Automatic dry-type air-core reactor winding system and method

Abstract

The invention relates to the field of electric reactors, and provides an automatic dry-type air-core electric reactor winding system and method.The automatic dry-type air-core electric reactor winding system comprises an X-Y-Z three-axis linkage mechanical arm, a wire guiding device, a tension control system and an interlayer insulation isolation device; the X-Y-Z three-axis linkage mechanical arm is used for realizing three-dimensional space positioning of the coil; the wire guiding device comprises a plurality of guiding wheels which are arranged along a wire conveying path in a mode of being matched with the natural trend of a wire and guide the wire to be conveyed in the direction of the winding head. The tension control system is used for adjusting wire tension; the interlayer insulation isolation device inserts an insulating material provided by an insulating material supply unit into the interlayer through an automatic insertion mechanism after winding of each layer is completed; the control device is electrically connected with the X-Y-Z three-axis linkage mechanical arm, the tension control system and the interlayer insulation isolation device. According to the invention, the winding working efficiency of the large-section dry-type air-core reactor is obviously improved. The tension control system adjusts the tension of the wire in real time, so that the tension of the wire is stable and controllable in the winding process.

Description

Technical Field

[0001] This invention relates to the field of reactor technology, specifically to an automated dry-type air-core reactor winding system and method. Background Technology

[0002] Dry-type air-core reactors are widely used in power transmission and distribution as important reactive power compensation and filtering devices in power systems. Large-section dry-type air-core reactors have complex structures, with coils made of multiple turns of large-section wire.

[0003] When large-section dry-type air-core reactors are wound manually or semi-automatically, the large outer diameter and height of the coils lead to problems such as low working efficiency, poor winding consistency, easy damage to the wires, and uneven interlayer tension. Summary of the Invention

[0004] This invention provides an automated dry-type air-core reactor winding system and method to solve the technical problems mentioned in the background.

[0005] To address the above problems, this invention discloses an automated dry-type air-core reactor winding system, comprising: XYZ three-axis linkage robotic arm, wire guiding device, tension control system and interlayer insulation isolation device; The XYZ three-axis linkage robotic arm realizes three-dimensional spatial positioning of the coil; The conductor guiding device includes several guide wheels, which are arranged between the conductor feeding end and the winding head, and are arranged to adapt to the natural direction of the conductor along the conductor conveying path, guiding the conductor to be conveyed towards the winding head. The tension control system is used to adjust the tension of the conductor; After each layer of winding is completed, the interlayer insulation isolation device inserts the insulation material provided by the insulation material supply unit into the interlayer through an automatic insertion mechanism. The control device is electrically connected to the XYZ three-axis linkage robotic arm, the tension control system, and the interlayer insulation isolation device.

[0006] Preferred options also include: The spatial positioning component integrates a position detection device to obtain the three-dimensional coordinates of the winding head at the working end of the XYZ three-axis linkage robotic arm in real time, providing a spatial position reference for coil winding. The path planning module, based on the 3D model of the reactor coil, automatically generates the motion trajectory of the winding head and supports online modification of trajectory parameters.

[0007] Preferably, it includes a multi-stage guide wheel group arranged in sequence, consisting of an inlet guide wheel, a straightening guide wheel and an outlet guide wheel. Each guide wheel is fixed by a bracket, and the groove of the guide wheel is adapted to the conductor to limit the conductor offset. The infeed guide wheel is located near the wire feeding end, the straightening guide wheel is located in the middle and the wheel sets are arranged in an alternating manner, and the outfeed guide wheel is set close to the winding head. The three are arranged in a way that adapts to the natural direction of the wire along the wire conveying path, guiding the wire to be conveyed towards the winding head.

[0008] Preferably, the tension control system includes: Tension detection component: Installed between the guide device and the winding head, used to collect conductor tension information in real time; Control and adjustment module: Receives conductor tension information, combines it with the preset tension range corresponding to the conductor specifications, and outputs tension adjustment commands; Tension adjustment actuator: Adjusts the tension according to the tension adjustment command to the preset tension range corresponding to the wire specification; Module 1: Connect to the wire specification database and automatically read the basic parameters of the currently wound wire, including material, wire diameter, and storage duration; Module 2: Receives real-time operating information from the XYZ three-axis linkage robotic arm, including winding speed and position information, and the position information includes inter-layer switching commands.

