings, the algorithm module pre-stores multiple diameter-speed curve templates. When the real-time winding diameter change rate exceeds a set threshold, it automatically matches the closest curve template and smoothly transitions the wire speed. If a manual switch in wire type is forced, such as from round to flat wire, the equivalent diameter calculation logic is dynamically adjusted based on the new wire's cross-sectional shape, and the inter-layer overlap factor is reset. If the servo motor overheats due to prolonged operation of the winding machine, the algorithm module uses a built-in thermal drift compensation model and temperature sensor data to fine-tune the wire speed output to offset transmission errors caused by thermal expansion of mechanical components. If intermittent insulation damage or burrs are detected on the wire surface, the overlap factor will be dynamically fine-tuned according to the tension sensor's fluctuation frequency to avoid local accumulation that may aggravate wire damage.

[0051] The dual closed-loop control unit includes a main control loop and an auxiliary correction loop; the main control loop receives the wire-winding speed command output by the dynamic transmission ratio algorithm module and controls the pulse frequency of the servo motor; the auxiliary correction loop is connected to the winding tension sensor, which is set at the wire pulley of the wire-winding device. When the tension fluctuation is detected to exceed the preset range, the auxiliary correction loop sends a compensation signal to the main control loop to adjust the pulse frequency. It should be further explained that, in the specific implementation process, after the main control loop of the dual closed-loop control unit receives the wire-winding speed instruction generated by the dynamic transmission ratio algorithm module, it converts the instruction into a pulse frequency signal of the servo motor, and controls the lateral movement speed of the wire-winding device by adjusting the pulse duty cycle; at the same time, the auxiliary correction loop monitors the wire tension fluctuation in real time through the winding tension sensor. The tension sensor is installed in the transition area between the wire pulley and the winding layer of the wire-winding device. When the tension value is detected to exceed the preset upper limit, it is determined that the wire-winding speed lags behind the spindle speed, resulting in excessive stretching of the wire. An acceleration compensation signal is immediately sent to the main control loop to increase the servo motor pulse frequency to speed up the wire-winding movement speed. If the tension value is lower than the preset lower limit, it is determined that the wire-winding speed is ahead of the main shaft speed, resulting in wire slack, and a deceleration compensation signal is sent to reduce the pulse frequency.

[0052] When winding high-viscosity impregnated wire, the system automatically adjusts the compensation response speed based on the tension sensor's fluctuation frequency. For example, if the detected tension exceeds a threshold three times within 0.1 seconds, it identifies abnormal friction between the wire and the guide pulley, triggering an emergency speed reduction sequence and simultaneously reducing the spindle speed to a safe value. When winding fine wire with low tension requirements, a micro-oscillation compensation mode is activated, superimposing high-frequency, low-amplitude pulse disturbances on the winding speed baseline to prevent wire jamming caused by static friction. To prevent sudden wire breakage or mechanical jamming, an auxiliary correction loop analyzes the correlation between tension sensor data and servo motor current for dual verification. If the tension suddenly drops to zero and the motor current drops abnormally, it identifies a wire break and initiates an emergency shutdown. If the tension suddenly rises and the current continuously exceeds the limit, it identifies a mechanical jam and triggers a reverse retraction command. In the event of conflicting commands between the main control loop and the auxiliary correction loop—for example, if the main loop requires acceleration while the auxiliary loop requires deceleration—the system prioritizes the auxiliary loop's compensation signal and flags the conflict on the human-machine interface for process optimization.

[0053] When winding a gradual winding, the auxiliary correction loop predicts the direction of tension fluctuation based on the changing trend of the winding diameter, including: if the diameter continues to increase, the compensation response threshold is lowered in advance to avoid overshoot; if the diameter fluctuates in stages, the dynamic filtering algorithm is enabled to eliminate instantaneous interference signals. In response to the thermal expansion and contraction of the wire caused by changes in ambient temperature, the system corrects the tension threshold range in combination with the temperature sensor data: when the ambient temperature rises above the set value, the upper tension limit is proportionally relaxed to avoid false alarms; when the temperature drops sharply, the lower limit is tightened to prevent the wire from loosening. If the redundant check module detects that the encoder pulse data and the laser ranging unit continue to deviate and cannot recover by themselves, the auxiliary correction loop switches to pure tension feedback mode and estimates the wire speed reference value based on historical winding parameters until the detection module returns to normal.

