Automatic control adjusting system of energy-saving transformer system

Abstract

The invention discloses a self-control adjusting system of an energy-saving transformer system, and relates to the technical field of power distribution network adjustment. The self-control adjusting system of the energy-saving transformer system comprises a dust blocking thermal resistance sudden change self-checking module, a rubber damping self-checking module, a magnetic aging iron loss sudden increase self-checking module and a transformer three-dimensional evaluation regulation and control module. According to the method, three parameters of dust, vibration and magnetic loss are coupled through three-dimensional risk regulation, a historical risk time accumulation effect is fused, targeted quantitative adjustment of driving load migration, overheating protection and stress compensation is carried out through a comprehensive evaluation result, a real-time sensing, hierarchical control and historical tracking system is established, and the real-time risk of the system is evaluated. The problems of heat dissipation failure, vibration conduction and voltage fluctuation in a machine tool dense scene are solved, the adaptability of transformer self-control adjustment to a high-precision numerical control machine tool cluster scene is further improved, and the problem that in the prior art, in the high-precision numerical control machine tool cluster scene, the transformer self-control adjustment adaptability is insufficient is solved.

Description

Technical Field

[0001] This invention relates to the field of power distribution network regulation technology, and in particular to an energy-saving transformer system automatic control and regulation system. Background Technology

[0002] The high-density layout of modern CNC machine tool clusters imposes three rigid constraints on the supporting transformers: spatial thermal constraints: workshop dust intrudes into the open heat dissipation structure, forming a heat island effect in densely populated equipment areas, leading to uncontrolled temperature rise. Traditional air-cooling solutions cannot balance protection and heat dissipation efficiency. Composite vibration coupling: machine tool processing vibration (low-frequency mechanical shock + high-frequency magnetostriction) is transmitted through the rigid foundation. Rubber damping elements have aging failures and spectrum adaptation defects, causing output voltage fluctuations to exceed the precision machining tolerance threshold. Energy efficiency time paradox: during continuous production, a large number of standby or light-load periods expose the defect of excessive no-load loss of silicon steel sheet cores. Static energy efficiency design cannot adapt to dynamic load spectrum.

[0003] Under the current technological framework, the openness of heat dissipation structures, the simplification of vibration damping materials, and the static nature of energy efficiency regulation constitute insurmountable generational bottlenecks.

[0004] For example, patent application CN118889432A discloses an automatic voltage regulation method for a novel power system, comprising: using an automatic voltage regulator to control the generator excitation system to maintain the output voltage at the nominal level; estimating the total system disturbance through an extended state observer and monitoring the voltage and current changes of the power system in real time; using a PID controller to compensate for the error of the ESO estimation in real time to obtain the difference between the actual output voltage and the set voltage; tuning the PID controller parameters using the pole placement method; and introducing an anti-saturation compensation method to achieve anti-saturation control effect through compensation signal processing when the actuator enters the constrained region.

[0005] For example, the patent application CN115173422B discloses a type of interconnected power supply transformer and its control method, which includes: a multi-phase parallel transformer, a multi-phase series transformer, and multiple safety protection auxiliary adjustment devices. The primary side of the multi-phase parallel transformer is connected to the first line. The secondary side of the parallel transformer has at least one power supply winding and multiple asymmetrical windings. The power supply winding is connected to the power supply end. The multiple asymmetrical windings are interconnected with the asymmetrical windings of the secondary side of the adjacent phase parallel transformer through their respective corresponding switch bridge arm modules to obtain a first electrical quantity. The first electrical quantity is coupled to the primary side of the corresponding series transformer through the secondary side of the series transformer. The multiple safety protection auxiliary adjustment devices are connected in series between the first line and the second line.

[0006] However, in the process of implementing the inventive technical solution in the embodiments of this application, it was found that the above-mentioned technology has at least the following technical problems:

[0007] In existing technologies, high-precision CNC machine tool clusters are often densely arranged in a limited space. This environment poses a severe challenge to the transformers that power them. For heat dissipation, existing small transformers mainly rely on natural air convection or the addition of fans. This method has limited effectiveness in densely packed machine tool layouts. The mechanical vibrations generated during machine tool processing are directly transmitted to their associated transformers, exacerbating the loosening of internal components and leading to significant output voltage fluctuations. The transformers are insufficient to withstand the risks of this production environment. There is a problem with the transformers' insufficient self-regulation adaptability in high-precision CNC machine tool cluster scenarios. Summary of the Invention

[0008] This application provides an energy-saving transformer system self-control regulation system, which solves the problem of insufficient adaptability of transformer self-control regulation in high-precision CNC machine tool cluster scenarios in the prior art, and improves the adaptability of transformer self-control regulation to high-precision CNC machine tool cluster scenarios.

[0009] This application provides an energy-saving transformer system self-control and regulation system, including: a dust blockage thermal resistance sudden change self-detection module, a rubber damping self-detection module, a magnetic aging iron loss sudden increase self-detection module, and a transformer three-dimensional evaluation and control module; wherein, the dust blockage thermal resistance sudden change self-detection module is used to perform dust blockage thermal resistance analysis using raw dust blockage thermal resistance data, and to perform automatic control and regulation of dust blockage thermal resistance sudden change based on the analysis results; the rubber damping self-detection module is used to perform rubber damping frequency analysis using raw rubber damping frequency data, and to perform automatic control and regulation of rubber damping frequency sudden change based on the analysis results; the magnetic aging iron loss sudden increase self-detection module is used to perform magnetic aging iron loss analysis, and to provide early warning of magnetic aging iron loss analysis based on the analysis results; the transformer three-dimensional evaluation and control module is used to perform transformer three-dimensional evaluation analysis, and to perform transformer three-dimensional evaluation and regulation based on the analysis results.

[0010] Furthermore, the dust blockage thermal resistance mutation self-test module includes a transformer calibration value setting unit, a transformer actual value setting unit, and a dust blockage thermal resistance mutation self-test evaluation unit. The transformer calibration value setting unit is used to measure the stable oil pressure difference between the inlet and outlet of the transformer heat sink via a differential pressure transmitter when the transformer is initially running at its rated operating speed with the oil pump stable at its rated value. This value is recorded as the heat sink differential pressure benchmark calibration value. The unit also measures the volume of cooling oil flowing through the heat sink per unit time using a vortex flowmeter, recording this as the cooling oil flow rate benchmark calibration value. The incremental cooling oil flow rate is compared and analyzed with the incremental heat sink surface temperature to obtain the temperature-velocity gradient benchmark calibration index of the transformer oil cooling system. The transformer actual value setting unit measures the actual difference between the inlet and outlet oil pressures of the transformer heat sink, recording this as the heat sink differential pressure. It also synchronously records the cooling oil flow rate. The actual flow rate of the cooling oil is recorded as the cooling oil velocity; the rate of change of the surface temperature of the heat sink is measured and recorded as the temperature rate gradient index of the transformer oil cooling system; the actual pressure difference flow rate ratio is obtained by comparing and analyzing the pressure difference of the heat sink with the cooling oil velocity; the pressure difference flow rate degradation rate is obtained by comparing and analyzing the actual pressure difference flow rate ratio with the heat sink pressure difference reference calibration value flow rate ratio. The larger the value of the pressure difference flow rate degradation rate, the more serious the impact of dust blockage. The heat dissipation efficiency reduction rate is obtained by comparing and analyzing the temperature rate gradient index of the transformer oil cooling system with the temperature rate gradient reference calibration index of the transformer oil cooling system. The larger the value of the heat dissipation efficiency reduction rate, the more serious the negative impact of heat dissipation; the dust blockage thermal resistance mutation self-check evaluation unit is used to couple and analyze the pressure difference flow rate degradation rate and the heat dissipation efficiency reduction rate to obtain the dust blockage thermal resistance index.

[0011] Furthermore, the self-detection module for sudden changes in thermal resistance due to dust blockage also includes a self-control adjustment unit for sudden changes in thermal resistance due to dust blockage. This self-control adjustment unit is used to adjust the self-control of sudden changes in thermal resistance due to dust blockage based on the analysis results. Specifically, this includes: if the thermal resistance index is less than the second thermal resistance threshold, then a first-level control is performed, subtracting the thermal resistance index from the second thermal resistance threshold to obtain the second thermal resistance difference; based on this difference, the opening of the transformer electromagnetic current limiting valve is increased via a PWM signal, thereby increasing the oil flow rate; and the intermittent operation interval of the transformer cooling fan is shortened based on the second thermal resistance difference. If the thermal resistance index is equal to or greater than the second thermal resistance threshold and the thermal resistance index is less than... If the first dust blockage thermal resistance threshold is reached, secondary control is implemented. The newly added piezoelectric ceramic plate emits high-frequency sound waves, continuously vibrating the surface of the heat sink fins. The transformer's micro oil pump is activated in reverse, creating turbulent flow to scour the inner wall of the oil guide pipe. If the dust blockage thermal resistance index is equal to or greater than the first dust blockage thermal resistance threshold, tertiary control is implemented. The duration for which the dust blockage thermal resistance index is equal to or greater than the first dust blockage thermal resistance threshold is recorded as the dust blockage thermal resistance over-threshold duration. The backup oil guide channel is switched: the transformer's redundant oil guide pipe structure is activated, bypassing the blocked main channel; the built-in micro hydraulic rod is activated to restore the original spacing of the heat sink fins; and compressed air is injected through an external air pump, flushing the dust-laden oil guide pipe's multi-channel switching architecture from the bottom of the fins upwards. If the dust blockage thermal resistance over-threshold duration exceeds the upper limit of the dust blockage thermal resistance over-threshold duration, an alarm is issued and relevant personnel are notified.

