A low leakage resistance type protective current transformer production management system

Abstract

The application relates to the technical field of current transformer production management, in particular to a low leakage reactance type protection current transformer production management system, which comprises a data processing module for obtaining a control coefficient based on detection results and monitoring results; the absolute value of the control coefficient is directly proportional to the adjustment amount of the linear velocity of the external circumference when the preset transformer rotates; the positive and negative values of the control coefficient are used for judging the adjustment direction of the linear velocity; and the numerical value of the control coefficient is used for judging whether the linear velocity can be adjusted. The application realizes intelligent control of the production process by monitoring the production process and detection data after production, keeps the compound error of most products in the preset transformer within a small range, that is, the production precision is increased, and the demand for customized production process can be met in the daily production process.

Description

Technical Field

[0001] This invention relates to the field of current transformer production management technology, specifically to a production management system for low leakage reactance type protection current transformers. Background Technology

[0002] Current transformers are key devices used in power systems for current measurement, protection, monitoring, and control. They typically consist of a core, windings, and a casing. Current transformers are used for both measurement and protection. Depending on the application, some prioritize low leakage reactance performance, while others prioritize measurement accuracy; sometimes, both must be considered simultaneously. Generally, for transformers requiring a balance, a request needs to be made to the manufacturer for customization or selection. This is especially true for low leakage reactance current transformers. Due to various factors during production, even if the leakage reactance levels of different transformers produced in the same batch meet national standards, there can still be significant differences between the minimum and maximum values. This difference is unacceptable in high-requirement environments such as laboratory settings. Therefore, a customization request is often made to the manufacturer, who will then either customize the transformer or re-measure and select from existing models.

[0003] In other words, the current demand for this type of current transformer faces the problem that the leakage reactance level is difficult to maintain at a stable level due to external factors during normal production. In order to obtain a current transformer that meets the requirements, it is often necessary to redesign and adjust the production process for customization or to repeatedly test from a large number of existing products. In view of this, the present invention proposes a production management system for low leakage reactance protection current transformers to optimize the production process and increase the effective production volume of products with high requirements for leakage reactance stability. Summary of the Invention

[0004] The purpose of this invention is to provide a production management system for low leakage reactance protection current transformers, solving the following technical problems:

[0005] How to optimize the production process and increase the effective production volume of products with high requirements for leakage resistance stability.

[0006] The objective of this invention can be achieved through the following technical solutions:

[0007] A production management system for low leakage reactance protection current transformers includes a winding module, a detection module, a monitoring module, and a data processing module.

[0008] The winding module includes a wiring unit, a fixing unit, and a control unit. The wiring unit is used to output the copper wire used in the winding process. The fixing unit is used to fix the preset current transformer and drive the fixed preset current transformer to rotate. The preset current transformer includes an iron core, a secondary winding, and several low leakage magnetic windings with equal number of turns arranged on the outer circumference of the secondary winding. The control unit controls the linear velocity of the outer circumference when the fixing unit drives the preset current transformer to rotate according to a preset program.

[0009] The detection module is used to detect the preset current transformer after the winding is completed, and to obtain the detection results, which include the composite error and level of the preset current transformer.

[0010] The monitoring module monitors the production process and obtains monitoring results, including the pressure of the copper wire on the bending wheel during the pre-bending process before entering the winding unit and the internal stress of the low leakage magnetic winding after the winding process is completed.

[0011] The data processing module obtains control coefficients based on detection and monitoring results. The absolute value of the control coefficient is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset current transformer rotates. The positive or negative value of the control coefficient is used to determine the adjustment direction of the linear velocity, and the numerical value of the control coefficient is used to determine whether the linear velocity can be adjusted.

