A winding device and method for manufacturing the core of a current transformer.

Abstract

This invention relates to the field of electrical equipment manufacturing and automation equipment, specifically to a winding device and method for manufacturing the core of an instrument transformer; it includes an industrial control computer, a main drive motor, a stepper drive motor, a core encoder, and a support and clamping mechanism; the system combines the torque current of the main drive motor under no-load and winding conditions to construct a reference resistance torque feedforward sequence, and calculates the real-time dynamic tension of the enameled wire; its core is to perform speed compensation of the stepper drive motor based on the dynamic tension and a set threshold, and to perform a slippage compensation strategy by comparing the actual and theoretical linear speeds; this invention eliminates the interference of inherent mechanical resistance and inertia of the wire storage ring, so that the speed of the receiving end accurately matches the actual load, smooths out the periodic fluctuations of tension, and reduces the probability of wire breakage and insulation layer abrasion.

Description

Technical Field

[0001] This invention relates to the field of electrical equipment manufacturing and automation equipment, specifically to a winding device and method for manufacturing the iron core of a current transformer. Background Technology

[0002] In the current environment of the instrument transformer manufacturing industry, core winding is a critical production process. Typically, the wire storage ring of the winding device drives the enameled wire through the inner hole of the toroidal iron core and rotates it at high speed around its outer circumference to coat it. Simultaneously, a drive clamping mechanism drives the iron core to complete circumferential feeding to achieve continuous wire arrangement. To complete this winding operation, existing solutions generally adopt an open-loop speed regulation or a control architecture with an external independent tension sensor, i.e., winding is performed by setting a fixed main drive speed and the feed speed at the receiving end. Although this solution has certain processing capabilities under conventional wire diameters and low-speed scenarios, the alternating path length difference created by the wire storage ring's lead hole when passing through the inner hole and around the outer circumference of the iron core leads to high... During high-speed winding, the tension of the enameled wire undergoes severe periodic fluctuations. Furthermore, existing systems heavily rely on external sensors, whose detection results are easily obscured and interfered with by the elastic deformation of the mechanical transmission chain, bearing friction, and inherent eccentric resistance, making it difficult to accurately obtain the true instantaneous tension changes of the enameled wire. At the same time, slight slippage often occurs between the active pressure roller at the receiving end and the outer surface of the iron core due to dimensional tolerances of the iron core surface, local deposits, or pressure fluctuations. These defects result in a severe mismatch between the wire suction speed at the receiving end and the actual load requirements at the releasing end, high control link response delay, and large cumulative error in wire spacing, which can easily lead to wire breakage, localized loose coils, or insulation abrasion of fine-diameter enameled wire during high-speed processing.

[0003] Therefore, how to eliminate inherent mechanical resistance and inertial interference to accurately calculate dynamic winding tension, and thereby achieve adaptive compensation of feed speed and correction of drive slippage, so as to improve the uniformity and insulation safety of high-speed winding, has become an urgent technical problem to be solved. Summary of the Invention

[0004] To solve the above-mentioned technical problems, the present invention provides a winding device and method for manufacturing the iron core of a current transformer. Specifically, the technical solution of the present invention is as follows: A winding method for manufacturing a winding device for the iron core of a current transformer includes: Industrial control computer, base, winding head frame set on the base, wire storage ring set inside the winding head frame and main drive motor on top, iron core support frame set on the front side of the base, self-centering chuck set on the iron core support frame, floating clamping wheel connected to the self-centering chuck, and stepper drive motor and iron core encoder respectively connected to the floating clamping wheel. The floating clamping wheels work together to press and support the annular iron core from the outside; The floating clamping wheel connected to the stepper drive motor is the active floating clamping wheel, and the floating clamping wheel connected to the iron core encoder is the driven floating clamping wheel; The winding methods executed by the industrial control computer include: Obtain the output torque current of the main drive motor under no-load conditions, and determine the reference resistance torque feedforward sequence accordingly; The total output torque current of the main drive motor in the winding state is obtained. Based on the total current, the reference resistance torque feedforward sequence, and the inertial compensation parameter to overcome the rotational inertia of the storage ring, the real-time dynamic tension of the enameled wire is determined. Based on the real-time dynamic tension, determine the speed compensation strategy for the stepper drive motor; The actual linear velocity collected by the iron core encoder and the theoretical linear velocity output by the stepper drive motor are obtained, and a slippage compensation strategy for the stepper drive motor is determined accordingly.