[0054] The main control loop and the auxiliary correction loop exchange data through the timestamp synchronization module, which ensures that the timing matching error between the wire drawing speed instruction and the spindle speed is less than 5 milliseconds. It should be further explained that in the specific implementation process, the timestamp synchronization module of the dual closed-loop control unit uses the hardware clock signal to accurately mark the time of the wire drawing speed instruction and the spindle speed data. Before the wire drawing speed instruction generated by the main control loop is sent to the servo motor, it must be time-aligned with the spindle rotation angle data fed back by the encoder in real time. This includes: when it detects that the instruction transmission delay exceeds 2 milliseconds, the synchronization module automatically inserts the instruction to be executed into the cache queue, and predicts the angle change within the next 5 milliseconds based on the spindle speed, dynamically adjusting the triggering time point of the wire drawing speed instruction to eliminate the lag error; if the servo motor response delay causes the actual wire drawing displacement and the spindle angle to continue to increase, the synchronization module forcibly shortens the calculation cycle of the main control loop and prioritizes the processing of the unsynchronized instruction queue until the timing error returns to within the threshold. When winding high-speed thin wires, the system enables high-frequency synchronization mode, increasing the data exchange frequency to 2,000 times per second, while reducing the capacity of a single data packet to avoid communication congestion; when winding low-speed thick wires, it switches to redundant verification mode and performs a double comparison of the instructions and feedback data of the same timing node. If the verification fails three times in a row, it is determined that the clock signal is out of sync and triggers system self-calibration.

[0055] To prevent timestamp corruption caused by sudden electromagnetic interference, the synchronization module has a built-in anti-interference protocol. This includes: If clock signal jitter exceeding 0.1 microseconds is detected, the current instruction execution chain is immediately frozen, the encoder's historical pulse data is used to rebuild the timing logic, and synchronization control is restored within 10 milliseconds. If the interference lasts for more than 50 milliseconds, a switch is made to a backup oscillator independent of the main clock to maintain basic synchronization while reducing the spindle speed to a safe value. If the servo motor drive temperature of the winding machine rises due to prolonged operation, the synchronization module, combined with temperature sensor data, predicts signal transmission delay trends. If the temperature rise rate exceeds 2°C per minute, the data exchange frequency is preemptively reduced and the instruction cache time is extended to prevent timing loss due to hardware performance degradation.

[0056] For non-uniform motion scenarios during the gradual winding process, the synchronization module dynamically adjusts the weight coefficient of the prediction algorithm according to the spindle speed change rate, including: if the speed change rate exceeds 5rpm / s during the acceleration phase, the weight of the future angle prediction is increased; if it is in the deceleration phase, the reference ratio of historical data is increased to ensure a smooth transition. When the instructions of the main control loop and the auxiliary correction loop conflict due to timing misalignment, the synchronization module prioritizes the execution of instructions with greater timeliness based on the timestamp priority arbitration mechanism, such as the emergency deceleration signal for tension excess, and regenerates the instruction stream adapted to the current state after marking the delayed instructions as invalid. In addition, before each winding task is started, the system automatically performs a timing calibration self-test: simulating the sending of the wire speed step signal and monitoring the actual response time of the servo motor. If the overall synchronization error exceeds 5 milliseconds, the winding process is prohibited from starting and a hardware maintenance prompt is issued.

[0057] The control center is also connected to the offline simulation verification unit, which pre-stores the winding dynamics model for simulating the matching relationship between the wire arrangement speed and the spindle speed under different wire specifications. A high-precision grating ruler is installed on the frame to detect the actual ratio of the wire arrangement displacement to the spindle rotation angle in real time. If the deviation between the actual value and the simulation value exceeds 0.05mm / turn for three consecutive times, the control center triggers a shutdown and resets the parameters. It should be further explained that in the specific implementation process, before the winding machine starts the winding task, the control center calls the pre-stored winding dynamics model in the offline simulation verification unit, generates a theoretical matching curve of the wire arrangement speed and the spindle rotation angle according to the input wire diameter, interlayer winding coefficient and spindle speed parameters, and loads it into the main control loop as a reference.