[0012] The above technical solution provides a pre-defined production management process for current transformers. Specifically, this invention intelligently controls the production process by monitoring the production process and collecting post-production testing data. It adjusts the spacing between the turns of the low-leakage flux winding by adjusting the linear velocity of the outer circumference of the pre-defined transformer as it rotates on a fixed unit. Increasing the spacing increases leakage reactance and composite error, while decreasing it decreases them. However, generally, adjusting the spacing easily leads to changes in the number of transformer stages. In this invention, the pre-defined transformer uses a symmetrical low-leakage flux winding. Changes in the number of stages mainly depend on the number of low-leakage flux windings and the cross-section of the copper wire used. Fine-tuning the spacing does not significantly alter the number of stages in the pre-defined transformer. Therefore, during the production of pre-defined transformers, especially before and after switching copper coils, the composite error of most products remains within a small range. In other words, production accuracy is increased, allowing requirements that previously required customized production processes to be met during routine production.

[0013] As a further technical solution of the present invention: the process of obtaining the control coefficient includes:

[0014] Set a first homogeneous value, then obtain the composite error of several preset current transformers produced in the same batch after the copper coil is switched, and generate a second homogeneous value based on the obtained composite error;

[0015] Obtain the difference between the first homopolymer value and the second homopolymer value;

[0016] The pressure of the copper wire on the bending wheel during the pre-bending process before entering the wiring unit before the copper coil switching and after switching are obtained respectively, as well as the internal stress of the low leakage magnetic winding after the winding process is completed.

[0017] The control coefficient is calculated based on the difference between the first and second homogeneous aggregation values, as well as the data before and after the copper coil switching.

[0018] The above technical solution provides a process for obtaining the control coefficient. The control coefficient of this invention is obtained based on the detection and monitoring data before and after the copper coil switching. The control coefficient is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset current transformer rotates. When the control coefficient is too large, it indicates that the adjustment range required to achieve the target low leakage state is too large. It can be determined that no adjustment can be made, and the supervisor needs to be notified to replace the copper coil to continue production. In addition, the positive and negative values ​​of the control coefficient can also be used to determine the adjustment direction.

[0019] As a further technical solution of the present invention, the process of calculating and obtaining the control coefficient includes:

[0020] Through formula Calculate and obtain control coefficients ,in , For the preset level, To preset the actual number of current transformers, It is about Numerical evaluation functions It is the first homogeneous value. It is the second homogeneous value. It is the preset first weight value. It is the preset second weight value. It refers to the pressure exerted on the bending wheel during the pre-bending process of the copper wires in the next batch before they enter the wiring unit. It refers to the pressure applied to the bending wheel during the pre-bending process of the copper wires in the previous batch before they enter the wiring unit. It refers to the internal stress of the low leakage flux winding after the switching process is completed. It is the internal stress of the low leakage magnetic winding that has completed the winding process before switching, and 'a' is a preset correction value.

[0021] The above technical solution provides a process for calculating the control coefficient, and the control coefficient is related to... Value and It is directly proportional, meaning that if the ductility of the copper wire deteriorates after switching or the difference between the first and second homogeneous aggregate values ​​is too large, the control coefficient will increase.

[0022] As a further technical solution of the present invention: the process of determining whether the linear velocity can be adjusted includes:

[0023] control coefficients With threshold range Compare;

[0024] like If the value falls within the threshold range, it is determined that the linear velocity can be adjusted; otherwise, it is determined that the linear velocity cannot be adjusted.

[0025] in, The range of values ​​is , The range of values ​​is .

[0026] As a further technical solution of the present invention: the process of adjusting the linear velocity includes:

[0027] The control coefficient is obtained and its positive or negative state is determined. If it is positive, the linear velocity is adjusted in the positive direction; if it is negative, the linear velocity is adjusted in the negative direction.

[0028] The number of steps in the adjustment step is set based on the adjustment range of the linear velocity;

[0029] The initial step number of the adjustment process is obtained based on the control coefficient value.

[0030] As a further technical solution of the present invention: the process of obtaining the initial step number of the adjustment process includes:

[0031] Get Adjustment Index If the control coefficient is negative, then If the control coefficient is positive, then ;

[0032] Substitute the adjustment index into the preset lookup table to select the starting step number.

