Amorphous alloy three-dimensional wound core stress detection device and detection method

Abstract

The invention relates to an amorphous alloy three-dimensional wound core stress detection device and detection method, and belongs to the technical field of power equipment monitoring. Comprising a pressure monitoring system which comprises a plurality of uniformly distributed pressure sensors and is used for monitoring pressure distribution between a transformer iron core and an iron yoke cushion block at the upper end of a coil; the intelligent control module is connected with the pressure monitoring system and used for processing the pressure data and generating a control instruction; the multi-channel driving module is connected with the intelligent control module; the plurality of servo motor systems are respectively connected with the multi-channel driving module; and a rotor of each servo motor is connected with the corresponding pull screw rod through a transmission mechanism. Through multi-sensor cooperative monitoring and independent servo control, the uniformity of pressure distribution of the transformer iron core is improved, and meanwhile the manufacturing quality and the use performance of the amorphous alloy transformer iron core are improved.

Description

Technical Field

[0001] This invention belongs to the field of power equipment monitoring technology, and in particular relates to a stress detection device and method for amorphous alloy three-dimensional wound iron core. Background Technology

[0002] Amorphous alloy three-dimensional wound iron cores play a vital role in electrical and electronic equipment. They exhibit low hysteresis and eddy current losses, significantly reducing energy loss and improving equipment efficiency. They also generate low noise during operation, effectively reducing noise pollution. They are widely used in transformers, motors, generators, and induction heating equipment, performing particularly well in high-frequency and high-efficiency power electronic equipment.

[0003] In transformers, the magnitude of stress on the core is crucial, primarily because it directly affects the core's magnetic properties and energy efficiency. Excessive stress can lead to magnetic saturation of the core material, thereby reducing the transformer's efficiency and output power, while also increasing hysteresis and eddy current losses. Properly controlling the core stress not only prevents mechanical damage and avoids material fatigue or failure but also improves noise performance. Furthermore, the core stress directly relates to equipment safety; excessive stress can lead to overheating or malfunction.

[0004] Existing technology cannot accurately determine the magnitude of the force between the core and each phase coil, nor can it confirm whether the force is balanced. It can only rely on experience and manual judgment to adjust the tightness of the screws to adjust the pressure, which affects the core performance and results in the problem of not being able to accurately adjust the pressure. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a stress detection device and method for amorphous alloy three-dimensional wound cores, solving the aforementioned problems in the background technology and improving the stress uniformity of amorphous alloy three-dimensional wound cores.

[0006] A stress detection device for amorphous alloy three-dimensional coiled iron core includes: a pressure monitoring system comprising multiple uniformly distributed pressure sensors for monitoring the pressure distribution between the transformer iron core and the upper end yoke pad of the coil; The intelligent control module, connected to the pressure monitoring system, is used to process pressure data and generate control commands; A multi-channel drive module is connected to the intelligent control module; Multiple servo motor systems are connected to the multi-channel drive module, respectively; Each servo motor's rotor is connected to its corresponding pull screw via a transmission mechanism.

[0007] Optionally, the pressure monitoring system includes at least three pressure sensors, which are distributed in an equilateral triangle on the yoke pad.

[0008] Optionally, the intelligent control module includes: The signal conditioning unit is used to filter and amplify the pressure sensor signal; The data analysis unit is used to calculate pressure distribution uniformity indicators; The decision control unit is used to generate closed-loop control strategies.

[0009] Optionally, the multi-channel drive module includes multiple independent drive circuits, each drive circuit corresponding to a servo motor, which can realize independent control of each pull screw.

[0010] Optionally, it also includes a force transmission mechanism, the force transmission mechanism comprising: A speed reducer connected to the rotor of a servo motor; A torque sensor connected to the output shaft of the reducer; Tightening head for screws connected to torque sensor.

[0011] A detection method for a stress detection device for amorphous alloy three-dimensional wound iron cores. Place the pressure sensor on the yoke pad and put it into the upper gap between the three-dimensional wound core and the coil to ensure that the pressure sensor can contact the core to read the force data of the core in real time. The control module receives feedback values ​​from the pressure sensor in real time, compares the feedback values ​​with the optimal force value of the iron core in real time, generates a control signal, and then transmits the control signal to the drive module. The drive module controls the servo motor to adjust the tightness of the screw on the pull rod to change the magnitude of the force applied to the iron core.

