Portable transformer test automatic gear shifting remote control device

Abstract

The invention discloses a portable automatic gear shifting remote control device for a transformer test. The portable automatic gear shifting remote control device comprises a shell, and a control unit, a dual-mode driving mechanism, a wireless communication module and a sensor assembly which are integrated in the shell, a video monitoring module and a magnetic attraction mounting unit are assembled on the shell; the magnetic attraction mounting unit is used for detachably fixing the device near a voltage regulating switch panel of a transformer; the risks of electric shock and high-altitude falling caused by the fact that an operator must approach to live high-voltage equipment for manual operation are solved. By designing a wireless remote control and video monitoring integrated system, an operator can complete all gear shifting operations and state confirmation outside a safe distance, and an intrinsically safe operation mode of man-machine separation is realized.

Description

Technical Field

[0001] This invention relates to the field of transformer tap adjustment, and in particular to a portable transformer testing automatic tap adjustment remote control device. Background Technology

[0002] With the development of power system operation and maintenance towards intelligence and unmanned operation, the on-load tap changer switching operation during transformer testing is a frequent and critical task, and the need for improvement in its operation methods is increasingly urgent. Currently, the existing technologies and operating methods in the industry for transformer tap changer switching operations have the following main shortcomings: Traditional voltage regulation operations rely entirely on manual on-site operation. Workers must approach and even touch the energized transformer and its voltage regulating switch mechanism. Working in high-voltage equipment areas carries the risk of electric shock; if the voltage regulating switch is located high above the transformer or requires climbing the equipment frame, there is also the risk of falls from height. This risk is further amplified by the complex on-site environment, especially at night, in inclement weather, or during emergency repairs. Current technology lacks reliable remote control methods, making it impossible to achieve a safe "human-machine separation" operation mode.

[0003] A complete transformer test (such as a DC resistance test) typically requires multiple range switching. The manual operation process is cumbersome, requiring at least two people (one to operate and one to monitor) or even three (plus a recorder) to complete it. Operators must travel between the control room and the equipment area, or remotely confirm via walkie-talkie. A single range switching operation can take several minutes, unnecessarily extending the overall test time and impacting the utilization rate of the power supply reliability maintenance window.

[0004] Manual operation relies entirely on the operator's experience and feel. For push-button switches, the pressing force and travel are difficult to control precisely; too little pressure may lead to poor contact, while too much pressure or misalignment may damage the microswitch mechanism. For rotary switches, the rotation angle is estimated visually, which is prone to error. This may result in the switch not being fully engaged or fluctuating between positions, affecting the accuracy of test data (requiring repeated testing) and potentially causing abnormal wear of the internal mechanical or electrical components of the voltage regulator switch due to improper operation, thus shortening the equipment's lifespan.

[0005] Many existing auxiliary tools or simple electric devices on the market have very limited functions. Some can only be used to press specific push-button switches, while others are designed specifically for certain types of knobs. A single device cannot be compatible with both push-button and knob operation modes. Given the diverse range of transformer voltage regulators with varying interfaces in substations, multiple tools are required, increasing equipment complexity and the cumbersome nature of on-site use. Furthermore, most of these tools lack status feedback and intelligent control functions, remaining essentially "open-loop" replacements for manual operation, failing to guarantee accuracy and reliability.

[0006] Existing manual or simple tool-based operation methods heavily rely on the operator's visual observation (reading the gear indicator) and experience judgment, which carries the risk of misjudgment and omission. The operation process lacks digital recording and traceability. At the same time, the entire operation chain lacks embedded security protection mechanisms, such as the inability to implement gear upper and lower limit protection, operation command encryption authentication, and overload protection at the software level, resulting in significant shortcomings in preventing misoperation and malicious interference. Summary of the Invention

[0007] Therefore, the technical problem that this invention aims to solve is: the inability to fundamentally eliminate the risk to personal safety.

[0008] The above-mentioned technical problems are solved by the following technical solution: This invention proposes a portable transformer testing automatic range adjustment remote control device, which includes, It includes a housing, and a control unit, a dual-mode drive mechanism, a wireless communication module, and sensor components integrated within the housing; The housing is equipped with a video monitoring module and a magnetic mounting unit; The magnetic mounting unit is used to detachably fix the device to the vicinity of the transformer voltage regulating switch panel; The dual-mode drive mechanism includes a switchable knob drive module and a button drive module, which can adapt to both knob and button voltage regulating switch operation modes. The sensor assembly is used to collect pressure, angle, and displacement signals during the operation process; The video monitoring module is used to collect the voltage regulator switch's position indication information and operation video in real time; The wireless communication module is used to receive remote control commands and transmit back operation data and status information. The control unit is electrically connected to the dual-mode drive mechanism, the wireless communication module, and the sensor assembly, respectively.