[0009] Preferably, the surface of the guide wheel is made of a highly wear-resistant material.

[0010] Preferred options also include: Roughness detection module: used to detect the surface roughness of the wire to be wound; Oxide layer thickness detection module: used to detect the surface oxide layer thickness of the wire to be wound.

[0011] Preferably, the tension control system includes: Correction Unit 1: Based on the basic parameters obtained by the acquisition unit and the built-in basic parameter-basic tension mapping model, the first tension is obtained; Surface condition correction unit: used to correct the first tension based on the surface roughness of the current wire to be wound and the thickness of the surface oxide layer of the current wire to be wound, so as to obtain the second tension; Correction Unit Two: When the running information shows acceleration, the theoretical value of the increase in tension inertia is calculated based on the real-time acceleration value, according to the preset mathematical model of acceleration-tension inertia change. When switching between layers, the corresponding tension compensation value is determined based on the change in position and in conjunction with a pre-calibrated position-tension compensation mapping table. The third tension is obtained by combining the second tension with the theoretical value of tension inertia rise or the tension compensation value; Deviation analysis unit: used to calculate the deviation between the actual tension detected by the tension detection component and the third tension, and to determine the duration of the deviation; Adjustment Analysis Unit: Receive real-time tension deviation data and classify the tension deviation into mild deviation, moderate deviation, and severe deviation according to the deviation magnitude; Adjustment is triggered based on the duration of deviation. For mild deviation that lasts for a first preset duration or longer, for moderate deviation that lasts for a second preset duration or longer, adjustment is triggered immediately for severe deviation. When the adjustment is triggered, the tension adjustment actuator adjusts the tension based on the deviation between the actual tension detected by the tension detection component and the third tension.

[0012] Preferably, the tension control system includes: Adaptor Unit 1: Receives the winding speed and determines the tension adjustment rate coefficient corresponding to the winding speed based on the speed-tension adjustment rate coefficient mapping relationship; Adaptor Unit 2: When a sudden change in winding speed is detected, a sudden change correction coefficient is generated. Acquisition Unit: Acquires the current basic tension adjustment rate of the coil to be wound; Calculation unit: used to correct the basic tension adjustment rate of the current coil to be wound based on the tension adjustment rate coefficient and the mutation correction coefficient, to obtain the current tension adjustment rate of the current coil to be wound, and the tension adjustment actuator performs tension adjustment based on the current tension adjustment rate.

[0013] This invention also discloses an automated dry-type air-core reactor winding method, applied to the aforementioned automated dry-type air-core reactor winding system, comprising: Positioning and guiding steps: The control device manipulates the XYZ three-axis linkage robotic arm to complete the three-dimensional spatial positioning of the coil; at the same time, several guide wheels of the wire guiding device guide the wire from the unloading end to the winding head by adapting to the natural direction of the wire along the wire conveying path. Winding and tension control steps: Carry out coil winding operation. During the process, the tension control system adjusts the wire tension in real time, and the XYZ three-axis linkage robotic arm cooperates to perform the winding action. Interlayer insulation treatment steps: After one layer of coil is wound, the control device controls the interlayer insulation isolation device to insert the insulation material provided by the insulation material supply unit into the interlayer with the help of the automatic insertion mechanism. Cyclic steps: Repeat the positioning and guiding steps, winding and tension control steps, and interlayer insulation treatment steps until the dry-type air-core reactor is wound.

[0014] Compared with the prior art, the present invention has the following beneficial effects: The XYZ three-axis linkage robotic arm realizes automatic three-dimensional positioning of the coil, and the path planning module automatically generates the movement trajectory of the winding head, replacing manual or semi-automatic manual operation, greatly reducing the time of manual intervention in the winding process, and significantly improving the winding efficiency of large cross-section dry air reactors.

[0015] The spatial positioning component acquires the three-dimensional coordinates of the winding head in real time, providing a precise spatial position reference for winding. The path planning module precisely plans the motion trajectory, enabling the winding head to run stably along the preset trajectory. At the same time, the multi-stage guide wheel group of the wire guiding device effectively limits and guides the wire, ensuring that the tightness and regularity of the coil winding remain highly consistent.

