Full-automatic winding process method and device for layered coil of transformer

Abstract

The invention belongs to the field of power transformer coil manufacturing, and relates to a transformer layer type coil full-automatic winding process method and device.The method comprises the following steps that S1, a round wire is flattened; s2, coil insulation selection is carried out; s3, a coil winding and on-line monitoring step; according to the technical scheme, through the modes of wire flattening, coil insulation selection, constant-tension winding, online monitoring and the like, the problems that the manual participation degree is high and the automation degree falls behind in the current transformer layer type coil winding process can be effectively solved, meanwhile, the use amount of insulation materials is reduced to the maximum extent, cost is saved, and the production efficiency is improved. And the reliability of the product is improved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the field of power transformer coil manufacturing, and particularly relates to a full-automatic winding process method and device for a transformer layered coil. BACKGROUND

[0002] At present, intelligent manufacturing technology has been widely popularized and applied in the electric power manufacturing industry in China. The intelligentization of logistics distribution has been basically completed, and the automation and intelligentization of key manufacturing processes have become a problem to be solved for electric power manufacturing enterprises. Advanced automated equipment has gradually begun to be successfully developed and gradually popularized and applied. The advanced manufacturing process technology matched therewith is relatively lagging behind, which affects the process of popularization and application of advanced intelligent manufacturing technology. The full-automatic winding device in the industry has begun to be applied, and there is no mature full-automatic winding technology matched therewith. The present process method can completely solve this problem.

[0003] The winding process of the layered coil of the distribution transformer in the industry involves high degree of manual participation, and the degree of automation is backward. The skill level of the operator is required to be high. At present, the situation of labor shortage is becoming more and more common, and the problems of difficult recruitment and difficult training of the workers with high technical level are very prominent. This is the deficiency of the prior art.

[0004] Therefore, it is necessary to provide a full-automatic winding process method and device for a transformer layered coil to solve the above-mentioned defects in the prior art. SUMMARY

[0005] The present application aims at the defects in the prior art, and provides a full-automatic winding process method and device for a transformer layered coil to solve the above-mentioned technical problems.

[0006] To achieve the above-mentioned purpose, the present application provides the following technical scheme: A full-automatic winding process method for a transformer layered coil, comprising the following steps: Step S1, a step of flattening a round wire, in which: Before winding the wire, the round wire is flattened into a flat wire to improve the strength of the wire. After flattening, the filling rate of the coil wire is high, the amount of copper and oil used is correspondingly reduced, the wire contact between the wire and the interlayer insulation is changed into surface contact, the bonding effect is better, and the strength of the coil is high.

[0007] Step S2, a step of selecting a coil insulation, in which: The original point gluing paper insulation and paper board end insulation in the coil are replaced by narrow paper tape insulation.

[0008] The thickness of the narrow paper tape insulation is determined based on the interlayer voltage gradient. The narrow paper tapes are stacked layer by layer with a progressive overlap rate to form a wedge-shaped insulation structure, minimizing the amount of insulation material used while ensuring insulation strength. The overlap rate is generally set within the range of 25% progressively increasing to 85%.

[0009] Step S3, the coil winding and online monitoring step, in which: The coil winding process employs constant tension technology. Simultaneously, during the winding process, a high-precision visual sensor is used to monitor the moving wires online.

[0010] Preferably, step S1 specifically includes: Before winding the conductor, set the flattening parameters, i.e., the flattening ratio. Based on the flattening curve of the conductor material, select the flattening ratio within the maximum flattening limit of the conductor, and then flatten the conductor.

[0011] Round conductors are flattened by a flattening wheel, changing their cross-sectional area from circular to oblong. The conductor width increases accordingly, while the cross-sectional area decreases. During flattening, the air gap within the coil decreases, increasing the bonding area between the conductor and insulation. The reduction in air gap between the conductors is... The calculation method is as follows:

[0012] in, The flattening ratio is denoted as .