[0058] During actual operation, the high-precision grating ruler monitors the displacement of the wiring device along the guide rail in real time, while the encoder records the rotation angle of the main shaft. The control center compares the proportional relationship between the actual displacement and the rotation angle with the theoretical value of the simulation model on a circle-by-circle basis, including: if the single-circle deviation exceeds 0.05mm but does not reach 0.1mm, the system automatically fine-tunes the overlapping winding coefficient compensation parameters of the dynamic transmission ratio algorithm; if the deviation exceeds 0.1mm for three consecutive circles, it is judged as a mechanical transmission abnormality or model mismatch, and the winding process is immediately paused and the parameter reset program is triggered, including: clearing the current algorithm parameters, reloading the basic wire data and performing zero point calibration of the grating ruler and encoder.

[0059] When winding highly elastic wires such as silicone rubber insulated wire, the simulation model introduces an additional wire expansion / contraction correction factor, presetting redundant compensation for the wire winding speed in the theoretical curve. If, during actual operation, the grating ruler detects cumulative errors in the wire winding displacement due to wire stretching, the displacement baseline value for subsequent windings is dynamically adjusted to prevent error transmission and amplification. To address sudden wear of mechanical transmission components, such as increased clearance between the ball screw nut and the winding system, the system predicts the deviation trend by comparing historical winding data with the current actual value. If the same direction of deviation is observed in five consecutive winding batches and the value increases linearly, a maintenance warning is automatically generated and the deviation parameters are locked, forcing manual inspection of the guide rail and screw coordination before resuming operation.

[0060] When changes in ambient temperature and humidity cause the scale's measurement accuracy to drift, the system initiates self-calibration mode: the wire routing device is controlled to move along the full travel of the guide rail three times, and the linearity error of the scale's output data is recorded. If the maximum deviation exceeds 0.02 mm / m, a compensation factor is embedded in subsequent measurements. For specialized winding structures such as segmented step windings, a simulation verification unit generates a multi-segment matching curve based on manually input step diameter parameters. During actual winding, the scale verifies the displacement continuity of the transition areas between segments in real time. This includes: if a sudden shift in the wire displacement between adjacent segments exceeds 1.5 times the wire diameter, a transition buffer algorithm is inserted to smooth the speed curve, while simultaneously reducing the spindle speed to 70% of its original value to ensure stacking accuracy. After completing the winding task, the system automatically generates a deviation analysis report between the simulated data and the actual operating data. If the RMS value of key parameters exceeds the process standard, batch production mode is disabled and process parameter optimization is prompted. Key parameters include wire routing displacement error and spindle angle deviation.

[0061] The servo motor and ball screw of the wire arrangement device are rigidly connected through a coupling, and the ratio of the lead of the ball screw to the wire diameter ranges from 1:0.8 to 1:1.2. It should be further explained that, in the specific implementation process, the servo motor of the wire arrangement device is directly connected to the ball screw through a rigid coupling, and the flange of the coupling and the end of the screw shaft adopt a conical surface matching locking structure to ensure zero backlash in the transmission; the lead of the ball screw is dynamically matched according to the current wire diameter: when the wire diameter is input, the system automatically calculates the ratio of the lead to the wire diameter and limits it to the range of 1:0.8 to 1:1.2, during which: if the wire is a thin-diameter enameled wire, that is, if the diameter of the wire is less than or equal to 0.5mm, the lead is selected as 1.2 times the wire diameter to increase the single-turn wire arrangement displacement and avoid dense accumulation of wire turns; if the wire is a thick-diameter paper-wrapped wire, that is: if the diameter of the wire is greater than or equal to 2mm, a lead ratio of 1:0.8 is used to reduce the displacement and ensure close fit between wire layers. If the actual lead ratio exceeds the set range due to wire diameter measurement errors during the winding process, the system uses a high-precision grating scale to provide real-time feedback on the wire displacement for reverse verification. This includes: If the single-turn displacement exceeds ±10% of the theoretical value, it is determined to be a lead mismatch, automatically pausing the winding process and prompting a manual review of the wire parameters or coupling locking status. For high-load winding scenarios such as multi-strand or high-tension wire, the system monitors the servo motor output torque in real time. If the current value continuously reaches more than 90% of the rated value, the lead ratio is dynamically reduced to a safe threshold, for example, from 1:1 to 1:0.9, while the spindle speed is proportionally increased to compensate for the loss of wire winding efficiency.