[0012] Furthermore, the rubber vibration damping self-test module includes a rubber vibration damping frequency monitoring and early warning unit and a rubber vibration damping frequency analysis and control unit. The rubber vibration damping frequency monitoring and early warning unit is used to continuously scan the surface vibration of the transformer rubber pad vibration damping pad using a laser vibrometer, and directly output the natural frequency of the transformer rubber pad vibration damping pad using a simulation filter and moving average algorithm. The natural frequency of the transformer rubber pad vibration damping pad is compared and analyzed with the standard frequency of the transformer rubber pad vibration damping pad to obtain the frequency deviation rate of the transformer rubber pad vibration damping pad. The rubber vibration damping frequency analysis and control unit is used to automatically control and adjust the thermal resistance change due to dust blockage based on the rubber vibration damping frequency analysis results.

[0013] Furthermore, based on the frequency analysis results of the rubber damping system, automatic control adjustment is implemented to address sudden changes in thermal resistance caused by dust blockage. Specifically, this includes: if the frequency deviation rate of the transformer rubber damping pad is less than the first threshold, no adjustment is made; if the frequency deviation rate of the transformer rubber damping pad is equal to or greater than the first threshold and less than the second threshold, an alarm is triggered, and the current is automatically adjusted by the magnetorheological damper based on the frequency deviation rate of the transformer rubber damping pad; if the frequency deviation rate of the transformer rubber damping pad is equal to or greater than the first threshold, no adjustment is made; if the frequency deviation rate of the transformer rubber damping pad is equal to or greater than the second threshold, an alarm is triggered, and the current is automatically adjusted by the magnetorheological damper based on the frequency deviation rate of the transformer rubber damping pad; if the frequency deviation rate of the transformer rubber damping pad is equal to or greater than the first threshold, no adjustment is made. If the frequency deviation rate of the transformer rubber pad is less than the second threshold and less than the third threshold, the silicone repair adhesive is precisely injected into the target area using an injection robotic arm. After a predefined time, the rubber vibration damping frequency monitoring and early warning unit monitors and judges again whether the frequency deviation rate of the transformer rubber pad is less than the first threshold. If it is less than the first threshold, no adjustment is made. If it is equal to or greater than the first threshold, an early warning is issued and relevant personnel are notified.

[0014] Furthermore, based on the results of magnetic aging iron loss analysis, early warning of magnetic aging iron loss is conducted. Specifically, this includes: continuously measuring the magnetic flux density of the iron core using a through-core flux sensor; synchronously measuring the excitation current using a Rogowski coil and converting it into the corresponding magnetic field strength; and calculating the dynamic hysteresis loop area of ​​the transformer core silicon steel sheets in real time. A reference value for the dynamic hysteresis loop area is extracted from the automatic control database of the energy-saving transformer system. A comparative analysis of the reference value and the dynamic hysteresis loop area of ​​the transformer core silicon steel sheets is performed to obtain the hysteresis loop area difference coefficient. If the hysteresis loop area difference coefficient is less than the first threshold of the dynamic hysteresis loop area, no adjustment is made. If the hysteresis loop area difference coefficient is equal to or greater than the first threshold of the dynamic hysteresis loop area, an inverse-time tripping algorithm is implemented through predefined software to confirm the tripping command and execute the protection sequence.

[0015] Furthermore, a three-dimensional assessment and analysis of the transformer is conducted, specifically including: obtaining the dust blockage thermal resistance index, the frequency offset rate of the transformer rubber pad vibration damping pad, and the hysteresis loop area difference coefficient; performing a coupling analysis on the dust blockage thermal resistance index, the frequency offset rate of the transformer rubber pad vibration damping pad, and the hysteresis loop area difference coefficient to obtain the three-dimensional transient risk item of the transformer system, which is used to reflect the coupled risk of the current state of the transformer equipment; retrieving all historical risk values ​​from the automatic control and regulation database of the energy-saving transformer system, calculating the weight of each historical value according to the time distance, summing all weight values ​​after coupling with the corresponding historical risks, and then performing a coupling analysis with the dynamically adjusted historical effect factor to obtain the three-dimensional historical data of the transformer system. Risk items: The transient risk item of the three-dimensional risk of the transformer system is coupled with the historical risk item of the three-dimensional risk of the transformer system to obtain the three-dimensional risk value of the energy-saving transformer system. If the three-dimensional risk value of the energy-saving transformer system is less than the first threshold of the three-dimensional risk of the energy-saving transformer system, then the first-level control of the machine tool transformer is performed. If the three-dimensional risk value of the energy-saving transformer system is equal to or greater than the first threshold of the three-dimensional risk of the energy-saving transformer system and less than the second threshold of the three-dimensional risk of the energy-saving transformer system, then the second-level control of the machine tool transformer is performed. If the three-dimensional risk value of the energy-saving transformer system is equal to or greater than the second threshold of the three-dimensional risk of the energy-saving transformer system, then the third-level control of the machine tool transformer is performed.

[0016] Furthermore, the machine tool transformer primary control is performed, specifically including: the result of the comparative analysis of the three-dimensional risk value of the energy-saving transformer system and the first threshold of the three-dimensional risk of the energy-saving transformer system, which is recorded as the first coefficient of the three-dimensional risk difference of the transformer; the basic migration ratio is extracted from the automatic control and regulation database of the energy-saving transformer system, and the compensation migration ratio is increased according to the first coefficient of the three-dimensional risk difference of the transformer to obtain the comprehensive compensation migration ratio; the load is transferred to the standby transformer by controlling the intelligent busbar switching device according to the comprehensive compensation migration ratio.

[0017] Furthermore, secondary control of the machine tool transformer is carried out, specifically including: extracting the basic trigger temperature from the automatic control and regulation database of the energy-saving transformer system, and reducing the trigger temperature by using a shape memory alloy actuator based on the historical effect accumulation factor; extracting the basic compensation intensity from the automatic control and regulation database of the energy-saving transformer system, and increasing the compensation intensity when the partial discharge level of the transformer exceeds the standard value by continuously monitoring the discharge of the active filter.

[0018] Furthermore, the machine tool transformer is subjected to three-level control, specifically including: real-time monitoring of the core stress level, generating reverse hydraulic pressure proportionally according to the core stress level through a hydraulic compensation device; detecting the insulation response of the transformer insulating oil at different frequency bands, increasing the oil cooling oil flow rate if a low-frequency abnormality is detected, and extending the DC bias repair time if a high-frequency abnormality is detected.

[0019] One or more technical solutions provided in the embodiments of this application have at least the following technical effects or advantages:

[0020] 1. This invention couples three parameters—dust, vibration, and magnetic loss—through three-dimensional risk regulation and integrates the cumulative effect of historical risks over time. Based on the comprehensive evaluation results, it performs targeted quantitative adjustments to drive load migration, overheat protection, and stress compensation, establishing a real-time perception, hierarchical control, and historical tracking system. This addresses the triple pain points of heat dissipation failure, vibration transmission, and voltage fluctuation in dense machine tool scenarios, thereby improving the adaptability of transformer self-regulation to high-precision CNC machine tool cluster scenarios. It also solves the problem of insufficient adaptability of transformer self-regulation in high-precision CNC machine tool cluster scenarios in existing technologies.

[0021] 2. By using non-contact laser scanning to scan the vibration spectrum of the damping pad, the frequency shift caused by rubber aging is accurately captured, thereby enabling graded vibration control: For minor aging: the current intensity of the magnetorheological damper is adjusted to enhance the damping stiffness; for moderate aging: a robotic arm precisely injects nano-repair material to fill rubber cracks; for repair verification: after the material has cured, the frequency characteristics are retested, thereby reducing transformer output voltage fluctuations in precision parts processing areas, improving machine tool processing accuracy, reducing the loss of high-value workpieces due to batch scrapping, achieving self-inspection and evaluation of transformer rubber damping, self-healing of the damping system, and blocking vibration transmission.