[0013] Preferably, in step S2, the narrow paper tapes are stacked layer by layer to form a wedge-shaped insulation structure with a progressive overlap rate. The overlap rate is calculated as follows: To achieve fully automated winding, the number of turns of the narrow paper tape must match the number of turns of the conductor. When the number of conductor turns (X) equals the number of turns of the narrow paper tape (Y), the winding is synchronized, enabling fully automated winding. If the number of conductor turns (X) and the number of turns of the narrow paper tape (Y) are not equal, the overlap ratio of the narrow paper tape needs to be adjusted until the matching condition is met. The number of conductor turns (X) is a fixed value and cannot be changed, while the number of turns of the narrow paper tape (Y) varies according to the overlap ratio.

[0014] The number of turns Y of the narrow paper tape is related to the initial layer insulation thickness in the target wedge-shaped insulation structure. and end layer insulation thickness The relevant information is calculated using the following formula:

[0015] in, The height of the conductor coil, For narrow paper strip width, For the thickness of the paper tape, This refers to the thickness of the conductor.

[0016] The overlap ratio defines the proportion of overlap between adjacent paper tapes, and its initial and final values ​​directly determine the starting and ending thicknesses of the wedge-shaped insulation structure. Initial overlap ratio The calculation formula is as follows, corresponding to the starting end (thinnest part) of the wedge-shaped insulation:

[0017] in, For the thickness of the paper tape, This represents the initial layer insulation thickness.

[0018] End-of-line overlap rate The calculation formula is as follows, corresponding to the termination end (thickest part) of the wedge-shaped insulation:

[0019] in, For the thickness of the paper tape, In the actual winding process, the overlap rate changes from the initial value. To the endpoint value The gradual changes between these elements form the desired wedge-shaped insulation structure.

[0020] Preferably, the coil winding process in step S3 employs a constant tension technique, specifically including: The winding process is carried out in a constant tension control system. This system includes a wire feeding mechanism and a rocker arm mechanism. The wire feeding mechanism comprises two counter-rotating drive wheels. The constant tension control system calculates the required winding speed from the winding speed, and then calculates the wire feeding speed of the feeding wheels based on the required winding speed, ensuring a perfect match between the wire feeding speed and the winding speed. Once a dynamic balance is achieved between the wire feeding speed and the winding speed, the rocker arm mechanism applies pressure to the running conductor via a cylinder, providing constant tension to the conductor.

[0021] Preferably, in step S3, the moving wire is monitored online using a high-precision vision sensor during the winding process, specifically including: The online monitoring process during winding is conducted within an online monitoring system. Visual sensors in this system continuously monitor the moving conductors during coil winding, collecting data including surface defects and conductor dimensions. The system intelligently analyzes the real-time data, continuously assessing conductor appearance quality and accurately identifying defects such as insulation damage. Upon detecting a quality defect, the system outputs a quality alarm signal and controls the constant tension control system to stop, upgrading the quality inspection model from "post-production sampling" to "full-process inspection," effectively improving defect interception rate and first-pass yield.

[0022] Furthermore, this invention provides a fully automated winding process apparatus for transformer layer coils, comprising: A module for flattening round wires, in which: Before winding the wire, the round wire is first flattened to increase its strength. The flattened coil wire has a higher fill rate, which reduces the amount of copper and oil used. In addition, the line contact between the wire and the interlayer insulation becomes a surface contact, resulting in better bonding and higher coil strength.

[0023] The module for selecting coil insulation includes: The original adhesive paper insulation and cardboard end insulation inside the coil were replaced with narrow paper tape insulation.

[0024] The thickness of the narrow paper tape insulation is determined based on the interlayer voltage gradient. The narrow paper tapes are stacked layer by layer with a progressive overlap rate to form a wedge-shaped insulation structure, minimizing the amount of insulation material used while ensuring insulation strength. The overlap rate is generally set within the range of 25% progressively increasing to 85%.

[0025] A module for coil winding and online monitoring, in which: The coil winding process employs constant tension technology. Simultaneously, during the winding process, a high-precision visual sensor is used to monitor the moving wires online.

[0026] Preferably, the round wire flattening module specifically includes: Before winding the conductor, set the flattening parameters, i.e., the flattening ratio. Based on the flattening curve of the conductor material, select the flattening ratio within the maximum flattening limit of the conductor, and then flatten the conductor.

