Winding device for current transformer processing and winding method thereof

Abstract

The invention discloses a winding device for current transformer machining and a winding method thereof, and relates to the technical field of current transformer production equipment.The winding device for current transformer machining comprises a supporting seat, a winding device, a winding device, a winding device and a winding device, the wire winding assembly is used for winding a wire; the tensioning and guiding assembly is used for guiding and tensioning the wire; the detecting and correcting assembly is used for detecting and correcting the wound wire and comprises an electric push rod, a support is arranged at the telescopic end of the top of the electric push rod, a supporting seat is arranged at the end of the support, a supporting frame is arranged at the bottom of the supporting seat, a base is arranged at the bottom of the supporting frame, side seats are arranged on the two sides of the base, and rotating seats are rotationally connected to the side seats in a penetrating mode. According to the current transformer winding device, accurate tension control is achieved, the functions of online detection and automatic correction are achieved, the current transformer winding device adapts to various wire characteristics, intelligent control is integrated, and the winding quality, the production efficiency and the product consistency are improved.

Description

Technical Field

[0001] This invention relates to the field of current transformer manufacturing equipment technology, specifically to a winding device and winding method for processing current transformers. Background Technology

[0002] Current transformers are key devices in power systems used for current measurement, energy metering, and relay protection. The winding quality of the primary winding of a current transformer directly affects its performance, accuracy, and reliability.

[0003] Chinese Patent Application No. 202411645619.8 discloses a winding device and method for the primary coil of a current transformer, including a base and a stand. The stand is vertically mounted on the base, and a ring seat is rotatably mounted on the stand. A mounting ring is provided on the outer side of the ring seat, and a rectangular seat is bolted to the outer side of the mounting ring. A toothed ring is mounted on the inner side of the ring seat. Notches are formed on the ring seat, mounting ring, rectangular seat, and toothed ring. A rotating plate is rotatably mounted within the notch of the rectangular seat. A core seat is slidably mounted on the stand, and an inverted isosceles trapezoidal core groove is formed inside the core seat. Limiting plates are slidably mounted on both sides of the core groove. However, it is difficult to dynamically adjust and stably maintain the tension during the winding process, and tension fluctuations easily occur in the conductor during winding.

[0004] In addition, most existing winding devices lack online detection functions, making it impossible to identify defects such as overlapping wires, skipped turns, and uneven wire arrangement during the winding process in real time. They also often cannot achieve automatic correction, requiring machine stoppage and intervention, which affects production efficiency. Furthermore, wires of different specifications and materials have different mechanical properties during the winding process. Traditional equipment cannot adjust the clamping force, pushing frequency, and tensioning strategy in a targeted manner, which can easily lead to phenomena such as poor contact between the wire and the winding seat and elastic reset, affecting the winding quality and the structural stability of the coil. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the existing defects and provide a winding device and winding method for current transformer processing, which realizes precise tension control, has online detection and automatic correction functions, adapts to various conductor characteristics, and integrates intelligent control of the current transformer winding device, so as to improve winding quality, production efficiency and product consistency, and can effectively solve the problems in the background art.

[0006] To achieve the above objectives, the present invention discloses the following technical solution: a winding device for processing current transformers, comprising:

[0007] The support base has a pedestal at the bottom and a movable seat at the top.

[0008] Winding assembly for winding wires;

[0009] Tensioning guide assembly, used for guiding and tensioning conductors;

[0010] The detection and correction assembly is used to detect and correct the wound wire. It includes an electric push rod, a bracket at the top telescopic end of the electric push rod, a support at the end of the bracket, a support frame at the bottom of the support, a base at the bottom of the support frame, side seats on both sides of the base, a rotating seat rotatably connected through the side seats, a guide rod slidably connected inside the rotating seat, and an auxiliary seat at the bottom of the guide rod.

[0011] The side seat is equipped with a rotating mechanism for driving the rotating seat to rotate;

[0012] The base is equipped with a drive mechanism for driving the side seats on both sides to move linearly.

[0013] The detection and correction assembly also includes a trapezoidal base and two corresponding movable rods. The distal ends of the movable rods on both sides are provided with limiting wedges, and the proximal ends of the movable rods on both sides are provided with transmission wedges. An electric cylinder is provided at the top of the support, and the telescopic end of the electric cylinder passes through the trapezoidal base at the top of the support frame.

[0014] Preferably, the winding assembly includes two sets of positioning wheels, which are rotatably connected to the sides of the movable seat and the support seat, respectively. A turntable is rolled together between the positioning wheels, and a winding seat is provided on the side of the turntable.

[0015] The inner side of the turntable is provided with a toothed disc, and a transmission gear is meshed on one side of the toothed disc. The transmission gear is rotatably connected to the side of the support base through a rotating shaft. A rotating motor is provided on the base, and the output shaft of the rotating motor is connected to the end of the rotating shaft through a belt drive mechanism.

[0016] Preferably, the tensioning guide assembly includes a guide groove, which is opened on one side of the support base. A slide block is slidably connected in the guide groove. One end of the slide block is fixedly connected to the telescopic end of a hydraulic rod located on the side of the support base. The other end of the slide block is provided with an electric telescopic rod. The telescopic end of the electric telescopic rod is provided with a frame seat. The frame seat has a U-shaped structure. Slide rods slide through both ends of the frame seat. Pressure seats are provided at opposite ends of the slide rods on both sides. Elastic pads are provided on opposite sides of the two pressure seats. A tension sensor is provided between the elastic pads and the pressure seats. A traction spring is sleeved on the outside of the slide rod. Guide wheel assemblies corresponding to the pressure seats are provided on both sides of the frame seat.