[0033] The above technical solution provides a step adjustment strategy. The step adjustment process of this invention can obtain the initial step number based on the calculated control coefficient. By using the initial step number, the problem of repeatedly adjusting the linear speed is avoided, thereby achieving the purpose of quickly adjusting the production process.

[0034] As a further technical solution of the present invention: the pre-bending process includes at least one roller, which is disposed between the wire feeding roller and the wire supply roller of the wire feeding unit.

[0035] As a further technical solution of the present invention: the first homogeneous value is a preset value set relative to the second homogeneous value, and the second homogeneous value is the mode among several composite errors of mutual inductors.

[0036] As a further technical solution of the present invention: the process of adjusting the linear velocity also includes:

[0037] Obtain the preset current transformers produced within a certain period of time after a step adjustment is completed. Numerical value;

[0038] Will Numerical values ​​and critical intervals If a comparison is made, If the value falls into the critical range, the step adjustment is stopped and the preset current transformer is produced at the linear speed after the step adjustment is completed.

[0039] like If the value does not fall within the critical range, an additional step number is added to obtain and a preset current transformer is produced according to the new linear velocity.

[0040] The beneficial effects of this invention are:

[0041] (1) This invention achieves intelligent control of the production process by monitoring the production process and testing the data after production. By adjusting the linear velocity of the outer circumference of the preset current transformer when it rotates on the fixed unit, the spacing between the turns of the low leakage flux winding is adjusted. Increasing the spacing will increase the leakage reactance and composite error, while decreasing it will decrease the leakage reactance and composite error. This achieves that during the production of the preset current transformer, especially before and after switching the copper coil, the composite error of most products in the production of the preset current transformer is kept within a small range. In other words, the production accuracy is increased, and the requirement that originally required customized production process can be completed in the daily production process.

[0042] (2) The control coefficient of the present invention is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset transformer rotates. When the control coefficient is too large, it means that the adjustment range required to achieve the target low leakage state is too large. It can be judged that no adjustment can be made and the supervisor needs to be notified to replace the copper coil to continue production. In addition, the positive and negative values ​​of the control coefficient can also be used to determine the adjustment direction.

[0043] (3) Through the step adjustment process, the present invention can obtain the initial step number based on the calculated control coefficient, and avoid the problem of repeatedly adjusting the linear speed by using the initial step number, thereby achieving the purpose of quickly adjusting the production process. Attached Figure Description

[0044] The invention will now be further described with reference to the accompanying drawings.

[0045] Figure 1 This is a schematic diagram of the module composition of the management system of the present invention;

[0046] Figure 2 This is a planar schematic diagram of the fixed unit of the present invention;

[0047] Figure 3 This is a side view of the wiring unit of the present invention.

[0048] Explanation of reference numerals in the attached figures:

[0049] 1. Cable guide roller; 2. Cable supply roller; 3. Roller. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] Please see Figures 1-3 As shown, in one embodiment, a production management system for low leakage reactance protection current transformers is provided, including a winding module, a detection module, a monitoring module, and a data processing module:

[0052] The winding module includes a wiring unit, a fixing unit, and a control unit. The wiring unit is used to output the copper wire used in the winding process. The fixing unit is used to fix the preset current transformer and drive the fixed preset current transformer to rotate. The preset current transformer includes an iron core, a secondary winding, and several low leakage magnetic windings with equal number of turns arranged on the outer circumference of the secondary winding. The control unit controls the linear velocity of the outer circumference when the fixing unit drives the preset current transformer to rotate according to a preset program.

[0053] In one embodiment, reference Figure 2 The change in linear velocity is driven by the power wheel 4.

[0054] The detection module is used to detect the pre-set current transformer after the winding is completed and obtain the detection results. The detection results include the composite error and the number of the pre-set current transformer. The composite error is calculated by the harmonics and phase shift of the secondary current after the pre-set current transformer after the winding is completed is energized.

[0055] The monitoring module monitors the production process and obtains monitoring results, including the pressure of the copper wire on the bending wheel during the pre-bending process before entering the winding unit and the internal stress of the low leakage magnetic winding after the winding process is completed.