[0027] Round conductors are flattened by a flattening wheel, changing their cross-sectional area from circular to oblong. The conductor width increases accordingly, while the cross-sectional area decreases. During flattening, the air gap within the coil decreases, increasing the bonding area between the conductor and insulation. The reduction in air gap between the conductors is... The calculation method is as follows:

[0028] in, The flattening ratio is denoted as .

[0029] Preferably, in the coil insulation selection module, narrow paper tapes are stacked layer by layer to form a wedge-shaped insulation structure with a progressive overlap rate. The overlap rate is calculated as follows: To achieve fully automated winding, the number of turns of the narrow paper tape must match the number of turns of the conductor. When the number of conductor turns (X) equals the number of turns of the narrow paper tape (Y), the winding is synchronized, enabling fully automated winding. If the number of conductor turns (X) and the number of turns of the narrow paper tape (Y) are not equal, the overlap ratio of the narrow paper tape needs to be adjusted until the matching condition is met. The number of conductor turns (X) is a fixed value and cannot be changed, while the number of turns of the narrow paper tape (Y) varies according to the overlap ratio.

[0030] The number of turns Y of the narrow paper tape is related to the initial layer insulation thickness in the target wedge-shaped insulation structure. and end layer insulation thickness The relevant information is calculated using the following formula:

[0031] in, The height of the conductor coil, For narrow paper strip width, For the thickness of the paper tape, This refers to the thickness of the conductor.

[0032] The overlap ratio defines the proportion of overlap between adjacent paper tapes, and its initial and final values ​​directly determine the starting and ending thicknesses of the wedge-shaped insulation structure. Initial overlap ratio The calculation formula is as follows, corresponding to the starting end (thinnest part) of the wedge-shaped insulation:

[0033] in, For the thickness of the paper tape, This represents the initial layer insulation thickness.

[0034] End-of-line overlap rate The calculation formula is as follows, corresponding to the termination end (thickest part) of the wedge-shaped insulation:

[0035] in, For the thickness of the paper tape, In the actual winding process, the overlap rate changes from the initial value. To the endpoint value The gradual changes between these elements form the desired wedge-shaped insulation structure.

[0036] Preferably, in the coil winding and online monitoring module, the coil winding process employs constant tension technology, specifically including: The winding process is carried out in a constant tension control system. This system includes a wire feeding mechanism and a rocker arm mechanism. The wire feeding mechanism comprises two counter-rotating drive wheels. The constant tension control system calculates the required winding speed from the winding speed, and then calculates the wire feeding speed of the feeding wheels based on the required winding speed, ensuring a perfect match between the wire feeding speed and the winding speed. Once a dynamic balance is achieved between the wire feeding speed and the winding speed, the rocker arm mechanism applies pressure to the running conductor via a cylinder, providing constant tension to the conductor.

[0037] Preferably, in the coil winding and online monitoring module, a high-precision vision sensor is used to monitor the moving wire online during the winding process, specifically including: The online monitoring process during winding is conducted within an online monitoring system. Visual sensors in this system continuously monitor the moving conductors during coil winding, collecting data including surface defects and conductor dimensions. The system intelligently analyzes the real-time collected data, continuously monitoring conductor appearance quality and accurately identifying defects such as insulation damage. Upon detecting a quality defect, the system outputs a quality alarm signal and controls the constant tension control system to stop, effectively improving defect interception rate and first-pass yield.