[0062] When the ambient temperature changes and causes the ball screw to expand thermally, the temperature sensor installed at the screw support seat collects data in real time. If the temperature rise of the screw exceeds 30°C, the lead ratio calculation model is dynamically corrected according to the linear expansion coefficient, and the compensation coefficient adjustment value is displayed on the human-machine interface. For the cumulative error of reverse clearance, the system executes a pre-tightening compensation procedure when the wire arrangement device is reversing, including: the servo motor first drives the screw in reverse to rotate 0.5 turns to eliminate the mechanical clearance, and then executes the forward instruction. If the grating scale detects that there is still residual error in the actual displacement after compensation, the number of compensation turns is automatically increased until the error is cleared. When winding special-shaped wires such as flat wire or stranded wire, the system substitutes the equivalent diameter of the wire into the lead ratio calculation. If the deviation between the equivalent diameter and the measured external dimensions exceeds 15%, it is forced to switch to manual mode and lock the lead ratio parameters. Automatic operation is resumed after manual confirmation of the wire type. In addition, each time the wire specifications are changed, the system automatically performs a lead ratio self-check process, including: driving the wire arrangement device to move the full lead distance and comparing it with the actual displacement measured by the grating scale. If the error exceeds 0.05mm, the screw lead calibration program is triggered and the servo motor pulse equivalent parameters are updated.

[0063] The easily adjustable transformer winding machine also includes a human-machine interface (HMI) integrating a parameter input module and a status display module. The parameter input module is used to set the wire diameter, interlayer overlap factor, and tension threshold. The status display module displays a real-time matching curve of the winding diameter, winding speed, and spindle speed. It should be further explained that, in specific implementations, the HMI's parameter input module includes a pre-selection library for wire types. Once the operator selects a wire type, the system automatically matches the corresponding default diameter range and recommended interlayer overlap factor. If the manually entered parameters exceed the recommended range, the interface triggers a red border warning and locks the winding start button until the parameters are corrected. Wire types include round enameled wire and flat paper-covered wire. The status display module displays a dynamic curve showing the real-time matching ratio of the measured winding diameter, the set winding speed, and the spindle speed. If the three ratios deviate by more than ±5%, the abnormal section of the curve automatically highlights and flashes, and a diagnostic prompt pops up indicating the cause of the deviation, such as "laser ranging unit obstruction" or "tension sensor failure."

[0064] When winding a tapered winding, the interface offers manual slope input. After the operator sets the target diameter change rate, the system automatically generates a predicted matching curve and overlays it with the actual operating curve. If the actual curve deviates from the predicted range by more than 10% for three consecutive turns, winding is paused and a parameter optimization pop-up window appears. When the winding layer diameter reaches the preset upper limit, the interface automatically switches to the next layer's winding parameter preset page, retaining key data for historical purposes. If the operator forcibly skips parameter settings, the system forces the winding speed to a safe mode and logs the violation. For sudden alarms such as wire breakage or mechanical jams, the interface prioritizes displaying a 3D schematic of the fault point, occupying 70% of the screen. This guides the troubleshooting process step by step, first highlighting the alarm source component, such as the tension sensor, then displaying a five-minute trend chart of the operating parameters, and finally providing emergency action buttons, such as "Emergency Rewind" or "Reset Detection Module."

[0065] When the winding machine is in automatic batch production mode, the interface automatically hides the non-essential parameter display area, retaining only the core indicator dashboard and abnormal status indicator light. If there is no human interaction for two consecutive hours, the screen saver will be activated to reduce power consumption, and the full-function interface will be restored immediately after any touch operation. In working scenarios with strong ambient light, the interface automatically switches to high-contrast mode and increases the font size. If the light sensor detects that the ambient illumination is continuously below 50 lux, the night mode is enabled and the screen brightness is reduced to avoid glare interference. After each winding task is completed, the system automatically generates a process report summary interface to summarize the key parameter compliance rate. If a certain indicator fails to meet the process standard for three consecutive times, the parameter calibration wizard interface will be forced to pop up, and it is prohibited to directly start a new task until the calibration process is completed. Among them, the key parameters include diameter fluctuation and wire synchronization error.