[0009] In a preferred embodiment of the portable transformer testing automatic range adjustment remote control device of the present invention: the sensor assembly is a four-channel pressure sensor, and the control unit achieves pattern recognition through a differential detection algorithm. Define the real-time readings of four pressure sensors as P1~P4, and set the preset contact detection threshold as P. th The calculation detected a pressure exceeding P. th Number of sensors N contact ; When N contact When the two trigger sensors are equal to 2 and the time difference Δt < 0.5s and the displacement difference Δd < 2mm, it is determined to be in knob mode; When N contact=4 and the trigger time difference of all sensors is max(|t) i -t j If |) < 0.3s, it is determined to be button mode.

[0010] In a preferred embodiment of the portable transformer test automatic gear adjustment remote control device of the present invention: the dual-mode drive mechanism further includes a dual-mode switching servo motor and a gear and rack transmission mechanism. The control unit controls the servo motor to drive the knob drive module and the button drive module to move to the working position through the gear and rack transmission mechanism according to the mode recognition result.

[0011] In a preferred embodiment of the portable transformer test automatic gear adjustment remote control device of the present invention: the knob drive module includes a stepper motor, a reduction gear set, and an adjustable clamp; the angle sensor in the sensor assembly is a stepper motor encoder; and the pressure sensor is integrated into the adjustable clamp. The control unit adopts a PID force-displacement closed-loop control algorithm, which adjusts the output torque and speed of the stepper motor based on the reaction force signal fed back by the pressure sensor and the rotation angle signal fed back by the angle sensor.

[0012] In a preferred embodiment of the portable transformer test automatic range adjustment remote control device of the present invention: the button drive module includes an electric push rod, a DC electromagnet, an adjustable travel rod and a micro switch, and the displacement sensor in the sensor assembly is a Hall displacement sensor integrated into the electromagnet.

[0013] In a preferred embodiment of the portable transformer test automatic range adjustment remote control device of the present invention: the wireless communication module adopts LoRa technology, operates at a frequency of 433MHz, and uses the AES-128 encryption algorithm to encrypt and transmit control commands and feedback data.

[0014] In a preferred embodiment of the portable transformer test automatic gear adjustment remote control device of the present invention: the security verification of the remote control command by the control unit includes timestamp verification, verification code verification, and gear legality verification.

[0015] In a preferred embodiment of the portable transformer test automatic gear adjustment remote control device of the present invention: the video monitoring module includes two cameras: the optical axis of the first camera is aligned with the gear indicator, and the control unit reads the current gear through template matching and OCR technology; the second camera monitors the operation action, calculates the actual action parameters through optical flow method, and realizes the consistency verification between gear change and operation action.

[0016] In a preferred embodiment of the portable transformer testing automatic range adjustment remote control device of the present invention: it further includes hardware protection components and a data storage module; The hardware protection components include an overcurrent protection unit, an overload protection unit, and a mechanical limit unit; The data storage module records operation time, gear information, sensor data sequence, visual verification results, and alarm information. The data can be transmitted back to the backend via the wireless communication module.

[0017] In a preferred embodiment of the portable transformer test automatic gear adjustment remote control device of the present invention: the housing is made of alloy material, and the adjustable clamp of the knob drive module includes four evenly distributed clamping rubber blocks.

[0018] The beneficial effects of this invention are: it solves the risks of electric shock and falls from heights faced by operators who must be close to live high-voltage equipment for manual operation. By designing an integrated wireless remote control and video monitoring system, operators can complete all gear adjustment operations and status confirmations from a safe distance, achieving an inherently safe operating mode with separation of human and machine. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings of the embodiments of the present invention will be briefly described below. Obviously, the drawings described below only relate to some embodiments of the present invention and are not intended to limit the present invention. Wherein: Figure 1 A flowchart of the operation of the portable transformer testing automatic range adjustment remote control device is shown. Figure 2 A schematic diagram of the portable transformer testing automatic range adjustment remote control device is shown. Figure 3 The diagram shows the electrical component connections of a portable transformer testing automatic range adjustment remote control device. Detailed Implementation

[0020] To enable those skilled in the art to better understand the present invention, the present invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0021] The terminology used in this invention is that which is currently widely used in the art in consideration of the function of the invention; however, these terms may vary according to the intent of those skilled in the art, precedent, or new technology in the art. Furthermore, specific terms may be chosen by the applicant, and in such cases, their detailed meanings will be described in the detailed description of the invention. Therefore, the terms used in this specification should not be construed as simple names, but rather based on their meanings and the overall description of the invention.

