Energy-saving transformer system automatic control and regulation system

Abstract

The application discloses an energy-saving transformer system automatic control adjusting system and relates to the technical field of power distribution network adjusting. The energy-saving transformer system automatic control adjusting system comprises a dust blockage thermal resistance mutation 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. The application couples three parameters of dust, vibration and magnetic loss through three-dimensional risk regulation, fuses historical risk time cumulative effects, carries out targeted quantitative adjustment of driving load migration, overheat protection and stress compensation according to comprehensive evaluation results, establishes a real-time sensing, hierarchical control and historical tracking system, solves three pain points of heat dissipation failure, vibration conduction and voltage fluctuation in a machine tool intensive scene, and further improves the adaptability of transformer automatic control adjustment to a high-precision numerical control machine tool cluster scene, and solves the problem of insufficient adaptability of transformer automatic control adjustment to the high-precision numerical control machine tool cluster scene in the prior art.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of power distribution network regulation, and particularly relates to an energy-saving transformer system automatic control regulation system. BACKGROUND

[0002] The high-density layout of a modern numerical control machine tool cluster forms three rigid constraints on the matching transformer: spatial thermal constraint: dust intrusion into the open heat dissipation structure of the workshop forms a heat island effect in the equipment-intensive area, resulting in uncontrolled temperature rise, and the traditional air cooling scheme cannot balance between protection and heat dissipation efficiency; composite vibration coupling: machine tool processing vibration (low-frequency mechanical impact + high-frequency magnetostriction) is conducted through a rigid foundation, and the aging failure and frequency spectrum adaptation defects of rubber damping elements cause the output voltage fluctuation to break through the precision machining tolerance threshold; energy efficiency time paradox: a large number of standby or light load periods in continuous production expose the defect of excessively high no-load loss of the silicon steel sheet core, and the static energy efficiency design cannot adapt to the dynamic load spectrum.

[0003] Under the existing technical framework, the open heat dissipation structure, the single damping material, and the static energy efficiency regulation constitute an insurmountable generational bottleneck.

[0004] For example, the automatic voltage regulation method for the new power system disclosed in patent application No. CN118889432A includes: the automatic voltage regulator is used to control the generator excitation system to maintain the output voltage at the nominal level; the total disturbance of the system is estimated by the extended state observer to monitor the voltage and current changes of the power system in real time; the error estimated by the ESO is compensated in real time by using the PID controller to obtain the difference between the actual output voltage and the set voltage; the parameters of the PID controller are adjusted by the pole placement method; the anti-saturation compensation method is introduced to achieve the anti-saturation control effect through compensation signal processing when the actuator enters the constraint region.

[0005] For example, the patent application No. CN115173422B discloses a contact type power supply transformer and a regulation method thereof, which includes: a multi-phase parallel transformer, a multi-phase series transformer, and a plurality of safety protection auxiliary regulation devices, the primary side first end 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 a plurality of asymmetric windings, the power supply winding is connected with the power supply end, the plurality of asymmetric windings are interconnected with the asymmetric windings of the adjacent phase parallel transformer through the respective corresponding switch bridge arm modules to obtain a first electrical quantity, the first electrical quantity is coupled to the primary side of the series transformer through the secondary side of the corresponding series transformer, and the plurality of safety protection auxiliary regulation devices are connected in series between the first line and the second line.

[0006] However, in the process of implementing the technical scheme of the present application, the above-mentioned technology at least has the following technical problems:

[0007] In the prior art, high-precision numerical control machine tool clusters are often densely arranged in a limited space. Such an environment poses a severe challenge to the transformers that supply power to them. In terms of heat dissipation, existing small transformers mainly rely on natural convection of air or are cooled by installing fans. This method has limited effect under the dense layout of machine tools; the mechanical vibration generated during machine tool processing is directly transmitted to the transformers, which aggravates the loosening of internal components, resulting in significant fluctuations in output voltage, and the transformers are insufficient to cope with the risks in this production environment. There is a problem of insufficient adaptability of transformer self-control adjustment in the high-precision numerical control machine tool cluster scenario. SUMMARY

[0008] The embodiments of the present application provide an energy-saving transformer system self-control adjustment system, which solves the problem of insufficient adaptability of transformer self-control adjustment in the high-precision numerical control machine tool cluster scenario in the prior art, and achieves the effect of improving the adaptability of transformer self-control adjustment in the high-precision numerical control machine tool cluster scenario.

[0009] The embodiments of the present application provide an energy-saving transformer system self-control adjustment system, which includes a dust blockage thermal resistance mutation self-checking module, a rubber shock absorption self-checking module, a magnetic aging iron loss sudden increase self-checking module, and a transformer three-dimensional evaluation and control module. The dust blockage thermal resistance mutation self-checking module is used to perform dust blockage thermal resistance analysis through dust blockage thermal resistance original data, and to perform dust blockage thermal resistance mutation self-control adjustment according to the dust blockage thermal resistance analysis result. The rubber shock absorption self-checking module is used to perform rubber shock absorption frequency analysis through rubber shock absorption frequency original data, and to perform rubber shock absorption frequency mutation self-control adjustment according to the rubber shock absorption frequency analysis result. The magnetic aging iron loss sudden increase self-checking module is used to perform magnetic aging iron loss analysis, and to perform magnetic aging iron loss analysis early warning according to the magnetic aging iron loss analysis result. The transformer three-dimensional evaluation and control module is used to perform transformer three-dimensional evaluation analysis, and to perform transformer three-dimensional evaluation adjustment according to the transformer three-dimensional evaluation analysis result.