[0022] 3. By non-invasively monitoring the magnetic flux characteristics of the iron core and calculating the degree of energy loss of the iron core in real time, and then taking risk-based measures: actively enhancing harmonic filtering capabilities and enabling intelligent power-off protection mechanisms, the response speed to iron loss anomalies in micron-level processing workshops is increased several times, thereby stabilizing the power supply voltage within the allowable fluctuation range of precision processing, thus avoiding the scrapping of an entire batch of precision parts due to a single voltage surge, and achieving iron loss abrupt change protection to ensure voltage stability.

[0023] 4. By integrating real-time parameters of dust, vibration, and magnetic loss, and superimposing the cumulative effect of historical operating risks of the equipment, intelligent hierarchical execution is achieved: for low risks, part of the load is dynamically transferred to the backup transformer; for medium risks, the overheat protection trigger temperature threshold is lowered; and for high risks, the hydraulic balancing device offsets mechanical stress in real time. This significantly improves the identification rate of sudden faults in workshops with ultra-dense machine tool layouts, reduces equipment maintenance costs, and extends the service life of transformers by several years compared to the average level, realizing a historically enhanced decision-making system for three-dimensional risk control. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of the structure of the automatic control and regulation system of the energy-saving transformer system provided in the embodiments of this application;

[0025] Figure 2This is a schematic diagram of the three-dimensional parameter acquisition process in the automatic control and regulation system of the energy-saving transformer system provided in the embodiments of this application;

[0026] Figure 3 This is a schematic diagram of the three-dimensional evaluation and control module of the transformer in the automatic control and regulation system of the energy-saving transformer system provided in the embodiments of this application. Detailed Implementation

[0027] This application provides an energy-saving transformer system self-control and regulation system, which solves the problem of insufficient adaptability of transformer self-control and regulation in high-precision CNC machine tool cluster scenarios in the prior art. By coupling three parameters of dust, vibration and magnetic loss through three-dimensional risk control and integrating the cumulative effect of historical risk time, the system performs targeted quantitative adjustment of drive load migration, overheat protection and stress compensation based on comprehensive evaluation results, thereby improving the adaptability of transformer self-control and regulation to high-precision CNC machine tool cluster scenarios.

[0028] To better understand the above technical solutions, the following will provide a detailed explanation of the technical solutions in conjunction with the accompanying drawings and specific implementation methods.

[0029] like Figure 1 The diagram shown is a structural schematic of the automatic control and regulation system of the energy-saving transformer system provided in this application embodiment. The automatic control and regulation system of the energy-saving transformer system provided in this application embodiment includes: a dust blockage thermal resistance sudden change self-detection module, a rubber vibration damping self-detection module, a magnetic aging iron loss sudden increase self-detection module, and a transformer three-dimensional evaluation and control module. Specifically, the dust blockage thermal resistance sudden change self-detection module is used to perform dust blockage thermal resistance analysis using raw dust blockage thermal resistance data, and to perform automatic control and regulation of dust blockage thermal resistance sudden change based on the analysis results; the rubber vibration damping self-detection module is used to perform rubber vibration frequency analysis using raw rubber vibration frequency data, and to perform automatic control and regulation of rubber vibration frequency sudden change based on the analysis results; the magnetic aging iron loss sudden increase self-detection module is used to perform magnetic aging iron loss analysis, and to provide early warning of magnetic aging iron loss based on the analysis results; the transformer three-dimensional evaluation and control module is used to perform transformer three-dimensional evaluation analysis, and to perform transformer three-dimensional evaluation and regulation based on the analysis results.

[0030] In this embodiment, high-precision CNC machine tool clusters are often densely arranged in a limited space. This environment poses a severe challenge to the transformers that power them. For heat dissipation, existing small transformers mainly rely on natural air convection or the addition of fans. This method has limited effectiveness in densely packed machine tool layouts, and heat sinks are easily clogged by workshop dust, leading to high temperatures accumulating inside the electrical cabinet. The continuous overheating environment not only affects the transformer's own lifespan but also threatens surrounding precision control components. Vibration is another major problem. The mechanical vibration generated during machine tool processing is directly transmitted to its associated transformer. Traditional vibration damping measures (such as simple rubber pads) are ineffective and prone to aging and failure. As a result, internal transformer components become looser, leading to significant output voltage fluctuations. This voltage instability directly impairs the machining accuracy of the machine tools. Furthermore, industrial production lines require 24-hour continuous operation, but in actual production, machine tools have considerable downtime. Existing transformers are inefficient under no-load or light-load conditions, consuming considerable electrical energy even during standby, resulting in long-term unnecessary energy waste and economic losses.

[0031] A mounting plate is bolted to the top of the transformer body. A switch panel is located on one side of the transformer. Several connecting posts are located on the top of the mounting plate. An oil tank is located on one side of the top of the transformer body. A heat dissipation mechanism is fixedly installed on one side of the transformer body. The heat dissipation mechanism includes a heat-conducting plate fixedly installed on one side of the transformer body, with a sealing plate on the outer wall of the heat-conducting plate. An oil guide pipe with a wavy shape is arranged on one side of the heat-conducting plate. In actual use, the cooling oil in the transformer body absorbs heat and flows into the oil guide pipe, where it releases heat to reduce the heat of the cooling oil. A miniature oil pump is located on one side of the heat-conducting plate, and an electromagnetic current-limiting valve is located on the other side. The oil outlet of the miniature oil pump and the oil inlet of the electromagnetic current-limiting valve are sealed and connected to both ends of the oil guide pipe. In actual use, the miniature oil pump pumps oil into the oil guide pipe and returns it to the transformer body from the electromagnetic current-limiting valve, completing the cooling oil circulation and enabling heat exchange within the transformer body. A protective cover is located on the outer edge of the sealing plate, and transformer cooling fans are located on both sides of the protective cover. In practical use, the transformer cooling fan creates airflow within the protective cover, carrying away the surface temperature of the oil guide pipe. Annular heat sinks are located on the top and bottom edges of the heat-conducting plate, embedded in one side of the protective cover. During operation, these annular heat sinks dissipate the heat absorbed by the heat-conducting plate, simultaneously working with the transformer cooling fan to reduce the surface temperature and improve the cooling effect within the transformer body. Working principle: After absorbing heat, the cooling oil inside the transformer body flows into the oil guide pipe, where it releases heat, reducing the oil's temperature. A miniature oil pump pumps oil into the oil guide pipe and returns it to the transformer body through the electromagnetic current-limiting valve, completing the cooling oil circulation and facilitating heat exchange within the transformer body. The transformer cooling fan creates airflow within the protective cover, carrying away the surface temperature of the oil guide pipe. The annular heat sinks dissipate the heat absorbed by the heat-conducting plate, simultaneously working with the transformer cooling fan to reduce the surface temperature and improve the cooling effect within the transformer body.

[0032] Furthermore, during the first operation after a new installation or thorough cleaning of the transformer, the oil pump speed is kept stable at the rated operating value, and the stable oil pressure difference between the inlet and outlet of the heat sink is recorded as the heat sink pressure difference benchmark calibration value; the volume of cooling oil flowing through the heat sink per unit time is recorded as the cooling oil flow rate benchmark calibration value; the decrease in surface temperature of the heat sink when the oil flow rate increases by one-thousandth is recorded as the temperature rate gradient benchmark calibration index of the transformer oil cooling system; in order to establish a heat transfer efficiency benchmark under dust-free conditions.

[0033] The actual difference between the inlet and outlet oil pressures of the heat sink is measured every 10 seconds and recorded as the heat sink differential pressure. The actual flow rate of the cooling oil at the corresponding moment is recorded simultaneously and recorded as the cooling oil velocity. When the cooling oil velocity changes slightly (e.g., fluctuates by 1%), the rate of change of the surface temperature of the heat sink is measured and recorded as the temperature rate gradient index of the transformer oil cooling system. The actual differential pressure is divided by the cooling oil velocity to obtain the current actual differential pressure-to-flow ratio. The differential pressure-to-flow ratio is divided by the differential pressure-to-flow ratio of the heat sink to obtain the differential pressure-to-flow degradation rate. The larger the differential pressure-to-flow degradation rate, the more severe the impact of dust blockage. The heat dissipation efficiency reduction rate is obtained by real-time monitoring of the temperature rise rate caused by the change in unit oil flow rate (temperature rate gradient index) and comparing it with the baseline value under clean system conditions. This parameter innovatively establishes a dynamic thermal resistance evaluation mechanism: revealing the intrinsic relationship between oil flow changes and temperature rise response, replacing traditional static temperature monitoring, identifying thermal conductivity degradation in the early stages of radiator blockage, significantly earlier than absolute temperature alarms, achieving automatic adjustment when heat dissipation efficiency slightly decreases, overcoming the response lag defects of traditional solutions, and eliminating interference from environmental and medium changes through a built-in compensation mechanism, greatly improving reliability in industrial scenarios.