[0017] Preferably, the inner wall of the frame is provided with an electromagnetic push rod, the telescopic end of the electromagnetic push rod is provided with a U-shaped seat, both ends of the U-shaped seat are provided with inclined surfaces facing each other, the sides of the two pressure seats are provided with wedges facing away from each other, and the inclined surfaces at both ends of the U-shaped seat cooperate with the two wedges respectively.

[0018] Preferably, the electric push rod is embedded in the movable seat, the support and the support frame are both U-shaped structures, the bottom of the auxiliary seat has chamfers on both sides, the bottom of the auxiliary seat is provided with a photoelectric sensor, the bottom of the guide rod is sleeved with a limit spring, and a pressure sensor is provided between the limit spring and the auxiliary seat.

[0019] Preferably, the rotating mechanism includes a secondary gear fixedly sleeved on a rotating base, a primary gear meshing with one side of the secondary gear, and the primary gear fixedly sleeved on the output shaft of a rotary motor mounted on a side seat.

[0020] Preferably, the driving mechanism includes a slide groove and a drive motor located in the middle of the base. A screw is rotatably connected in the slide groove, and a slider is threaded onto the screw. The slider is slidably connected to the slide groove, and both sides of the slider are fixedly connected to the ends of the side seats on both sides. The drive motor is located at the end of the base, and the output shaft of the drive motor is fixedly connected to the end of the screw.

[0021] Preferably, the two movable rods slide through both sides of the support frame, and a return spring is sleeved on the outside of each movable rod;

[0022] The limiting wedge seat is matched with the top of the guide rod;

[0023] The trapezoidal seat corresponds to and engages with the transmission wedge seats on both sides.

[0024] Preferably, one end of the movable seat is movably connected to the top of the support seat, and the other end of the movable seat is detachably connected to the top of the support seat.

[0025] This invention also discloses a winding method for a winding device used in the processing of current transformers, comprising the following steps:

[0026] S1. Assemble the turntable and winding seat, lock the movable seat and the support seat, so that the positioning wheel and the turntable roll together, and pass the wire through the inlet side guide wheel group, the two side pressure seats and the outlet side guide wheel group in sequence, and fix the end to the starting position of the winding seat.

[0027] S2. The control system starts the electromagnetic push rod, which drives the pressure seat to close and clamp the wire through the cooperation of the U-shaped seat and the wedge block. The tension sensor detects the traction force signal and feeds it back. The control system adjusts the extension and retraction of the hydraulic rod according to the preset tension threshold to set the initial tension of the wire.

[0028] S3. Start the rotating motor, which drives the winding seat to rotate through the transmission mechanism consisting of belt transmission mechanism, rotating shaft, transmission gear and toothed disc for winding. The control system collects the winding turn signal in real time, and at the same time controls the electric telescopic rod to extend synchronously, driving the frame seat to move to match the winding position of the wire.

[0029] S4. During the winding process, the tension sensor continuously feeds back the tension signal. The control system compares the detected value with the preset threshold. If the tension is insufficient, the hydraulic rod is extended to increase the tension. If the tension is too large, the hydraulic rod is contracted to reduce the tension. At the same time, the extension and retraction of the electromagnetic push rod is adjusted to optimize the clamping force and maintain stable tension.

[0030] S5. Every time the winding seat rotates to a horizontal position, the control system triggers the electric push rod to drive the auxiliary seat to press down and fit the coil. The pressure sensor detects the resistance force, and the photoelectric sensor detects the coil gap.

[0031] S6. If the pressure exceeds the threshold and is determined to be a wire overlap, the control system starts the rotation mechanism to rotate the auxiliary seat to the direction parallel to the wire, and the drive mechanism drives the auxiliary seat to move and correct it.

[0032] S7. If the gap light signal exceeds the threshold and is determined to be a skipped turn, the control auxiliary seat reciprocates to push the wire to eliminate the gap. The high hardness wire is adapted to the electric cylinder for high-frequency reciprocating pressure, and the high toughness wire is adapted to the electric cylinder for continuous pressure and the hydraulic rod for synchronous tensioning composite control.

[0033] S8. When the number of winding turns reaches the preset value, the control system cuts off the power of the rotating motor, each actuator resets, the clamp between the pressure seat and the wire is released, the movable seat is unlocked, and the wound coil is removed.

[0034] Compared with the prior art, the present invention has the following beneficial effects:

[0035] 1. In the winding process of this invention, the electromagnetic push rod drives the U-shaped seat to cooperate with the wedge block to close the pressure seat and clamp the wire. The tension sensor detects the traction force in real time and feeds it back to the control system. The system dynamically adjusts the extension and retraction of the hydraulic rod according to the preset tension threshold, thereby actively adjusting the tension of the wire to continuously maintain the tension stability and effectively avoid the problem of large tension fluctuations in the traditional winding process.

[0036] 2. When the winding seat of this invention rotates to the horizontal position, the electric push rod drives the auxiliary seat to press down and fit the coil. The pressure sensor and photoelectric sensor detect the stacked wire and skipped turn signals respectively. Once a defect is identified, the rotation mechanism drives the auxiliary seat to rotate to the direction parallel to the conductor. The drive mechanism drives the auxiliary seat to move linearly to push and correct the stacked wire part, or to push and push the skipped turn part to eliminate the gap. This realizes online detection and real-time intervention, ensuring the tight fit and uniform arrangement of each turn of conductor.