[0010] Further, the dust blockage thermal resistance mutation self-checking module comprises a transformer calibration value setting unit, a transformer actual value setting unit and a dust blockage thermal resistance mutation self-checking evaluation unit; the transformer calibration value setting unit is used for measuring the stable oil pressure difference value of the inlet and outlet of the transformer cooling fin through a differential pressure transmitter when the transformer first keeps the oil pump rotating speed stable at the rated working value, which is recorded as the cooling fin pressure difference reference calibration value; the volume of the cooling oil flowing through the cooling fin per unit time is measured through a vortex flowmeter, which is recorded as the cooling oil flow rate reference calibration value; the cooling oil flow rate increment is compared and analyzed with the cooling fin surface temperature increment to obtain the transformer oil cooling heat dissipation system temperature speed gradient reference calibration index; the transformer actual value setting unit is used for measuring the actual difference value of the oil pressure of the inlet and outlet of the transformer cooling fin, which is recorded as the cooling fin pressure difference; the actual flow rate of the cooling oil is recorded synchronously, which is recorded as the cooling oil flow rate; the change rate of the cooling fin surface temperature is measured, which is recorded as the transformer oil cooling heat dissipation system temperature speed gradient index; the cooling fin pressure difference is compared and analyzed with the cooling oil flow rate to obtain the current actual pressure difference flow rate ratio; the pressure difference flow rate degradation rate is obtained through the comparison and analysis of the actual pressure difference flow rate ratio and the cooling fin pressure difference reference calibration value flow rate ratio, and the greater the value of the pressure difference flow rate degradation rate, the more serious the influence of the dust blockage; the heat dissipation efficiency reduction rate is obtained through the comparison and analysis of the transformer oil cooling heat dissipation system temperature speed gradient index and the transformer oil cooling heat dissipation system temperature speed gradient reference calibration index, and the greater the value of the heat dissipation efficiency reduction rate, the more serious the negative influence of the heat dissipation; the dust blockage thermal resistance mutation self-checking evaluation unit is used for coupling analysis of the pressure difference flow rate degradation rate and the heat dissipation efficiency reduction rate to obtain the dust blockage thermal resistance index.

[0011] Further, the dust blockage thermal resistance mutation self-checking module further comprises a dust blockage thermal resistance mutation self-control adjusting unit; the dust blockage thermal resistance mutation self-control adjusting unit is used for performing dust blockage thermal resistance mutation self-control adjusting according to the dust blockage thermal resistance analysis result; the dust blockage thermal resistance mutation self-control adjusting according to the dust blockage thermal resistance analysis result specifically comprises: if the dust blockage thermal resistance index is less than the second dust blockage thermal resistance threshold, first-level regulation is performed, the second dust blockage thermal resistance threshold is subtracted by the dust blockage thermal resistance index to obtain a second dust blockage thermal resistance difference value, the oil flow rate is increased by increasing the opening of the PWM signal transformer electromagnetic current-limiting valve according to the second dust blockage thermal resistance difference value, and the intermittent operation interval of the transformer cooling fan is shortened according to the second dust blockage thermal resistance difference value; if the dust blockage thermal resistance index is equal to or greater than the second dust blockage thermal resistance threshold and the dust blockage thermal resistance index is less than the first dust blockage thermal resistance threshold, second-level regulation is performed, the newly added piezoelectric ceramic sheet is started to emit high-frequency sound waves to continuously vibrate the surface of the heat dissipation fin, and the micro oil pump of the transformer is started to operate in reverse to form a turbulent flow to flush and guide the inner wall of the oil pipe; if the dust blockage thermal resistance index is equal to or greater than the first dust blockage thermal resistance threshold, third-level regulation is performed, the duration that the dust blockage thermal resistance index is equal to or greater than the first dust blockage thermal resistance threshold is recorded and is recorded as a dust blockage thermal resistance threshold exceeding duration, a standby oil guiding channel is switched: the redundant oil guiding pipe structure of the transformer is enabled to bypass the blocked main channel, the built-in micro hydraulic rod is activated to restore the original spacing of the heat dissipation fin, the external air pump is activated to inject compressed air to flush the multi-channel switching architecture of the dust hard block oil guiding pipe from the bottom of the fin upwards, and if the dust blockage thermal resistance threshold exceeding duration is greater than an upper limit of the dust blockage thermal resistance threshold exceeding duration, an alarm is sent and relevant personnel are notified.

[0012] Further, the rubber shock absorption self-checking module comprises a rubber shock absorption frequency monitoring and early warning unit and a rubber shock absorption frequency analysis and regulation unit; the rubber shock absorption frequency monitoring and early warning unit is used for continuously scanning the surface vibration of the transformer rubber pad shock pad by a laser vibration meter, directly outputting by an analog filter and a moving average algorithm to obtain the natural frequency of the transformer rubber pad shock pad, comparing and analyzing the natural frequency of the transformer rubber pad shock pad with the standard frequency of the transformer rubber pad shock pad to obtain the frequency deviation rate of the transformer rubber pad shock pad, and the rubber shock absorption frequency analysis and regulation unit is used for performing dust blockage thermal resistance mutation self-control adjusting according to the rubber shock absorption frequency analysis result.

[0013] Further, according to the rubber shock absorption frequency analysis result, dust blockage thermal resistance mutation self-control adjustment is carried out, specifically including: if the frequency deviation rate of the transformer rubber pad shock pad is less than the frequency deviation rate first threshold value of the transformer rubber pad shock pad, no adjustment is made; if the frequency deviation rate of the transformer rubber pad shock pad is equal to or greater than the frequency deviation rate first threshold value of the transformer rubber pad shock pad and the frequency deviation rate of the transformer rubber pad shock pad is less than the frequency deviation rate second threshold value of the transformer rubber pad shock pad, an alarm is issued, and the current is automatically adjusted by the magneto-rheological damper according to the frequency deviation rate of the transformer rubber pad shock pad; if the frequency deviation rate of the transformer rubber pad shock pad is equal to or greater than the frequency deviation rate second threshold value of the transformer rubber pad shock pad and the frequency deviation rate of the transformer rubber pad shock pad is less than the frequency deviation rate third threshold value of the transformer rubber pad shock pad, silicone repair glue is accurately injected into the target area by the injection mechanical arm, and after a pre-defined time period, the frequency deviation rate of the transformer rubber pad shock pad is monitored again by the rubber shock absorption frequency monitoring and warning unit to determine whether it is less than the frequency deviation rate first threshold value of the transformer rubber pad shock pad, if it is less than the frequency deviation rate first threshold value of the transformer rubber pad shock pad, no adjustment is made, and if it is equal to or greater than the frequency deviation rate first threshold value of the transformer rubber pad shock pad, an early warning is issued and relevant personnel are notified.

[0014] Further, according to the magnetic aging iron loss analysis result, magnetic aging iron loss analysis warning is carried out, specifically including: continuously measuring the core magnetic flux density using a core-penetrating magnetic flux sensor, synchronously measuring the excitation current using a Rogowski coil and converting to obtain the corresponding magnetic field strength, and calculating the dynamic hysteresis loop area of the transformer core silicon steel sheet in real time; extracting the dynamic hysteresis loop area reference value from the energy-saving transformer system self-control adjustment database, comparing the dynamic hysteresis loop area reference value with the dynamic hysteresis loop area of the transformer core silicon steel sheet, and obtaining the hysteresis loop area difference coefficient; if the hysteresis loop area difference coefficient is less than the dynamic hysteresis loop area first threshold value, no adjustment is made; if the hysteresis loop area difference coefficient is equal to or greater than the dynamic hysteresis loop area first threshold value, a reverse time limit trip algorithm is realized through a pre-defined software, a trip instruction is confirmed and a protection sequence is executed.

