Magnetic core winding control system and control method

Abstract

According to the magnetic core winding control system, the surface of the magnetic core body is provided with the groove used for winding, a wire can be wound in the groove, the winding position is more accurate, the winding precision is remarkably improved through introduction of the laser emission module, the position sensing module and the control module, and the winding precision is improved. The problem of wire deviation caused by manual operation or mechanical errors is reduced; the closed-loop control system can adjust a laser guiding path in real time to adapt to groove structures with different shapes and depths; through dynamic guidance, the production efficiency and the product consistency are effectively improved, the rejection rate and the reworking cost are reduced, and the problems of electrical performance degradation and even equipment physical damage caused by inaccurate magnetic core winding position are effectively avoided.

Description

Technical Field

[0001] The present invention relates to the technical field of magnetic core processing, and in particular to a magnetic core winding control system and a control method. Background Art

[0002] Magnetic core winding is widely used in various electronic devices, including transformers, generators, control circuits, filters, circuit protectors, converters, and amplifiers. Magnetic core winding can reduce electromagnetic interference signals in space and prevent these signals from being superimposed on the transmitted signal, thereby ensuring the stability and speed of transmission. For example, shielded magnetic core winding isolates the data line from spatial interference signals through an electrostatic shielding layer, effectively improving the transmission rate and stability. It can also suppress electromagnetic interference: magnetic core winding is often used in anti-interference components, especially ferrite core winding, which can effectively suppress high-frequency noise and electromagnetic interference. It forms an inductance by winding the wire on the magnetic core, thereby suppressing common-mode interference signals and protecting the circuit from interference. This design is particularly effective in balanced lines, and can suppress high-frequency interference signals such as lightning without affecting the normally transmitted differential-mode signals.

[0003] Inaccurate core winding position can trigger a series of chain reactions, easily leading to degraded electrical performance and even physical damage to the equipment. For example, when the wire is off-center, it can easily increase the magnetic flux leakage path. Uneven winding can cause the local magnetic flux density (B) of the core to exceed the saturation point (for example, Bs ≈ 0.3T for ferrite), resulting in: a sudden drop in inductance of more than 50%; and distortion of the excitation current waveform (THD increases by 15%). Summary of the Invention

[0004] Based on this, it is necessary to provide a magnetic core winding control system and control method to solve the problem mentioned in the background art that inaccurate magnetic core winding positions lead to electrical performance degradation and even physical damage to the equipment.

[0005] A magnetic core winding control system includes a magnetic core body, a groove for winding is opened on the surface of the magnetic core body, and a laser emission module. The laser emission module is rigidly connected to the winding head and moves synchronously with the winding head to project a laser beam onto the groove surface. The position sensing module captures the offset between the wire and the laser beam in real time and feeds back to the control module. The control module drives the servo motor through the PID algorithm to dynamically adjust the position of the winding head so that the laser beam always moves along the center line of the groove.

[0006] In one embodiment, the magnetic core winding control system also includes an electromagnetic module, and a micron-level ferromagnetic coating or an embedded soft magnetic alloy layer is provided on the bottom or side wall of the groove. The micron-level ferromagnetic coating or the embedded soft magnetic alloy layer is electrically connected to the electromagnetic module. During winding, a controllable current is used to excite the magnetic core to generate a directional magnetic field, and the magnetic adsorption effect is used to enhance the contact stability between the wire and the groove body.

[0007] In one embodiment, the laser emission module further includes a polarization control unit for suppressing light reflection interference from the metal surface by adjusting the polarization direction of the laser.

[0008] In one embodiment, the magnetic core winding control system further includes a fiber Bragg grating sensing module, which is used to detect the temperature value of the magnetic core in real time and send the detected temperature value to the control module.

[0009] In one embodiment, the magnetic core winding control system also includes a visual control module, which includes an industrial camera array unit and an image processing unit. The industrial camera array unit is connected to the image processing unit. The industrial camera array unit is used to collect images of the wire in the magnetic core groove during the winding process in real time. The image processing unit is connected to the control module and is used to analyze and identify the collected images to determine whether there is winding offset or overlap.