[0005] In one possible implementation, obtaining the output torque current of the main drive motor under no-load conditions and determining the reference resistance torque feedforward sequence based on the output torque current includes: In the unloaded state where the enameled wire is not inserted into the wire storage ring, the main drive motor drives the wire storage ring to rotate at a preset rated speed at a uniform speed. The output torque current of the main drive motor is continuously recorded at a preset period; wherein, the output torque current reflects the mechanical frictional resistance torque of the storage ring at different rotation angles and the eccentric torque caused by the shift of the center of gravity; The curve of the output torque current changing with the rotation angle during the complete rotation cycle is stored as the reference resistance torque feedforward sequence.

[0006] In one possible implementation, the wire storage ring is provided with a wire-passing circular hole; the step of obtaining the total output torque current of the main drive motor in the wound state, and determining the real-time dynamic tension of the enameled wire based on the total output torque current, the reference resistance torque feedforward sequence, and the inertial compensation parameter used to overcome the rotational inertia of the wire storage ring, includes: Subtract the reference current value in the reference resistance torque feedforward sequence corresponding to the current rotation angle from the total output torque current, and subtract the inertial compensation current used to overcome the angular acceleration generated by the rotational inertia of the storage ring, to obtain the reverse load current generated by the enameled wire acting on the wire passage hole of the storage ring. Multiplying the reverse load current by a conversion factor yields the real-time dynamic tension of the enameled wire; wherein the conversion factor is related to the motor torque coefficient and the radial distance from the wire passage hole to the rotation center of the wire storage ring.

[0007] In one possible implementation, determining the speed compensation strategy of the stepper drive motor based on the real-time dynamic tension includes: When the real-time dynamic tension exceeds the preset safety upper limit threshold, the industrial control computer controls the stepper drive motor to reduce its speed in order to reduce the rotational displacement of the iron core in the circumferential direction. When the real-time dynamic tension is less than the preset lower limit threshold, the industrial control computer controls the stepper drive motor to increase its speed in order to accelerate the rotational displacement of the iron core. When the real-time dynamic tension is between the preset lower tension threshold and the preset upper safety threshold and includes the endpoint value, the current speed of the stepper drive motor is maintained.

[0008] In one possible implementation, the step of acquiring the actual linear velocity collected by the core encoder and the theoretical linear velocity output by the stepper drive motor, and determining a slippage compensation strategy for the stepper drive motor based on the actual linear velocity and the theoretical linear velocity, includes: Calculate the velocity difference between the theoretical linear velocity and the actual linear velocity; When the theoretical linear velocity is greater than the actual linear velocity and the velocity difference is greater than the preset judgment threshold, the velocity difference is integrated over time to calculate the lost circumferential arc length, and in the stepping instruction of the next winding cycle, the rotation angle corresponding to the lost circumferential arc length is superimposed on the stepper drive motor. No slippage compensation is performed when the theoretical linear velocity is not greater than the actual linear velocity or the velocity difference is not greater than the preset judgment threshold.

[0009] In one possible implementation, the winding head frame is supported by evenly distributed deep groove ball bearings inside the winding head frame; the inner diameter of the winding head ring is larger than the outer diameter of the iron core to be processed; the outer circumferential surface of the winding head ring is machined with a straight toothed ring of a preset module; the ring body of the winding head ring is provided with a wire-passing circular hole of a preset diameter for guiding the enameled wire out.

[0010] In one possible implementation, the main drive motor is an absolute value servo motor; the output shaft of the main drive motor is connected to the main drive gear via a flat key; the main drive gear directly meshes with the spur gear ring of the wire storage ring.

[0011] In one possible implementation, the self-centering chuck has jaws that move synchronously in the radial direction; the top ends of the jaws are respectively connected to the corresponding floating clamping wheels via rotating shafts; the main body of the floating clamping wheels is made of aluminum alloy; the outer circumference of the floating clamping wheels is covered with a polyurethane friction layer of a preset thickness; the Shore hardness of the polyurethane friction layer is a preset hardness.

[0012] In one possible implementation, the stepper drive motor is fixedly connected to the jaw on one side via a flange; the stepper drive motor is a servo motor; the output shaft of the stepper drive motor is directly connected to the corresponding floating clamping wheel via a flexible coupling. The iron core encoder is fixedly connected to the jaw on the other side; the resolution of the iron core encoder is a preset resolution; the input shaft of the iron core encoder is connected to the corresponding floating clamping wheel through a cross slider coupling.