[0012] Optionally, the optimal value of the core stress may vary depending on the core size.

[0013] Optionally, the process of obtaining the optimal value of the core stress includes: By statistically analyzing the stress values ​​of transformer cores of the same model and specifications in the past, and combining the performance indicators of the cores, the data is plotted into a curve, and the stress value when the core performance is optimal is marked as the optimal stress value of the core.

[0014] Optionally, the control module compares the received pressure value with the preset optimal core force value in the control module, and controls the pull screw, including: Determine the optimal core stress value for the current transformer model; The pressure value received by the control module is compared with the optimal stress value of the iron core in real time. If the pressure value is not equal to the optimal stress value of the iron core, the control module sends a command to the drive module to drive the servo motor to adjust the tightness of the pull screw, thereby changing the pressure value until it equals the optimal pressure value of the iron core.

[0015] Optionally, three pressure sensors are located between the upper part of each phase winding and the transformer core. When the pressure value of one phase reaches the optimal value of the core force, the servo motor moves to the next phase for corresponding adjustment.

[0016] Beneficial technical effects: The applied pressure is acquired, compared, and adjusted in real time, avoiding the problem of uneven force on the transformer core during the tightening of the coil by the pull screw, which affects performance.

[0017] By using multi-sensor collaborative monitoring and independent servo control, the uniformity of transformer core pressure distribution is improved.

[0018] This improves the manufacturing quality and performance of amorphous alloy transformer cores. Attached Figure Description

[0019] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of preferred embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the invention. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 This application provides a schematic diagram of a stress detection device for amorphous alloy three-dimensional coiled iron core.

[0020] The components are: 1. Coil; 2. Iron core; 3. Pull screw; 4. Pull screw; 5. Yoke pad; 6. Pressure sensor; 7. Control module; 8. Drive module; 9. Servo motor. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without inventive effort are within the scope of protection of this invention.

[0022] It should be noted that, in this document, 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. Unless otherwise specified, 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 that element.

[0023] Example 1 See Figure 1 This embodiment provides a stress detection device and method for amorphous alloy three-dimensional coiled iron core, including: a pressure sensor 6 that monitors the pressure between the transformer iron core 2 and the upper end yoke pad 5 of the coil 1; a control module 7 connected to the pressure sensor 6; the output end of the control module 7 connected to a drive module 8; the drive module 8 connected to a servo motor 9; and the rotor of the servo motor 9 connected to a pull screw 3. The pressure sensor 6 detects the pressure value in real time during the transformer coil compression process and transmits the pressure value to the control module 7. The control module 7 compares the received pressure value with the preset optimal stress value in the control module and generates a control signal that is transmitted to the drive module 8 to control the pull screw 4 of the servo motor 9, adjusting the tightness of the pull screw 3 to control the pressure between the transformer iron core 2 and the upper end yoke pad 5 of the coil.

[0024] Optionally, three pressure sensors 6 are provided and evenly distributed between the transformer core 2 and the yoke pad 5 at the upper end of the coil. During the pressing process of the transformer coil 1, the pressure sensors 6 can further transmit the force to the control module 7.

[0025] Optionally, the pull screw 4 and the pull screw screw 3 are both located between the coil 1 and the upper iron yoke pad 5.

[0026] Optionally, the lower end of the monitoring transformer core 2 and coil 1 also includes another set of pull screws 4 and pull screw screws 3. The control module can adjust the other set of pull screws 4 and pull screw screws 3. The adjustment process of the other set of pull screws 4 and pull screw screws 3 is synchronized with the adjustment process of the pull screws 4 and pull screw screws 3 at the upper end of coil 1. That is, if the upper pull screws 4 and pull screw screws 3 are loosened, the other set of pull screws 4 and pull screw screws 3 at the lower end will be tightened; if the upper pull screws 4 and pull screw screws 3 are tightened, the other set of pull screws 4 and pull screw screws 3 at the lower end will be loosened.