[0034] The heat dissipation efficiency reduction rate is obtained by comparing and analyzing the temperature rate gradient index of the transformer oil cooling heat dissipation system with the temperature rate gradient benchmark calibration index of the transformer oil cooling heat dissipation system. The larger the value of the heat dissipation efficiency reduction rate, the more serious the negative impact of heat dissipation.

[0035] By coupling the differential pressure flow rate degradation rate and the heat dissipation efficiency reduction rate, the thermal resistance index of dust blockage is obtained.

[0036] In this embodiment,

[0037] α represents the thermal resistance index of dust blockage, which is dimensionless.

[0038] ΔPSR represents the differential pressure of the heat sink, which is dimensionless. It is obtained by measuring the differential pressure difference between the inlet and outlet of the oil-cooled heat dissipation system through a differential pressure transmitter and normalizing the result. The differential pressure transmitter is installed at both ends of the heat-conducting plate of the transformer.

[0039] VOIL represents the cooling oil flow rate, which is dimensionless and is measured by a vortex flow meter installed on the transformer's oil guide pipe.

[0040] The average fin pressure difference measured during the first operation of the transformer at rated power after installation is recorded as the fin pressure difference reference calibration value, and ΔPSR0 represents the fin pressure difference reference calibration value.

[0041] The average cooling oil flow rate measured during the first operation of the transformer at rated power after installation is recorded as the cooling oil flow rate reference calibration value. VOIL0 represents the cooling oil flow rate reference calibration value.

[0042] TF represents the surface temperature of the heat sink, which is acquired through non-contact scanning of the annular heat sink surface using an infrared thermopile array transformer.

[0043] dTF / dVOIL represents the temperature rate gradient index of the transformer oil cooling system. Similarly, dTF0 / dVOIL0 represents the benchmark calibration index of the temperature rate gradient of the transformer oil cooling system, which is the benchmark calibration index of the temperature rate gradient of the transformer oil cooling system measured when the transformer is first run at rated power after installation.

[0044] Dust clogging oil channels increases flow resistance, leading to a sharp increase in pressure difference on the heat sink at the same flow rate. Dust covering the heat sink also increases thermal resistance, slowing down the temperature rise of the heat sink as oil velocity increases. Dust is more likely to accumulate in low-flow-rate areas, accelerating the clogging process. When dust accumulates between the heat sink fins: dust covers the fin surface, forming an insulating layer and reducing the fin's thermal conductivity; the increased dust accumulation thickness compresses the spacing between adjacent fins, causing fin deformation and pressing down on the underlying metal oil pipe, flattening the oil pipe and reducing the oil flow cross-section. For example, a machine tool factory dismantling report shows that in a transformer heat sink used for two years, the solidified dust caused the fin spacing to decrease from 1.5mm to 0.7mm, and the ellipticity of the oil guide pipe cross-section reached 0.25 (roundness deviation > 20%).

[0045] Furthermore, if the thermal resistance index of dust blockage is less than the second thermal resistance threshold of dust blockage, then a first-level control is performed. The thermal resistance index of dust blockage is subtracted from the second thermal resistance threshold of dust blockage to obtain the second thermal resistance difference of dust blockage. Based on the second thermal resistance difference of dust blockage, the opening of the electromagnetic current limiting valve of the transformer is increased through the PWM signal to increase the oil flow rate. Based on the second thermal resistance difference of dust blockage, the intermittent operation interval of the transformer cooling fan is shortened.

[0046] If the thermal resistance index of dust blockage is equal to or greater than the second thermal resistance threshold of dust blockage and less than the first thermal resistance threshold of dust blockage, then secondary control is performed. The newly added piezoelectric ceramic sheet is activated to emit 40kHz high-frequency sound waves to continuously vibrate the surface of the heat sink fins for 10 minutes, causing uncured dust to fall off. The piezoelectric ceramic sheet is installed at the root of the fins. The transformer's micro oil pump is activated to run in reverse for 30 seconds to form turbulent flow to flush the inner wall of the oil guide pipe. Intermittent reverse pulses are used.

[0047] If the thermal resistance index of dust blockage is equal to or greater than the first thermal resistance threshold of dust blockage, then three-level control is performed. The duration of the thermal resistance index of dust blockage being equal to or greater than the first thermal resistance threshold of dust blockage is recorded as the duration of the thermal resistance exceeding the threshold of dust blockage. The backup oil guide channel is switched: the redundant oil guide pipe structure of the transformer is activated to bypass the blocked main channel; the built-in micro hydraulic rod is activated to push open the heat dissipation fins that have been deformed by the dust and restore the original spacing of the heat dissipation fins (about 1.5mm); the external air pump is linked to inject 0.5MPa compressed air to flush the dust blockage from the bottom of the fins upwards through the multi-channel switching architecture of the oil guide pipe.

[0048] If the duration of dust blockage exceeding the thermal resistance threshold is greater than the upper limit of the duration of dust blockage exceeding the thermal resistance threshold, an alarm will be issued and relevant personnel will be notified.

[0049] In this embodiment, it should be noted that the specific parameters in the multi-level control within the context are example steps in the specific implementation process, and the specific numerical settings can be set independently by technical personnel. The mapping relationship between the second dust blockage thermal resistance difference and the increase in the opening degree of the transformer electromagnetic current limiting valve is extracted from the energy-saving transformer system automatic control and regulation database; the mapping relationship between the second dust blockage thermal resistance difference and the intermittent operation interval of the transformer cooling fan is also extracted from the energy-saving transformer system automatic control and regulation database.

[0050] In high-dust industrial settings such as CNC machine tools and foundries, the dust blockage coefficient-based quantitative grading control strategy demonstrates three core values: First, by accurately classifying risk levels through quantified thresholds of the blockage coefficient, it completely changes the traditional extensive mode that relies on manual experience for judgment, avoiding resource waste caused by premature intervention or equipment damage caused by delayed handling. Second, the three-level progressive response mechanism perfectly matches production line conditions: Level 1 control maintains continuous production with "flexible intervention" by finely adjusting the oil speed, suitable for light dust environments such as automotive parts production lines; Level 2 physical stripping addresses the risk of metal dust solidification in foundries, actively cutting off the deterioration chain in the early stages of dust thermal adhesion; Level 3 reconstruction focuses on the supercritical conditions of heavy machinery processing, resolving sudden failures through structural self-recovery technology, compressing the traditional dust removal operation that requires several hours of downtime to tens of minutes. Finally, the deep integration of patented hardware and intelligent algorithms forms a closed-loop system that resists degradation—the solenoid valve's dynamic speed regulation counteracts oil circuit aging, the acoustic stripping technology solves the stubborn problem of dust caking, and the mechanical struts and redundant oil circuit design ultimately achieve engineering results such as a reduction of maintenance costs by more than 40% and an unexpected downtime reduction of nearly 90% under high dust conditions.

[0051] Furthermore, the specific process for automatically adjusting the thermal resistance change due to dust blockage based on the frequency analysis results of the rubber damping is as follows:

[0052] The laser vibrometer (Polytec OFV-505, wavelength 632.8nm) acquires vibration signals (50Hz sampling) based on the Doppler interferometry principle. Signal processing is simplified to two-stage noise reduction + peak tracking: an analog bandpass filter (70-100Hz) directly removes ambient noise, a moving average algorithm (50ms window width) smooths the signal, and the main frequency peak is directly extracted; the frequency offset rate is calculated in real time, and a three-color LED alarm is triggered when the offset is ≥1%, and the alarm is pushed to the main control system via OPC UA.

[0053] If the frequency offset rate of the transformer rubber pad is less than the first threshold of the frequency offset rate of the transformer rubber pad, no adjustment is required.

[0054] If the frequency deviation rate of the transformer rubber pad is equal to or greater than the first threshold and less than the second threshold, an alarm is triggered. The magnetorheological damper automatically adjusts the current based on the frequency deviation rate, and the PID controller ensures precise damping force matching. The PT100 temperature sensor automatically derates above 85℃.

[0055] If the frequency deviation rate of the transformer rubber pad is equal to or greater than the second threshold of the frequency deviation rate of the transformer rubber pad, and less than the third threshold of the frequency deviation rate of the transformer rubber pad, the silicone repair adhesive is precisely injected into the target area using a five-point micro-dose gradient injection method via an injection robotic arm (single dose 0.1ml, needle inner diameter 0.2mm, flow rate controlled by a Nordson EFD precision metering valve). After a predefined time, the rubber vibration damping frequency monitoring and early warning unit monitors again to determine whether the frequency deviation rate of the transformer rubber pad is less than the first threshold of the frequency deviation rate of the transformer rubber pad (used for stiffness verification, delayed retesting, and allowing time for silicone crosslinking; curing time is approximately 5 minutes). If it is less than the first threshold of the frequency deviation rate of the transformer rubber pad, no adjustment is made. If it is equal to or greater than the first threshold of the frequency deviation rate of the transformer rubber pad, an early warning is issued and relevant personnel are notified.