[0016] The multi-stage guide wheel assembly of the conductor guiding device has wheel grooves that are adapted to the conductor, limiting conductor deviation and being laid out along the natural direction of the conductor. During the conductor transportation process, it avoids improper stress such as dragging and bending that may be caused by manual operation, effectively reducing conductor damage and ensuring the electrical performance and service life of the reactor.

[0017] The tension control system adjusts the conductor tension in real time, making the conductor tension stable and controllable during the winding process. This solves the problem of uneven tension between layers that is prone to occur in manual winding, and avoids faults such as coil deformation and insulation damage caused by inconsistent forces between layers, thereby improving the safe and stable operation capability of the reactor.

[0018] The path planning module supports online modification of trajectory parameters, and can flexibly adjust the winding trajectory according to the winding requirements of different specifications and models of dry-type air-core reactors, adapting to various production scenarios; the reasonable layout and structural design of the multi-stage guide wheel group can also better adapt to the conveying and guiding of different types of conductors.

[0019] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic block diagram illustrating the components of the present invention. Detailed Implementation

[0021] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0022] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0023] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.

[0024] The present invention provides the following embodiments, such as Figure 1 , Example 1: This embodiment of the invention provides an automated dry-type air-core reactor winding system, such as... Figure 1 As shown, it includes: XYZ three-axis linkage robotic arm, wire guiding device, tension control system and interlayer insulation isolation device; The XYZ three-axis linkage robotic arm realizes three-dimensional spatial positioning of the coil; The conductor guiding device includes several guide wheels, which are arranged between the conductor feeding end and the winding head, and are arranged to adapt to the natural direction of the conductor along the conductor conveying path, guiding the conductor to be conveyed towards the winding head. The tension control system is used to adjust the tension of the conductor; After each layer of winding is completed, the interlayer insulation isolation device inserts the insulation material provided by the insulation material supply unit into the interlayer through an automatic insertion mechanism. The control device is electrically connected to the XYZ three-axis linkage robotic arm, the tension control system, and the interlayer insulation isolation device.

[0025] Also includes: The spatial positioning component integrates a position detection device to obtain the three-dimensional coordinates of the winding head at the working end of the XYZ three-axis linkage robotic arm in real time, providing a spatial position reference for coil winding. The path planning module, based on the 3D model of the reactor coil, automatically generates the motion trajectory of the winding head and supports online modification of trajectory parameters.

[0026] This invention also discloses an automated dry-type air-core reactor winding method, applied to the aforementioned automated dry-type air-core reactor winding system, comprising: Positioning and guiding steps: The control device manipulates the XYZ three-axis linkage robotic arm to complete the three-dimensional spatial positioning of the coil; at the same time, several guide wheels of the wire guiding device guide the wire from the unloading end to the winding head by adapting to the natural direction of the wire along the wire conveying path. Winding and tension control steps: Carry out coil winding operation. During the process, the tension control system adjusts the wire tension in real time, and the XYZ three-axis linkage robotic arm cooperates to perform the winding action. Interlayer insulation treatment steps: After one layer of coil is wound, the control device controls the interlayer insulation isolation device to insert the insulation material provided by the insulation material supply unit into the interlayer with the help of the automatic insertion mechanism. Cyclic steps: Repeat the positioning and guiding steps, winding and tension control steps, and interlayer insulation treatment steps until the dry-type air-core reactor is wound.

[0027] It includes a multi-stage guide wheel group arranged in sequence, consisting of an inlet guide wheel, a straightening guide wheel and an outlet guide wheel. Each guide wheel is fixed by a bracket, and the groove of the guide wheel is adapted to the conductor to limit the conductor deviation. The infeed guide wheel is located near the wire feeding end, the straightening guide wheel is located in the middle and the wheel sets are arranged in an alternating manner, and the outfeed guide wheel is set close to the winding head. The three are arranged in a way that adapts to the natural direction of the wire along the wire conveying path, guiding the wire to be conveyed towards the winding head.

[0028] The guide wheel surface is made of a highly wear-resistant material.