[0015] Further, the transformer three-dimensional evaluation analysis is performed, specifically including: obtaining the dust blockage thermal resistance index, the frequency offset rate of the transformer rubber pad shock pad, and the magnetic hysteresis loop area difference coefficient; coupling analysis is performed on the dust blockage thermal resistance index, the frequency offset rate of the transformer rubber pad shock pad, and the magnetic hysteresis loop area difference coefficient to obtain a transformer system three-dimensional risk transient risk item for reflecting the coupling risk of the current state of the transformer equipment; all historical risk values in the energy-saving transformer system self-control regulation database are retrieved, the weight of each historical value is calculated according to the time distance, all weight values are coupled with the corresponding historical risks and summed, and then coupled analysis is performed with the dynamically adjusted historical effect factor to obtain a transformer system three-dimensional historical risk item; coupling analysis is performed on the transformer system three-dimensional risk transient risk item and the transformer system three-dimensional historical risk item to obtain a transformer system three-dimensional risk value; if the transformer system three-dimensional risk value is less than a transformer system three-dimensional risk first threshold value, primary regulation of the machine tool transformer is performed; if the transformer system three-dimensional risk value is equal to or greater than the transformer system three-dimensional risk first threshold value and less than a transformer system three-dimensional risk second threshold value, secondary regulation of the machine tool transformer is performed; and if the transformer system three-dimensional risk value is equal to or greater than the transformer system three-dimensional risk second threshold value, tertiary regulation of the machine tool transformer is performed.

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

[0017] Further, the secondary regulation of the machine tool transformer is performed, specifically including: a basic trigger temperature is extracted from the energy-saving transformer system self-control regulation database, and the trigger temperature is reduced according to the historical effect cumulative factor by the shape memory alloy actuator; a basic compensation strength is extracted from the energy-saving transformer system self-control regulation database, the transformer partial discharge level is continuously monitored, and the compensation strength is increased when the monitored value exceeds the standard value by the active filter discharge.

[0018] Further, the tertiary regulation of the machine tool transformer is performed, specifically including: the core stress level is monitored in real time, the reverse hydraulic pressure is generated according to the core stress level in proportion by the hydraulic compensation device; the insulation response of the transformer insulation oil in different frequency bands is detected, the oil cooling oil flow rate is increased if the detection is low-frequency abnormality, and the direct current bias repair time is extended if the detection is high-frequency abnormality.

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

[0020] 1、The present application couples three parameters of dust, vibration and magnetic loss through three-dimensional risk regulation, fuses the historical risk time cumulative effect, and quantitatively adjusts the targeted load migration, overheat protection and stress compensation through comprehensive evaluation results, establishes a real-time sensing, hierarchical control and historical tracking system, solves the three pain points of heat dissipation failure, vibration conduction and voltage fluctuation in the machine tool intensive scene, and further improves the adaptability of the transformer self-control regulation in the high-precision numerical control machine tool cluster scene, solving the problem of insufficient adaptability of the transformer self-control regulation in the high-precision numerical control machine tool cluster scene in the prior art.

[0021] 2、Through non-contact laser scanning of the vibration frequency spectrum of the shock absorbing pad, the frequency shift caused by rubber aging is accurately captured, and vibration control is implemented in stages: slight aging: adjust the current intensity of the magnetorheological damper to enhance the shock absorbing stiffness; moderate aging: accurately inject nanorepair materials into the mechanical arm to fill rubber cracks; repair verification: after the material is cured, the frequency characteristics are retested, and then the transformer output voltage fluctuation is reduced in the precision part machining area, the machining precision of the machine tool is improved, the loss of high-value workpiece batch rejection is reduced, the transformer rubber shock absorption self-checking and evaluation is realized, the shock absorption system self-healing is realized, and the vibration transmission is blocked.

[0022] 3、Through non-invasive monitoring of the magnetic flux characteristics of the core, the core energy loss degree is calculated in real time, and then the risk is disposed in stages: actively enhance the harmonic filtering capability and enable the intelligent power-off protection mechanism to make the response speed of the iron loss anomaly in the micron-level machining workshop increase several times, so that the power supply voltage is stabilized within the precision machining allowable fluctuation range, thereby avoiding the rejection of a whole batch of precision parts caused by a single voltage surge, and the iron loss mutation protection is realized to ensure voltage stability.

[0023] 4、By fusing real-time parameters of dust, vibration and magnetic loss, superimposing the cumulative effect of historical operation risk of the equipment, and intelligently executing in stages: low risk, dynamically shift part of the load to the standby transformer; medium risk, reduce the overheat protection trigger temperature threshold; high risk, the hydraulic balancing device offsets the mechanical stress in real time, thereby greatly improving the burst fault recognition rate in the ultra-dense machine tool layout workshop, reducing equipment maintenance costs, and prolonging the service life of the transformer compared to the average level, and realizing the historical enhancement decision of three-dimensional risk regulation. BRIEF DESCRIPTION OF DRAWINGS

[0024] Figure 1 The structural diagram of the energy-saving transformer system self-control regulation system provided in the embodiments of the present application is shown in the figure;

[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 limited space. This environment poses a serious challenge to the transformers that power them. In terms of heat dissipation, existing small transformers mainly rely on natural air convection or are equipped with fans for cooling. This approach is limited in the case of dense machine tool layout, and the heat sink is easily blocked by workshop dust, causing high temperatures to accumulate inside the electrical cabinet. The continuous overheating environment not only affects the service life of the transformer itself but also poses a threat to the surrounding precision control components. Vibration is another major problem. Mechanical vibrations generated during machine tool processing are directly transmitted to the transformers that support them. Traditional shock absorption measures, such as simple rubber pads, are ineffective and prone to aging and failure. As a result, the internal components of the transformer become loose, causing significant fluctuations in the output voltage. This voltage instability directly compromises the machining accuracy of the machine tool. In addition, industrial production lines require 24-hour continuous operation, but in actual production, there is a significant amount of standby time for machine tools. Existing transformers are inefficient under no-load or light-load conditions, and still consume considerable electrical energy during standby periods, resulting in long-term unnecessary energy waste and economic losses.