[0010] In one embodiment, the inner surface of the groove is plasma sprayed to form a layer of micro-rough structure with a high friction coefficient, and the micro-rough structure is composed of irregular protrusions and depressions formed by spraying, which is used to increase the contact area and mechanical bite force between the wire and the groove.

[0011] In one embodiment, the magnetic core winding control system also includes a pressure sensor module; the pressure sensor module is installed inside the winding head, and is used to detect the lateral offset force generated during the winding process in real time, and feed back the detection signal to the control module; the control module adjusts the motion trajectory of the winding drive mechanism according to the received pressure signal to achieve dynamic compensation of the winding position.

[0012] A magnetic core winding control method is applied to the control method in the magnetic core winding control system, the method comprising: The laser emitting module moves synchronously with the winding head and projects the laser beam onto the groove surface; The position sensing module captures the offset between the wire and the laser beam in real time and feeds it back to the control module; The control module drives the servo motor through the PID algorithm to dynamically adjust the position of the winding head so that the laser beam always moves along the center line of the groove.

[0013] A computer device includes a processor and a memory, wherein the memory is used to store a computer program, and when the computer program is executed by the processor, the magnetic core winding control method is implemented.

[0014] A computer-readable storage medium stores a computer program, which implements the magnetic core winding control method when executed by a processor.

[0015] The above-mentioned magnetic core winding control system has grooves for winding on the surface of the magnetic core body, which can be used to wind the wire in the grooves, making the winding position more accurate. The introduction of the laser emission module, position sensing module and control module significantly improves the winding accuracy and reduces the problem of wire deviation caused by manual operation or mechanical errors; the closed-loop control system can adjust the laser guidance path in real time to adapt to groove structures of different shapes and depths; through dynamic guidance, it effectively improves production efficiency and product consistency, reduces scrap rate and rework costs, and effectively avoids the problem of electrical performance degradation or even physical damage to the equipment due to inaccurate magnetic core winding position. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 A schematic structural diagram of a magnetic core winding control system according to an embodiment of the present invention; Figure 2 for Figure 1 A schematic structural diagram of a visual control module of a magnetic core winding control system according to an embodiment of the present invention. DETAILED DESCRIPTION

[0017] To make the above-mentioned objects, features, and advantages of the present invention more readily apparent, specific embodiments of the present invention are described in detail below with reference to the accompanying drawings. The following description sets forth numerous specific details to facilitate a full understanding of the present invention. However, the present invention can be implemented in many other ways than those described herein, and those skilled in the art may make similar modifications without departing from the scope of the present invention. Therefore, the present invention is not limited to the specific embodiments disclosed below.

[0018] It should be noted that when an element is considered to be "connected" to another element, it can be directly connected to the other element or there may be an intermediate element. In contrast, when an element is said to be "directly" connected to another element, there are no intermediate elements.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which the present invention pertains. The terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0020] like Figure 1As shown, a magnetic core winding control system includes a magnetic core body, a groove for winding is opened on the surface of the magnetic core body, and a laser emitting module 1. The laser emitting module 1 is rigidly connected to the winding head and moves synchronously with the winding head to project a laser beam onto the groove surface. The position sensing module 2 captures the offset between the wire and the laser beam in real time and feeds back to the control module 3. The control module 3 drives the servo motor through the PID algorithm to dynamically adjust the position of the winding head so that the laser beam always moves along the center line of the groove.