[0029] The beneficial effects of the above technical solution are as follows: The XYZ three-axis linkage robotic arm realizes automatic three-dimensional positioning of the coil, and the path planning module automatically generates the movement trajectory of the winding head, replacing manual or semi-automatic manual operation, greatly reducing the time of manual intervention in the winding process, and significantly improving the winding efficiency of large cross-section dry air reactors.

[0030] The spatial positioning component acquires the three-dimensional coordinates of the winding head in real time, providing a precise spatial position reference for winding. The path planning module precisely plans the motion trajectory, enabling the winding head to run stably along the preset trajectory. At the same time, the multi-stage guide wheel group of the wire guiding device effectively limits and guides the wire, ensuring that the tightness and regularity of the coil winding remain highly consistent.

[0031] The multi-stage guide wheel assembly of the conductor guiding device has wheel grooves that are adapted to the conductor, limiting conductor deviation and being laid out along the natural direction of the conductor. During the conductor transportation process, it avoids improper stress such as dragging and bending that may be caused by manual operation, effectively reducing conductor damage and ensuring the electrical performance and service life of the reactor.

[0032] The tension control system adjusts the conductor tension in real time, making the conductor tension stable and controllable during the winding process. This solves the problem of uneven tension between layers that is prone to occur in manual winding, and avoids faults such as coil deformation and insulation damage caused by inconsistent forces between layers, thereby improving the safe and stable operation capability of the reactor.

[0033] The path planning module supports online modification of trajectory parameters, and can flexibly adjust the winding trajectory according to the winding requirements of different specifications and models of dry-type air-core reactors, adapting to various production scenarios; the reasonable layout and structural design of the multi-stage guide wheel group can also better adapt to the conveying and guiding of different types of conductors.

[0034] Example 2, based on Example 1, The tension control system includes: Tension detection component: Installed between the guide device and the winding head, used to collect conductor tension information in real time; Control and adjustment module: Receives conductor tension information, combines it with the preset tension range corresponding to the conductor specifications, and outputs tension adjustment commands; Tension adjustment actuator: Adjusts the tension according to the tension adjustment command to the preset tension range corresponding to the wire specification; Module 1: Connect to the wire specification database and automatically read the basic parameters of the currently wound wire, including material, wire diameter, and storage duration; Module 2: Receives real-time operating information from the XYZ three-axis linkage robotic arm, including winding speed and position information, and the position information includes inter-layer switching commands.

[0035] The beneficial effects of the above technical solution are as follows: By collecting conductor tension information in real time through the tension detection component, the control and adjustment module outputs adjustment commands in combination with the preset tension range, and the tension adjustment actuator responds accurately, which can stabilize the conductor tension within the preset range that matches the conductor specifications, avoid damage to the conductor due to excessive tension or affect the winding quality due to insufficient tension, and ensure the accuracy of tension control during the winding of dry-type air-core reactors.

[0036] The acquisition module automatically reads basic parameters such as the material, diameter, and storage time of the currently wound conductor. Based on the characteristics of different conductors, it can more accurately determine the preset tension range, enhance the adaptability of the tension control system to conductors of different specifications, and expand the application range of the system.

[0037] The acquisition module 2 receives real-time operating information such as the winding speed and inter-layer switching commands of the XYZ three-axis linkage robotic arm. The tension control system can combine these dynamically changing operating states to adjust the tension adjustment strategy in a timely manner. For example, when the winding speed changes or inter-layer switching occurs, the tension can be adjusted in advance or in a timely manner to further improve the dynamic adaptability of tension control and ensure that the winding process is stable and efficient.

[0038] Example 3, based on Example 2, further includes: Roughness detection module: used to detect the surface roughness of the wire to be wound; Oxide layer thickness detection module: used to detect the surface oxide layer thickness of the wire to be wound.