[0037] 3. For high-hardness wires, the electric cylinder can reciprocate at high frequency. The trapezoidal seat and the transmission wedge seat work together to drive the limiting wedge seat to apply pressure to the guide rod, thereby achieving high-frequency pressure on the auxiliary seat and causing the hard wire to adhere to the surface of the winding seat. For high-toughness wires, a composite control method is adopted, which uses the electric cylinder to continuously apply pressure and the hydraulic rod to synchronously increase the tension, thereby suppressing the elastic reset of the wire, expanding the applicable wire range of the device, and further optimizing the winding forming quality. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the structure of the present invention;

[0039] Figure 2 This is a schematic diagram of the axial structure of the present invention;

[0040] Figure 3 For the present invention Figure 2 Enlarged structural diagram at point A in the middle;

[0041] Figure 4 This is a schematic diagram of the structure of the present invention from another angle;

[0042] Figure 5 For the present invention Figure 4 Enlarged structural diagram at point B.

[0043] In the diagram: 1. Support base; 101. Movable base; 2. Winding assembly; 201. Positioning wheel; 202. Turntable; 203. Winding base; 204. Gear plate; 205. Rotating shaft; 206. Transmission gear; 207. Belt drive mechanism; 208. Rotary motor; 3. Tensioning guide assembly; 301. Guide groove; 302. Slide; 303. Hydraulic rod; 304. Electric telescopic rod; 305. Frame base; 306. Slide rod; 307. Pressure base; 308. Traction spring; 309. Guide wheel assembly; 310. Electromagnetic push rod; 311. U-shaped base; 312. Wedge block ; 4. Detection and correction components; 401. Electric push rod; 402. Bracket; 403. Support; 404. Support frame; 405. Base; 406. Side seat; 407. Rotating seat; 408. Guide rod; 409. Auxiliary seat; 410. Limiting spring; 411. Secondary gear; 412. Rotary motor; 413. Main gear; 414. Slide groove; 415. Screw; 416. Slider; 417. Drive motor; 418. Movable rod; 419. Limiting wedge seat; 420. Transmission wedge seat; 421. Return spring; 422. Electric cylinder; 423. Trapezoidal seat. Detailed Implementation

[0044] 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.

[0045] Example 1

[0046] Please see Figure 1-5 The present invention discloses a winding device for processing current transformers, including a support base 1, a platform at the bottom, and a movable seat 101 at the top of the support base 1. One end of the movable seat 101 is movably connected to the top of the support base 1, and the other end of the movable seat 101 is detachably connected to the top of the support base 1.

[0047] Specifically, one end of the movable seat 101 is rotatably connected to the top side of the support seat 1, and the other end is detachably connected to the other top side of the support seat 1, so that the movable seat 101 can be separated from the support seat 1, making it easier to remove the turntable 202 and the winding seat 203.

[0048] It also includes a winding assembly 2 for winding wires. The winding assembly 2 includes two sets of positioning wheels 201, which are rotatably connected to the sides of the movable seat 101 and the support seat 1, respectively. A turntable 202 is rolled together between the positioning wheels 201. A winding seat 203 is provided on the side of the turntable 202. A toothed disc 204 is provided on the inner side of the turntable 202. A transmission gear 206 is meshed on one side of the toothed disc 204. The transmission gear 206 is rotatably connected to the side of the support seat 1 through a rotating shaft 205. A rotating motor 208 is provided on the platform. The output shaft of the rotating motor 208 is connected to the end of the rotating shaft 205 through a belt transmission mechanism 207.

[0049] Specifically, both the turntable 202 and the winding seat 203 are detachable and separate designs. The rotating motor 208 drives the rotating shaft 205 to rotate through the belt transmission mechanism 207. The rotation of the turntable 202 is achieved by the meshing of the transmission gear 206 with the gear plate 204, thereby driving the winding seat 203 to rotate. At the same time, the positioning groove on the positioning wheel 201 cooperates with the flange on the circumference of the turntable 202 to position the turntable 202.

[0050] It also includes a tensioning guide assembly 3 for guiding and tensioning the conductor. The tensioning guide assembly 3 includes a guide groove 301, which is opened on one side of the support base 1. A slide block 302 is slidably connected in the guide groove 301. One end of the slide block 302 is fixedly connected to the telescopic end of the hydraulic rod 303 located on the side of the support base 1. The other end of the slide block 302 is provided with an electric telescopic rod 304. The telescopic end of the electric telescopic rod 304 is provided with a frame seat 305. The frame seat 305 has a U-shaped structure. Both ends of the frame seat 305 are slidably connected to slide rods 306. Each side of the slide rods 306 is provided with a pressure seat 307. An elastic pad is provided on the opposite side of the two pressure seats 307. A tension sensor is provided between the elastic pad and the pressure seat 307. A traction spring 308 is sleeved on the outside of the slide rod 306. Both sides of the frame seat 305 are provided with guide wheel sets 309 corresponding to the pressure seats 307.

[0051] The inner wall of the frame 305 is provided with an electromagnetic push rod 310. The telescopic end of the electromagnetic push rod 310 is provided with a U-shaped seat 311. Both ends of the U-shaped seat 311 are provided with inclined surfaces facing each other. The sides of the two pressure seats 307 are provided with wedges 312 facing away from each other. The inclined surfaces at both ends of the U-shaped seat 311 are respectively engaged with the two wedges 312.

[0052] Specifically, the end of the wire passes through the guide wheel assembly 309 on the inlet side and enters between the two pressure seats 307, and is led out and fixed on the winding seat 203 through the guide wheel assembly 309 on the outlet side. During the wire winding process, the guide wheel assembly 309 guides the wire. The extension of the electromagnetic push rod 310 drives the U-shaped seat 311 to extend. With the inclined surfaces at both ends of the U-shaped seat 311 cooperating with the two wedges 312 respectively, the pressure seats 307 on both sides that are in a separated state are driven to close and clamp the wire. The traction spring 308 is compressed, thereby increasing the frictional resistance when the wire is fed. The extension of the hydraulic rod 303 drives the frame seat 305 to move away from the winding seat 203, thereby increasing the tension of the wire during the winding process. The tension of the wire during winding can be adjusted by adjusting the extension and retraction of the electromagnetic push rod 310 and the hydraulic rod 303. The tension sensor is used to detect the traction force applied by the wire to the elastic pad, thereby indirectly detecting the tension of the wire.