[0021] Winding grooves are provided on the surface of the core body to provide a physical guide path for the wire. This ensures geometric constraints on the winding path and prevents disordered wire arrangement. Laser emission module 1, rigidly connected to the winding head, ensures complete synchronization of the laser beam and the winding action. It projects the laser beam onto the groove surface, forming an optical reference line (the groove centerline). Position sensing module 2 detects the offset between the wire position and the laser reference line in real time (e.g., through image recognition or a photoelectric sensor) and feeds this offset data back to the control module, forming the basis for closed-loop control. Control module 3 uses a PID control algorithm (proportional-integral-differential) to dynamically calculate the correction amount. It drives the servo motor to adjust the winding head position, ensuring that the laser beam always moves along the groove centerline. The control module is a multi-source data fusion controller.

[0022] In this way, the magnetic core winding control system, through the grooves for winding opened on the surface of the magnetic core body, can wind the wire in the grooves, making the winding position more accurate. The introduction of the laser emission module 1, the position sensing module 2 and the control module 3 significantly improves the winding accuracy and reduces the problem of wire deviation caused by manual operation or mechanical errors; the closed-loop control system can adjust the laser guidance path in real time to adapt to groove structures of different shapes and depths; through dynamic guidance, it effectively improves production efficiency and product consistency, reduces scrap rate and rework cost, and effectively avoids the problem of electrical performance degradation or even physical damage to the equipment due to inaccurate magnetic core winding position.

[0023] In one embodiment, the magnetic core winding control system also includes an electromagnetic module, and a micron-level ferromagnetic coating or an embedded soft magnetic alloy layer is provided on the bottom or side wall of the groove. The micron-level ferromagnetic coating or the embedded soft magnetic alloy layer is electrically connected to the electromagnetic module. During winding, a controllable current is used to excite the magnetic core to generate a directional magnetic field, and the magnetic adsorption effect is used to enhance the contact stability between the wire and the groove body.

[0024] In this way, on the basis of the original magnetic core groove, an embedded micron-level magnetic coating or an embedded soft magnetic alloy layer is added, and a controllable electromagnetic adsorption system is introduced to enable the winding process to have active positioning capabilities, and an increase in the control system to realize intelligent adjustment of the electromagnetic adsorption process; the embedding of the micron-level magnetic coating improves the accuracy of the magnetic field action and enhances the uniformity of adsorption; the electromagnetic adsorption technology significantly improves the positioning stability of the wire during the winding process, and reduces offset and misalignment; the overall improvement effectively improves the winding efficiency and consistency, reduces the need for manual adjustment in production, and improves product quality and automation level.

[0025] In one embodiment, the laser emission module further includes a polarization control unit for suppressing light reflection interference from the metal surface by adjusting the polarization direction of the laser.

[0026] In this way, the reflectivity of the core surface (such as ferrite) to linearly polarized light can be as high as 80%, causing overexposure of the sensor.

[0027] Adjust the laser to circularly polarized light (left-handed / right-handed) to change the polarization state of the reflected light and reduce mirror reflection. In the magnetic core winding system, the polarization control unit significantly improves the laser positioning accuracy by suppressing metal reflection interference and enhancing signal contrast.

[0028] In one embodiment, the magnetic core winding control system further includes a fiber Bragg grating sensor module 4 , which is used to detect the temperature value of the magnetic core in real time and send the detected temperature value to the control module 3 .

[0029] In this way, the fiber Bragg grating sensing module 4 is used to detect the temperature value of the magnetic core in real time and send the detected temperature value to the control module 3. When the temperature value exceeds the preset threshold, the control module 3 sends a control signal to the winding control device to reduce the winding rate to prevent the temperature of the magnetic core from further increasing.

[0030] like Figure 2 As shown, in one embodiment, the magnetic core winding control system also includes a visual control module 5, and the visual control module 5 includes an industrial camera array unit 51 and an image processing unit 52. The industrial camera array unit 51 is connected to the image processing unit 52. The industrial camera array unit is used to collect images of the wire in the magnetic core groove during the winding process in real time. The image processing unit 52 is connected to the control module 3 for analyzing and identifying the collected images to determine whether there is a winding offset or overlap.