[0022] Reference Figures 1 to 3This embodiment provides a portable transformer test automatic range adjustment remote control device, including a housing 1, and a control unit 2, a dual-mode drive mechanism 3, a wireless communication module 4, and a sensor assembly 5 integrated in the housing 1; The housing 1 is equipped with a video monitoring module 6 and a magnetic mounting unit; The magnetic mounting unit is used to detachably fix the device to the vicinity of the transformer voltage regulating switch panel; The dual-mode drive mechanism 3 includes a switchable knob drive module 31 and a button drive module 32, which can adapt to both knob and button voltage regulating switch operation modes. The sensor assembly 5 is used to collect pressure, angle, and displacement signals during the operation process; The video monitoring module 6 is used to collect the voltage regulator switch's position indication information and operation video in real time; The wireless communication module 4 is used to receive remote control commands and transmit back operation data and status information. The control unit 2 is electrically connected to the dual-mode drive mechanism 3, the wireless communication module 4, and the sensor assembly 5, respectively.

[0023] Control unit 2 detects that the rotary gear selector head is installed via a Hall sensor and determines that it is in rotary mode. The dual-mode switching servo motor is activated, which moves the rotary drive module 31 to the working position via a gear and rack. The stepper motor drives the elastic retaining ring inside the gear selector head to open, fit into the knob, and clamp it.

[0024] The operator fixes the device near the pressure regulating switch panel using the magnetic mounting unit with magnetic clamps, achieving strong magnetic attraction of the housing 1 to the switch knob, ensuring that the actuator of the knob drive module 31 or button drive module 32 is roughly aligned with the gear shift button or knob. After the device is connected to a 220V power supply and initialized, the four-channel pressure sensor in the adjustable clamp of the knob drive module 31 first detects whether the pressure regulating switch knob is touched. If no pressure is detected, a stepper motor is started, driving the clamping rubber block 7 forward to the pressure regulating switch knob via a reduction gear set. When two of the pressure sensors detect the critical predetermined pressure value, the stepper motor is triggered to stop. The other two clamping rubber blocks 7, because their corresponding pressure sensors have not detected pressure signals, are continued to be pushed by the stepper motor to the center position of the switch knob. When these two pressure sensors detect pressure signals, the stepper motor is triggered to stop. In this way, the adjustable clamp completes the adaptive knob fixing installation. When controlling the operation of the pressure regulating switch knob, the control unit 2 starts the knob drive module 31 to rotate forward to realize the switch up gear operation and reverse to realize the switch down gear operation.

[0025] The first camera 61 of the video monitoring module 6 monitors the voltage regulating switch position in real time, and the second camera 62 monitors whether the voltage regulating knob has completed the rotation of one level, collecting signals including rotation angle, speed, and whether the knob has returned to its original position.

[0026] When the number of gear changes monitored by the first camera 61 is inconsistent with the number of times the pressure regulating knob is operated in real time monitored by the second camera 62, the control unit 2 triggers an alarm signal to prompt the operator to check on-site whether there is mechanical jamming in the pressure regulating switch.

[0027] Installation mode recognition process of the pressure regulating switch button: When the four-channel pressure sensor in the adjustable clamp of the knob drive module 31 simultaneously detects the pressure of the clamping rubber block 7 contacting the pressure regulating switch button, the control unit 2 determines that the pressure regulating switch is a button switch based on the time difference of the received signals from the four pressure sensors and the displacement distance moved by the stepper motor through the reduction gear set. The control unit 2 controls the dual-mode switching servo motor to operate and starts the button drive module 32 to realize the button control function, thus completing the installation and mode recognition of the button-type pressure regulating switch control device.

[0028] Control unit 2 detects that the actuator of knob drive module 31 has been installed via Hall sensor in sensor assembly 5, and thus determines that it is in knob mode. The dual-mode switching servo motor actuates, moving knob drive module 31 to the working position via rack and pinion transmission mechanism. A stepper motor drives the elastic retaining ring inside the actuator of knob drive module 31 to open, engage with the knob, and clamp it. As an optional embodiment, the sensor assembly 5 is a four-channel pressure sensor, and the control unit 2 achieves pattern recognition through a differential detection algorithm. Define the real-time readings of four pressure sensors as P1~P4, and set the preset contact detection threshold as P. th The calculation detected a pressure exceeding P. th Number of sensors N contact ; When N contact When the two trigger sensors are equal to 2 and the time difference Δt < 0.5s and the displacement difference Δd < 2mm, it is determined to be in knob mode; When N contact =4 and the trigger time difference of all sensors is max(|t) i -t j When |)<0.3si, j∈{1,2,3,4}, it is determined to be button mode.

[0029] Specifically, control unit 2 employs a four-channel pressure sensor differential detection algorithm for pattern recognition. The real-time readings of the four pressure sensors are defined as follows: , , , Unit: Newton, preset contact detection threshold is The stepper motor moves at a fixed step speed. The driving clamping rubber block 7 moves forward, and the control unit 2 calculates in real time the number of sensors among the four sensors that have detected pressure exceeding the threshold. : (1) in Let H(x) be the Heaviside step function, where H(x) = 1 when x > 0, and H(x) = 0 otherwise. Simultaneously, record the trigger times of each sensor. , , , and the corresponding cumulative displacement of the stepper motor , , , .