[0053] During the winding process, as the number of coil turns increases, the electric telescopic rod 304 gradually extends to match the wire delivery position with the winding position of the wire on the winding seat 203.

[0054] It also includes a detection and correction component 4 for detecting and correcting the wound wire, including an electric push rod 401, which is embedded in the movable seat 101. The top telescopic end of the electric push rod 401 is provided with a bracket 402, the end of the bracket 402 is provided with a support 403, and the bottom of the support 403 is provided with a support frame 404. Both the support 403 and the support frame 404 are U-shaped structures. The bottom of the support frame 404 is provided with a base 405, and both sides of the base 405 are provided with side seats 406. A rotating seat 407 is rotatably connected through the side seats 406. A guide rod 408 is slidably connected inside the rotating seat 407. The bottom end of the guide rod 408 is provided with an auxiliary seat 409. The bottom sides of the auxiliary seat 409 are chamfered. A photoelectric sensor is provided at the bottom of the auxiliary seat 409. A limit spring 410 is sleeved on the bottom of the guide rod 408. A pressure sensor is provided between the limit spring 410 and the auxiliary seat 409.

[0055] Specifically, a limiting structure is provided between the rotating seat 407 and the guide rod 408, so that the guide rod 408 can only slide axially along the rotating seat 407. During the process of the winding seat 203 rotating to wind the wire, every time the winding seat 203 rotates to a horizontal state, the electric push rod 401 retracts and drives the bracket 402 to move downward. That is, through the support 403 and the support frame 404, the base 405 and the auxiliary seat 409 move downward. The auxiliary seat 409 is lower than the base 405, so that the auxiliary seat 409 presses tightly against the coil wound on the winding seat 203, so that the wound wire is further attached to the winding seat 203. At the same time, the limiting spring 410 is compressed, and the amount of retraction of the electric push rod 401 is preset according to the specifications of the winding seat 203. Under normal circumstances, the pressure value detected by the pressure sensor is within the normal pressure threshold range.

[0056] The detection and correction assembly 4 also includes a trapezoidal seat 423 and two corresponding movable rods 418. The two movable rods 418 slide through both sides of the support frame 404. The distal ends of the movable rods 418 on both sides are provided with limiting wedges 419, which are correspondingly engaged with the top of the guide rod 408. The proximal ends of the movable rods 418 on both sides are provided with transmission wedges 420. A return spring 421 is sleeved on the outside of the movable rods 418. An electric cylinder 422 is provided on the top of the support 403. The telescopic end of the electric cylinder 422 passes through the top of the support frame 404 and is provided with a trapezoidal seat 423. The trapezoidal seat 423 is correspondingly engaged with the transmission wedges 420 on both sides.

[0057] Specifically, the trapezoidal seat 423 is preferably an isosceles trapezoid. The extension of the electric cylinder 422 drives the trapezoidal seat 423 to move downward, so that the trapezoidal seat 423 engages with the transmission wedge seats 420 on both sides, thereby driving the movable rods 418 on both sides to move horizontally to both sides. The return spring 421 is stretched, so that the limiting wedge seats 419 on both sides abut against the top of the guide rods 408 on both sides, which makes the guide rods 408 tend to move downward, providing downward pressure to the auxiliary seat 409.

[0058] In use, first assemble the separate turntable 202 and winding seat 203, lift one end of the movable seat 101 upwards, and roll the turntable 202 with the positioning groove of the positioning wheel 201 on the lower side of the support seat 1 through the circumferential flange. Then lower the movable seat 101 and limit the end of the movable seat 101 with the top of the support seat 1, so that the positioning wheel 201 on the movable seat 101 rolls with the top of the turntable 202, thus completing the positioning and installation of the turntable 202 and the winding seat 203.

[0059] The end of the wire to be wound is passed sequentially through the guide wheel group 309 on the inlet side, then through the space between the two pressure seats 307, and led out through the guide wheel group 309 on the outlet side. Finally, it is fixed at the preset winding start position of the winding seat 203. At this time, the control system starts the electromagnetic push rod 310. The telescopic end of the electromagnetic push rod 310 pushes the U-shaped seat 311 to move towards the pressure seat 307. The inclined surfaces at both ends of the U-shaped seat 311 and the wedges 312 on the sides of the two pressure seats 307 form an inclined surface cooperation, which drives the two pressure seats 307 to close inward along the slide rod 306 to clamp the wire and increase the frictional resistance when the wire is passively fed, so that the wire is initially tensioned when passively fed.

[0060] The rotating motor 208 is started, and the output shaft of the rotating motor 208 transmits power to the rotating shaft 205 through the belt transmission mechanism 207, causing the rotating shaft 205 and the transmission gear 206 to rotate synchronously. The transmission gear 206 drives the gear disk 204 to rotate, which in turn drives the turntable 202 and the winding seat 203 to rotate. During the rotation of the winding seat 203, the wire is continuously pulled along the outer circumference of the winding seat 203 to form the coil structure of the current transformer. During this process, the two sets of positioning wheels 201 limit the rotation trajectory of the turntable 202 through rolling cooperation with the turntable 202, ensuring the coaxiality of the winding seat 203 and avoiding eccentric offset during the winding process.