[0031] The transformer body top is threadedly connected with a mounting plate, one side of the transformer is provided with a switch panel, the mounting plate top is provided with a plurality of connecting columns, one side of the transformer body top is provided with an oil tank, and one side of the transformer body is fixedly installed with a heat dissipation mechanism. The heat dissipation mechanism comprises a heat conduction plate fixedly installed on one side of the transformer body, and a sealing plate is arranged on the outer wall of the heat conduction plate. One side of the heat conduction plate is provided with an oil guide pipe, and the oil guide pipe is in a wave shape. In specific use, the cooling oil in the transformer body absorbs heat and flows into the oil guide pipe, and the heat is dissipated through the oil guide pipe to reduce the heat of the cooling oil. One side of the heat conduction plate is provided with a micro oil pump, the other side of the heat conduction plate is provided with an electromagnetic flow limiting valve, and the oil outlet end of the micro oil pump and the oil inlet end of the electromagnetic flow limiting valve are in sealed communication with both ends of the oil guide pipe. In specific use, the micro oil pump pumps oil into the oil guide pipe and returns to the transformer body from the electromagnetic flow limiting valve, completing the circulation of the cooling oil and enabling heat exchange in the transformer body. The outer wall edge of the sealing plate is provided with a protective cover, and the protective cover is provided with transformer cooling fans on both sides. In specific use, the transformer cooling fans form an air flow in the protective cover, which carries away the surface temperature of the oil guide pipe; the top and bottom edges of the heat conduction plate are provided with annular heat sinks, and the annular heat sinks are embedded on one side of the protective cover. In specific use, the annular heat sinks discharge the heat absorbed by the heat conduction plate and cooperate with the transformer cooling fans to reduce the surface temperature, thereby improving the cooling effect in the transformer body. Working principle: the cooling oil in the transformer body absorbs heat and flows into the oil guide pipe, and the heat is dissipated through the oil guide pipe to reduce the heat of the cooling oil. The micro oil pump pumps oil into the oil guide pipe and returns to the transformer body from the electromagnetic flow limiting valve, completing the circulation of the cooling oil and enabling heat exchange in the transformer body. The transformer cooling fans form an air flow in the protective cover, which carries away the surface temperature of the oil guide pipe. The annular heat sinks discharge the heat absorbed by the heat conduction plate and cooperate with the transformer cooling fans to reduce the surface temperature, thereby improving the cooling effect in the transformer body.

[0032] Further, when the transformer is first operated after being newly installed or thoroughly cleaned, the oil pump speed is kept stable at the rated working value, the stable oil pressure difference between the inlet and outlet of the cooling fin at this time is recorded, and is denoted as a cooling fin pressure difference reference calibration value; the volume of cooling oil flowing through the cooling fin per unit time is denoted as a cooling oil flow rate reference calibration value; and when the oil flow rate increases by one thousandth, the decreasing value of the surface temperature of the cooling fin is denoted as a transformer oil cooling heat dissipation system temperature speed gradient reference calibration index, so as to establish a heat transfer efficiency reference under a dust-free state.

[0033] The actual difference value of the oil pressure between the inlet and outlet of the cooling fin is measured every 10 seconds, and is denoted as a cooling fin pressure difference; the actual flow rate of the cooling oil at the corresponding time is recorded synchronously, and is denoted as a cooling oil flow rate; when the cooling oil flow rate changes slightly (for example, fluctuates by 1%), the change rate of the surface temperature of the cooling fin is measured, and is denoted as a transformer oil cooling heat dissipation system temperature speed gradient index; the cooling fin pressure difference is divided by the cooling oil flow rate to obtain a current actual pressure difference flow rate ratio; the actual pressure difference flow rate ratio is divided by the cooling fin pressure difference reference calibration value flow rate ratio to obtain a pressure difference flow rate degradation rate; the greater the value of the pressure difference flow rate degradation rate, the more serious the influence of dust blockage; and the heat dissipation efficiency reduction rate is obtained by comparing the reference value under the system cleaning state. The parameter innovatively establishes a dynamic thermal resistance evaluation mechanism: reveals the internal correlation between oil flow change and temperature rise response, replaces traditional static temperature monitoring, identifies heat conduction performance degradation at an early stage of the heat sink blockage, significantly earlier than absolute temperature alarm, realizes automatic adjustment when the heat dissipation efficiency slightly decreases, overcomes the response lag defect of the traditional scheme, eliminates environmental and medium change interference through an internal compensation mechanism, and greatly improves the reliability in industrial scenes;

[0034] The heat dissipation efficiency reduction rate is obtained by comparing and analyzing the transformer oil cooling heat dissipation system temperature speed gradient index and the transformer oil cooling heat dissipation system temperature speed gradient reference calibration index; the greater the value of the heat dissipation efficiency reduction rate, the more serious the negative influence of heat dissipation.

[0035] The dust blockage thermal resistance index is obtained by coupling analysis of the pressure difference flow rate degradation rate and the heat dissipation efficiency reduction rate.

[0036] In the present embodiment,

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

[0038] ΔPSR represents the cooling fin pressure difference, which is dimensionless, is measured by a differential pressure transmitter, and is normalized to obtain the cooling fin pressure difference; the differential pressure transmitter is installed at both ends of the heat conduction plate of the transformer.

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

[0040] The average fin pressure difference measured when the transformer is first operated 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 when the transformer is first operated at rated power after installation is recorded as the cooling oil flow rate reference calibration value, and VOIL0 represents the cooling oil flow rate reference calibration value.

[0042] TF represents the fin surface temperature, which is collected by the infrared thermocouple array transformer non-contact scanning of the annular fin surface.

[0043] dTF / dVOIL represents the temperature-velocity gradient index of the transformer oil cooling heat dissipation system, and dTF0 / dVOIL0 represents the temperature-velocity gradient reference calibration index of the transformer oil cooling heat dissipation system, which is measured when the transformer is first operated at rated power after installation.

[0044] Dust clogging the oil way increases the flow resistance, which greatly increases the fin pressure difference at the same flow rate, dust covering the fin increases the thermal resistance, which slows down the fin temperature rise when the oil speed increases, and dust is more likely to deposit in the low flow rate area, which accelerates the clogging process; when dust accumulates between the fins: dust covering the fin surface forms an insulating layer, reducing the fin heat conduction efficiency; the accumulation of dust thickness increases the compression of the adjacent fin spacing, the deformation of the fin under compression compresses the lower metal oil pipe, and the oil pipe is flattened, reducing the oil flow cross section. For example, the machine tool factory disassembly report shows that the dust solidification block in the transformer radiator used for 2 years causes the fin spacing to decrease from 1.5 mm to 0.7 mm, and the oil pipe cross section ovality reaches 0.25 (roundness deviation > 20%).