[0056] In this embodiment, f n The natural frequency of the transformer rubber pad is represented by f, where π represents pi, k represents the stiffness of the transformer rubber pad, and m represents the mass of the transformer rubber pad. When rubber aging causes a decrease in stiffness k, the natural frequency f... n It will inevitably decrease. f is directly captured through non-contact laser vibration measurement. n The offset is significantly accurate and efficient, with a laser detection delay of less than 1ms, which is much faster than the minute-level cycle of damage accumulation. The laser wavelength is stable and is not affected by oil or temperature.

[0057] f0 represents the standard frequency of the transformer rubber pad vibration damping pad, which is extracted from the energy-saving transformer system automatic control database. Specifically, it can be directly extracted from the manufacturer's production log.

[0058] The frequency offset rate of the transformer rubber pad vibration damping pad is... Dimensionless.

[0059] The magnetorheological damper automatically adjusts the current based on the frequency offset rate of the transformer's rubber pad vibration damper. The magnetorheological damper is a vibration damping device designed to reduce the impact of high-frequency vibrations encountered by the transformer in the machine tool environment on the internal electronic components of the transformer. Different damping forces can be set by setting different currents.

[0060] The current is automatically adjusted by the magnetorheological damper based on the frequency offset rate of the transformer's rubber pad vibration damper. The specific current setting constraint is as follows:

[0061] I n =I0×(Δf n +1) 2 ;I n I0 represents the set current of the magnetorheological damper; I0 represents the base current of the magnetorheological damper, which is extracted from the automatic control database of the energy-saving transformer system. Specifically, it can be directly extracted from the manufacturer's production log.

[0062] Furthermore, based on the results of magnetic aging iron loss analysis, early warning of magnetic aging iron loss is conducted. Specifically, this includes: continuously measuring the magnetic flux density of the iron core using a through-core flux sensor; synchronously measuring the excitation current using a Rogowski coil and converting it into the corresponding magnetic field strength; and calculating the dynamic hysteresis loop area of ​​the transformer core silicon steel sheets in real time. A reference value for the dynamic hysteresis loop area is extracted from the automatic control database of the energy-saving transformer system. A comparative analysis of the reference value and the dynamic hysteresis loop area of ​​the transformer core silicon steel sheets is performed to obtain the hysteresis loop area difference coefficient. If the hysteresis loop area difference coefficient is less than the first threshold of the dynamic hysteresis loop area, no adjustment is made. If the hysteresis loop area difference coefficient is equal to or greater than the first threshold of the dynamic hysteresis loop area, an inverse-time tripping algorithm is implemented through predefined software to confirm the tripping command and execute the protection sequence. This is part of a real-time monitoring and control technology scheme for sudden increases in magnetic aging iron loss.

[0063] In this embodiment, as Figure 2 The figure shows a schematic diagram of the three-dimensional parameter acquisition process in the automatic control and regulation system of the energy-saving transformer system provided in this application embodiment. As shown in the figure, the acquired three-dimensional parameters are used to obtain and calculate the subsequent three-dimensional risk value of the energy-saving transformer system.

[0064] I. Monitoring Objects and Principles

[0065] Monitoring object: Hysteresis loss (P_fe) of silicon steel sheets in transformer core.

[0066] Monitoring location: Surface of the iron core yoke (non-invasive monitoring point)

[0067] Real-time monitoring principle:

[0068] The magnetic flux density B(t) of the iron core was continuously measured using a through-core flux sensor (Yokogawa GM100).

[0069] The magnetic field strength H(t) is calculated by synchronously measuring the excitation current using a Rogowski coil (PEM CWT Ultra).

[0070] Real-time calculation of the dynamic hysteresis loop area: P_fe=∮H·dB.

[0071] It performs 3 complete measurements per second with a sampling rate of 100 kS / s, capturing microsecond-level mutations.

[0072] All sensors are designed with electromagnetic isolation and can continuously monitor under rated load.

[0073] P_fe represents the hysteresis loss of the silicon steel sheets in the transformer core.

[0074] Example of establishing a benchmark value: After 72 hours of no-load testing after commissioning, P_fe0 is obtained, which is the benchmark value of the dynamic hysteresis loop area. The benchmark value of the dynamic hysteresis loop area is then uploaded to the automatic control database of the energy-saving transformer system. P c This represents the hysteresis loop area difference coefficient. The larger the hysteresis loop area difference coefficient, the greater the magnetic aging iron loss of the silicon steel sheets in the transformer core. Generally speaking, the hysteresis loss of the silicon steel sheets in the transformer core is equal to or greater than the dynamic hysteresis loop area reference value, and there will be no case where P_fe-P_fe is negative.

[0075] The following is a code example of implementing an inverse time-limited tripping algorithm using Python:

[0076] if P c Less than or equal to 75%

[0077] Risk = P c *(1+0.02*(T_hotspot-100)) #T_hotspot is the core hotspot temperature (fiber optic temperature measurement system)

[0078] If Risk is less than 20:

[0079] trip_delay = max(0.5, 15 / P) c #Basic Delay

[0080] elif 20 is less than or equal to Risk and less than 30:

[0081] trip_delay = max(0.3, 10 / P) c )

[0082] else: #Risk≥30

[0083] trip_delay = 0.1 # Immediate action

[0084] The following are sample steps for confirming the trip command and executing the protection sequence:

[0085] Hall array detects local magnetic field distortion: if the distortion rate is greater than 18%, a trip command is confirmed; if the distortion rate is less than 10%, a secondary hysteresis loop verification is initiated; the main circuit breaker trips (action time less than or equal to 60ms), synchronously triggering: the reactive power compensation device quickly exits, and the backup power supply is automatically switched on (ATS switching); fault data is sealed: data is written to the fault recorder 60 seconds before the trip, and key parameters are stored on the blockchain.

[0086] Furthermore, a three-dimensional evaluation and analysis of the transformer is conducted, specifically including: obtaining the thermal resistance index of dust blockage, the frequency offset rate of the transformer rubber pad anti-vibration pad, and the hysteresis loop area difference coefficient; the system performs three full-parameter synchronous acquisitions per second to ensure that the time alignment accuracy of all data reaches the millisecond level. The collected parameters are used to generate the current risk value through a specific fusion algorithm. The thermal resistance index of dust blockage, the frequency offset rate of the transformer rubber pads and vibration damping pads, and the hysteresis loop area difference coefficient are coupled and analyzed to obtain the three-dimensional transient risk item of the transformer system, which reflects the coupled risk of the current state of the transformer equipment. The historical effect factor is automatically adjusted according to the equipment's operating years, reflecting the aging characteristics of "slow initial growth followed by accelerated growth." The time decay coefficient is automatically adjusted according to oil temperature; the decay coefficient decreases when the oil temperature rises, making the impact of historical risks more persistent, and increases when the oil temperature falls, accelerating the dissipation of historical risks. The system scans every historical time point from commissioning to the present moment, and the risk value at each historical moment is weighted according to the time distance. All historical risk weights are summed and multiplied by the historical effect factor to obtain the three-dimensional historical risk item of the transformer system. The three-dimensional transient risk item of the transformer system is coupled and analyzed with the three-dimensional historical risk item of the transformer system to obtain the three-dimensional risk value of the energy-saving transformer system.

[0087] In this embodiment, the constraint formula for the three-dimensional risk value of the energy-saving transformer system is as follows:

[0088]

[0089] e represents the natural constant.

[0090] α(t) represents the thermal resistance index of dust blockage at time t, which is a real-time parameter reflecting the degree of dust blockage in the heat dissipation system. Dust accumulation on the heat sink forms an insulation layer, reducing heat dissipation efficiency. Simultaneously, dust blockage increases oil circuit resistance, leading to increased oil pump load and additional vibration. This vibration is transmitted to the rubber damping pads through mechanical connections, accelerating their aging process. More seriously, the temperature rise caused by decreased heat dissipation efficiency exacerbates the magnetic aging effect of the iron-core silicon steel sheets, creating a thermal-vibration-magnetic chain reaction.

[0091] Δf n (t) represents the frequency shift rate of the transformer rubber pad vibration damping system at time t, which quantifies the degree of aging of the rubber damping system. Frequency shift caused by rubber aging directly reduces the damping effect, intensifying the vibration of the transformer itself. This vibration has a dual effect: on the one hand, it accelerates the dust accumulation rate between the radiator fins; on the other hand, it induces microscopic displacement of the silicon steel sheets in the core, altering their magnetic domain structure. This interaction between mechanical vibration and magnetic circuit changes significantly accelerates the magnetic aging process.