[0030] Knob mode determination logic: When When two relative sensors are triggered sequentially, control unit 2 calculates the time difference between the two triggering sensors. and displacement difference Because the knob is cylindrical, the two opposing sensors will contact each other almost simultaneously with a very small time difference, at which point the mode is determined to be knob mode. The determination condition is... and Control unit 2 immediately stops the movement of the clamping rubber blocks 7 in the other two directions, and maintains the two currently triggered clamping rubber blocks 7 to continue applying a constant clamping force. This torque is maintained by a stepper motor. Then, the remaining two clamping rubber blocks 7 are activated to continue moving towards the center until their corresponding pressure sensors also reach their set point. At this point, the four clamping rubber blocks 7 evenly wrap around the knob, forming a stable radial clamp. The control unit 2 records the absolute position of the stepper motor at this moment. As a zero-point reference.

[0031] Button mode determination logic: when That is, the four sensors trigger almost simultaneously, and the time difference satisfies Control unit 2 determines that the contact object is a flat button. At this time, control unit 2 drives the dual-mode switching servo motor to operate. The servo motor moves module 3 - the button electric push rod - to the working position through the gear and rack mechanism to replace the knob drive module 31, thus completing the mode switching.

[0032] In this embodiment, the device is identified as a knob mode. After the control unit 2 confirms that the four clamping rubber blocks 7 have reliably clamped the knob, it detects the installation status of the knob-type gear shifting head through a Hall sensor. The gear shifting head has a permanent magnet embedded in it, and the Hall sensor is installed in the corresponding position inside the housing 1. When the gear shifting head is correctly installed, the Hall sensor outputs a high-level signal, and the control unit 2 ultimately confirms that it is in knob mode based on this signal.

[0033] As an optional embodiment, the dual-mode drive mechanism 3 further includes a dual-mode switching servo motor and a gear and rack transmission mechanism. The control unit 2 controls the servo motor to drive the knob drive module 31 and the button drive module 32 to move to the working position through the gear and rack transmission mechanism according to the mode recognition result.

[0034] The dual-mode drive mechanism 3 is newly equipped with a dual-mode switching servo motor and a gear and rack transmission mechanism. The dual-mode switching servo motor serves as the power output component, and its output shaft is fixedly connected to the gear in the gear and rack transmission mechanism. The gear and rack are in a meshing state, and the rack is rigidly connected to the mounting slide of the knob drive module 31 and the button drive module 32. This forms a complete and stable power transmission link, ensuring that the power can be accurately transmitted to the corresponding drive module.

[0035] After the control unit 2 completes the voltage regulation switch mode identification through the differential detection algorithm of the four-channel pressure sensor, it will send the corresponding direction control signal and action command to the dual-mode switching servo motor according to the identification result. When the identification result is the knob mode, the control unit 2 controls the dual-mode switching servo motor to start in the forward direction. The motor output shaft drives the gear to rotate synchronously. The gear drives the rack meshing with it to move in a straight line, thereby driving the mounting slide of the knob drive module 31 to move along the preset trajectory. When the recognition result is button mode, the control unit 2 controls the dual-mode switching servo motor to start in reverse. Through the power transmission of the gear and rack transmission mechanism, the mounting slide of the button drive module 32 is driven to move in reverse linear motion. The travel of the drive module is preset to 10mm in both modes. The dual-mode switching servo motor has a built-in encoder, which can collect the motor rotation angle signal in real time and feed it back to the control unit 2. The control unit 2 calculates the actual travel distance of the rack by reading the encoder signal, thereby accurately controlling the knob drive module 31 or the button drive module 32 to move to the preset working position. This ensures that the execution end of the drive module is exactly aligned with the center of the knob or button of the voltage regulating switch, providing a reliable position guarantee for the accurate execution of subsequent gear adjustment actions. This structural design effectively solves the defect of existing tools that cannot adaptively switch between two operating modes.

[0036] As an optional embodiment, the knob drive module 31 includes a stepper motor, a reduction gear set, and an adjustable clamp. The angle sensor in the sensor assembly 5 is a stepper motor encoder, and the pressure sensor is integrated into the adjustable clamp. The control unit 2 adopts a PID force-displacement closed-loop control algorithm, which adjusts the output torque and speed of the stepper motor based on the reaction force signal fed back by the pressure sensor and the rotation angle signal fed back by the angle sensor.

[0037] As an optional embodiment, the button drive module 32 includes an electric push rod, a DC electromagnet, an adjustable travel rod, and a micro switch, and the displacement sensor in the sensor assembly 5 is a Hall displacement sensor integrated into the electromagnet.