[0061] During the winding process, the guide wheel group 309 on the inlet and outlet sides provides bidirectional guidance for the conductor, limiting the lateral deviation of the conductor and ensuring that the conductor is always fed to the winding seat 203 along the preset feed path. The tension sensor between the pressure seat 307 and the elastic pad detects the traction force applied by the conductor to the elastic pad in real time. The traction force indirectly reflects the current tension of the conductor and feeds the detection signal back to the control system to form a closed-loop control of tension.

[0062] When the tension sensor detects insufficient tension, the control system activates the hydraulic rod 303. The telescopic end of the hydraulic rod 303 pushes the slide 302 along the guide groove 301 in a direction away from the winding seat 203, further increasing the tensile tension of the wire and adjusting the tension. Conversely, when the tension is too high, the tension of the wire can be reduced by retracting the hydraulic rod 303 to move the slide 302 towards the winding seat 203. Thus, by controlling the telescopic amount of the hydraulic rod 303, the tension of the wire can be precisely controlled during the winding process, avoiding excessive tension fluctuations.

[0063] As the number of coil turns on the winding base 203 increases, the control system controls the electric telescopic rod 304 to extend synchronously and gradually according to the preset correspondence between the number of turns and the extension amount, driving the frame base 305 to move away from the support base 1, so as to realize the winding of the wire turn by turn.

[0064] Since the winding seat 203 has a square structure, when the winding seat 203 rotates to a horizontal state, the control system synchronously triggers the electric push rod 401 to move. The telescopic end of the electric push rod 401 retracts, and through the bracket 402, support 403, and support frame 404, it drives the base 405 and the auxiliary seats 409 on both sides to move downward, so that the auxiliary seats 409 press tightly against the wire layer that has just been wound on the winding seat 203, so that the wire further fits against the outer circumference of the winding seat 203. During this process, the guide rod 408 slides axially along the rotating seat 407, the limiting spring 410 is compressed, and the pressure sensor between the auxiliary seat 409 and the limiting spring 410 detects the pressure value of the pressing in real time.

[0065] When the wound conductor has high rigidity, the downward pressure of the auxiliary seat 409 makes it difficult for the conductor to adhere to the winding seat 203. Therefore:

[0066] When winding high-hardness wires, after the auxiliary seat 409 moves downward and presses against the wire, the electric cylinder 422 is activated, and the electric cylinder 422 reciprocates, driving the trapezoidal seat 423 to move up and down. When the trapezoidal seat 423 moves downward, the limit wedges 419 on both sides apply downward pressure to the guide rod 408 through the transmission wedge 420, and the return spring 421 is stretched. When the electric cylinder 422 retracts and drives the trapezoidal seat 423 to move upward, the return spring 421 drives the limit wedges 419 to return to their original position. Therefore, the reciprocating extension and retraction of the electric cylinder 422 realizes the high-frequency downward compression of the wire by the auxiliary seat 409, so that the high-hardness wire is completely in contact with the surface of the winding seat 203. The reciprocating extension and retraction frequency of the electric cylinder 422 is determined by the hardness of the wire. High-hardness wires are suitable for the high-frequency reciprocating extension and retraction of the electric cylinder 422.

[0067] In addition, when winding high-toughness conductors, after the conductor is flattened by the downward pressure of the auxiliary seat 409, the conductor will exhibit a small amount of elastic recovery, which will increase the gap between the conductor and the winding seat 203. Therefore, the following improvements are made when winding high-toughness conductors:

[0068] After the first turn of the high-toughness wire is wound, and after the auxiliary seat 409 presses against the wire, the electric cylinder 422 is activated to drive the trapezoidal seat 423 to move downward. By cooperating with the transmission wedge seats 420 on both sides, the movable rods 418 on both sides are pushed to slide outward along the support frame 404. The return spring 421 is stretched, and the limiting wedge seat 419 at the far end of the movable rod 418 abuts against the top of the guide rod 408, applying downward pressure to the guide rod 408. This increases the pressure of the auxiliary seat 409 against the wire layer, forcibly adhering the high-toughness wire to the surface of the winding seat 203. At the same time, the hydraulic rod 303 is activated to extend and further tighten the wire by clamping it, increasing the wire tension and preventing the wire from elastically returning to its original position after adhering to the surface of the winding seat 203. After the electric cylinder 422 returns to its original position, the tension is maintained at this time, thus ensuring that the subsequent winding of the high-toughness wire can completely adhere to the surface of the winding seat 203.

[0069] Example 2

[0070] However, during the winding process, if uneven inter-turn gaps or wire overlap occur, timely intervention and correction are not possible, resulting in coils that fail to meet production requirements after winding. Therefore, the following improvements are made:

[0071] The side seat 406 is provided with a rotating mechanism for driving the rotating seat 407 to rotate. The rotating mechanism includes a secondary gear 411 fixedly sleeved on the rotating seat 407. A main gear 413 meshes with one side of the secondary gear 411. The main gear 413 is fixedly sleeved on the output shaft of the rotary motor 412 provided on the side seat 406.

[0072] Specifically, the rotary motor 412 drives the rotating seat 407 to rotate through the meshing of the main gear 413 and the auxiliary gear 411, so that the auxiliary seats 409 on both sides rotate from a position perpendicular to the conductor to a position parallel to the conductor, that is, from longitudinal to lateral.