[0092] P c (t) represents the hysteresis loop area difference coefficient at time t, which characterizes the severity of magnetic aging damage to the core. Increased iron losses lead to a rise in core temperature, and the resulting thermal expansion compresses the gaps between the heat sinks, creating a physical environment where dust can more easily deposit. Simultaneously, the increased core temperature accelerates the aging of transformer oil, altering its viscosity characteristics. This viscosity change, in turn, affects the suspension state and deposition rate of dust in the oil circuit, forming a closed-loop interaction between magnetism, heat, and dust.

[0093] τ represents the historical time integration variable, which represents any historical point in time from system commissioning to the current time t. For example, τ could be 12 noon yesterday or the 15th of last month. As an integration variable, it iterates through the entire historical timeline of system operation, ensuring that all historical states are taken into account. The upper limit of integration t represents the current time, and the lower limit 0 represents the initial commissioning time of the system.

[0094] R sys (t) represents the three-dimensional risk value of the energy-saving transformer system at time t; R sys (τ) represents the three-dimensional risk value of the energy-saving transformer system at any historical time point between system commissioning and the current time t. This function records the composite risk value of the system at historical time τ. The risk value at each historical time is expressed through an exponential decay factor e. -β(t-τ) The weighted average, in its physical sense, means that recent risk events have a greater impact on the current state, while the impact of long-term risk events diminishes over time.

[0095] λ represents the historical effect cumulative factor, which determines the weight of the impact of historical risk on the current state. Its verification formula is: λ=HG1×ln(SJ)+HG2; where HG1 and HG2 represent the two fitting coefficients of the regression analysis, and SJ represents the number of years of operation, which is dimensionless and non-zero. For example, the optimal fitting value obtained by regression analysis of 23 transformers operating for 5 years is HG1 set to 0.08 and HG2 set to 0.05. The significance of the logarithmic function: The logarithmic function form is used because equipment aging has the characteristic of "fast in the early stage and slow in the later stage". For a transformer that has been operating for 3 years, its λ=0.08×ln(3)+0.05≈0.14.

[0096] β represents the time decay coefficient, which controls the decay rate of historical risk. Its verification formula is as follows: Among them, E a =1.2eV, which is the activation energy for thermal aging of transformer oil, determined through accelerated aging tests. R = 8.314J / mol·K represents the ideal gas constant, TY represents the transformer hot spot temperature (in Kelvin), and φ represents the aging preconditioning factor. For example, φ = 0.01, obtained through standard aging tests at 55℃. Temperature correlation: When the transformer oil pump temperature rises from 55℃ to 75℃, the β value decreases from 0.02 to 0.015, indicating that the historical risk decays more slowly at high temperatures.

[0097] Coupling mechanisms: Thermal-vibration coupling: Dust blockage leads to decreased heat dissipation efficiency, resulting in increased oil temperature, accelerated rubber aging, damping failure, and intensified vibration; Vibration-magnetic coupling: Vibration is transmitted to the iron core, causing displacement of the magnetic domain structure, increasing iron loss, and further raising the temperature; Magnetism-thermal coupling: Increased iron loss leads to temperature rise, decreasing oil viscosity, accelerating suspended dust deposition, and intensifying blockage; Time-cumulative effect: The above coupling processes form a positive feedback loop, and as the operating time increases, the system enters an accelerated aging stage. High-precision CNC machine tool clusters are often densely arranged in a limited space, resulting in significant coupling effects in terms of heat dissipation, mechanical vibration, and magnetic loss. Over a long timescale, the longer the operating period, the greater the fluctuation level under sudden risks.

[0098] Furthermore, the machine tool transformer is controlled at the first level, specifically including: setting a basic migration ratio, increasing the compensation migration ratio based on the historical effect accumulation factor to obtain a comprehensive compensation migration ratio, and transferring the load to the standby transformer by controlling the intelligent busbar switching device according to the comprehensive compensation migration ratio; the higher the risk, the larger the migration ratio. The actual effect is to transfer sensitive loads to the standby transformer, reducing the main transformer's heating and vibration.

[0099] The baseline migration ratio can be obtained from the average of historical migration ratio data or from expert prior knowledge.

[0100] The secondary control of machine tool transformers includes: extracting the basic trigger temperature from the automatic control database of energy-saving transformer systems, and reducing the trigger temperature by using shape memory alloy actuators based on the historical effect accumulation factor, so that older equipment can start protection in advance and prevent heat accumulation in dense areas of machine tools from causing transformer overheating.

[0101] The basic compensation strength is extracted from the automatic control and regulation database of the energy-saving transformer system. By continuously monitoring the partial discharge level of the transformer, the compensation strength is increased when the discharge of the active filter exceeds the standard value. This allows high-risk equipment to use a larger compensation coefficient, ensuring that the output voltage fluctuation is less than the set threshold and meets the requirements of precision machining.

[0102] The specific implementation steps of shape memory alloy (SMA) overheat protection are as follows: Install a shape memory alloy (SMA) actuator at a critical location for transformer heat dissipation (such as between the radiator and the transformer body). Shape memory alloys are temperature-sensitive; when the temperature reaches their phase transition temperature, they undergo a shape change (e.g., elongation or bending). We set the base trigger temperature to 60°C, but based on historical risks, the actual trigger temperature may be lower (e.g., for older equipment, the trigger temperature may be as low as 50°C). When the temperature reaches the actual trigger temperature, the SMA actuator deforms. This deformation drives a mechanical structure (e.g., pushes a linkage), thereby altering the heat dissipation path: opening an additional vent; pushing a valve to increase the flow of cooling oil; changing the spacing of the heat sink fins, etc. In this way, heat dissipation is automatically enhanced before the temperature rises to a dangerous level, preventing overheating.

[0103] The machine tool transformer is subjected to three-level regulation, which includes: real-time monitoring of the core stress level, and generating reverse hydraulic pressure proportionally according to the core stress level through a hydraulic compensation device; the greater the stress, the stronger the compensation force, which counteracts the core displacement caused by machine tool vibration and prevents the internal structure from loosening.

[0104] The insulation response of the transformer insulating oil at different frequency bands is tested. If a low-frequency anomaly is detected, the oil cooling oil flow rate is increased. If a high-frequency anomaly is detected, the DC bias repair time is extended. For high-frequency anomalies, the electromagnetic treatment time is extended to resolve oil quality deterioration and restore insulation performance.

[0105] In this embodiment, Figure 3 This is a schematic diagram of the transformer three-dimensional evaluation and control module in the automatic control system of the energy-saving transformer system provided in this application embodiment. As shown in the figure, calculations are performed using three-dimensional data dimensions to obtain a comprehensive value, followed by graded control.

[0106] R sys 1 represents the first coefficient of the three-dimensional risk difference of the transformer. YZ1 represents the first three-dimensional risk threshold of the energy-saving transformer system, Rsys (t1) represents the current three-dimensional risk value of the energy-saving transformer system. The first coefficient of the transformer three-dimensional risk difference accurately identifies high-risk locations (such as winding ends, radiator dead corners, etc.) by comparing the difference between the parameter benchmark values ​​and measured values ​​of each region in the three-dimensional model, overcoming the limitations of traditional single-point monitoring. Combined with the time dimension change rate, the static difference is upgraded to a dynamic risk coefficient, which can predict the development trend of potential faults such as "hot spot migration" and "accelerated oil flow decay", achieving early warning several hours before the fault. Optimize operation and maintenance decisions by classifying risk levels (such as low / medium / high) according to the coefficient size and triggering graded responses: integrating the electromagnetic-thermal-fluid multi-physics field coupling effect, it analyzes chain reactions such as "increased eddy current loss → local temperature rise → oil viscosity change → heat dissipation deterioration", avoiding misjudgments of traditional single-parameter protection. The difference algorithm suppresses interference factors such as ambient temperature fluctuations and load changes, ensuring the stability of risk judgment.

[0107] The following is sample code for the first, second, and third-level control of a machine tool transformer:

[0108] #= ...

[0109] def level 1_control(vibration, temp, historical_risk):

[0110] #1. Dynamic load migration (mitigation of overheating + reduction of vibration)

[0111] base_migration = 0.2 # Base migration amount 20%

[0112] risk_compensation = historical_risk * 0.15 # Historical risk compensation coefficient total_migration = base_migration + risk_compensation

[0113] #2. Vibration triggers oil circuit self-cleaning (inhibits dust accumulation)

[0114] cleaning_pulse_freq = 2# Basic pulse frequency (Hz)

[0115] If vibration > 0.5: #Vibration intensity threshold (0.5g)

[0116] cleaning_pulse_freq*=(1+historical_risk1)

[0117] return total_migration, cleaning_pulse_freq

[0118] Practical significance of the code:

[0119] 1. When the vibration of the machine tool cluster intensifies, the load transfer ratio is automatically increased to disperse the hot spot temperature.