[0066] The detection end of the winding tension sensor, where it contacts the wire, is made of ceramic, and the contact surface is provided with a V-shaped guide groove. The opening width of the guide groove is 1.2-1.5 times the diameter of the wire. It should be further explained that, in the specific implementation process, the detection end of the winding tension sensor uses alumina ceramic to make the contact head. The sidewall of its V-shaped guide groove has an inclination angle of 60 degrees, and the opening width is automatically adjusted according to the current wire diameter. This includes: when the wire diameter is less than or equal to 1mm, the guide groove opening width is set to 1.5 times the wire diameter to prevent the wire from getting stuck; when the wire diameter is greater than 1mm, the opening width is proportionally reduced to 1.2 times the diameter, ensuring that the wire maintains bilateral contact with the guide groove sidewall for accurate tension detection. When winding high-tension wires, such as alloy wires, the piezoelectric film sensor built into the contact head monitors the pressure distribution of the wire on the side wall of the guide groove in real time. If the pressure on one side exceeds 30% of the other side, it is determined that the wire is offset or the guide groove is worn, and the servo motor is automatically triggered to fine-tune the lateral position of the wire arrangement device to correct the wire path; when winding low-tension thin wires, the guide groove surface is coated with polytetrafluoroethylene to reduce frictional resistance. If it is detected that the wire slips and causes the tension fluctuation frequency to exceed 10 times per second, the guide groove clamping force is automatically increased to the preset safety value.

[0067] For corrosive environments, such as those impregnated with volatile gases from insulating varnish, an airtight isolation cavity is embedded inside the contact head to isolate the piezoelectric sensor from the external environment. If the humidity sensor in the cavity detects that the humidity exceeds 60%, the heating and dehumidification module is activated and the detection sensitivity is reduced to 80% of the baseline value to avoid false triggering.

[0068] When the wire's tension suddenly increases due to surface burrs or foreign matter, the system analyzes the sudden gradient of the tension curve to distinguish between true load and interference signals. For example, if the tension value suddenly rises by more than 50% of the rated value within 0.05 seconds and then quickly drops back, it is judged as a transient interference and ignored. If it exceeds 20% of the rated value for more than 1 second, it is considered a true abnormality and emergency deceleration is implemented. Regarding the wear self-detection of V-shaped guide grooves, the system automatically performs a calibration process after completing every 100 hours of winding tasks. This includes driving the wire through the guide groove at a standard tension. If the pressure difference between the two sides exceeds 15% three times in a row, an alarm for asymmetric guide groove wear is generated, prompting the replacement of the contact head.

[0069] When winding stranded wire, the guide slot opening width is increased by an additional 0.2 times the stranded outer diameter. If the wire is detected rotating in the guide slot, causing periodic tension fluctuations, the dynamic clamping force adjustment mode is activated, causing the clamping force to change synchronously with the stranded wire rotation cycle to offset the fluctuations. When the ambient temperature exceeds 40°C, causing the ceramic contact head to thermally expand, the system reversely compensates the guide slot opening width setting value according to the expansion coefficient of 0.02mm / °C based on the temperature sensor data to ensure the actual fit accuracy between the wire and the guide slot. If the wire breaks, causing the tension to suddenly drop to zero, the infrared photoelectric sensor built into the contact head synchronously detects the presence of the wire. After double verification, the cable arrangement position is immediately locked and the broken wire reeling program is activated to prevent loose wire from wrapping around the spindle.

[0070] A method for using a winding machine for a transformer winding that is easy to adjust comprises the following steps:

[0071] Step S1: The operator selects the wire type and inputs the wire diameter, interlayer winding coefficient, and tension threshold parameters through the human-computer interaction interface. The system automatically loads the corresponding winding dynamics model in the offline simulation verification unit, generates a matching curve between the theoretical wire speed and the spindle speed, and simultaneously executes the equipment self-test program to calibrate the grating scale zero point and the encoder initial angle.

[0072] Step S2: The control center starts the spindle drive motor and the servo motor of the wire arrangement device. The spindle drives the winding frame to rotate. The servo motor drives the ball screw to push the wire arrangement device to move laterally along the guide rail. The non-contact laser ranging unit of the real-time detection module scans the outer contour of the winding layer at multiple angles, and the synchronous encoder collects the spindle rotation pulse signal.