[0039] The tension control system includes: Correction Unit 1: Based on the basic parameters obtained by the acquisition unit and the built-in basic parameter-basic tension mapping model, the first tension is obtained; Surface condition correction unit: used to correct the first tension based on the surface roughness of the current wire to be wound and the thickness of the surface oxide layer of the current wire to be wound, so as to obtain the second tension; Correction Unit Two: When the running information shows acceleration, the theoretical value of the increase in tension inertia is calculated based on the real-time acceleration value, according to the preset mathematical model of acceleration-tension inertia change. When switching between layers, the corresponding tension compensation value is determined based on the change in position and in conjunction with a pre-calibrated position-tension compensation mapping table. The third tension is obtained by combining the second tension with the theoretical value of tension inertia rise or the tension compensation value; Deviation analysis unit: used to calculate the deviation between the actual tension detected by the tension detection component and the third tension, and to determine the duration of the deviation; Adjustment Analysis Unit: Receive real-time tension deviation data and classify the tension deviation into mild deviation, moderate deviation, and severe deviation according to the deviation magnitude; Adjustment is triggered based on the duration of deviation. For mild deviation that lasts for a first preset duration or longer, for moderate deviation that lasts for a second preset duration or longer, adjustment is triggered immediately for severe deviation. When the adjustment is triggered, the tension adjustment actuator adjusts the tension based on the deviation between the actual tension detected by the tension detection component and the third tension.

[0040] Roughness detection module: Using a laser profilometer, the surface of the conductor is scanned non-contactly before it enters the winding process. By analyzing the scattering of reflected light, the surface roughness data of the conductor is obtained and transmitted to the control system in real time.

[0041] Oxide layer thickness detection module: Using eddy current detection technology, an alternating electromagnetic field is applied to the surface of the conductor. Based on the attenuation effect of the oxide layer on the eddy current, the oxide layer thickness is determined, and the detection results are simultaneously sent to the surface condition correction unit.

[0042] The implementation of Correction Unit 1 is as follows: First, the acquisition unit obtains the basic parameters of the conductor to be wound from the conductor specification database, such as the conductor material, diameter, and storage time. Then, Correction Unit 1 utilizes a built-in basic parameter tension mapping model, which is formed through extensive experiments that establishes a correlation between different conductor basic parameters and corresponding suitable basic tensions. The acquired basic parameters are input into this mapping model, and the model calculates and outputs the first tension, which is the initial reference tension suitable for the current conductor, based on the correspondence between the parameters and the tension.

[0043] Surface condition correction unit: Based on experiments, the correlation rules between surface roughness, oxide layer thickness, and tension correction amount are clarified. The detected roughness and oxide layer thickness are substituted into the rules to calculate the total correction amount, which is then used to adjust the first tension to obtain the second tension.

[0044] Correction Unit Two: Acceleration scenario compensation: Real-time acceleration is obtained by using the encoder of the robotic arm's servo motor. Combined with empirical data, the approximate increase in tension due to inertia is judged, and the second tension is pre-reduced and corrected.

[0045] Interlayer switching compensation: Through numerous interlayer switching experiments, the tension fluctuations corresponding to changes in different positions are recorded, forming a position-tension compensation reference table. When an interlayer switching command is received, the reference table is consulted based on the real-time position change to obtain the corresponding compensation value, and the second tension is dynamically adjusted to ultimately obtain the third tension (dynamic reference tension).

[0046] The beneficial effects of the above technical solution are as follows: The surface condition parameters of the conductor are obtained by the roughness detection module and the oxide layer thickness detection module. Based on this, the surface condition correction unit makes targeted corrections to the basic tension, so that the initial tension setting can be adapted to the actual surface characteristics of the conductor (such as adaptive adjustment when the roughness increases or the oxide layer exceeds the threshold). This solves the adaptation deviation problem that may exist in the traditional method of setting tension by relying solely on basic parameters.

[0047] The second correction unit is designed for dynamic scenarios such as robotic arm acceleration and interlayer switching. It predicts changes in tension inertia through mathematical models or determines compensation values ​​based on experimental data, thereby achieving proactive adjustment of tension. This avoids large fluctuations in tension caused by sudden changes in working conditions and ensures the continuity and stability of tension during the winding process.

[0048] The deviation analysis unit and the adjustment analysis unit combine the deviation amplitude and duration to make graded judgments, which not only prevents erroneous adjustment caused by instantaneous fluctuations, but also responds in a timely manner when the deviation is continuous, making the tension adjustment more targeted and effective, and avoiding over-adjustment or adjustment lag that affects the winding quality.