[0027] The force monitored by the pressure sensor 6 represents the pressure between the transformer core 2 and the upper yoke pad 5 of the coil. The coil is tightened by rotating the pull screws at the upper and lower ends of the coil through the servo motor, thereby transmitting the force to the pressure sensor.

[0028] The process of selecting the optimal stress value in this implementation includes: statistically analyzing the pressure values ​​between the iron core and the upper yoke pad of the coil for different models, specifications and sizes; using the performance indicators of the iron core as a criterion to select the optimal stress value of the iron core; finally obtaining the pressure curves under different iron core sizes; and selecting the optimal stress value.

[0029] The pressure value in the pressure information received by the control module is compared with the optimal pressure value in real time. If the pressure value in the pressure information is not equal to the optimal pressure value, a command is sent to the drive module to control the servo motor to adjust the tightness of the pull screw screw through the pull screw until it is equal to the optimal pressure value.

[0030] The beneficial effects of this invention are that, compared with the prior art, The applied pressure is acquired, compared, and adjusted in real time, avoiding the problem of uneven force on the transformer core during the tightening of the coil by the pull screw, which affects performance.

[0031] A stress detection device and method for amorphous alloy three-dimensional wound iron core includes a three-dimensional wound iron core, coils, a pressure sensor, a yoke pad, a tie rod screw, a control module, a drive module, and a servo motor. The pressure sensor is placed on the yoke pad and then inserted into the upper gap between the three-dimensional wound iron core and the coils, ensuring contact between the pressure sensor and the iron core. This allows for real-time reading of the iron core's stress data. The control module receives feedback values ​​from the pressure sensor in real-time, compares these values ​​with the optimal stress value, generates a control signal, and transmits it to the drive module. The drive module controls the servo motor to adjust the tightness of the tie rod screw, thereby changing the stress applied to the iron core to achieve the optimal stress value and ensuring that the stress values ​​between the three coils and the iron core are equal.

[0032] The optimal stress value for the iron core varies depending on the size of the iron core.

[0033] The process of obtaining the optimal value of the core stress includes: The stress values ​​of transformer cores of the same model and specifications in the past were statistically analyzed. Combined with the core performance indicators, the data were plotted into a curve, and the stress value when the core performance was optimal was marked as the optimal stress value.

[0034] The control module compares the received pressure value with the preset optimal force value in the controller, and controls the pull screw, including: Determine the optimal stress value for the core of the current transformer model; The pressure value received by the control module is compared with the optimal pressure value in real time. If the pressure value is not equal to the optimal pressure value, the control module sends a command to the drive module to drive the servo motor to adjust the tightness of the pull screw, thereby changing the pressure value until it equals the optimal pressure value.

[0035] A pressure sensor is installed between the transformer core and the upper part of the winding coil.

[0036] Each of the three pressure sensors is located between the upper part of each phase winding and the transformer core. When the pressure value of one phase reaches the optimal force value, the servo motor moves to the next phase for corresponding adjustment.

[0037] This invention discloses a stress detection device and method for amorphous alloy three-dimensional wound iron cores, including a three-dimensional wound iron core, coils, a pressure sensor, a yoke pad, a tie rod screw, a control module, a drive module, and a servo motor. The pressure sensor is placed on the yoke pad and then inserted into the upper gap between the three-dimensional wound iron core and the coils, ensuring contact between the pressure sensor and the iron core. This allows for real-time reading of the iron core's stress data. The control module receives feedback values ​​from the pressure sensor in real time, compares these values ​​with the optimal values ​​to generate a control signal, and then transmits this signal to the drive module. The drive module controls the servo motor to adjust the tightness of the tie rod screw, thereby changing the stress applied to the iron core to approach the optimal stress value and ensuring that the stress values ​​between the three coils and the iron core are equal. A significant advantage of this invention is its ability to acquire applied pressure in real time and precisely control the applied pressure by adjusting the tightness of the tie rod screw. This effectively avoids excessive or uneven stress on the transformer iron core during the process of the tie rod screw tightening the coils, reducing the risk of core noise and coil damage. This technology can significantly improve the working stability and reliability of amorphous alloy three-dimensional wound cores.