[0073] Step S3: The control center cross-validates the laser distance measurement data with the equivalent diameter converted from the encoder pulse. If the deviation does not exceed the preset threshold, the real-time winding diameter is calculated based on the laser data. If the deviation exceeds the limit, the control center switches to the encoder data and triggers the redundant calibration program, pausing the spindle drive motor, retracting the wire arrangement device to the end position of the previous circle, and reversely verifying the actual diameter of the winding layer before resuming operation.

[0074] Step S4: The main control loop of the dual closed-loop control unit calculates the wire speed instruction based on the real-time winding diameter, wire diameter, and dynamically corrected interlayer winding coefficient, and converts it into a servo motor pulse frequency signal; the auxiliary correction loop monitors the wire tension through the tension sensor, and sends a compensation signal to the main control loop if the tension exceeds the limit. The timestamp synchronization module ensures that the timing matching error of the two loop instructions is lower than the threshold;

[0075] Step S5: The servo motor drives the ball screw to rotate according to the pulse frequency, and the wire arrangement moves along the guide rail. The high-precision grating ruler monitors the displacement in real time and compares it with the theoretical value of the simulation model on a turn-by-turn basis. If the single-turn displacement deviation exceeds the limit, the system pauses winding and prompts to check the mechanical transmission or wire parameters. If the deviation exceeds the process standard for multiple turns in a row, the parameters are reset and the grating ruler and encoder are recalibrated.

[0076] Step S6: During the winding process, the human-machine interface dynamically displays the matching curve of the winding diameter, winding speed, and spindle speed. Abnormal sections are highlighted and associated with fault diagnosis suggestions. For gradual winding, the interface superimposes the predicted curve and actual data. If the deviation continues to increase, the winding is suspended and the parameters are optimized.

[0077] Step S7: When a wire breakage or loosening is detected, the tension sensor and infrared photoelectric sensor dually verify the abnormal state, triggering an emergency stop and executing the broken wire rewinding procedure. If the guide groove is worn or the pressure distribution is unbalanced, the system fine-tunes the position of the cable arrangement device and generates a maintenance warning.

[0078] Step S8: When the ambient temperature changes and the mechanical components expand thermally, the control center dynamically corrects the cable displacement reference value based on the temperature sensor data; when there is a sudden electromagnetic interference or clock signal abnormality, the synchronization module switches to the backup oscillator and reduces the spindle speed to a safe value;

[0079] Step S9: After the winding task is completed, the system generates a process report and forces calibration of key parameters; if the key indicators fail to meet the standards continuously, batch production is prohibited until the optimization process is completed;

[0080] Step S10: After changing the wire specifications, the system automatically performs lead ratio self-check and servo motor pulse equivalent calibration to ensure the accuracy consistency of subsequent winding tasks.

[0081] The real-time detection module accurately captures winding layer diameter data. Combined with the dynamic synchronization mechanism of the dual closed-loop control unit, this ensures real-time matching of wire arrangement speed and spindle speed, effectively eliminating the problems of turn gap, overlap, and tightness fluctuations caused by parameter mismatch in traditional winding machines. The synergy between the redundant calibration program and the offline simulation verification unit improves the uniformity and consistency of winding layer distribution, eliminating reliance on manual experience and ensuring that the electromagnetic and insulation properties of winding processes of different specifications meet standardized requirements.

[0082] Adaptive speed regulation and intelligent exception handling mechanisms significantly reduce equipment downtime and adjustment time. The human-machine interface provides intuitive fault diagnosis and parameter optimization guidance, reducing operational complexity and the risk of misadjustment. The dynamic lead matching design and thermal drift compensation model of the mechanical transmission structure extend the service life of key components such as ball screws and guide rails. Combined with self-test procedures and wear warning functions, preventive maintenance is implemented, reducing overall equipment maintenance costs and process scrap rates. It is suitable for the mass production needs of a wide variety of high-precision transformer windings.

[0083] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, so that a process, method, article, or device comprising a series of elements includes not only those elements, but also other elements not explicitly listed, or elements inherent to such process, method, article, or device. In the absence of further limitations, an element defined by the phrase "comprising a ..." does not exclude the presence of additional identical elements in the process, method, article, or device comprising the element.