[0049] From benchmark tension setting and dynamic operating condition compensation to deviation adjustment triggering, a precise tension control logic is formed throughout the entire process, which effectively reduces problems such as wire damage and irregular coil arrangement caused by unstable tension, and significantly improves the winding quality and product consistency of dry-type air-core reactors.

[0050] Example 4, based on Example 2 or 3, includes the following tension control system: Adaptor Unit 1: Receives the winding speed and determines the tension adjustment rate coefficient corresponding to the winding speed based on the speed-tension adjustment rate coefficient mapping relationship; Adaptor Unit 2: When a sudden change in winding speed is detected, a sudden change correction coefficient is generated. Acquisition Unit: Acquires the current basic tension adjustment rate of the coil to be wound; Calculation unit: used to correct the basic tension adjustment rate of the current coil to be wound based on the tension adjustment rate coefficient and the mutation correction coefficient, to obtain the current tension adjustment rate of the current coil to be wound, and the tension adjustment actuator performs tension adjustment based on the current tension adjustment rate.

[0051] The beneficial effects of the above technical solution are as follows: The first adapter unit uses the speed-tension adjustment rate coefficient mapping relationship to match the corresponding tension adjustment rate coefficient for different winding speeds, so that the tension adjustment rate can be flexibly adjusted according to the winding speed, avoiding the adjustment mismatch problem caused by the fixed speed adjustment rate, and improving the adaptability of tension adjustment and winding speed.

[0052] The second adapter unit generates a sudden change correction coefficient when the winding speed changes abruptly. This can promptly correct the tension adjustment rate, prevent large fluctuations in tension caused by sudden speed changes, enhance the system's adaptability to dynamic working conditions, and ensure the stability of tension during the winding process.

[0053] The calculation unit combines the tension adjustment rate coefficient and the mutation correction coefficient to correct the basic tension adjustment rate, thereby obtaining a current tension adjustment rate that better meets the actual winding requirements. The tension adjustment actuator adjusts the tension according to this rate, which can control the tension more accurately and further improve the winding quality of dry-type air-core reactors.

[0054] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.

Claims

1. An automated dry-type air-core reactor winding system, characterized in that, include: XYZ three-axis linkage robotic arm, wire guiding device, tension control system and interlayer insulation isolation device; The XYZ three-axis linkage robotic arm realizes three-dimensional spatial positioning of the coil; The conductor guiding device includes several guide wheels, which are arranged between the conductor feeding end and the winding head, and are arranged to adapt to the natural direction of the conductor along the conductor conveying path, guiding the conductor to be conveyed towards the winding head. The tension control system is used to adjust the tension of the conductor; After each layer of winding is completed, the interlayer insulation isolation device inserts the insulation material provided by the insulation material supply unit into the interlayer through an automatic insertion mechanism. The control device is electrically connected to the XYZ three-axis linkage robotic arm, the tension control system, and the interlayer insulation isolation device.

2. The automated dry-type air-core reactor winding system according to claim 1, characterized in that, Also includes: The spatial positioning component integrates a position detection device to obtain the three-dimensional coordinates of the winding head at the working end of the XYZ three-axis linkage robotic arm in real time, providing a spatial position reference for coil winding. The path planning module, based on the 3D model of the reactor coil, automatically generates the motion trajectory of the winding head and supports online modification of trajectory parameters.

3. The automated dry-type air-core reactor winding system according to claim 1, characterized in that, It includes a multi-stage guide wheel group arranged in sequence, consisting of an inlet guide wheel, a straightening guide wheel and an outlet guide wheel. Each guide wheel is fixed by a bracket, and the groove of the guide wheel is adapted to the conductor to limit the conductor deviation. The infeed guide wheel is located near the wire feeding end, the straightening guide wheel is located in the middle and the wheel sets are arranged in an alternating manner, and the outfeed guide wheel is set close to the winding head. The three are arranged in a way that adapts to the natural direction of the wire along the wire conveying path, guiding the wire to be conveyed towards the winding head.