[0056] The data processing module obtains control coefficients based on the detection and monitoring results. The absolute value of the control coefficient is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset current transformer rotates. The positive or negative value of the control coefficient is used to determine the direction of the linear velocity adjustment, and the numerical value of the control coefficient is used to determine whether the linear velocity can be adjusted.

[0057] This embodiment provides a pre-defined production management process for current transformers. Specifically, the present invention intelligently controls the production process by monitoring the production process and collecting post-production testing data. The spacing between the turns of the low-leakage flux winding is adjusted by regulating the linear velocity of the outer circumference of the pre-defined current transformer as it rotates on a fixed unit. Increasing the spacing increases leakage reactance and composite error, while decreasing it decreases them. However, generally, adjusting the spacing easily leads to changes in the number of transformer stages. The pre-defined current transformer of this invention uses a symmetrical low-leakage flux winding. Changes in the number of stages mainly depend on the number of low-leakage flux windings and the cross-section of the copper wire used for winding. Fine-tuning the spacing does not cause significant changes in the number of stages of the pre-defined current transformer. Therefore, during the production of pre-defined current transformers, especially before and after switching copper coils, the composite error of most products remains within a small range. In other words, production accuracy is increased, allowing requirements that previously required customized production processes to be met during routine production.

[0058] It should be noted that, generally speaking, the ductility of materials such as copper wire has a relatively small impact on the final product, and will not cause the composite error of the produced product to exceed the specified range. However, generally speaking, if the specified composite error is 10%, then 1-9% is obviously within the national standard requirements. But for products with special requirements that need to be customized, such as products that require a composite error of 7-8% in experiments, normal production will produce many products with composite errors that are not within 7-8% due to material changes, etc., which requires repeated rework and reduces production efficiency. Custom design is obviously too costly. Therefore, this invention can adjust the production process when switching copper coils, which can easily cause fluctuations in composite error, so that the final product is closer to the special requirements, achieving a dual improvement in production accuracy and efficiency.

[0059] The process of obtaining control coefficients includes:

[0060] Set a first average aggregation value, and then obtain the composite error of several preset current transformers produced in the same batch after the copper coil is switched. Generate a second average aggregation value based on the obtained composite error. The same batch refers to preset current transformers produced using the same copper coil. The first average aggregation value is a preset value set with reference to the second average aggregation value. The second average aggregation value is the mode of the composite error of several current transformers.

[0061] Obtain the difference between the first homopolymer value and the second homopolymer value;

[0062] The pressure of the copper wire on the bending wheel during the pre-bending process before entering the wiring unit before the copper coil switching and after switching are obtained respectively, as well as the internal stress of the low leakage magnetic winding after the winding process is completed.

[0063] The control coefficient is calculated based on the difference between the first and second homogeneous aggregation values, as well as the data before and after the copper coil switching.

[0064] This embodiment provides a process for obtaining the control coefficient. The control coefficient of this invention is obtained based on the detection data and monitoring data before and after the copper coil switching. The control coefficient is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset current transformer rotates. When the control coefficient is too large, it indicates that the adjustment range required to achieve the target low leakage state is too large. It can be determined that no adjustment can be made and the supervisor needs to be notified to replace the copper coil to continue production. In addition, the positive and negative values ​​of the control coefficient can also be used to determine the adjustment direction.

[0065] The process of calculating and obtaining control factors includes:

[0066] Through formula Calculate and obtain control coefficients ,in , For the preset level, To preset the actual number of current transformers, It is about The numerical judgment function determines the value if the actual number of all preset current transformers is less than the preset number of current transformers. Output 1 if the output is positive, otherwise output 0. It is the first homogeneous value. It is the second homogeneous value. It is the preset first weight value. It is the preset second weight value, where and , It refers to the pressure exerted on the bending wheel during the pre-bending process of the copper wires in the next batch before they enter the wiring unit. It refers to the pressure applied to the bending wheel during the pre-bending process of the copper wires in the previous batch before they enter the wiring unit. It refers to the internal stress of the low leakage flux winding after the switching process is completed. It refers to the internal stress of the low leakage flux winding after the winding process is completed before switching, where 'a' is a preset correction value, and its value range is within... The value of 'a' differs from that of different batches in historical data. The discreteness of the numerical values ​​is relevant; the more discrete the data, the smaller the value of 'a'.