[0120] 2. Strong vibration synchronously triggers high-voltage pulse self-cleaning: uses oil circuit to flush away dust from the heat sink.

[0121] 3. historical_risk1 is the first coefficient of the three-dimensional risk difference of the transformer.

[0122] The more historical faults a similar machine tool has, the greater the amount of compensation migration required.

[0123] Achieving a closed loop of "stronger vibration → stronger heat dissipation".

[0124] #= ...

[0125] def level 2_control(core_temp, partial_discharge, historical_risk):

[0126] #1. Shape memory alloy overheat protection

[0127] base_trigger_temp = 60 # Base trigger temperature (°C)

[0128] trigger_offset = 10 * historical_risk # Historical risk compensation

[0129] actual_trigger_temp=base_trigger_temp-trigger_offset

[0130] #2. Harmonic compensation enhancement (suppressing voltage fluctuations)

[0131] compensation_strength = 1.0 # Basic compensation strength

[0132] if partial_discharge > 100: # Partial discharge threshold (100 pC)

[0133] #High-risk equipment reinforcement compensation (to prevent impact on precision machining)

[0134] compensation_strength=1.5*(1+historical_risk1)

[0135] return actual_trigger_temp, compensation_strength

[0136] Practical significance of the code:

[0137] 1. Based on historical risk, anti-overheating protection trigger points are established in advance:

[0138] The trigger temperature of the old equipment has dropped to 50℃

[0139] Prevent heat accumulation in densely populated machine tool areas

[0140] 2. Enhanced harmonic compensation when discharge exceeds limits:

[0141] Specifically enhance the compensation strength of old transformers.

[0142] Ensure output voltage fluctuation is ≤ ±0.3‰

[0143] #= ...

[0144] def level 3_control(mechanical_stress, dielectric_response): #1. Multi-objective particle swarm optimization reset (PSO)

[0145] optimization_target = current_risk + 0.3 * historical_risk # Optimization under heat dissipation / vibration / electromagnetic constraints

[0146] #2. Dynamic compensation of core stress: hydraulic_pressure = 0

[0147] if mechanical_stress>18: #Stress threshold (18MPa)

[0148] # Apply reverse hydraulic pressure proportionally to relieve stress: hydraulic_pressure = mechanical_stress * 0.8

[0149] #3. Directed Handling of Insulation Faults if dielectric_response<0.95: #Low-frequency dielectric response

[0150] #Increase hydraulic pulse pressure to clean oil passages pulse_pressure=15*(1-dielectric_response)

[0151] elif dielectric_response>1.05: #High-frequency dielectric response

[0152] #Extend DC bias repair time dc_bias_time=180*dielectric_response

[0153] return optimization_result, hydraulic_pressure

[0154] Practical significance of the code:

[0155] 1. Mechanical stress compensation: When machine tool vibration causes the core stress to exceed the standard...

[0156] Automatic generation of reverse hydraulic pressure balance stress

[0157] To prevent long-term vibration from causing core displacement

[0158] 2. Dielectric response treatment: Detecting the degree of insulation oil degradation.

[0159] Low-frequency abnormality: Oil passage blockage → Pulse boost unblocking

[0160] High-frequency anomaly: Insulation deterioration → Extended DC treatment

[0161] 3. PSO Optimization Module:

[0162] Simultaneously optimize current temperature / vibration / voltage parameters

[0163] Special emphasis is placed on items with high historical risk.

[0164] Solving the problem of multiple constraints in cluster environments

[0165] #======Main Control Loop (Executes every 200ms)======

[0166] while True:

[0167] #Real-time data acquisition (via industrial bus)

[0168] vibration=read_vibration_sensor()

[0169] core_temp=read_core_thermocouple()

[0170] discharge = read_uhf_sensor()

[0171] stress = read_fbg_sensor()

[0172] #...Other sensor readouts...

[0173] #Historical Risk Inquiry (with Time Decay)

[0174] historical_risk=query_risk_db(time_decay=0.02)

[0175] #Implementation of Level 3 Regulation

[0176] if system_risk < 0.3:

[0177] migrate_ratio, pulse_freq=level 1_control(vibration, core_temp, historical_risk)

[0178] execute_migration(migrate_ratio) # Perform load migration

[0179] start_pulse_cleaning(pulse_freq) # Starts the oil circuit cleaning process

[0180] elif system_risk < 0.6:

[0181] trigger_temp, comp_strength=level 2_control(core_temp, discharge, historical_risk)

[0182] set_sma_trigger(trigger_temp) # Sets the action point of the shape memory alloy

[0183] adjust_compensator(comp_strength) # Adjust the harmonic compensator

[0184] else:

[0185] opt_result, pressure=level 3_control(stress, read_dielectric())

[0186] apply_hydraulic(pressure) # Hydraulic compensation for mechanical stress

[0187] execute_pso_reset(opt_result) # Perform optimized reset

[0188] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, the present invention can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, the present invention can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, CD-ROM, optical storage, etc.) containing computer-usable program code.

[0189] This invention is described with reference to flowchart illustrations and / or block diagrams of systems, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0190] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0191] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0192] Although preferred embodiments of the invention have been described, those skilled in the art, upon learning the basic inventive concept, can make other changes and modifications to these embodiments. Therefore, the appended claims are intended to be interpreted as including both the preferred embodiments and all changes and modifications falling within the scope of the invention.

[0193] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An energy-saving transformer system automatic control and regulation system, characterized in that, Includes a dust blockage thermal resistance change self-test module, a rubber shock absorption self-test module, a magnetic aging iron loss increase self-test module, and a transformer three-dimensional evaluation and control module; The dust blockage thermal resistance mutation self-test module is used to perform dust blockage thermal resistance analysis using the original dust blockage thermal resistance data, and to perform automatic control adjustment of dust blockage thermal resistance mutation based on the dust blockage thermal resistance analysis results. The rubber damping self-test module is used to perform rubber damping frequency analysis using the raw rubber damping frequency data, and to automatically control and adjust the rubber damping frequency sudden change based on the rubber damping frequency analysis results. The self-detection module for sudden increase in magnetic aging iron loss is used to perform magnetic aging iron loss analysis and to provide early warning of magnetic aging iron loss based on the analysis results. The transformer three-dimensional evaluation and control module is used to perform three-dimensional evaluation and analysis of the transformer, and to adjust the transformer three-dimensional evaluation based on the results of the three-dimensional evaluation and analysis.

2. The energy-saving transformer system automatic control and regulation system as described in claim 1, characterized in that, The dust blockage thermal resistance mutation self-test module includes a transformer calibration value setting unit, a transformer actual value setting unit, and a dust blockage thermal resistance mutation self-test evaluation unit. The transformer calibration setting unit is used to measure the stable oil pressure difference between the inlet and outlet of the transformer heat sink via a differential pressure transmitter when the transformer is running for the first time with the oil pump speed stable at the rated operating value. This value is recorded as the heat sink differential pressure reference calibration value. The unit also measures the volume of cooling oil flowing through the heat sink per unit time via a vortex flow meter and records it as the cooling oil flow rate reference calibration value. By comparing and analyzing the increase in cooling oil flow rate with the increase in heat sink surface temperature, the temperature-velocity gradient reference calibration index of the transformer oil cooling system is obtained. The transformer actual value setting unit is used to measure the actual difference between the inlet and outlet oil pressures of the transformer heat sink, which is recorded as the heat sink pressure difference; and to simultaneously record the actual flow rate of the cooling oil, which is recorded as the cooling oil flow rate. The rate of change of surface temperature of the heat sink is measured and recorded as the temperature rate gradient index of the transformer oil cooling system. The actual pressure difference flow rate ratio is obtained by comparing and analyzing the pressure difference of the heat sink with the cooling oil flow rate. The pressure difference flow rate degradation rate is obtained by comparing and analyzing the actual pressure difference flow rate ratio with the pressure difference reference calibration value flow rate ratio of the heat sink. The larger the value of the pressure difference flow rate degradation rate, the more serious the impact of dust blockage. The heat dissipation efficiency reduction rate is obtained by comparing and analyzing the temperature rate gradient index of the transformer oil cooling system with the temperature rate gradient reference calibration index of the transformer oil cooling system. The larger the value of the heat dissipation efficiency reduction rate, the more serious the negative impact of heat dissipation. The dust blockage thermal resistance mutation self-test evaluation unit is used to couple the pressure difference flow rate degradation rate and heat dissipation efficiency reduction rate to obtain the dust blockage thermal resistance index.