[0045] Further, if the dust clogging thermal resistance index is less than the second dust clogging thermal resistance threshold, a first level of control is performed, the second dust clogging thermal resistance threshold is reduced by the dust clogging thermal resistance index to obtain a second dust clogging thermal resistance difference value, the oil flow rate is increased by increasing the PWM signal transformer electromagnetic flow limiting valve opening, and the intermittent operation interval of the transformer cooling fan is shortened according to the second dust clogging thermal resistance difference value.

[0046] If the dust clogging thermal resistance index is equal to or greater than the second dust clogging thermal resistance threshold and the dust clogging thermal resistance index is less than the first dust clogging thermal resistance threshold, a second level of control is performed, a newly added piezoelectric ceramic sheet is started to emit 40 kHz high frequency sound waves, the surface of the heat dissipation fin is vibrated for 10 minutes, the unhardened dust is shaken off, the piezoelectric ceramic sheet is installed at the root of the fin, and the micro oil pump of the transformer is started to operate in reverse for 30 seconds to form a turbulent flow to flush the inner wall of the oil pipe, and an intermittent reverse pulse is used.

[0047] If the dust blockage thermal resistance index is equal to or greater than the first dust blockage thermal resistance threshold, a third level of regulation is performed, 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, denoted as dust blockage thermal resistance threshold duration, and the standby oil guide channel is switched: the redundant oil guide pipe structure of the transformer is enabled, bypassing the blocked main channel; the built-in micro hydraulic rod is activated to open the heat dissipation fins deformed by dust extrusion and restore the original spacing (about 1.5 mm) of the heat dissipation fins; the external air pump is linked to inject 0.5 MPa compressed air to flush the dust hard block guide pipe from the bottom of the fin upwards;

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

[0049] In this embodiment, it is noted that the specific parameters in the multi-level regulation in the context are example steps in the specific implementation process, and the specific numerical setting can be set by the technician. The mapping relationship between the second dust blockage thermal resistance difference and the opening of the transformer electromagnetic flow 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 running interval of the transformer cooling fan is extracted from the energy-saving transformer system automatic control and regulation database.

[0050] In high-dust industrial scenarios such as numerical control machine tools and foundry workshops, the dust blockage index quantitative grading regulation strategy exhibits three core values: First, by accurately dividing the risk level through quantitative threshold of blockage index, the traditional extensive mode relying on manual experience is completely changed, avoiding resource waste caused by premature intervention or equipment damage caused by delayed disposal. Second, the three-level progressive response mechanism perfectly matches the production line conditions: the first level of regulation maintains continuous production with "flexible intervention" of fine-tuning oil speed, suitable for light dust environment such as automobile parts production line; the second level of physical separation actively cuts off the deterioration chain at the initial stage of dust thermal bonding, focusing on the risk of metal dust solidification in foundry workshops; the third level of reconstruction focuses on supercritical conditions of heavy machining, resolves sudden failures through structure self-recovery technology, and compresses the traditional cleaning operation time from hours to tens of minutes. Finally, the deep embedding of patented hardware and intelligent algorithms forms a closed-loop system resistant to degradation - electromagnetic valve dynamic speed regulation offsets oil line aging, sound wave stripping technology solves the problem of dust hardening, and mechanical support rod and redundant oil line design make it possible to reduce maintenance costs by more than 40% and reduce unexpected downtime by nearly 90% in high-dust working conditions.

[0051] Further, the specific process of dust blockage thermal resistance mutation automatic control and regulation according to the rubber shock absorption frequency analysis result is as follows:

[0052] A laser vibrometer (Polytec OFV-505, wavelength 632.8 nm) acquires the vibration signal (50 Hz sampling) by the principle of Doppler interference. The signal processing is simplified as double-stage noise reduction + peak tracking: an analog band-pass filter (70-100 Hz) directly removes the environmental noise, a moving average algorithm (window width 50 ms) smooths the signal, and the main frequency peak is directly extracted; the frequency offset rate is calculated in real time, and when the offset is greater than or equal to 1%, a three-color LED alarm is triggered and pushed to the main control system through OPC UA;

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

[0054] If the frequency offset rate of the transformer rubber pad shock pad is equal to or greater than the first threshold value of the frequency offset rate of the transformer rubber pad shock pad and the frequency offset rate of the transformer rubber pad shock pad is less than the second threshold value of the frequency offset rate of the transformer rubber pad shock pad, an alarm is issued, and the current is automatically adjusted by the magnetorheological damper according to the frequency offset rate of the transformer rubber pad shock pad, and the PID controller ensures accurate matching of the damping force. The PT100 temperature sensor automatically derates above 85°C.

[0055] If the frequency offset rate of the transformer rubber pad shock pad is equal to or greater than the second threshold value of the frequency offset rate of the transformer rubber pad shock pad and the frequency offset rate of the transformer rubber pad shock pad is less than the third threshold value of the frequency offset rate of the transformer rubber pad shock pad, the silicone repair glue is accurately injected into the target area by a five-point micro-dose gradient injection method through a injection robot (single dose 0.1 ml, needle inner diameter 0.2 mm, Nordson EFD precision metering valve controls flow), after a pre-defined time, the frequency offset rate of the transformer rubber pad shock pad is monitored again by the rubber shock absorption frequency monitoring and early warning unit to determine whether it is less than the first threshold value of the frequency offset rate of the transformer rubber pad shock pad (for stiffness verification, delayed retest, silicone crosslinking time, curing time about 5 minutes), if it is less than the first threshold value of the frequency offset rate of the transformer rubber pad shock pad, no adjustment is made, if it is equal to or greater than the first threshold value of the frequency offset rate of the transformer rubber pad shock pad, an early warning is issued and relevant personnel are notified.

[0056] In this embodiment, f n represents the natural frequency of the transformer rubber pad shock pad, π represents the circular constant, k represents the stiffness of the transformer rubber pad, and m represents the mass of the transformer rubber pad. When the rubber ages and causes the stiffness k to decrease, the natural frequency f n must decrease. The f n offset is directly captured by the non-contact laser vibration, which is obviously accurate and efficient, with a laser detection delay of less than 1 ms, which is much faster than the minute-level period of damage accumulation, and the laser wavelength is stable and not affected by oil stains / temperature.

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

[0058] The frequency offset rate of the transformer rubber pad shock pad is Non-dimensional.