[0067] This embodiment provides the calculation process for the control coefficient, and the control coefficient is related to... Value and It is directly proportional, meaning that if the ductility of the copper wire deteriorates after switching or the difference between the first and second homogeneous aggregate values ​​is too large, the control coefficient will increase.

[0068] The process of determining whether the linear velocity can be adjusted includes:

[0069] control coefficients With threshold range Compare;

[0070] like If the value falls within the threshold range, it is determined that the linear velocity can be adjusted; otherwise, it is determined that the linear velocity cannot be adjusted.

[0071] in, The range of values ​​is , The range of values ​​is Choose based on empirical data.

[0072] The process of adjusting the linear velocity includes:

[0073] The control coefficient is obtained and its positive or negative state is determined. If it is positive, the linear velocity is adjusted in the positive direction; if it is negative, the linear velocity is adjusted in the negative direction.

[0074] The adjustment range of linear velocity determines the number of adjustment steps. Linear velocity affects the spacing of each turn of the coil during winding, therefore the adjustment range of linear velocity is generally limited. Adjustments will be made within the specified timeframe;

[0075] The initial step number of the adjustment process is obtained based on the control coefficient value.

[0076] The process of obtaining the starting step number for the adjustment process includes:

[0077] Get Adjustment Index If the control coefficient is negative, then If the control coefficient is positive, then ;

[0078] Substitute the adjustment index into the preset lookup table to select the starting step number.

[0079] In one embodiment, the adjustment range is Within this range, the number of steps is set to ten, with each step spaced 0.5% apart. The corresponding table is as follows:

[0080]

[0081] If the initial step number is 2 and the adjustment direction is positive, the linear velocity after the first adjustment is (100 + 2 * 0.5)% of the initial linear velocity. It should be noted that even in multiple switching processes, the calculation of the adjustment velocity is based on the initial linear velocity. This embodiment is just one example, but obviously other step division methods can also be used and different comparison tables can be set.

[0082] This embodiment provides a step adjustment strategy. The step adjustment process of the present invention can obtain the initial step number based on the calculated control coefficient. By using the initial step number, the problem of repeatedly adjusting the linear speed is avoided, thereby achieving the purpose of quickly adjusting the production process.

[0083] The pre-bending process includes at least one roller 3, which is disposed between the wire feeding roller 1 and the wire supply roller 2 of the wire feeding unit.

[0084] The first homogeneous value is a preset value set relative to the second homogeneous value, which is the mode among several composite errors of mutual inductors.

[0085] The process of adjusting the linear velocity also includes:

[0086] Obtain the preset current transformers produced within a certain period of time after a step adjustment is completed. Numerical value;

[0087] Will Numerical values ​​and critical intervals If a comparison is made, If the value falls into the critical range, the step adjustment is stopped and the preset current transformer is produced at the linear speed after the step adjustment is completed.

[0088] like If the value does not fall within the critical range, an additional step number is added to obtain and a preset current transformer is produced according to the new linear velocity.