3. The automatic control and regulation system for the energy-saving transformer system as described in claim 1, characterized in that, The dust blockage thermal resistance change change self-test module also includes a dust blockage thermal resistance change change self-control adjustment unit; The dust blockage thermal resistance change change self-control adjustment unit is used to perform dust blockage thermal resistance change change self-control adjustment based on the dust blockage thermal resistance analysis results. The automatic control adjustment of sudden changes in thermal resistance due to dust blockage based on the analysis results of dust blockage thermal resistance specifically includes: If the thermal resistance index of dust blockage is less than the second thermal resistance threshold of dust blockage, then first-level control is performed. The thermal resistance index of dust blockage is subtracted from the second thermal resistance threshold of dust blockage to obtain the second thermal resistance difference of dust blockage. Based on the second thermal resistance difference of dust blockage, the opening of the electromagnetic current limiting valve of the transformer is increased through the PWM signal to increase the oil flow rate. Based on the second thermal resistance difference of dust blockage, the intermittent operation interval of the transformer cooling fan is shortened. If the thermal resistance index of dust blockage is equal to or greater than the second thermal resistance threshold of dust blockage and less than the first thermal resistance threshold of dust blockage, then secondary control is performed, the newly added piezoelectric ceramic sheet is activated to emit high-frequency sound waves, continuously vibrating the surface of the heat sink fins, and the micro oil pump of the transformer is activated to run in reverse, forming turbulent flow to scour the inner wall of the oil guide pipe. If the thermal resistance index of dust blockage is equal to or greater than the first thermal resistance threshold of dust blockage, then three-level control is performed. The duration for which the thermal resistance index of dust blockage is equal to or greater than the first thermal resistance threshold of dust blockage is recorded as the duration of dust blockage thermal resistance exceeding the threshold. The backup oil guide channel is switched: the redundant oil guide pipe structure of the transformer is activated to bypass the blocked main channel; the built-in micro hydraulic rod is activated to restore the original spacing of the heat dissipation fins; and the external air pump is linked to inject compressed air to flush the dust hard blockage from the bottom of the fins upwards. This is part of the multi-channel switching architecture of the oil guide pipe. If the duration of dust blockage exceeding the thermal resistance threshold is greater than the upper limit of the duration of dust blockage exceeding the thermal resistance threshold, an alarm will be issued and relevant personnel will be notified.

4. The automatic control and regulation system for the energy-saving transformer system as described in claim 1, characterized in that, The rubber damping self-test module includes a rubber damping frequency monitoring and early warning unit and a rubber damping frequency analysis and control unit. The rubber vibration damping frequency monitoring and early warning unit is used to continuously scan the surface vibration of the transformer rubber pad vibration damping pad through a laser vibrometer, and directly output the simulation filter and moving average algorithm to obtain the natural frequency of the transformer rubber pad vibration damping pad. The natural frequency of the transformer rubber pad vibration damping pad is compared and analyzed with the standard frequency of the transformer rubber pad vibration damping pad to obtain the frequency deviation rate of the transformer rubber pad vibration damping pad. The rubber damping frequency analysis and control unit is used to automatically adjust the thermal resistance change due to dust blockage based on the rubber damping frequency analysis results.

5. The energy-saving transformer system automatic control and regulation system as described in claim 4, characterized in that, The automatic adjustment of thermal resistance change due to dust blockage based on the analysis results of rubber damping frequency specifically includes: If the frequency offset rate of the transformer rubber pad is less than the first threshold of the frequency offset rate of the transformer rubber pad, no adjustment is required. If the frequency deviation rate of the transformer rubber pad is equal to or greater than the first threshold of the frequency deviation rate of the transformer rubber pad and less than the second threshold of the frequency deviation rate of the transformer rubber pad, an alarm is issued, and the current is automatically adjusted by the magnetorheological damper according to the frequency deviation rate of the transformer rubber pad. If the frequency offset rate of the transformer rubber pad is equal to or greater than the second threshold of the frequency offset rate of the transformer rubber pad and less than the third threshold of the frequency offset rate of the transformer rubber pad, the silicone repair adhesive is precisely injected into the target area by the injection robotic arm. After a predefined time, the rubber vibration damping frequency monitoring and early warning unit monitors and judges again whether the frequency offset rate of the transformer rubber pad is less than the first threshold of the frequency offset rate of the transformer rubber pad. If it is less than the first threshold of the frequency offset rate of the transformer rubber pad, no adjustment is made. If it is equal to or greater than the first threshold of the frequency offset rate of the transformer rubber pad, an early warning is issued and relevant personnel are notified.

6. The automatic control and regulation system for the energy-saving transformer system as described in claim 1, characterized in that, The method of providing early warning of magnetic aging iron loss based on the results of magnetic aging iron loss analysis specifically includes: A through-core flux sensor is used to continuously measure the magnetic flux density of the iron core. A Rogowski coil is used to synchronously measure the excitation current and convert it into the corresponding magnetic field strength. The dynamic hysteresis loop area of ​​the silicon steel sheet of the transformer core is calculated in real time. The reference value of the dynamic hysteresis loop area is extracted from the automatic control and regulation database of the energy-saving transformer system. The dynamic hysteresis loop area reference value is compared and analyzed with the dynamic hysteresis loop area of ​​the silicon steel sheet of the transformer core to obtain the hysteresis loop area difference coefficient. If the hysteresis loop area difference coefficient is less than the first threshold of the dynamic hysteresis loop area, no adjustment is made; If the hysteresis loop area difference coefficient is equal to or greater than the first threshold of the dynamic hysteresis loop area, then the inverse time-delay trip algorithm is implemented through predefined software to confirm the trip command and execute the protection sequence.

7. The energy-saving transformer system automatic control and regulation system as described in claim 6, characterized in that, The aforementioned three-dimensional evaluation and analysis of the transformer specifically includes: Obtain the thermal resistance index of dust blockage, the frequency offset rate of transformer rubber pad anti-vibration pad, and the hysteresis loop area difference coefficient; By coupling analysis of the thermal resistance index of dust blockage, the frequency offset rate of transformer rubber pad vibration damping pad, and the hysteresis loop area difference coefficient, a three-dimensional transient risk term of the transformer system is obtained, which is used to reflect the coupled risk of the current state of the transformer equipment. Retrieve all historical risk values ​​from the automatic control and regulation database of energy-saving transformer systems, calculate the weight of each historical value according to the time distance, couple all weight values ​​with the corresponding historical risks and sum them, and then perform coupling analysis with the dynamically adjusted historical effect factors to obtain the three-dimensional historical risk items of the transformer system; By coupling the transient risk item of the three-dimensional risk of the transformer system with the historical risk item of the three-dimensional risk of the transformer system, the three-dimensional risk value of the energy-saving transformer system is obtained. If the three-dimensional risk value of the energy-saving transformer system is less than the first threshold of the three-dimensional risk of the energy-saving transformer system, then the machine tool transformer is controlled at level one. If the three-dimensional risk value of the energy-saving transformer system is equal to or greater than the first threshold of the three-dimensional risk of the energy-saving transformer system and less than the second threshold of the three-dimensional risk of the energy-saving transformer system, then the machine tool transformer is controlled at level two. If the three-dimensional risk value of the energy-saving transformer system is equal to or greater than the second threshold of the three-dimensional risk of the energy-saving transformer system, then the machine tool transformer is controlled at level three.

8. The energy-saving transformer system automatic control and regulation system as described in claim 7, characterized in that, The aforementioned primary control of the machine tool transformer specifically includes: The result of the comparative analysis between the three-dimensional risk value of the energy-saving transformer system and the first threshold of the three-dimensional risk of the energy-saving transformer system is denoted as the first coefficient of the three-dimensional risk difference of the transformer. The basic migration ratio is extracted from the automatic control and regulation database of the energy-saving transformer system. The compensation migration ratio is increased according to the first coefficient of the three-dimensional risk difference of the transformer to obtain the comprehensive compensation migration ratio. Based on the comprehensive compensation migration ratio, the load is transferred to the standby transformer by controlling the intelligent busbar switching device.

9. The energy-saving transformer system automatic control and regulation system as described in claim 7, characterized in that, The aforementioned two-stage control of the machine tool transformer specifically includes: The basic trigger temperature is extracted from the automatic control database of the energy-saving transformer system, and the trigger temperature is reduced by the shape memory alloy actuator based on the historical effect accumulation factor. The basic compensation strength is extracted from the automatic control database of the energy-saving transformer system. By continuously monitoring the partial discharge level of the transformer, the compensation strength is increased when the discharge exceeds the standard value through the active filter.

10. The energy-saving transformer system automatic control and regulation system as described in claim 7, characterized in that, The aforementioned three-level regulation of the machine tool transformer specifically includes: Real-time monitoring of core stress level; and generation of reverse hydraulic pressure proportionally based on core stress level via hydraulic compensation device. The insulation response of the transformer insulating oil at different frequency bands is tested. If a low-frequency anomaly is detected, the oil cooling oil flow rate is increased. If a high-frequency anomaly is detected, the DC bias repair time is extended.

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