[0073] The base 405 is provided with a drive mechanism for driving the linear movement of the side seats 406 on both sides. The drive mechanism includes a slide groove 414 opened in the middle of the base 405 and a drive motor 417. A screw 415 is rotatably connected in the slide groove 414. A slider 416 is threaded on the screw 415. The slider 416 is slidably connected to the slide groove 414. The two sides of the slider 416 are respectively fixedly connected to the ends of the side seats 406 on both sides. The drive motor 417 is located at the end of the base 405. The output shaft of the drive motor 417 is fixedly connected to the end of the screw 415.

[0074] Specifically, the drive motor 417 drives the screw 415 to rotate, thereby realizing the linear sliding of the slider 416 and the linear movement of the auxiliary seats 409 on both sides. When the auxiliary seats 409 on both sides rotate to a position parallel to the wire, the linear movement of the auxiliary seats 409 is used to promptly handle the problems of wire overlap and skipped turns when the winding wire is detected to have overlap and skipped turns.

[0075] When the wire overlaps during the winding process, i.e. the wire is stacked on the wire of the adjacent turn, the auxiliary seat 409 will first come into contact with the stacked wire when it moves downward. As a result, when the electric push rod 401 retracts to a fixed length, the pressure value detected by the pressure sensor will increase and exceed the preset pressure threshold range, thus indicating that the wire overlap has occurred.

[0076] When a defect of overlapping wires is detected in the newly wound conductor on the winding seat 203, the auxiliary seat 409 is first raised. The control system starts the rotary motor 412 in the rotating mechanism, driving the rotating seat 407 to rotate 90° to a position parallel to the conductor. Then, the drive motor 417 is started, and the slider 416 is driven by the screw 415 to move the auxiliary seat 409 to a position close to the overlapping wires. The auxiliary seat 409 then falls down again to contact the conductor. At this time, the position of the auxiliary seat 409 corresponds to the overlapping conductors. Driven by the drive motor 417, the slider 416 drives the auxiliary seat 409 to move linearly toward the overlapping conductors. When the auxiliary seat 409 moves linearly, it pushes the overlapping conductors to the correct winding position on the winding seat 203, thus correcting the overlapping wire defect. After the correction is completed, the auxiliary seat 409 is reset to a state perpendicular to the conductors, and subsequent winding work is carried out.

[0077] When a loop skips during the winding process, i.e. when the gap between the coils increases, the auxiliary seat 409 presses down to the top of the wound coil. As the gap between the coils increases, the amount of light entering the gap increases, and the photoelectric sensor recognizes the enhanced light signal, thus actively determining that the gap between the coils has increased.

[0078] When the gap between the coils being wound increases, the control system controls the rotating mechanism to drive the auxiliary seat 409 to rotate to a position parallel to the wire. Then, by starting the drive motor 417, the slider 416 is driven to move the auxiliary seat 409 to the end of the wound coil. The retraction of the electric push rod 401 causes the bottom of the auxiliary seat 409 to abut against the top of the winding seat 203. The drive motor 417 is then started again, causing it to rotate in both directions, which causes the auxiliary seat 409 to move back and forth. During this process, the side of the auxiliary seat 409 repeatedly pushes the wire at the end of the coil, thereby bringing the wire at the end of the coil closer to the wound coil, thus eliminating the gap between the coil turns and ensuring that each turn of the wire is tightly fitted, improving the winding quality. The pushing time of the auxiliary seat 409 on the wire at the end of the coil is determined by the size of the coil gap.

[0079] Example 3

[0080] This embodiment also provides a winding method for a winding device used in the processing of current transformers, including the following steps:

[0081] S1. Assemble the turntable 202 and the winding seat 203, lock the movable seat 101 and the support seat 1, so that the positioning wheel 201 and the turntable 202 roll together, and pass the wire through the inlet side guide wheel group 309, the two side pressure seats 307 and the outlet side guide wheel group 309 in sequence, and fix the end to the starting position of the winding seat 203.

[0082] Specifically, the locking of the movable seat 101 and the support seat 1 is achieved by detachable connectors such as bolts. The installation position of the connectors corresponds precisely to the pre-set threaded holes on the top of the support seat 1. The positioning groove depth of the positioning wheel 201 is adapted to the thickness of the circumferential flange of the turntable 202, with a fitting gap of ≤0.1mm. The end of the wire is fixed by the fixing slot or clamping bolt on the winding seat 203 to ensure that there is no loosening after fixing.

[0083] S2. The control system starts the electromagnetic push rod 310, which drives the pressure seat 307 to close and clamp the wire through the cooperation of the U-shaped seat 311 and the wedge block 312. The tension sensor detects the traction force signal and feeds it back. The control system adjusts the extension and retraction of the hydraulic rod 303 according to the preset tension threshold to set the initial tension of the wire.

[0084] Specifically, the preset tension threshold needs to be input into the control system in advance according to the conductor diameter, material and current transformer design requirements. The initial extension amount of the electromagnetic push rod 310 is set to the minimum stroke of the elastic pad on the pressure seat 307 just touching the surface of the conductor, so as to avoid excessive initial clamping force and damage to the conductor insulation layer.

[0085] S3. Start the rotating motor 208, which drives the winding seat 203 to rotate through the transmission mechanism composed of belt transmission mechanism 207, rotating shaft 205, transmission gear 206, and gear plate 204 to wind the wire. The control system collects the winding turn signal in real time and controls the electric telescopic rod 304 to extend synchronously, driving the frame seat 305 to move to match the wire winding position.

[0086] Specifically, the winding turn count signal is acquired by an encoder installed at the end of the rotating shaft 205. The encoder has a detection accuracy of 1 revolution / pulse and corresponds one-to-one with the winding turn count. The correspondence table of "turn count - electric telescopic rod 304 extension amount" needs to be calibrated by test. For example, for each additional turn of wire, the electric telescopic rod 304 extends by 0.5mm, and the extension speed matches the rotation speed of the winding seat 203. For example, when the rotation speed of the winding seat 203 is 10r / min, the extension speed of the electric telescopic rod 304 is 15mm / min.