[0013] A core winding device for manufacturing current transformers includes: an industrial control computer, a base, a winding head frame, a wire storage ring, a main drive motor, a main drive gear, a core support frame, a self-centering chuck, a floating clamping wheel, a stepper drive motor, and a core encoder. The upper surface of the base is fixedly connected to the winding head frame; the inside of the winding head frame is supported by a deep groove ball bearing for the wire storage ring; the outer circumferential surface of the wire storage ring is machined with a straight toothed ring; and a wire-passing circular hole is formed on the ring body of the wire storage ring. The main drive motor is fixedly connected to the top of the winding head frame; the output shaft of the main drive motor is connected to the main drive gear; the main drive gear meshes with the spur gear ring. The iron core support frame is fixedly connected to the front side of the base; the self-centering chuck is fixedly connected to the top surface of the iron core support frame; the self-centering chuck has jaws that move synchronously in the radial direction; the top ends of the jaws are respectively connected to the floating clamping wheels through rotating shafts; the floating clamping wheels are used to jointly press and support the iron core from the outside. The stepper drive motor is fixedly connected to the chuck located on one side; the output shaft of the stepper drive motor is connected to the corresponding floating clamping wheel; The iron core encoder is fixedly connected to the jaw located on the other side; the input shaft of the iron core encoder is connected to the corresponding floating clamping wheel; The industrial control computer is communicatively connected to the main drive motor, the stepper drive motor and the iron core encoder, and is used to execute the winding method as described in any one of claims 1 to 9.

[0014] Compared with the prior art, the present invention has at least the following advantages: 1. This invention determines the reference resistance torque feedforward sequence by obtaining the output torque current of the main drive motor under no-load conditions, and subtracts the reference current value in the reference resistance torque feedforward sequence corresponding to the current rotation angle and the inertial compensation current used to overcome the angular acceleration generated by the rotational inertia of the storage ring based on the total output torque current under the winding state, thereby accurately determining the real-time dynamic tension of the enameled wire. This process effectively eliminates inherent mechanical resistance and inertial interference. Furthermore, by combining the preset safety upper limit threshold and the preset tension lower limit threshold, a speed compensation strategy of deceleration or acceleration is implemented on the stepper drive motor, so that the speed at the receiving end matches the actual load, smoothing out the periodic fluctuations of tension and reducing the probability of wire breakage or insulation layer abrasion. 2. This invention compares the actual linear velocity collected by the core encoder with the theoretical linear velocity output by the stepper motor. When the theoretical linear velocity is greater than the actual linear velocity and the speed difference is greater than a preset threshold, the lost circumferential arc length is calculated by time integration of the speed difference. Subsequently, in the stepping instruction of the next winding cycle, the rotation angle corresponding to the lost circumferential arc length is superimposed on the stepper motor to execute a slippage compensation strategy. This method effectively overcomes the slight slippage generated when the floating clamping wheels jointly press and support the core drive from the outside, eliminates the cumulative error of the wire spacing, and improves the uniformity of wire laying. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort. In the drawings: Figure 1 This is a schematic diagram of the overall structure of the device; Figure 2 This is a schematic diagram of the deep groove ball bearing structure of the device; Figure 3 This is a schematic diagram of the device's storage ring structure; Figure 4 This is a schematic diagram of the self-centering chuck structure of the device; Figure 5 This is a flowchart of the method of the present invention.

[0016] In the diagram: 1. Industrial computer; 2. Base; 3. Winding head frame; 4. Wire storage ring; 5. Main drive motor; 6. Main drive gear; 7. Iron core support frame; 8. Self-centering chuck; 9. Floating clamping wheel; 10. Stepper drive motor; 11. Iron core encoder; 12. Deep groove ball bearing; 13. Spur gear ring; 14. Wire guide hole; 15. Output shaft of main drive motor; 16. Flat key; 17. Clamping jaw; 18. Rotating shaft; 19. Polyurethane friction layer; 20. Flange; 21. Output shaft of stepper drive motor; 22. Plum blossom flexible coupling; 23. Input shaft of iron core encoder; 24. Cross slider coupling. Detailed Implementation

[0017] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. 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 should fall within the scope of protection of the present invention.