[0038] As an optional embodiment, the wireless communication module 4 adopts LoRa technology, operates at a frequency of 433MHz, and uses the AES-128 encryption algorithm to encrypt and transmit control commands and feedback data.

[0039] As an optional embodiment, the control unit 2 performs security verification of remote control commands, including timestamp verification, verification code verification, and gear position legality verification.

[0040] As an optional embodiment, the video monitoring module 6 includes two cameras: the first camera 61 has its optical axis aligned with the gear indicator, and the control unit 2 reads the current gear position through template matching and OCR technology; the second camera 62 monitors the operation action and calculates the actual action parameters through optical flow method to realize the consistency verification between gear position change and operation action.

[0041] As an optional embodiment, it also includes a hardware protection component 8 and a data storage module; The hardware protection component 8 includes an overcurrent protection unit, an overload protection unit, and a mechanical limit unit; The data storage module records operation time, gear information, sensor data sequence, visual verification results and alarm information. The data can be transmitted back to the backend via the wireless communication module 4.

[0042] As an optional embodiment, the housing 1 is made of alloy material, and the adjustable chuck of the knob drive module 31 includes four evenly distributed clamping rubber blocks 7.

[0043] Specifically, the operator selects the target gear in the monitoring backend of the safe zone, for example, adjusting from the current gear N=5 to the target gear N=9. The monitoring software sends encrypted command packets to the device via wireless communication module 4 using LoRa technology and AES-128 encryption. These packets contain information such as the operating mode knob, the rotation of the action type, and the target gear. timestamp and dynamic verification codes The control unit 2 receives encrypted command packets via the wireless communication module 4 using LoRa technology, operating at a frequency of 433MHz, with a communication distance of up to 500 meters. The command packets are encrypted using the AES-128 encryption algorithm, and the control unit 2 decrypts them using a pre-stored key.

[0044] After decryption, control unit 2 first performs security verification. Verification includes three levels: First, timestamp verification, checking... in To prevent replay attacks, the device uses its local time; secondly, it verifies the CAPTCHA. The system is generated by the backend using a hash algorithm based on the timestamp and the device's unique ID; control unit 2 calculates and compares the hash using the same algorithm; third, the gear position is validated. in This refers to the maximum number of positions for this switch model. Only after all three verifications pass will control unit 2 accept the instruction and enter the execution phase. If the verification fails, control unit 2 returns an error code to the backend and stops operation, simultaneously triggering a buzzer alarm.

[0045] After decrypting and verifying the command, control unit 2 activates the core control algorithm for knob adjustment. This algorithm consists of three stages: contact detection, rotation switching, and position confirmation. The entire process achieves closed-loop control through data fusion from pressure sensors, angle sensors, stepper motors, encoders, and video monitoring module 6.

[0046] Control unit 2 drives a stepper motor to slowly rotate the knob at an extremely low speed to detect the engagement state between the knob and the gear slot. The output shaft of the stepper motor is connected to the rotating shaft of the knob's gear shifting head via a reduction gear set with a reduction ratio of 10:1. Control unit 2 sets the stepper motor speed to... The corresponding linear velocity of the end knob is approximately During rotation, control unit 2 reads data from the pressure sensor integrated within the gear shifting head in real time. This sensor measures the axial reaction force during rotation.

[0047] Control unit 2 uses a sliding window algorithm to detect the pressure increase trend. The time window length is defined as... At each time t, calculate the pressure increment within the window: when Preset threshold And the absolute value of pressure Contact detection threshold At this point, control unit 2 determines that the gear shifting head and the knob's toothed groove have made reliable contact. Control unit 2 immediately stops the stepper motor and reads the current rotation angle via the stepper motor encoder. This is recorded as the zero angle point. This mechanism ensures that the device can automatically find a reliable engagement point even if the knob's initial position is not at the center of the gear position.

[0048] Control unit 2 based on the current gear and target gear Calculate the required rotation angle Because the voltage regulator switch has a uniform circular distribution of ranges, the total number of ranges is [number missing]. The angle interval corresponding to a single gear is: Substitution ,have to The formula for calculating the target rotation angle is: In this embodiment, .

[0049] Control unit 2 uses an adaptive PID control algorithm based on pressure feedback to drive the stepper motor to rotate. The core of this algorithm is to dynamically adjust the motor output torque to adapt to the differences in mechanical resistance that may exist between different knob positions, such as spring locking force and toothed friction, to ensure that the rotation process is smooth and completes in one go.