4. The automated dry-type air-core reactor winding system according to claim 1, characterized in that, The tension control system includes: Tension detection component: Installed between the guide device and the winding head, used to collect conductor tension information in real time; Control and adjustment module: Receives conductor tension information, combines it with the preset tension range corresponding to the conductor specifications, and outputs tension adjustment commands; Tension adjustment actuator: Adjusts the tension according to the tension adjustment command to the preset tension range corresponding to the wire specification; Module 1: Connect to the wire specification database and automatically read the basic parameters of the currently wound wire, including material, wire diameter, and storage duration; Module 2: Receives real-time operating information from the XYZ three-axis linkage robotic arm, including winding speed and position information, and the position information includes inter-layer switching commands.

5. The automated dry-type air-core reactor winding system according to claim 3, characterized in that, The guide wheel surface is made of highly wear-resistant material.

6. The automated dry-type air-core reactor winding system according to claim 3, characterized in that, Also includes: Roughness detection module: used to detect the surface roughness of the wire to be wound; Oxide layer thickness detection module: used to detect the surface oxide layer thickness of the wire to be wound.

7. An automated dry-type air-core reactor winding system according to claim 6, characterized in that, The tension control system includes: Correction Unit 1: Based on the basic parameters obtained by the acquisition unit and the built-in basic parameter-basic tension mapping model, the first tension is obtained; Surface condition correction unit: used to correct the first tension based on the surface roughness of the current wire to be wound and the thickness of the surface oxide layer of the current wire to be wound, so as to obtain the second tension; Correction Unit Two: When the running information shows acceleration, the theoretical value of the increase in tension inertia is calculated based on the real-time acceleration value, according to the preset mathematical model of acceleration-tension inertia change. When switching between layers, the corresponding tension compensation value is determined based on the change in position and in conjunction with a pre-calibrated position-tension compensation mapping table. The third tension is obtained by combining the second tension with the theoretical value of the tension inertia rise or the tension compensation value; Deviation analysis unit: used to calculate the deviation between the actual tension detected by the tension detection component and the third tension, and to determine the duration of the deviation; Adjustment Analysis Unit: Receive real-time tension deviation data and classify the tension deviation into mild deviation, moderate deviation, and severe deviation according to the deviation magnitude; Adjustment is triggered based on the duration of deviation. For mild deviation that lasts for a first preset duration or longer, for moderate deviation that lasts for a second preset duration or longer, adjustment is triggered immediately for severe deviation. When the adjustment is triggered, the tension adjustment actuator adjusts the tension based on the deviation between the actual tension detected by the tension detection component and the third tension.

8. An automated dry-type air-core reactor winding system according to claim 6, characterized in that, The tension control system includes: Adaptor Unit 1: Receives the winding speed and determines the tension adjustment rate coefficient corresponding to the winding speed based on the speed-tension adjustment rate coefficient mapping relationship; Adaptor Unit 2: When a sudden change in winding speed is detected, a sudden change correction coefficient is generated. Acquisition Unit: Acquires the current basic tension adjustment rate of the coil to be wound; Calculation unit: used to correct the basic tension adjustment rate of the current coil to be wound based on the tension adjustment rate coefficient and the mutation correction coefficient, to obtain the current tension adjustment rate of the current coil to be wound, and the tension adjustment actuator performs tension adjustment based on the current tension adjustment rate.

9. An automated dry-type air-core reactor winding method, applied to an automated dry-type air-core reactor winding system as described in any one of claims 1-9, characterized in that, include: Positioning and guiding steps: The control device manipulates the XYZ three-axis linkage robotic arm to complete the three-dimensional spatial positioning of the coil; at the same time, several guide wheels of the wire guiding device guide the wire from the unloading end to the winding head by adapting to the natural direction of the wire along the wire conveying path. Winding and tension control steps: Carry out coil winding operation. During the process, the tension control system adjusts the wire tension in real time, and the XYZ three-axis linkage robotic arm cooperates to perform the winding action. Interlayer insulation treatment steps: After one layer of coil is wound, the control device controls the interlayer insulation isolation device to insert the insulation material provided by the insulation material supply unit into the interlayer with the help of the automatic insertion mechanism. Cyclic steps: Repeat the positioning and guiding steps, winding and tension control steps, and interlayer insulation treatment steps until the dry-type air-core reactor is wound.

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