[0038] A method for stress detection of amorphous alloy three-dimensional wound core includes the following steps: The pressure distribution between the transformer core and the upper yoke pad of the coil is monitored in real time by multiple pressure sensors. The control module receives the pressure values ​​from each pressure sensor and calculates the pressure distribution uniformity index. The pressure distribution uniformity index is compared with the preset optimal stress range; When the pressure distribution uniformity index exceeds the optimal stress range, the control module generates a closed-loop control signal. The drive module drives multiple servo motors according to the closed-loop control signal; The servo motor independently adjusts the tightness of the corresponding pull screw, thereby achieving precise control of the pressure between the transformer core and the upper yoke pad of the coil.

[0039] Optionally, the calculation of the pressure distribution uniformity index includes: Calculate the average value of the readings from each pressure sensor; Calculate the standard deviation of each monitored value from the mean; When the standard deviation exceeds the preset threshold, the pressure distribution is determined to be uneven.

[0040] Optionally, the process of determining the optimal force range includes: Establish a dimensional database for different types of amorphous alloy three-dimensional wound iron cores; Performance data of various types of iron cores under different pressures were obtained through experimental testing. Based on the aforementioned performance index data, a stress-performance relationship model is established through regression analysis. The optimal stress range for each type of iron core is determined based on the aforementioned relationship model.

[0041] A stress detection device for amorphous alloy three-dimensional coiled iron core includes: a pressure monitoring system comprising multiple uniformly distributed pressure sensors for monitoring the pressure distribution between the transformer iron core and the upper end yoke pad of the coil; The intelligent control module, connected to the pressure monitoring system, is used to process pressure data and generate control commands; A multi-channel drive module is connected to the intelligent control module; Multiple servo motor systems are connected to the multi-channel drive module, respectively; Each servo motor's rotor is connected to its corresponding pull screw via a transmission mechanism.

[0042] Optionally, the pressure monitoring system includes at least three pressure sensors, which are distributed in an equilateral triangle on the yoke pad.

[0043] The pressure monitoring system includes at least three pressure sensors. The number of pressure sensors on the left yoke pad is at least one more than the number on the right yoke pad. Through the asymmetrical arrangement, the asymmetry and imbalance of the pressure on both sides can be accurately monitored, avoiding over-adjustment and preventing damage to the coil or iron core during the adjustment process.

[0044] Optionally, the pressure sensor includes at least one over-adjustment pressure sensor for over-adjustment monitoring. When the tension of the pull screw 3 is normally adjusted to control the pressure between the transformer core 2 and the yoke pad 5 at the upper end of the coil, the over-adjustment pressure sensor does not generate strain. When the pull screw 3 exceeds the threshold, the over-adjustment pressure sensor generates strain and outputs a signal to the control module, so that the control module can adjust the operation in time to avoid damage caused by over-adjustment or over-adjustment.

[0045] Optionally, the intelligent control module includes: The signal conditioning unit is used to filter and amplify the pressure sensor signal; The data analysis unit is used to calculate pressure distribution uniformity indicators; The decision control unit is used to generate closed-loop control strategies.

[0046] Optionally, the multi-channel drive module includes multiple independent drive circuits, each drive circuit corresponding to a servo motor, which can realize independent and precise control of each pull screw.

[0047] Optionally, the servo motor system adopts a closed-loop servo system with absolute encoder feedback, achieving a control accuracy of ±0.1N.

[0048] Optionally, it also includes a force transmission mechanism, the force transmission mechanism comprising: A speed reducer connected to the rotor of a servo motor; A torque sensor connected to the output shaft of the reducer; Tightening head for screws connected to torque sensor.

[0049] Optionally, it also includes a human-computer interaction system, the human-computer interaction system comprising: A touchscreen display shows the real-time pressure distribution map and adjustment process. The operation panel is used to set control parameters and perform manual intervention; Audible and visual alarm devices are used to indicate abnormal conditions.

[0050] Optionally, the touch screen can display the pressure distribution of various parts of the core in a three-dimensional graphic manner and use different colors to indicate the pressure level.

[0051] Optionally, it also includes a data management system, the data management system comprising: Historical data storage unit, used to record complete data for each pressing process; The statistical analysis unit is used to generate pressure control quality reports. The remote communication unit is used for data interaction with the upper-level management system.