[0087] S4. During the winding process, the tension sensor continuously feeds back the tension signal. The control system compares the detected value with the preset threshold. If the tension is insufficient, the hydraulic rod 303 is extended to increase the tension. If the tension is too large, the hydraulic rod 303 is contracted to reduce the tension. At the same time, the extension and retraction of the electromagnetic push rod 310 is adjusted to optimize the clamping force and maintain stable tension.

[0088] Specifically, the signal acquisition frequency of the tension sensor is 0.1 seconds / time, the response delay of the control system is ≤0.2 seconds, and the traction spring 308 outside the slide bar 306 moves synchronously with the pressure seat 307 to help balance the force on the pressure seat 307 and avoid sudden changes in clamping force.

[0089] S5. Every time the winding seat 203 rotates to a horizontal position, the control system triggers the electric push rod 401 to drive the auxiliary seat 409 to press down and adhere to the coil. The pressure sensor detects the resistance force, and the photoelectric sensor detects the coil gap.

[0090] Specifically, the horizontal state of the winding seat 203 is triggered by a position sensor installed on the side of the support seat 1. The wire hardness and toughness parameters need to be input into the control system before winding. The preset threshold of the pressure sensor and the preset threshold of the photoelectric sensor need to be calibrated according to the specifications of the winding seat 203 and the wire parameters.

[0091] S6. If the pressure exceeds the threshold and is determined to be a wire overlap, the control system starts the rotation mechanism to rotate the auxiliary seat 409 to the direction parallel to the wire, and the drive mechanism drives the auxiliary seat 409 to move and correct it.

[0092] Specifically, during the alignment of overlapping lines, the auxiliary seat 409 rotates at an angle of 90°, which is achieved by the rotary motor 412 through the main gear 413 and the auxiliary gear 411.

[0093] S7. If the gap light signal exceeds the threshold and is determined to be a skipped turn, the control auxiliary seat 409 reciprocates to push the wire to eliminate the gap, the high hardness wire adapter electric cylinder 422 applies high-frequency reciprocating pressure, and the high toughness wire adapter electric cylinder 422 continuously applies pressure and the hydraulic rod 303 synchronously tensions the composite control.

[0094] Specifically, during the correction of skipped turns, the auxiliary seat 409 reciprocates with a push stroke of 5-10mm and a frequency of 1 time / second. When winding high-hardness wires, the electric cylinder 422 reciprocates with a frequency of 5 times / second. The guide rod 408 is driven to apply high-frequency pressure through the trapezoidal seat 423, the transmission wedge seat 420, the movable rod 418, and the limit wedge seat 419.

[0095] S8. When the number of winding turns reaches the preset value, the control system cuts off the power of the rotating motor 208, each actuator resets, the clamping of the pressure seat 307 and the wire is released, the movable seat 101 is unlocked, and the wound coil is removed.

[0096] Specifically, each telescopic component is reset sequentially in a preset order, with a 0.5-second interval between the resets of adjacent components to avoid interference. The coil is removed by disassembling the split structure of the winding base 203, ensuring that the coil is not deformed and the wires are not loose during the removal process.

[0097] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification and drawings, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A winding device for processing current transformers, characterized in that, include: The support base (1) has a base at the bottom and a movable seat (101) at the top. Winding assembly (2), used for winding wires; Tensioning guide assembly (3) is used for guiding and tensioning the conductor; The detection and correction assembly (4) is used to detect and correct the wound wire. It includes an electric push rod (401), a bracket (402) at the top telescopic end of the electric push rod (401), a support (403) at the end of the support (402), a support frame (404) at the bottom of the support (403), a base (405) at the bottom of the support frame (404), a side seat (406) on both sides of the base (405), a rotating seat (407) rotatably connected through the side seat (406), a guide rod (408) slidably connected inside the rotating seat (407), and an auxiliary seat (409) at the bottom end of the guide rod (408). The side seat (406) is provided with a rotating mechanism for driving the rotating seat (407) to rotate; The base (405) is provided with a drive mechanism for driving the side seats (406) on both sides to move linearly; The detection and correction assembly (4) also includes a trapezoidal seat (423) and two corresponding movable rods (418). The far ends of the movable rods (418) on both sides are provided with limiting wedges (419), and the near ends of the movable rods (418) on both sides are provided with transmission wedges (420). The top of the support (403) is provided with an electric cylinder (422), and the telescopic end of the electric cylinder (422) passes through the top of the support frame (404) and is provided with a trapezoidal seat (423).

2. The winding device for processing current transformers according to claim 1, characterized in that: The winding assembly (2) includes two sets of positioning wheels (201), which are rotatably connected to the sides of the movable seat (101) and the support seat (1), respectively. A turntable (202) is rolled together between each positioning wheel (201), and a winding seat (203) is provided on the side of the turntable (202). The inner side of the turntable (202) is provided with a toothed disc (204), and a transmission gear (206) is meshed on one side of the toothed disc (204). The transmission gear (206) is rotatably connected to the side of the support base (1) through a rotating shaft (205). A rotating motor (208) is provided on the base. The output shaft of the rotating motor (208) is connected to the end of the rotating shaft (205) through a belt transmission mechanism (207).