[0089] The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A production management system for low leakage reactance type protection current transformers, characterized in that, It includes a winding module, a detection module, a monitoring module, and a data processing module: The winding module includes a wiring unit, a fixing unit, and a control unit. The wiring unit is used to output the copper wire used in the winding process. The fixing unit is used to fix the preset current transformer and drive the fixed preset current transformer to rotate. The preset current transformer includes an iron core, a secondary winding, and several low leakage magnetic windings with equal number of turns arranged on the outer circumference of the secondary winding. The control unit controls the linear velocity of the outer circumference when the fixing unit drives the preset current transformer to rotate according to a preset program. The detection module is used to detect the preset current transformer after the winding is completed, and to obtain the detection results, which include the composite error and the number of stages of the preset current transformer. The monitoring module monitors the production process and obtains monitoring results, including the pressure of the copper wire on the bending wheel during the pre-bending process before entering the winding unit and the internal stress of the low leakage magnetic winding after the winding process is completed. The data processing module obtains control coefficients based on detection and monitoring results. The absolute value of the control coefficient is proportional to the adjustment amount of the linear velocity of the outer circumference when the preset current transformer rotates. The positive or negative value of the control coefficient is used to determine the adjustment direction of the linear velocity, and the numerical value of the control coefficient is used to determine whether the linear velocity can be adjusted. The process of calculating and obtaining control factors includes: Through formula Calculate and obtain control coefficients ,in , For the preset level, To preset the actual number of current transformers, It is about Numerical evaluation functions It is the first homogeneous value. It is the second homogeneous value. It is the preset first weight value. It is the preset second weight value. It refers to the pressure exerted on the bending wheel during the pre-bending process of the copper wires in the next batch before they enter the wiring unit. It refers to the pressure applied to the bending wheel during the pre-bending process of the copper wires in the previous batch before they enter the wiring unit. It refers to the internal stress of the low leakage flux winding after the switching process is completed. It is the internal stress of the low leakage magnetic winding that has completed the winding process before switching, and 'a' is a preset correction value.

2. The production management system for low leakage reactance type protection current transformers according to claim 1, characterized in that, The process of obtaining control coefficients includes: Set a first homogeneous value, then obtain the composite error of several preset current transformers produced in the same batch after the copper coil is switched, and generate a second homogeneous value based on the obtained composite error; Obtain the difference between the first homopolymer value and the second homopolymer value; The pressure of the copper wire on the bending wheel during the pre-bending process before entering the wiring unit before the copper coil switching and after switching are obtained respectively, as well as the internal stress of the low leakage magnetic winding after the winding process is completed. The control coefficient is calculated based on the difference between the first and second homogeneous aggregation values, as well as the data before and after the copper coil switching.

3. The production management system for low leakage reactance type protection current transformers according to claim 1, characterized in that, The process of determining whether the linear velocity can be adjusted includes: control coefficients With threshold range Compare; like If the value falls within the threshold range, it is determined that the linear velocity can be adjusted; otherwise, it is determined that the linear velocity cannot be adjusted. in, The range of values ​​is , The range of values ​​is .

4. The production management system for low leakage reactance type protection current transformers according to claim 1, characterized in that, The process of adjusting the linear velocity includes: The control coefficient is obtained and its positive or negative state is determined. If it is positive, the linear velocity is adjusted in the positive direction; if it is negative, the linear velocity is adjusted in the negative direction. The number of steps in the adjustment step is set based on the adjustment range of the linear velocity; The initial step number of the adjustment process is obtained based on the control coefficient value.

5. The production management system for a low leakage reactance type protection current transformer according to claim 4, characterized in that, The process of obtaining the starting step number for the adjustment process includes: Get Adjustment Index If the control coefficient is negative, then If the control coefficient is positive, then ; Substitute the adjustment index into the preset lookup table to select the starting step number.

6. The production management system for low leakage reactance type protection current transformers according to claim 1, characterized in that, The pre-bending process includes at least one roller (3), which is disposed between the wire feeding roller (1) and the wire supply roller (2) of the wire feeding unit.

7. A production management system for low leakage reactance protection current transformers according to claim 2, characterized in that, The first homogeneous value is a preset value set relative to the second homogeneous value, which is the mode among several composite errors of mutual inductors.

8. The production management system for low leakage reactance protection current transformers according to claim 1, characterized in that, The process of adjusting the linear velocity also includes: Obtain the preset current transformers produced within a certain period of time after a step adjustment is completed. Numerical value; Will Numerical values ​​and critical intervals If a comparison is made, If the value falls into the critical range, the step adjustment is stopped and the preset current transformer is produced at the linear speed after the step adjustment is completed. like If the value does not fall within the critical range, an additional step number is added to obtain and a preset current transformer is produced according to the new linear velocity.

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