[0038] The beneficial effects of this invention are as follows: First, by integrating multiple innovative processes such as online flattening of round conductors, automatic splicing of wedge insulation, constant tension control throughout the process, and online visual inspection of conductor quality, a complete, closed-loop, fully automated winding solution is constructed. This integrates the originally scattered, worker-dependent processes into a coherent, intelligent workflow, solving the industry pain point that advanced equipment is difficult to promote due to the lack of mature supporting processes, and promoting the industry's leap from "experience-driven" to "process and data-driven." Second, the skill requirements of the production process are greatly reduced, with skilled workers becoming ordinary operators, shortening the personnel training cycle by more than 85%, and increasing winding efficiency by 80%. Third, through "round conductor flattening" and "wedge insulation," both product performance and cost are optimized. The flattening technology changes the contact method between conductors from point to surface, improving the mechanical strength and heat dissipation of the coil, while the high filler ratio saves copper and transformer oil; wedge insulation ensures that the distribution of insulation material is precisely matched with the voltage gradient, minimizing the amount of insulation material used while ensuring insulation strength. Fourth, by constructing a full-process quality assurance system, the quality and reliability of the products are ensured; the constant tension control of the covering wire and insulation paper is integrated, which fundamentally eliminates coil defects caused by uneven tension; at the same time, online visual inspection is introduced to conduct real-time full inspection of the wires, realizing the upgrade of quality monitoring from "post-event sampling inspection" to "full-process inspection", thereby greatly improving the first-pass yield and product reliability.

[0039] Furthermore, the design principle of this invention is reliable, the structure is simple, and it has a very wide range of application prospects. Attached Figure Description

[0040] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0041] Figure 1 This is a flowchart of a fully automated winding process for transformer layered coils provided by the present invention.

[0042] Figure 2 This is a schematic diagram of a fully automatic winding process device for transformer layered coils provided by the present invention.

[0043] Figure 3 This is a diagram of the wedge-shaped insulation structure for the arrangement of wires inside the coil provided by the present invention.

[0044] Figure 4 This is a flattening curve of enameled round copper wire provided by the present invention.

[0045] Figure 5 This is a schematic diagram of the constant tension control system provided by the present invention.

[0046] Figure 6 This is a schematic diagram illustrating the principle of the constant tension control system provided by the present invention.

[0047] Among them, 1-round wire flattening module, 2-coil insulation selection module, 3-coil winding and online monitoring module. Detailed Implementation

[0048] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The following embodiments are explanations of the present invention, but the present invention is not limited to the following implementation methods.

[0049] Example 1: like Figure 1 As shown in the figure, this embodiment provides a fully automated winding process for transformer layer coils, including the following steps: Step S1, the step of flattening the round wire, in which: Before winding the wire, the round wire is first flattened to increase its strength. The flattened coil wire has a higher fill rate, which reduces the amount of copper and oil used. In addition, the line contact between the wire and the interlayer insulation becomes a surface contact, resulting in better bonding and higher coil strength.

[0050] Step S2, the coil insulation selection step, in which: The original adhesive paper insulation and cardboard end insulation inside the coil were replaced with narrow paper tape insulation.

[0051] The insulation thickness of the narrow paper tape is determined based on the interlayer voltage gradient, such as... Figure 3 As shown, narrow paper tapes are stacked layer by layer to form a wedge-shaped insulation structure with a progressive overlap rate, minimizing the amount of insulation material used while ensuring insulation strength. The overlap rate is generally set within the range of 25% progressively increasing to 85%.

[0052] Step S3, the coil winding and online monitoring step, in which: The coil winding process employs constant tension technology. Simultaneously, during the winding process, a high-precision visual sensor is used to monitor the moving wires online.

[0053] Step S1 specifically includes: Before winding the conductor, the flattening parameter, i.e., the flattening ratio, is set. In this embodiment, enameled round copper wire is used as the conductor. Figure 4 As shown, according to the flattening rate curve of enameled round copper wire obtained from the experiment, the maximum flattening limit of the conductor is 25%. At this time, the conductor width increases by 10.7% and the cross-sectional area loss is 2.6%. Therefore, a flattening rate of less than 25% is selected for flattening the conductor and winding the transformer coil.

[0054] Round conductors are flattened by a flattening wheel, changing their cross-sectional area from circular to oblong. The conductor width increases accordingly, while the cross-sectional area decreases. During flattening, the air gap within the coil decreases, increasing the bonding area between the conductor and insulation. The reduction in air gap between the conductors is... The calculation method is as follows:

[0055] in, The flattening ratio is denoted as .

[0056] Flattening the wire has a significant impact on reducing the overall air gap within the coil, resulting in a noticeable cost reduction.