[0031] Thus, the industrial camera array unit 51 is a multi-view camera array, avoiding visual blind spots. The multi-view industrial camera acquires the three-dimensional position of the wire in the groove and transmits this position information to the image processing unit 52. The image processing unit 52 uses edge detection and slot matching algorithms to calculate the offset and transmits the offset to the control module 3. The control module 3 dynamically generates a compensation path based on the offset and controls the winding head for online correction.

[0032] In one embodiment, the inner surface of the groove is plasma sprayed to form a layer of micro-rough structure with a high friction coefficient, and the micro-rough structure is composed of irregular protrusions and depressions formed by spraying, which is used to increase the contact area and mechanical bite force between the wire and the groove.

[0033] Thus, in the prior art, the surface of the magnetic core groove is a smooth or normal roughness surface formed by conventional machining. However, this application introduces a microscopic roughness structure formed by plasma spraying on the groove surface. The microscopic roughness structure has a controllable high friction coefficient and significantly enhances the adhesion between the wire and the magnetic core. By plasma spraying the groove surface to form a microscopic roughness, the adhesion between the wire and the magnetic core during the winding process is effectively improved, the slippage and loosening during the winding process are reduced, and the winding accuracy and stability are improved. At the same time, the microscopic roughness structure helps to improve the overall mechanical strength and long-term working reliability of the coil, and avoid the degradation of electrical performance due to wire displacement.

[0034] In one embodiment, the magnetic core winding control system also includes a pressure sensor module 6; the pressure sensor module 6 is installed inside the winding head, and is used to detect the lateral offset force generated during the winding process in real time, and feed back the detection signal to the control module 3; the control module 3 adjusts the motion trajectory of the winding drive mechanism according to the received pressure signal to achieve dynamic compensation of the winding position.

[0035] In this way, the setting of the pressure sensor module 6 realizes real-time monitoring of the lateral offset force during the winding process, thereby improving the winding accuracy; the dynamic compensation mechanism effectively reduces the winding defects caused by mechanical deviation or uneven wire tension, thereby improving product consistency; the optimized groove structure enhances the reliability of wire positioning, reduces the risk of sliding during the winding process, and overall improves the winding efficiency and product quality.

[0036] A magnetic core winding control method is applied to the control method in the magnetic core winding control system, the method comprising: The laser emitting module moves synchronously with the winding head and projects the laser beam onto the groove surface; The position sensing module captures the offset between the wire and the laser beam in real time and feeds it back to the control module; The control module drives the servo motor through the PID algorithm to dynamically adjust the position of the winding head so that the laser beam always moves along the center line of the groove.

[0037] The optional items in the above system embodiment are also applicable to this embodiment and will not be described in detail here. The rest of the contents of the embodiment of this application can refer to the contents of the above system embodiment and will not be described in detail in this embodiment.

[0038] A computer device includes a processor and a memory, wherein the memory is used to store a computer program, and when the computer program is executed by the processor, the magnetic core winding control method is implemented.

[0039] A computer-readable storage medium stores a computer program, which implements the magnetic core winding control method when executed by a processor.

[0040] An embodiment of the present application provides a computer program product. When the computer program product is run on a computer device, the computer device implements the steps in the above-mentioned various method embodiments when executing the computer program product.

[0041] In several embodiments provided in the present application, it is understood that each box in the flow chart or block diagram can represent a part of a module, program segment or code, and the part of the module, program segment or code contains one or more executable instructions for realizing the specified logical function. It should also be noted that in some alternative implementations, the functions marked in the box can also occur in an order different from that marked in the accompanying drawings. For example, two consecutive boxes can actually be executed substantially in parallel, and they can sometimes be executed in the opposite order, which depends on the functions involved.

[0042] If the functions are implemented in the form of software function modules and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of the present application, or the part that contributes to the prior art, or the part of the technical solution, can be embodied in the form of a software product. The computer software product is stored in a storage medium and includes a number of instructions for enabling a computer device to execute all or part of the steps of the method described in each embodiment of the present application. The aforementioned storage medium includes: U disk, mobile hard disk, read-only memory (ROM, Read-Only Memory), random access memory (RAM, Random Access Memory), disk or optical disk, and other media that can store program codes.