[0059] The magnetic flow damper automatically adjusts the current according to the frequency offset rate of the transformer rubber pad shock pad. The magnetic flow damper is a shockproof device set to reduce the influence of high-frequency vibration encountered by the transformer in the machine tool environment on the internal electronic devices of the transformer. By setting different currents, different damping forces can be set.

[0060] The magnetic flow damper automatically adjusts the current according to the frequency offset rate of the transformer rubber pad shock pad. The specific current setting constraint is as follows:

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

[0062] Further, according to the magnetic aging iron loss analysis result, the magnetic aging iron loss analysis early warning is carried out, which specifically includes: adopting a core-type magnetic flux sensor to continuously measure the magnetic flux density of the iron core, using a Rogowski coil to synchronously measure the excitation current and converting to obtain the corresponding magnetic field strength, and calculating the dynamic hysteresis loop area of the transformer iron core silicon steel sheet in real time; the dynamic hysteresis loop area reference value is extracted from the energy-saving transformer system automatic control adjustment database, and the dynamic hysteresis loop area reference value is compared with the dynamic hysteresis loop area of the transformer iron core silicon steel sheet. The difference value coefficient of the hysteresis loop area is obtained; if the hysteresis loop area difference value coefficient is less than the dynamic hysteresis loop area first threshold value, no adjustment is made; if the hysteresis loop area difference value coefficient is equal to or greater than the dynamic hysteresis loop area first threshold value, the inverse time limit trip algorithm is realized through the pre-defined software, the trip instruction is confirmed, and the protection sequence magnetic aging iron loss sudden increase real-time monitoring and control technical scheme is executed.

[0063] In the present embodiment, as shown in Figure 2 , it is a three-dimensional parameter acquisition process schematic diagram of the energy-saving transformer system automatic control adjustment system provided by the embodiment of the present application. As shown in the figure, the three-dimensional parameters are acquired for obtaining and calculating the subsequent energy-saving transformer system three-dimensional risk value.

[0064] I. Monitoring object and principle

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

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

[0067] Real-time monitoring principle:

[0068] The core magnetic flux density B(t) is continuously measured using a core-penetrating magnetic flux sensor (Kao GM100).

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

[0070] The dynamic hysteresis loop area is calculated in real time: P_fe = ∮H·dB.

[0071] Three complete measurements are performed per second, with a sampling rate of 100kS / s, capturing microsecond-level mutations.

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

[0073] P_fe is the hysteresis loss of the transformer core silicon steel sheet.

[0074] Reference value establishment example: Obtain P_fe0, the dynamic hysteresis loop area reference value, from the no-load test 72 hours after commissioning, and upload the dynamic hysteresis loop area reference value to the energy-saving transformer system self-control regulation database. P c represents the hysteresis loop area difference coefficient, the larger the hysteresis loop area difference coefficient, the greater the magnetic aging iron loss of the transformer core silicon steel sheet, in general, the hysteresis loss of the transformer core silicon steel sheet is equal to or greater than the dynamic hysteresis loop area reference value, and P_fe-P_fe will not be negative.

[0075] The code example for implementing the inverse time trip algorithm through python is as follows:

[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 < Risk < 30:

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

[0082] else: # Risk >= 30

[0083] trip_delay = 0.1 # immediate action

[0084] The confirmation of the trip command and the execution of the protection sequence are as follows:

[0085] The Hall array detects local magnetic field distortion: if the distortion rate is greater than 18%, the trip command is confirmed; if the distortion rate is less than 10%, the secondary hysteresis loop review is started; the main circuit breaker is tripped (the action time is less than or equal to 60 ms), the synchronous trigger: the reactive power compensation device quickly exits, the standby power supply is automatically switched (ATS switching); fault data archiving: 60 seconds of data before tripping is written to the fault recorder, and the key parameter block chain is stored.

[0086] Further, the transformer three-dimensional evaluation analysis is carried out, specifically including: obtaining the dust blockage thermal resistance index, the frequency deviation rate of the transformer rubber pad shock pad, and the hysteresis loop area difference coefficient; the system performs full parameter synchronous collection three times per second, ensuring that the time alignment accuracy of all data reaches the millisecond level. The collected parameters generate the current risk value through a specific fusion algorithm; the dust blockage thermal resistance index, the frequency deviation rate of the transformer rubber pad shock pad, and the hysteresis loop area difference coefficient are coupled and analyzed to obtain the transformer system three-dimensional risk transient risk term, which is used to reflect the coupled risk of the current state of the transformer equipment; the historical effect factor is automatically adjusted according to the equipment operation time, reflecting the aging characteristics of "initially gentle and later accelerated"; the time decay coefficient is automatically adjusted according to the oil temperature, and when the oil temperature rises, the decay coefficient decreases, making the historical risk influence more persistent, and when the oil temperature decreases, the decay coefficient increases, accelerating the historical risk decay; the system scans every historical time point from commissioning to the current time, and the risk value of each historical time is weighted according to the time distance, and all historical risk weighted values are added and multiplied by the historical effect factor to obtain the transformer system three-dimensional historical risk term; the transformer system three-dimensional risk transient risk term and the transformer system three-dimensional historical risk term are coupled and analyzed to obtain the energy-saving transformer system three-dimensional risk value.

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

[0088]

[0089] e represents a natural constant.

[0090] α(t) represents the dust clogging thermal resistance index at time t, which is a real-time parameter reflecting the degree of dust clogging of the heat dissipation system. The accumulation of dust on the cooling fins forms an insulating layer, reducing the heat dissipation efficiency. At the same time, dust clogging also increases the oil path resistance, causing the oil pump load to increase and produce additional vibration. This vibration is transmitted to the rubber shock pad through mechanical connection, accelerating the aging process of the rubber shock pad. More seriously, the temperature rise caused by the decrease of heat dissipation efficiency will exacerbate the magnetic aging effect of the silicon steel sheet of the iron core, forming a chain reaction of heat-vibration-magnetism.

[0091] Δf n (t) represents the frequency deviation rate of the transformer rubber pad shock pad at time t, which quantifies the aging degree of the rubber shock absorbing system. The frequency deviation caused by rubber aging will directly reduce the shock absorbing effect, causing the vibration of the transformer body to intensify. This vibration will have a double impact: on the one hand, it will accelerate the dust accumulation speed in the radiator fin gap; on the other hand, it will cause micro-displacement of the silicon steel sheet of the iron core, changing its magnetic domain structure. The interaction between mechanical vibration and magnetic circuit change will significantly accelerate the magnetic aging process.