[0052] Optionally, the performance indicators include at least three of the following: core no-load loss, noise level, vibration characteristics, temperature rise performance, and mechanical deformation.

[0053] Optionally, the closed-loop control employs an adaptive PID algorithm, and the control parameters can be automatically adjusted according to the core size and material properties.

[0054] Optionally, the pressure sensor is a thin-film matrix pressure sensor, which can simultaneously monitor the pressure magnitude and distribution location.

[0055] Optionally, a pressure calibration step is also included: Before each press fitting, the pressure sensor is zero-point calibrated; The pressure sensor was calibrated using a standard force measurement device. Establish a pressure-voltage conversion curve based on the calibration results.

[0056] Those skilled in the art will 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.

[0057] It should be noted that the sequence numbers of the embodiments of the present invention are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0058] The above are merely preferred embodiments of the present invention and do 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, and any combination of embodiments or solutions, are similarly included within the patent protection scope of the present invention.

Claims

1. A stress detection device for amorphous alloy three-dimensional wound iron core, Its features are, Includes: a pressure monitoring system containing multiple evenly distributed pressure sensors for monitoring the pressure distribution between the transformer core and the upper yoke pad of the coil; The intelligent control module, connected to the pressure monitoring system, is used to process pressure data and generate control commands; A multi-channel drive module is connected to the intelligent control module; Multiple servo motor systems are connected to the multi-channel drive module, respectively; Each servo motor's rotor is connected to its corresponding pull screw via a transmission mechanism.

2. The amorphous alloy three-dimensional wound core stress detection device according to claim 1, characterized in that, The pressure monitoring system includes at least three pressure sensors, which are distributed in an equilateral triangle on the iron yoke pad.

3. The amorphous alloy three-dimensional wound core stress detection device according to claim 1, characterized in that, The intelligent control module includes: The signal conditioning unit is used to filter and amplify the pressure sensor signal; The data analysis unit is used to calculate pressure distribution uniformity indicators; The decision control unit is used to generate closed-loop control strategies.

4. The amorphous alloy three-dimensional wound core stress detection device according to claim 1, characterized in that, The multi-channel drive module includes multiple independent drive circuits, each corresponding to a servo motor, enabling independent control of each pull screw.

5. The amorphous alloy three-dimensional wound core stress detection device according to claim 1, characterized in that, It also includes a force transmission mechanism, which comprises: A speed reducer connected to the rotor of a servo motor; A torque sensor connected to the output shaft of the reducer; Tightening head for screws connected to torque sensor.

6. A method for detecting the stress on an amorphous alloy three-dimensional wound core as described in any one of claims 1-5, characterized in that, Place the pressure sensor on the yoke pad and put it into the upper gap between the three-dimensional wound core and the coil to ensure that the pressure sensor can contact the core to read the force data of the core in real time. The control module receives feedback values ​​from the pressure sensor in real time, compares the feedback values ​​with the optimal force value of the iron core in real time, generates a control signal, and then transmits the control signal to the drive module. The drive module controls the servo motor to adjust the tightness of the screw on the pull rod to change the magnitude of the force applied to the iron core.

7. The detection method according to claim 6, characterized in that, The optimal value of the core stress will vary depending on the core size.

8. The detection method according to claim 7, characterized in that, The process for obtaining the optimal value of the core stress includes: By statistically analyzing the stress values ​​of transformer cores of the same model and specifications in the past, and combining the performance indicators of the cores, the data is plotted into a curve, and the stress value when the core performance is optimal is marked as the optimal stress value of the core.

9. The detection method according to claim 6, characterized in that, The control module compares the received pressure value with the preset optimal core force value in the control module, and controls the pull screw, including: Determine the optimal core stress value for the current transformer model; The pressure value received by the control module is compared with the optimal stress value of the iron core in real time. If the pressure value is not equal to the optimal stress value of the iron core, the control module sends a command to the drive module to drive the servo motor to adjust the tightness of the pull screw, thereby changing the pressure value until it equals the optimal pressure value of the iron core.

10. The detection method according to claim 6, characterized in that, The pressure sensors are located at the top of each phase winding and between the transformer core. When the pressure value of a phase reaches the optimal value of the core force, the servo motor moves to the next phase for corresponding adjustment.

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