[0043] The above-described embodiments merely illustrate several implementations of the present invention, and while their descriptions are relatively specific and detailed, they should not be construed as limiting the scope of the patent. It should be noted that a person skilled in the art would be able to make numerous variations and improvements without departing from the spirit of the present invention, all of which fall within the scope of protection of the present invention. Therefore, the scope of protection of the patent for this invention shall be determined by the appended claims.

Claims

1. A magnetic core winding control system, characterized in that: It includes a magnetic core body, the surface of which is provided with a groove for winding, and a laser emission module, which is rigidly connected to the winding head and moves synchronously with the winding head to project a laser beam onto the groove surface. The position sensing module captures the offset between the wire and the laser beam in real time and feeds back to the control module. The control module drives the servo motor through the PID algorithm and dynamically adjusts the position of the winding head so that the laser beam always moves along the center line of the groove.

2. A magnetic core winding control system according to claim 1, characterized in that: The magnetic core winding control system also includes an electromagnetic module, which is provided with a micron-level ferromagnetic coating or an embedded soft magnetic alloy layer at the bottom or side wall of the groove. The micron-level ferromagnetic coating or the embedded soft magnetic alloy layer is electrically connected to the electromagnetic module. During winding, a controllable current is used to excite and generate a directional magnetic field, and the magnetic adsorption effect is used to enhance the contact stability between the wire and the groove body.

3. A magnetic core winding control system according to claim 1, characterized in that: The laser emission module also includes a polarization control unit that suppresses light reflection interference from the metal surface by adjusting the polarization direction of the laser.

4. A magnetic core winding control system according to claim 1, characterized in that: The magnetic core winding control system further comprises a fiber Bragg grating sensing module, which is used to detect the temperature value of the magnetic core in real time and send the detected temperature value to the control module.

5. A magnetic core winding control system according to claim 1, characterized in that: The magnetic core winding control system also includes a visual control module, which includes an industrial camera array unit and an image processing unit. The industrial camera array unit is connected to the image processing unit. The industrial camera array unit is used to collect images of the wire in the magnetic core groove during the winding process in real time. The image processing unit is connected to the control module and is used to analyze and identify the collected images to determine whether there is winding offset or overlap.

6. A magnetic core winding control system according to claim 1, characterized in that: The inner surface of the groove is treated by plasma spraying to form a layer of microscopic rough structure with a high friction coefficient. The microscopic rough structure is composed of irregular protrusions and depressions formed by spraying, which is used to increase the contact area and mechanical bite force between the wire and the groove.

7. A magnetic core winding control system according to claim 1, characterized in that: The core winding control system also includes a pressure sensor module installed inside the winding head. This pressure sensor module is used to detect the lateral offset force generated during the winding process in real time and feed the detection signal back to the control module. The control module adjusts the motion trajectory of the winding drive mechanism based on the received pressure signal to achieve dynamic compensation of the winding position.

8. A magnetic core winding control method, characterized in that: A control method applied to a magnetic core winding control system according to any one of claims 1 to 7, the method comprising: The laser emitting module moves synchronously with the winding head and projects the laser beam onto the groove surface; The position sensing module captures the offset between the wire and the laser beam in real time and feeds it back to the control module; The control module drives the servo motor through the PID algorithm to dynamically adjust the position of the winding head so that the laser beam always moves along the center line of the groove.

9. A computer device, characterized in that: The method comprises a processor and a memory, wherein the memory is used to store a computer program, and when the computer program is executed by the processor, the magnetic core winding control method according to any one of claims 8 is implemented.

10. A computer-readable storage medium, characterized in that It stores a computer program, which, when executed by a processor, implements the magnetic core winding control method according to any one of claim 8.

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