[0092] P c (t) represents the difference coefficient of the hysteresis loop area at time t, which represents the severity of the magnetic aging damage of the iron core. The increase of iron loss will cause the temperature of the iron core to rise, and the thermal expansion will squeeze the gap of the cooling fin, forming a physical environment where dust is more likely to deposit. At the same time, the rise of the temperature of the iron core will accelerate the aging of the transformer oil, changing its viscosity characteristics. This change in viscosity will affect the suspension state and deposition speed of the dust in the oil circuit, forming a closed-loop interaction of magnetism-heat-dust.

[0093] τ represents the historical time integral variable, which represents any historical time point between the system commissioning and the current time t. For example, τ may be 12 noon yesterday, or 15th last month. As an integral variable, it traverses the entire historical time axis of the system operation, ensuring that all historical states are taken into account. The upper limit 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 the system commissioning and the current time t, which records the composite risk value of the system at historical time τ. The risk value at each historical time is weighted by the exponential decay factor e -β(t-τ) , which represents the physical meaning that recent risk events have a greater impact on the current state, and the impact of long-term risk events decays over time.

[0095] λ represents a historical effect accumulation factor, which determines the influence weight of historical risk on the current state. Its verification formula is: λ = HG1 x ln(SJ) + HG2; where HG1 and HG2 represent two fitting coefficients of regression analysis, respectively, and SJ represents the number of running years, dimensionless, non-zero number, for example, through the regression analysis of 23 transformers with 5 years of operation data, the optimal fitting value of HG1 is set to 0.08, and the optimal fitting value of HG2 is set to 0.05. The meaning of the logarithmic function: the logarithmic function is adopted because the device aging has the characteristics of "fast in the early stage and slow in the later stage". A transformer running for 3 years, λ = 0.08 x ln(3) + 0.05 ≈ 0.14.

[0096] β represents a time decay coefficient, which controls the decay rate of historical risk. Its verification formula is: where E a = 1.2eV, which is the activation energy of transformer oil thermal aging, determined by accelerated aging test, R = 8.314 J / mol·K represents the ideal gas constant, and TY represents the transformer hot spot temperature in Kelvin; φ represents the aging preposition coefficient, for example, φ = 0.01 is calibrated through the standard aging test at 55°C. Temperature correlation: when the transformer oil pump oil temperature rises from 55°C to 75°C, the value of β decreases from 0.02 to 0.015, indicating that the historical risk decay slows down at high temperature.

[0097] Coupling effect mechanism: thermal-vibration coupling: dust blockage leads to a decrease in heat dissipation efficiency, which causes the oil temperature to rise, which accelerates the aging of rubber, which causes the damping to fail, which causes the vibration to intensify; vibration-magnetic coupling: vibration is transmitted to the core, which causes the magnetic domain structure to displace, which increases the iron loss, which further increases the temperature; magnetic-thermal coupling: increased iron loss leads to temperature rise, which reduces oil viscosity, which accelerates the deposition of suspended dust, which intensifies blockage; time accumulation effect: the above coupling processes form a positive feedback loop, and as the running time increases, the system enters the accelerated aging stage. High-precision numerical control machine tool clusters are often densely arranged in limited space, and the coupling effect in terms of heat dissipation, mechanical vibration and magnetic loss is obvious. In the long time scale, the longer the running time, the greater the fluctuation level under the sudden risk.

[0098] Further, the machine tool transformer primary control is performed, specifically including: setting a basic migration proportion, increasing a compensation migration proportion according to a historical effect accumulation factor to obtain a comprehensive compensation migration proportion, and transferring the load to the standby transformer through the control of the intelligent busbar switching device according to the comprehensive compensation migration proportion; the higher the risk, the greater the migration proportion, and the actual effect: transferring the sensitive load to the standby transformer to reduce the heating and vibration of the main transformer.

[0099] The basic migration proportion can be obtained according to the average value of historical migration proportion data, or obtained from expert prior knowledge.

[0100] The secondary regulation of the machine tool transformer is performed, and specifically includes: obtaining a basic trigger temperature from an energy-saving transformer system automatic control adjustment database, and lowering the trigger temperature according to a historical effect cumulative factor through a shape memory alloy actuator, so that the old equipment starts protection in advance, and heat aggregation in the machine tool dense area is prevented to cause the transformer to overheat.

[0101] The basic compensation strength is obtained from the energy-saving transformer system automatic control adjustment database, the transformer partial discharge level is continuously monitored, and the compensation strength is increased when the monitored value exceeds the standard value through the active filter, so that the high-risk equipment adopts a larger compensation coefficient, the output voltage fluctuation is ensured to be less than a set threshold, and the precision machining requirement is met.

[0102] The specific implementation steps of the shape memory alloy overheat protection are as follows: a shape memory alloy (SMA) actuator is installed at a key position of transformer heat dissipation (such as between the heat sink and the transformer body). The shape memory alloy has temperature-sensitive characteristics, and when the temperature reaches its phase transition temperature, a shape change (such as elongation or bending) occurs. We set the basic trigger temperature to 60 DEG C, but according to the historical risk, the actual trigger temperature will be reduced (for example, for old equipment, the trigger temperature may be reduced to 50 DEG C). When the temperature reaches the actual trigger temperature, the shape memory alloy actuator deforms, and this deformation drives a mechanical structure (for example, pushes a connecting rod), thereby changing the heat dissipation channel: opening an additional vent; pushing a valve to increase the flow of cooling oil; changing the spacing of the heat sink, and the like, so that the heat dissipation is automatically enhanced before the temperature rises to a dangerous value, and the overheat is prevented.

[0103] The third regulation of the machine tool transformer is performed, and specifically includes: the iron core stress level is monitored in real time, and a reverse hydraulic pressure is generated according to the iron core stress level in proportion through a hydraulic compensation device; the greater the stress, the stronger the compensation force, which offsets the iron core displacement caused by the machine tool vibration, and prevents the internal structure from loosening.

[0104] The insulation response of the transformer insulating oil at different frequency bands is detected, if the low-frequency abnormality is detected, the oil cooling oil flow rate is increased, and if the high-frequency abnormality is detected, the direct current bias repair time is prolonged. High-frequency anomaly: prolong the electromagnetic treatment time, solve the oil quality deterioration problem, and restore the insulation performance.

[0105] In the embodiment, Figure 3 A flowchart of a transformer three-dimensional evaluation regulation module in an energy-saving transformer system automatic control adjustment system provided by the embodiment is shown in the figure. As shown in the figure, the calculation is performed through three-dimensional data dimensions, the comprehensive value is obtained, and the hierarchical regulation is performed.