[0050] Control unit 2 sets the basic rotational angular velocity At the same time, set the foundation to apply pressure. During rotation, control unit 2 reads pressure sensor data in real time. Calculate the deviation between the current pressure and the target pressure: in The target pressure is dynamically set by control unit 2 based on the rotation angle. The target pressure increases linearly with the rotation angle to simulate the "forceful turning" process in manual operation, preventing the knob from slipping or jamming due to friction. The formula for calculating the target pressure is: in The current rotation angle is read in real time via the stepper motor encoder. The pressure gain coefficient has a value of [value missing]. To prevent excessive pressure from damaging the knob, set a pressure limit. When the calculation is obtained At that time, forced .

[0051] Control unit 2 based on pressure deviation The output torque compensation of the stepper motor is calculated using a PID algorithm. : in For proportional gain, For integral gain, This is the differential gain. After experimental calibration, we take... , , Control unit 2 will compensate the amount. The output torque of a stepper motor is proportional to its current, and precise torque control is achieved by adjusting the drive current.

[0052] During rotation, control unit 2 simultaneously monitors the angle fed back by the stepper motor encoder. ,when When this occurs, control unit 2 immediately stops the stepper motor from rotating and enters the positioning confirmation phase. To prevent overshoot, when... At that time, control unit 2 will change the angular velocity from Reduce to This allows for deceleration and approach, improving positioning accuracy.

[0053] After the stepper motor stops, control unit 2 does not immediately consider the operation complete, but instead activates a dual verification mechanism to ensure the reliability of gear switching. The first verification is pressure holding verification, in which control unit 2 commands the stepper motor to maintain the current torque. Approximately the corresponding applied pressure Duration This ensures that the contacts inside the pressure regulating switch are fully engaged and stable. During the holding period, control unit 2 continuously monitors the pressure sensor data. If pressure fluctuations exceed the threshold If the system detects a problem, it determines that there may be poor contact or mechanical jamming. Control unit 2 then triggers an alarm and returns an exception code to the backend.

[0054] The second layer of verification is visual confirmation verification. For example... Figure 2 As shown, the first camera 61 is mounted on the housing 1, with its optical axis aligned with the gear indicator of the voltage regulator switch, which is typically a mechanical pointer or a digital display. The control unit 2 analyzes the video stream captured by the camera in real time using an image recognition algorithm. This image recognition algorithm, based on template matching and OCR optical character recognition technology, can automatically read the current gear value displayed on the gear indicator. Control Unit 2 Comparison and target gear ,like If so, the file transfer is confirmed to be successful.

[0055] Simultaneously, a second camera, positioned at location 62, monitors the rotation of the knob. This camera captures footage at a high frame rate of 60fps and calculates the actual rotation angle of the knob using an optical flow algorithm. Control unit 2 will Angle with stepper motor encoder feedback Perform cross-validation; if the difference between the two is... If the allowable error range is within acceptable limits, the reliability of the mechanical transmission can be further confirmed. If the difference is too large, it indicates that the knob may be slipping or the gear shift head may not be securely clamped, triggering an alarm in control unit 2.

[0056] Furthermore, control unit 2 also verifies the consistency between the number of gear shifts and the number of knob movements. (Definition of the number of gear shifts) The change in the gear indicator value detected by the first camera 61, in this example from gear 5 to gear 9. Define the number of times the knob can be clicked. The second camera 62 detects the number of complete rotation cycles of the knob using optical flow; each rotation corresponds to one cycle. Control unit 2 verification. Is this true? If not, it indicates that the voltage regulator switch may be mechanically jammed. The knob may have been turned but the gear position may not have been switched, or the gear position may have changed abnormally but the knob may not have been fully rotated. Control unit 2 will immediately trigger an audible and visual alarm and display abnormal information on the monitoring backend, prompting the operator to check the mechanical status of the voltage regulator switch on-site.

[0057] Control unit 2 commands the stepper motor to maintain the current torque for 2 seconds to ensure internal contact stability, and then releases the torque. The elastic retaining ring of the gear shifting head releases, and the servo motor retracts the drive module to its initial position. Throughout the operation, control unit 2 records key operational data in real time, including: operation start time, operation end time, total operation time, initial gear, target gear, trajectory of actual rotation angle, time series of pressure sensor data, time series of stepper motor current, visual confirmation results, and whether any abnormal alarms occur. This data is transmitted back to the monitoring backend via wireless communication module 4.

[0058] For the automatic gear shifting operation of the push-button on-load tap changer, after the device is installed, the four pressure sensors inside the knob clamping telescopic device simultaneously detect pressure signals, and the time difference meets the button mode determination condition as described in the aforementioned formula (1). Based on this, control unit 2 determines that it is a push-button switch and switches to push-button mode.