[0084] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A transformer winding machine that is easy to adjust, comprising a main shaft, a wire arrangement device, a control module, and a frame, characterized in that: The control module includes a real-time detection module and a dual closed-loop control unit; The real-time detection module is fixed on the frame and located outside the spindle winding layer, and is used to collect diameter change data of the winding layer in real time; The dual closed-loop control unit is electrically connected to the spindle drive motor and the servo motor of the wire arrangement device, and dynamically adjusts the lateral movement speed of the servo motor and the rotation speed of the spindle drive motor based on the diameter data output by the real-time detection module; The lateral moving guide rail of the wire arranging device is arranged parallel to the axial direction of the main shaft, and the servo motor drives the wire arranging device to move along the guide rail through the ball screw.

2. The transformer winding machine that is easy to adjust according to claim 1, characterized in that: The real-time detection module includes a non-contact laser ranging unit and an encoder. The laser ranging unit is symmetrically distributed on both sides of the main shaft, and its scanning direction is aligned with the outer contour of the winding layer; the encoder is coaxially connected to the main shaft and is used to output a pulse signal of the main shaft rotation angle.

3. The transformer winding machine that is easy to adjust according to claim 2, characterized in that: The control module also includes a control center, which receives the outer contour data of the winding layer scanned by the laser ranging unit and calculates the real-time winding diameter in combination with the pulse signal of the encoder; when the diameter difference calculated by the laser ranging unit and the encoder exceeds a preset threshold, the control center corrects the real-time winding diameter based on the encoder data.

4. The transformer winding machine that is easy to adjust according to claim 3, characterized in that: The control center has a built-in dynamic transmission ratio algorithm module, which calculates the wire arrangement speed in real time based on the following parameters: real-time winding diameter, spindle speed, wire diameter and inter-layer winding coefficient; The interlayer winding coefficient is dynamically corrected by matching a preset database according to the surface roughness of the wire.

5. The transformer winding machine that is easy to adjust according to claim 4, characterized in that: The dual closed-loop control unit includes a main control loop and an auxiliary correction loop; the main control loop receives the wire speed instruction output by the dynamic transmission ratio algorithm module and controls the pulse frequency of the servo motor; The auxiliary correction ring is connected to the winding tension sensor, which is arranged at the wire pulley of the wire arrangement device. When the tension fluctuation exceeds a preset range, the auxiliary correction ring sends a compensation signal to the main control ring to adjust the pulse frequency.

6. The transformer winding machine that is easy to adjust according to claim 5, characterized in that: The main control loop and the auxiliary correction loop exchange data through a timestamp synchronization module, and the synchronization module ensures that the timing matching error between the wire speed instruction and the spindle speed is less than 5 milliseconds.

7. The transformer winding machine that is easy to adjust according to claim 3, characterized in that: The control center is also connected to an offline simulation verification unit, which pre-stores a winding dynamics model for simulating the matching relationship between the wire arrangement speed and the spindle speed under different wire specifications; a high-precision grating scale is installed on the frame for real-time detection of the actual ratio of the wire arrangement displacement to the spindle rotation angle. If the deviation between the actual value and the simulation value exceeds 0.05mm / turn for three consecutive times, the control center triggers a shutdown and resets the parameters.

8. The transformer winding machine that is easy to adjust according to claim 1, characterized in that: The servo motor and the ball screw of the wire arrangement device are rigidly connected via a coupling, and the ratio of the lead of the ball screw to the wire diameter ranges from 1:0.8 to 1:1.

2.

9. The transformer winding machine that is easy to adjust according to claim 1, characterized in that: The winding machine for transformer windings that is easy to adjust also includes a human-computer interaction interface, which integrates a parameter input module and a status display module; the parameter input module is used to set the wire diameter, interlayer winding coefficient and tension threshold; the status display module displays the matching ratio curve of winding diameter, wire arrangement speed and spindle speed in real time.

10. The transformer winding machine that is easy to adjust according to claim 5, characterized in that: The contact portion between the detection end of the winding tension sensor and the wire is made of ceramic material, and the contact surface is provided with a V-shaped guide groove, the opening width of the guide groove is 1.2-1.5 times the diameter of the wire.

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