3. The winding device for processing current transformers according to claim 1, characterized in that: The tensioning guide assembly (3) includes a guide groove (301) which is located on one side of the support base (1). A slide block (302) is slidably connected inside the guide groove (301). One end of the slide block (302) is fixedly connected to the telescopic end of a hydraulic rod (303) located on the side of the support base (1). The other end of the slide block (302) is provided with an electric telescopic rod (304). The telescopic end of the electric telescopic rod (304) is provided with a frame seat (305). 305) has a U-shaped structure. Both ends of the frame (305) are slidably connected to slide rods (306). Each slide rod (306) on both sides is provided with a pressure seat (307) at one end. An elastic pad is provided on the opposite side of the two pressure seats (307). A tension sensor is provided between the elastic pad and the pressure seat (307). A traction spring (308) is sleeved on the outside of the slide rod (306). Both sides of the frame (305) are provided with guide wheel sets (309) corresponding to the pressure seats (307).

4. The winding device for processing current transformers according to claim 3, characterized in that: The inner wall of the frame (305) is provided with an electromagnetic push rod (310), and the telescopic end of the electromagnetic push rod (310) is provided with a U-shaped seat (311). Both ends of the U-shaped seat (311) are provided with inclined surfaces facing each other. The sides of the two pressure seats (307) are provided with wedges (312) facing away from each other. The inclined surfaces at both ends of the U-shaped seat (311) are respectively engaged with the two wedges (312).

5. The winding device for processing current transformers according to claim 1, characterized in that: The electric push rod (401) is embedded in the movable seat (101). The support (403) and the support frame (404) are both U-shaped structures. The bottom sides of the auxiliary seat (409) have chamfers. The bottom of the auxiliary seat (409) is equipped with a photoelectric sensor. The bottom of the guide rod (408) is sleeved with a limit spring (410). A pressure sensor is provided between the limit spring (410) and the auxiliary seat (409).

6. The winding device for processing current transformers according to claim 1, characterized in that: The rotating mechanism includes a secondary gear (411) fixedly sleeved on a rotating seat (407), a main gear (413) meshing on one side of the secondary gear (411), and the main gear (413) fixedly sleeved on the output shaft of a rotary motor (412) provided on a side seat (406).

7. The winding device for processing current transformers according to claim 1, characterized in that: The driving mechanism includes a slide groove (414) and a drive motor (417) located in the middle of the base (405). A screw (415) is rotatably connected in the slide groove (414). A slider (416) is threaded onto the screw (415). The slider (416) is slidably connected to the slide groove (414). The two sides of the slider (416) are fixedly connected to the ends of the side seats (406) on both sides. The drive motor (417) is located at the end of the base (405). The output shaft of the drive motor (417) is fixedly connected to the end of the screw (415).

8. The winding device for processing current transformers according to claim 1, characterized in that: The two movable rods (418) slide through both sides of the support frame (404) respectively, and a return spring (421) is sleeved on the outside of the movable rods (418). The limiting wedge (419) is correspondingly engaged with the top of the guide rod (408); The trapezoidal seat (423) is matched with the transmission wedge seats (420) on both sides.

9. The winding device for processing current transformers according to claim 1, characterized in that: One end of the movable seat (101) is movably connected to the top of the support seat (1), and the other end of the movable seat (101) is detachably connected to the top of the support seat (1).

10. A winding method for a winding device used in the fabrication of a current transformer, characterized in that, Includes the following steps: S1. Assemble the turntable (202) and the winding seat (203), lock the movable seat (101) and the support seat (1), so that the positioning wheel (201) and the turntable (202) roll together, and pass the wire through the inlet side guide wheel group (309), the two side pressure seats (307) and the outlet side guide wheel group (309) in sequence, and fix the end to the starting position of the winding seat (203); S2. The control system starts the electromagnetic push rod (310), which drives the pressure seat (307) to close and clamp the wire through the cooperation of the U-shaped seat (311) and the wedge (312). The tension sensor detects the traction force signal and feeds it back. The control system adjusts the extension and retraction of the hydraulic rod (303) according to the preset tension threshold to set the initial tension of the wire. S3. Start the rotating motor (208), which drives the winding seat (203) to rotate through the transmission mechanism composed of belt transmission mechanism (207), rotating shaft (205), transmission gear (206), and gear plate (204) to wind the wire. The control system collects the winding turn signal in real time and controls the electric telescopic rod (304) to extend synchronously, driving the frame seat (305) to move to match the wire winding position. S4. During the winding process, the tension sensor continuously feeds back the tension signal. The control system compares the detected value with the preset threshold. If the tension is insufficient, the hydraulic rod (303) is extended to increase the tension. If the tension is too large, the hydraulic rod (303) is contracted to reduce the tension. At the same time, the extension and retraction of the electromagnetic push rod (310) is adjusted to optimize the clamping force and maintain the tension stability. S5. When the winding seat (203) rotates to the horizontal position, the control system triggers the electric push rod (401) to drive the auxiliary seat (409) to press down and fit the coil. The pressure sensor detects the pressure and the photoelectric sensor detects the coil gap. S6. If the pressure exceeds the threshold and is determined to be a wire overlap, the control system starts the rotation mechanism to rotate the auxiliary seat (409) to the direction parallel to the wire, and the drive mechanism drives the auxiliary seat (409) to move and correct. S7. If the gap light signal exceeds the threshold and is determined to be a skipped turn, the control auxiliary seat (409) pushes the wire back and forth to eliminate the gap, the high hardness wire adapter electric cylinder (422) applies high-frequency reciprocating pressure, and the high toughness wire adapter electric cylinder (422) applies continuous pressure and the hydraulic rod (303) applies synchronous tension in a composite control. S8. When the number of winding turns reaches the preset value, the control system cuts off the power of the rotating motor (208), each actuator is reset, the clamping of the pressure seat (307) and the wire is released, the movable seat (101) is unlocked, and the wound coil is removed.

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