[0059] Control unit 2 drives the dual-mode switching servo motor. The output shaft of the servo motor is connected to the mounting slide of the push-button electric actuator via a rack and pinion mechanism. The servo motor rotation angle... At this time, the gear and rack mechanism moves the electric push rod of the button from the initial storage position to the working position, aligning the end of the adjustment head with the center of the button, and the movement stroke is [not specified]. After the control unit 2 confirms the movement is in place via the servo motor's built-in encoder, it locks the servo motor position. At this time, the end contact of the button's electric actuator is approximately [distance missing] from the button surface. .

[0060] Control unit 2 drives the DC motor of the electric actuator with a rated voltage of 12V and a rated thrust of 20N at low speed. Slowly extend the push rod. The push rod integrates a potentiometer; the resistance value of the potentiometer is related to the extension length of the push rod. The relationship is linear. Control unit 2 reads the potentiometer voltage in real time. Through calibration formula Calculate the current push rod extension length where These are calibration coefficients.

[0061] The trigger force of the micro switch embedded in the end contact of the push rod ,journey When the contact point touches the button surface, the button exerts a reaction force on the contact point, triggering the microswitch and causing it to output a high-level signal. Control unit 2 detected Then, immediately stop the push rod motor and read the push rod position at this time. This is recorded as the zero point of contact. This mechanism ensures that even if there are slight deviations in the button surface position, such as different button models having different protrusion heights, the device can automatically adapt and find a reliable contact point.

[0062] This is the core innovation of the button mode. Unlike simple push-button operation, which can easily damage the button due to excessive force or cause poor contact due to insufficient force, this device adopts a dual control strategy of "push-button positioning + electromagnet coordinated force" to achieve precise decoupled control of pressing depth and pressing force.

[0063] Control unit 2 first determines the target pressing stroke by querying a pre-stored device parameter database based on the button type. For common microswitches, the target travel is... For heavy-duty buttons, the target travel distance can reach... Control unit 2 calculates the coarse positioning stroke that the push rod needs to advance. : (8) in The precise pressing stroke is handled by the electromagnet. In this embodiment, .

[0064] Control unit 2 drives the push rod motor, causing the push rod to move from the contact zero point. Continue forward to During the forward movement, control unit 2 monitors the push rod position in real time via a potentiometer, employing closed-loop control to ensure positioning accuracy. The push rod reaches... Then, control unit 2 locks the push rod motor and applies braking current. At this time, the adjustable travel rod at the end of the push rod is approximately [distance missing] from the button surface. .

[0065] Next, control unit 2 activates the DC electromagnet. The electromagnet coil is mechanically connected to the armature of the adjustable stroke rod. When the electromagnet is energized, the armature is quickly attracted, driving the adjustable stroke rod forward. The final, precise press is then completed. The electromagnet's attraction characteristic curve has been pre-calibrated, and the attraction force... With coil current The relationship is: (9) in The force-current coefficient of the electromagnet was obtained through experimental measurement. Control unit 2 adjusts the pressure according to the target. For this embodiment, Calculate the required coil current: (10) Substitute the values, Control unit 2 precisely controls the current of the electromagnet coil through PWM modulation. This causes the electromagnet to generate a stable attractive force. .

[0066] The electromagnet's engagement speed is extremely fast, with a response time of less than 10ms, enabling rapid and decisive pressing actions that simulate the "decisive pressing" feel of manual operation. Simultaneously, due to the travel... With a diameter of only 0.5mm, the electromagnet's impact energy is limited and will not damage the button's mechanical structure. Control unit 2 monitors the armature displacement in real time using a Hall effect displacement sensor built into the electromagnet, with an accuracy of 0.01mm. This verifies whether the armature is fully engaged. If so, the pressing action is confirmed to be successful.

[0067] Duration of time that control unit 2 keeps the electromagnet energized To ensure reliable operation of the microswitch inside the button, most microswitches have a response time of less than 50ms. During the holding period, the control unit 2 monitors changes in the gear indicator via the first camera 61. If a change in gear value is detected, such as from gear 5 to gear 6, the button operation is confirmed to be valid.

[0068] Then, control unit 2 first releases the electromagnet to disconnect the coil current and resets the spring stiffness. Pre-compression amount The armature and adjustable travel lever are quickly returned to their initial positions. (Reset force) This is sufficient to overcome the residual magnetic attraction between the armature and the electromagnet core. Control unit 2 confirms that the armature has been reset via a Hall displacement sensor. Then, the drive push rod motor rotates in the opposite direction, causing the push rod to return to its initial position. .

[0069] The precision control throughout the pressing process is achieved through multi-sensor fusion. The push rod potentiometer provides coarse positioning feedback with an accuracy of 0.5mm, the electromagnet Hall displacement sensor provides fine positioning feedback with an accuracy of 0.01mm, the microswitch provides a contact confirmation signal, and the camera provides confirmation of the final gear position change. This multi-feedback system forms a closed loop, ensuring that the pressing depth error is controlled within a certain range. Within a certain range, the pressure error is controlled within a certain range. Within this range, the precision far exceeds that of manual operation.