[0057] In step S2, the narrow paper tapes are stacked layer by layer to form a wedge-shaped insulation structure with a progressive overlap rate. The overlap rate is calculated as follows: To achieve fully automated winding, the number of turns of the narrow paper tape must match the number of turns of the conductor. When the number of conductor turns (X) equals the number of turns of the narrow paper tape (Y), the winding is synchronized, enabling fully automated winding. If the number of conductor turns (X) and the number of turns of the narrow paper tape (Y) are not equal, the overlap ratio of the narrow paper tape needs to be adjusted until the matching condition is met. The number of conductor turns (X) is a fixed value and cannot be changed, while the number of turns of the narrow paper tape (Y) varies according to the overlap ratio.

[0058] The number of turns Y of the narrow paper tape is related to the initial layer insulation thickness in the target wedge-shaped insulation structure. and end layer insulation thickness The relevant information is calculated using the following formula:

[0059] in, The height of the conductor coil, For narrow paper strip width, For the thickness of the paper tape, This refers to the thickness of the conductor.

[0060] The overlap ratio defines the proportion of overlap between adjacent paper tapes, and its initial and final values ​​directly determine the starting and ending thicknesses of the wedge-shaped insulation structure. Initial overlap ratio The calculation formula is as follows, corresponding to the starting end (thinnest part) of the wedge-shaped insulation:

[0061] in, For the thickness of the paper tape, This represents the initial layer insulation thickness.

[0062] End-of-line overlap rate The calculation formula is as follows, corresponding to the termination end (thickest part) of the wedge-shaped insulation:

[0063] in, For the thickness of the paper tape, In the actual winding process, the overlap rate changes from the initial value. To the endpoint value The gradual changes between these elements form the desired wedge-shaped insulation structure.

[0064] The coil winding process in step S3 employs constant tension technology, specifically including: The winding process is carried out in a constant tension control system. For example... Figure 5As shown, the constant tension control system includes a wire feeding mechanism and a rocker arm mechanism. The wire feeding mechanism includes two counter-rotating drive wheels. The constant tension control system calculates the required winding speed from the winding speed, and then calculates the wire feeding speed of the wire feeding wheels based on the required winding speed, ensuring a perfect match between the wire feeding speed and the winding speed. Once a dynamic balance is achieved between the wire feeding speed and the winding speed, as shown... Figure 6 As shown, the rocker arm mechanism applies pressure to the running conductor through a cylinder, providing a constant tension to the conductor.

[0065] In step S3, during the winding process, a high-precision vision sensor is used to monitor the moving wire online, specifically including: The online monitoring process during winding is conducted within an online monitoring system. Visual sensors in this system continuously monitor the moving conductors during coil winding, collecting data including surface defects and conductor dimensions. The system intelligently analyzes the real-time data, continuously assessing conductor appearance quality and accurately identifying defects such as insulation damage. Upon detecting a quality defect, the system outputs a quality alarm signal and controls the constant tension control system to stop, upgrading the quality inspection model from "post-production sampling" to "full-process inspection," effectively improving defect interception rate and first-pass yield.

[0066] Example 2: like Figure 2 As shown, this embodiment provides a fully automated winding process device for transformer layer coils, comprising: A module for flattening round wires, in which: Before winding the wire, the round wire is first flattened to increase its strength. The flattened coil wire has a higher fill rate, which reduces the amount of copper and oil used. In addition, the line contact between the wire and the interlayer insulation becomes a surface contact, resulting in better bonding and higher coil strength.

[0067] The module for selecting coil insulation includes: The original adhesive paper insulation and cardboard end insulation inside the coil were replaced with narrow paper tape insulation.

[0068] The thickness of the narrow paper tape insulation is determined based on the interlayer voltage gradient. The narrow paper tapes are stacked layer by layer with a progressive overlap rate to form a wedge-shaped insulation structure, minimizing the amount of insulation material used while ensuring insulation strength. The overlap rate is generally set within the range of 25% progressively increasing to 85%.

[0069] A module for coil winding and online monitoring, in which: The coil winding process employs constant tension technology. Simultaneously, during the winding process, a high-precision visual sensor is used to monitor the moving wires online.