[0106] R sys 1 represents a transformer three-dimensional risk difference first coefficient, YZ1 represents a first threshold of an energy-saving transformer system three-dimensional risk, and Rsys (t1) represents the current energy-saving transformer system three-dimensional risk value. The transformer three-dimensional risk difference first coefficient accurately identifies the high-risk position (such as the winding end, the dead angle of the radiator, etc.) of local overheating, oil road blockage or insulation deterioration by comparing the parameter benchmark value and the measured value difference in each area of the three-dimensional model, breaking through 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 "oil flow attenuation acceleration", and realize early warning hours before failure. Optimize operation and maintenance decisions, divide risk levels (such as low / medium / high) according to the size of the coefficient, trigger a hierarchical response: integrate electromagnetic-thermal-fluid multi-physical field coupling effects to analyze the chain reaction such as "eddy current loss intensification → local temperature rise → oil viscosity change → heat dissipation deterioration", and avoid misjudgment of traditional single-parameter protection. Through difference algorithm to suppress interference factors such as environmental temperature fluctuations and load changes, ensure the stability of the risk criterion.

[0107] The example code of the first, second and third level control of the machine tool transformer is as follows:

[0108] #==========First level control: vibration and heat dissipation cooperation==========

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

[0110] #1. Dynamic load migration (alleviate overheating + reduce vibration)

[0111] base_migration = 0.2 # Basic 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 road self-cleaning (suppresses 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] Code practical significance:

[0119] 1. When the machine cluster vibration intensifies, automatically increase the load migration ratio, disperse the hotspot temperature.

[0120] 2. Strong vibration synchronously triggers high-pressure pulse self-cleaning: use oil flushing to disperse 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 of similar machine tools, the greater the compensation migration amount

[0123] Implement the closed loop of "the stronger the vibration, the stronger the heat dissipation"

[0124] # Second-level regulation: temperature and electromagnetic coordination

[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 (℃)

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

[0129] actual_trigger_temp = base_trigger_temp - trigger_offset

[0130] #2. Harmonic compensation enhancement (suppress 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 (prevent affecting precision machining)

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

[0135] return actual_trigger_temp, compensation_strength

[0136] Code actual meaning:

[0137] 1. Advance overheat protection trigger point according to historical risk:

[0138] Old device trigger temperature drops to 50°C

[0139] Prevent heat aggregation in machine tool intensive area

[0140] 2. Enhance harmonic compensation when discharge exceeds:

[0141] Particularly enhance the compensation strength of old transformer

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

[0143] #==========Third level control: stress and insulation coordination==========

[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 # Optimize under heat dissipation / vibration / electromagnetic constraints

[0146] #2. Iron core stress dynamic compensation hydraulic_pressure = 0

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

[0148] # Apply reverse hydraulic pressure to eliminate stress in proportion hydraulic_pressure = mechanical_stress * 0.8

[0149] #3. Insulation fault directional disposal if dielectric_response < 0.95: # Low-frequency dielectric response

[0150] # Increase hydraulic pulse pressure to clean oil way 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] Code practical significance:

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

[0156] Automatically generate reverse hydraulic pressure balance stress

[0157] Prevent long-term vibration from causing core displacement

[0158] 2. Dielectric response treatment: detect the degree of insulation oil deterioration

[0159] Low frequency anomaly: oil channel blockage → pulse pressure relief

[0160] High frequency anomaly: insulation deterioration → extend DC treatment

[0161] 3. PSO optimization module:

[0162] Optimize current temperature / vibration / voltage parameters at the same time

[0163] Particularly strengthen the weight of historical high-risk items

[0164] Solve the multi-constraint problem of cluster environment

[0165] # ======== Main control loop (executed every 200ms) =========

[0166] while True:

[0167] # Real-time data acquisition (through 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 readings...

[0173] # Historical risk query (with time decay)

[0174] historical_risk = query_risk_db(time_decay=0.02)

[0175] # Execute 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) # Execute load migration

[0179] start_pulse_cleaning(pulse_freq) # Start oil path cleaning

[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) # Set shape memory alloy action point

[0183] adjust_compensator(comp_strength) # Adjust 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) # Execute optimization reset

[0188] Those skilled in the art will appreciate that embodiments of the present application can be readily used as software, hardware, or a combination of software and hardware. In one

[0189] The present application is described in reference to the drawings using a flowchart and / or a block diagram of an embodiment of a system, apparatus (system), and computer program product according to the present application. It will be understood that each block of the flowchart and / or block diagram, and combinations of blocks in the flowchart and / or block diagram, 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, create means for implementing the functions specified in the flowchart and / or block diagram block or blocks. Figure 1 one or more functions specified in the flowchart and / or block diagram block or blocks. Figure 1 means for performing the function specified by the flowchart and / or block diagram block or blocks.

[0190] These computer program instructions can also be stored in a computer- readable memory that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable memory produce an article of manufacture including instructions which implement the flowchart and / or block diagram block or blocks. Figure 1 one or more functions specified in the flowchart and / or block diagram block or blocks. Figure 1 means for performing the function specified by the flowchart and / or block diagram block or blocks.

[0191] These computer program instructions can also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide steps for implementing the flowchart and / or block diagram block or blocks. Figure 1 one or more functions specified in the flowchart and / or block diagram block or blocks. Figure 1 means for performing the function specified by the flowchart and / or block diagram block or blocks.

[0192] While the preferred embodiments of the application have been described, additional variations and modifications can be employed by those skilled in the art. Therefore, the following claims are intended to cover all such modifications and variations as fall within the true scope of the present application.

[0193] Obviously, a person skilled in the art can make various modifications and variations to the present application without departing from the spirit and scope of the present application. Thus, if these modifications and variations of the present application belong to the scope of the claims of the present application and their equivalent technologies, the present application 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 magnetic aging iron loss surge self-test module is used to perform magnetic aging iron loss analysis and to provide early warning of magnetic aging iron loss analysis based on the results of the magnetic aging iron loss analysis. The transformer three-dimensional evaluation and control module is used to perform three-dimensional evaluation and analysis of the transformer and to adjust the three-dimensional evaluation of the transformer based on the results of the three-dimensional evaluation and analysis. 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.

2. 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 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 energy-saving transformer system automatic control and regulation system as described in claim 2, 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 1, 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.

8. The automatic control and regulation system for the energy-saving transformer system as described in claim 1, 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.

9. The automatic control and regulation system for the energy-saving transformer system as described in claim 1, 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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