[0070] Similar to the knob mode, control unit 2 monitors the gear indicator in real time via the first camera 61 to confirm that the gear has changed to the target value. Simultaneously, control unit 2 records key data throughout the pressing process: pressing start time, contact detection moment, push rod position trajectory, electromagnet current, armature displacement, and gear change moment. If the gear does not change or changes abnormally (e.g., pressing the upshift button once but the gear changes two gears), control unit 2 triggers an abnormal alarm and packages the abnormal data to send back to the backend.

[0071] After successful operation confirmation, control unit 2 drives the dual-mode switching servo motor to retract the button electric actuator module to its initial position. All process data is transmitted back to the monitoring backend via wireless communication module 4, generating an operation log. After operation, the device enters standby mode, awaiting the next operation command.

[0072] Finally, it should be noted that the methods and devices described in detail above are merely embodiments, and those skilled in the art can modify these embodiments in different ways as long as they do not depart from the scope of the present invention.

Claims

1. A portable transformer testing automatic range adjustment remote control device, characterized in that: It includes a housing (1), and a control unit (2), a dual-mode drive mechanism (3), a wireless communication module (4), and a sensor assembly (5) integrated within the housing (1). The housing (1) is equipped with a video monitoring module (6) and a magnetic mounting unit; The magnetic mounting unit is used to detachably fix the device to the vicinity of the transformer voltage regulating switch panel; The dual-mode drive mechanism (3) includes a switchable knob drive module (31) and a button drive module (32), which can adapt to both knob and button voltage regulating switch operation modes. The sensor assembly (5) is used to collect pressure, angle, and displacement signals during the operation process; The video monitoring module (6) is used to collect the position indication information and operation action images of the voltage regulator switch in real time; The wireless communication module (4) is used to receive remote control commands and transmit back operation data and status information; The control unit (2) is electrically connected to the dual-mode drive mechanism (3), the wireless communication module (4), and the sensor assembly (5), respectively.

2. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The sensor assembly (5) is a four-channel pressure sensor, and the control unit (2) achieves pattern recognition through a differential detection algorithm. Define the real-time readings of four pressure sensors as P1~P4, and set the preset contact detection threshold as P. th The calculation detected a pressure exceeding P. th Number of sensors N contact ; When N contact When the two trigger sensors are equal to 2 and the time difference Δt < 0.5s and the displacement difference Δd < 2mm, it is determined to be in knob mode; When N contact =4 and the trigger time difference of all sensors is max(|t) i -t j When |)<0.3s (i, j∈{1,2,3,4}), it is determined to be button mode.

3. The portable transformer testing automatic range adjustment remote control device according to claim 2, characterized in that: The dual-mode drive mechanism (3) also includes a dual-mode switching servo motor and a gear and rack transmission mechanism. The control unit (2) controls the servo motor to drive the knob drive module (31) and the button drive module (32) to move to the working position through the gear and rack transmission mechanism according to the mode recognition result.

4. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The knob drive module (31) includes a stepper motor, a reduction gear set, and an adjustable clamp. The angle sensor in the sensor assembly (5) is a stepper motor encoder, and the pressure sensor is integrated into the adjustable clamp. The control unit (2) adopts a PID force-displacement closed-loop control algorithm to adjust the output torque and speed of the stepper motor based on the reaction force signal fed back by the pressure sensor and the rotation angle signal fed back by the angle sensor.

5. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The button drive module (32) includes an electric push rod, a DC electromagnet, an adjustable stroke rod and a micro switch. The displacement sensor in the sensor assembly (5) is a Hall displacement sensor and is integrated into the electromagnet.

6. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The wireless communication module (4) adopts LoRa technology, operates at a frequency of 433MHz, and uses the AES-128 encryption algorithm to encrypt and transmit control commands and feedback data.

7. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The control unit (2) performs security verification of remote control commands, including timestamp verification, verification code verification, and gear position legality verification.

8. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The video monitoring module (6) includes two cameras. The first camera (61) has its optical axis aligned with the gear indicator. The control unit (2) reads the current gear through template matching and OCR technology. The second camera (62) monitors the operation action and calculates the actual action parameters through optical flow method to realize the consistency verification between gear changes and operation actions.

9. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: It also includes hardware protection components (8) and a data storage module; The hardware protection component (8) includes an overcurrent protection unit, an overload protection unit, and a mechanical limit unit; The data storage module records operation time, gear information, sensor data sequence, visual verification results and alarm information. The data can be transmitted back to the background through the wireless communication module (4).

10. The portable transformer testing automatic range adjustment remote control device according to claim 1, characterized in that: The housing (1) is made of alloy material, and the adjustable chuck of the knob drive module (31) includes four evenly distributed clamping rubber blocks (7).

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