[0070] The aforementioned round wire flattening module specifically includes: Before winding the conductor, set the flattening parameters, i.e., the flattening ratio. Based on the flattening curve of the conductor material, select the flattening ratio within the maximum flattening limit of the conductor, and then flatten the conductor.

[0071] Round conductors are flattened by a flattening wheel, changing their cross-sectional area from circular to oblong. The conductor width increases accordingly, while the cross-sectional area decreases. During flattening, the air gap within the coil decreases, increasing the bonding area between the conductor and insulation. The reduction in air gap between the conductors is... The calculation method is as follows:

[0072] in, The flattening ratio is denoted as .

[0073] In the coil insulation selection module, narrow paper tapes are stacked layer by layer to form a wedge-shaped insulation structure with a progressive overlap rate. The overlap rate is calculated as follows: To achieve fully automated winding, the number of turns of the narrow paper tape must match the number of turns of the conductor. When the number of conductor turns (X) equals the number of turns of the narrow paper tape (Y), the winding is synchronized, enabling fully automated winding. If the number of conductor turns (X) and the number of turns of the narrow paper tape (Y) are not equal, the overlap ratio of the narrow paper tape needs to be adjusted until the matching condition is met. The number of conductor turns (X) is a fixed value and cannot be changed, while the number of turns of the narrow paper tape (Y) varies according to the overlap ratio.

[0074] The number of turns Y of the narrow paper tape is related to the initial layer insulation thickness in the target wedge-shaped insulation structure. and end layer insulation thickness The relevant information is calculated using the following formula:

[0075] in, The height of the conductor coil, For narrow paper strip width, For the thickness of the paper tape, This refers to the thickness of the conductor.

[0076] The overlap ratio defines the proportion of overlap between adjacent paper tapes, and its initial and final values ​​directly determine the starting and ending thicknesses of the wedge-shaped insulation structure. Initial overlap ratio The calculation formula is as follows, corresponding to the starting end (thinnest part) of the wedge-shaped insulation:

[0077] in, For the thickness of the paper tape, This represents the initial layer insulation thickness.

[0078] End-of-line overlap rate The calculation formula is as follows, corresponding to the termination end (thickest part) of the wedge-shaped insulation:

[0079] in, For the thickness of the paper tape, In the actual winding process, the overlap rate changes from the initial value. To the endpoint value The gradual changes between these elements form the desired wedge-shaped insulation structure.

[0080] In the coil winding and online monitoring module, the coil winding process employs constant tension technology, specifically including: The winding process is carried out in a constant tension control system. This system includes a wire feeding mechanism and a rocker arm mechanism. The wire feeding mechanism comprises two counter-rotating drive wheels. The constant tension control system calculates the required winding speed from the winding speed, and then calculates the wire feeding speed of the feeding wheels based on the required winding speed, ensuring a perfect match between the wire feeding speed and the winding speed. Once a dynamic balance is achieved between the wire feeding speed and the winding speed, the rocker arm mechanism applies pressure to the running conductor via a cylinder, providing constant tension to the conductor.

[0081] In the coil winding and online monitoring module, a high-precision vision sensor is used to monitor the moving wire online during the winding process, specifically including: The online monitoring process during winding is conducted within an online monitoring system. Visual sensors in this system continuously monitor the moving conductors during coil winding, collecting data including surface defects and conductor dimensions. The system intelligently analyzes the real-time collected data, continuously monitoring conductor appearance quality and accurately identifying defects such as insulation damage. Upon detecting a quality defect, the system outputs a quality alarm signal and controls the constant tension control system to stop, effectively improving defect interception rate and first-pass yield.

[0082] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. The methods disclosed in the embodiments are described simply because they correspond to the systems disclosed in the embodiments; relevant details can be found in the method section.

[0083] Those skilled in the art will further recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, computer software, or a combination of both. To clearly illustrate the interchangeability of hardware and software, the components and steps of the various examples have been generally described in terms of functionality in the foregoing description. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementations should not be considered beyond the scope of this invention.

[0084] In the embodiments provided by this invention, it should be understood that the disclosed systems, methods, and approaches can be implemented in other ways. For example, the system embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between systems or units may be electrical, mechanical, or other forms.

[0085] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0086] In addition, the functional modules in the various embodiments of the present invention can be integrated into one processing unit, or each module can exist physically separately, or two or more modules can be integrated into one unit.

[0087] Similarly, in the various embodiments of the present invention, each processing unit can be integrated into a functional module, or each processing unit can exist physically, or two or more processing units can be integrated into a functional module.

[0088] The steps of the methods or algorithms described in conjunction with the embodiments disclosed herein can be implemented directly by hardware, a software module executed by a processor, or a combination of both. The software module can be located in random access memory (RAM), main memory, read-only memory (ROM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or any other form of storage medium known in the art.

[0089] Finally, it should be noted that in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0090] The above-disclosed embodiments are merely preferred embodiments of the present invention, but the present invention is not limited thereto. Any non-creative variations that can be conceived by those skilled in the art, as well as any improvements and modifications made without departing from the principles of the present invention, should fall within the protection scope of the present invention.

Claims

1. A fully automatic process for winding a transformer layer winding, characterized in that It comprises the following steps: Step S1, the step of flattening the round wire, in which: The round wire is flattened into a flat wire before winding; Step S2, the step of selecting coil insulation, in which: The original point gluing paper insulation inside the coil and the paperboard end insulation are replaced with narrow paper tape insulation; The thickness of the narrow paper tape insulation is determined according to the interlayer voltage gradient, and the narrow paper tape is arranged in a wedge-shaped insulation structure by layer-by-layer superposition according to a gradual lap rate; Step S3, the step of coil winding and online monitoring, in which: The constant tension technology is adopted in the winding process, and the moving wire is monitored online by a high-precision visual sensor during the winding process.

2. The full automatic process method for winding transformer layer coil according to claim 1, characterized in that, The step S1 specifically comprises: According to the flattening curve of the wire material, the flattening rate within the maximum flattening limit of the wire is selected, and the wire is flattened; The round wire is flattened by a flattening wheel, and the gap reduction amount between the wires during the flattening process is θ: wherein, is the flattening ratio.

3. The process for full automatic winding of transformer layer-winding according to claim 1, characterized in that, In the step S2, the narrow paper tape is arranged in a wedge-shaped insulation structure by layer-by-layer superposition according to a gradual lap rate, and the lap rate is calculated as follows: The winding turn number of the narrow paper tape is adjusted to match the number of turns of the wire, and when the number of turns of the wire X is equal to the winding turn number Y of the narrow paper tape, full-automatic winding is performed, and if the number of turns of the wire is not equal to the winding turn number of the narrow paper tape, the lap rate of the narrow paper tape is adjusted until the matching condition is met; The winding turn number of the narrow paper tape is calculated by the following formula: wherein, is the height of the conductor coil, is the width of the narrow paper strip, is the thickness of the paper strip, is the thickness of the conductor, is the initial layer insulation thickness, is the end layer insulation thickness; Initial overlap ratio For the wedge-shaped insulation, the formula is as follows: wherein, is the paper tape thickness, is the initial layer insulation thickness; End lap ratio For the wedge insulation, the formula is as follows: wherein is the paper tape thickness, ; During the winding process, the lap rate gradually changes from an initial value to a final value to form the desired wedge-shaped insulation structure.

4. The full automatic process of winding transformer layer coil according to claim 1, characterized in that, In the step S3, the constant tension technology is adopted in the winding process, specifically comprising: The winding process is carried out in a constant tension control system; The constant tension control system comprises a wire feeding mechanism and a swing lever mechanism, wherein the wire feeding mechanism comprises two counter-rotating driving wheels; The constant tension control system calculates the wire feeding speed according to the wire winding speed, so that the wire feeding speed and the wire winding speed are completely matched, and after the dynamic balance of the wire feeding speed and the wire winding speed is reached, the swing lever mechanism provides a constant tension of the running wire through a gas cylinder.

5. The full automatic process of winding transformer layer coil according to claim 1, characterized in that, In the step S3, the moving wire is monitored online by a high-precision visual sensor during the winding process, specifically comprising: The online monitoring is carried out during the winding process, and the visual sensor in the online monitoring system continuously detects the moving wire during the winding process of the coil, and the detection data includes surface defects and wire size of the wire, the online monitoring system intelligently analyzes the real-time collected detection data, and detects the appearance quality of the wire in real time to identify insulation damage defects; The online monitoring system outputs a quality alarm signal after identifying the quality defects, and controls the constant tension control system to stop.

6. A device for full automatic winding of transformer layer winding, characterized in that, It comprises: A module of flattening the round wire, in which: The round wire is flattened into a flat wire before winding; A module of selecting coil insulation, in which: The original point gluing paper insulation inside the coil and the paperboard end insulation are replaced with narrow paper tape insulation; The thickness of the narrow paper tape insulation is determined according to the interlayer voltage gradient, and the narrow paper tape is arranged in a wedge-shaped insulation structure by layer-by-layer superposition according to a gradual lap rate; A module of coil winding and online monitoring, in which: The constant tension technology is adopted in the winding process, and the moving wire is monitored online by a high-precision visual sensor during the winding process.

7. The apparatus for full-automatic winding process of transformer layer-type coil according to claim 6, characterized in that, The module of flattening the round wire specifically comprises: According to the flattening curve of the wire material, a flattening rate within the maximum flattening limit of the wire is selected, and the wire is flattened; The round wire is flattened by the flattening wheel; during the flattening process, the air gap in the coil is reduced, and the reduction amount θ of the air gap between the wires is calculated: wherein, is the flattening ratio.

8. The apparatus for full-automatic winding process of transformer layer-type coil according to claim 6, characterized in that, The narrow paper tape in the coil insulation selection module is arranged in a wedge-shaped insulation structure layer by layer according to a gradual lap rate, and the lap rate is calculated as follows: Adjust the winding turns of the narrow paper tape to match the number of turns of the wire: when the number of turns of the wire X is equal to the winding turns Y of the narrow paper tape, full-automatic winding is performed; if the number of turns of the wire and the winding turns of the narrow paper tape are not equal, the lap rate of the narrow paper tape is adjusted until the matching condition is met; The winding turns of the narrow paper tape are calculated by the following formula: wherein, is the wire loop height, is the narrow paper tape width, is the paper tape thickness, is the wire thickness, is the initial layer insulation thickness, is the end layer insulation thickness; Initial overlap ratio For the wedge-shaped insulation, the formula is as follows: wherein, is the paper tape thickness, is the initial layer insulation thickness; End lap ratio For the wedge insulation termination, the formula is as follows: wherein is the paper tape thickness, ; During the winding process, the lap rate gradually changes from an initial value to a final value to form the desired wedge-shaped insulation structure.

9. The apparatus for full-automatic winding process of transformer layer-type coil according to claim 6, characterized in that, In the coil winding and online monitoring module, the constant tension technology is used in the winding process, which specifically includes: The winding process is carried out in the constant tension control system; The constant tension control system includes a wire feeding mechanism and a swing lever mechanism, wherein the wire feeding mechanism includes two counter-rotating driving wheels; The constant tension control system calculates the wire winding speed to obtain the wire feeding speed, and then calculates the wire feeding speed of the wire feeding wheel according to the wire feeding speed, so that the wire feeding speed and the wire winding speed are completely matched. When the dynamic balance of the wire feeding speed and the wire winding speed is reached, the swing lever mechanism provides the running wire with pressure through the air cylinder, thereby providing the wire with constant tension.

10. The apparatus for full-automatic winding process of transformer layer-type coil according to claim 6, characterized in that, In the coil winding and online monitoring module, the moving wire is monitored online during the winding process through a high-precision visual sensor, which specifically includes: The online monitoring is carried out during the winding process, and the visual sensor in the online monitoring system continuously detects the moving wire during the winding process. The detection data includes the surface defects of the wire and the size of the wire. The online monitoring system intelligently analyzes the real-time collected detection data and detects the appearance quality of the wire in real time, accurately identifies insulation damage defects, and outputs quality alarm signals when quality defects are identified. The online monitoring system identifies quality defects and outputs quality alarm signals, and controls the constant tension control system to stop.

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