[0018] Example 1: Combination Figure 5 As shown, a winding method for manufacturing a winding device for the iron core of a current transformer includes: The components include an industrial computer 1, a base 2, a winding head frame 3 located on the base 2, a wire storage ring 4 located inside the winding head frame 3 and a main drive motor 5 on top, a core support frame 7 located on the front side of the base 2, a self-centering chuck 8 located on the core support frame 7, a floating clamping wheel 9 connected to the self-centering chuck 8, and a stepper drive motor 10 and a core encoder 11 respectively connected to the floating clamping wheel 9. The floating clamping wheels 9 work together to press and support the annular iron core from the outside; The floating clamping wheel 9 connected to the stepper drive motor 10 is the active floating clamping wheel, and the floating clamping wheel 9 connected to the iron core encoder 11 is the driven floating clamping wheel; The winding methods executed by industrial computer 1 include: Obtain the output torque current of the main drive motor 5 under no-load conditions, and determine the reference resistance torque feedforward sequence accordingly; The total output torque current of the main drive motor 5 under winding state is obtained. Based on the total current, the reference resistance torque feedforward sequence and the inertial compensation parameter to overcome the rotational inertia of the storage ring, the real-time dynamic tension of the enameled wire is determined. Based on the real-time dynamic tension, the speed compensation strategy of the stepper drive motor 10 is determined; The actual linear velocity collected by the iron core encoder 11 and the theoretical linear velocity output by the stepper drive motor 10 are obtained, and the slippage compensation strategy for the stepper drive motor 10 is determined accordingly. The core winding device for manufacturing the current transformer is installed on a rigid base 2. The winding head frame 3 supports the rotation of the wire storage ring 4. The main drive motor 5 drives the wire storage ring 4 to complete the wire feeding motion of the enameled wire. The self-centering chuck 8 on the core support frame 7 clamps the annular core. Three floating clamping wheels 9 provide clamping and support from the outer periphery of the core. One of the floating clamping wheels 9 is connected to the stepper drive motor 10 to drive the core to rotate. The other floating clamping wheel 9 is connected to the core encoder 11 to provide feedback on the actual linear speed. The industrial control computer 1 communicates with the main drive motor 5, the stepper drive motor 10, and the core encoder 11 respectively and executes the winding algorithm. This method sets up two parallel data processing paths to address the problems of periodic fluctuations in enameled wire tension and uneven wire laying caused by core drive slippage during high-speed winding. One path uses the output torque current of the main drive motor 5 to estimate the reverse load applied to the wire storage ring 4 at the wire passage hole 14 and determines the real-time dynamic tension accordingly. The other path uses the difference between the actual linear velocity fed back by the core encoder 11 and the theoretical linear velocity of the stepper drive motor 10 to identify drive slippage and implement compensation. After the equipment is started, the industrial control computer 1 first performs no-load reference sampling to establish a reference resistance torque feedforward sequence of the main drive motor 5 when there is no enameled wire load and the rotation angle of the wire storage ring 4 changes; after entering the winding state, it continuously reads the total output torque current of the main drive motor 5, and obtains the real-time dynamic tension after eliminating the influence of mechanical inherent resistance and inertia. Then, adjust the speed of the stepper drive motor 10 according to the relationship between the real-time dynamic tension and the preset threshold to reduce or increase the circumferential wire suction speed of the iron core accordingly; at the same time, continuously compare the theoretical line speed and the actual line speed, calculate the lost arc length when a continuous speed difference occurs, and convert the arc length into an additional rotation angle and add it to the step command of the next winding cycle. Through the above method, the load characteristics of the main drive motor 5 are directly related to the speed change of the stepper drive motor 10 at the wire receiving end. When the enameled wire tension suddenly increases, the wire receiving speed is reduced accordingly. When the enameled wire shows a loosening trend, the wire receiving speed is increased accordingly. With the help of slippage correction, the wire spacing error can be controlled within the set range, and the probability of broken wires and scratches on the insulation layer of thin-diameter enameled wires can be reduced. Obtain the output torque current of the main drive motor 5 under no-load conditions, and determine the reference resistance torque feedforward sequence based on the output torque current, including: When the wire storage ring 4 is not inserted into the enameled wire under no-load conditions, the main drive motor 5 drives the wire storage ring 4 to rotate at a preset rated speed at a uniform speed. The output torque current of the main drive motor 5 is continuously recorded at a preset period; the output torque current reflects the mechanical frictional resistance torque of the storage ring 4 at different rotation angles and the eccentric torque caused by the shift of the center of gravity. The curve of output torque current changing with rotation angle during a complete rotation cycle is stored as a reference resistance torque feedforward sequence. The reference resistance torque feedforward sequence is used to characterize the inherent load characteristics of the storage ring 4 when there is no enameled wire. It is established by the main drive motor 5 driving the storage ring 4 to rotate at a preset rated speed when the storage ring 4 is not inserted into the enameled wire and is not pulled by any wire at the wire hole 14. The preset rated speed can be set to 500 r / min, or it can be selected in the range of 300 r / min to 800 r / min according to the outer diameter of the storage ring 4 and the rated speed of the main drive motor 5, as long as the angular displacement resolution within the sampling period can distinguish the resistance change of the storage ring 4 within one revolution. The industrial computer 1 continuously records the output torque current of the main drive motor 5 at a preset period, preferably 1ms. When the main drive motor 5 is equipped with a servo driver, the output torque current can be provided by the current loop inside the driver, and the current value is sent to the industrial computer 1 through the digital interface. Since the storage ring 4 is supported by the deep groove ball bearing 12 and directly driven by the main drive gear 6, the fluctuation of the output torque current with the rotation angle mainly comes from bearing friction, tooth surface meshing resistance, mass distribution deviation of the storage ring 4, and periodic load caused by installation eccentricity. Therefore, the industrial control computer 1 establishes a one-to-one correspondence between the rotation angle of the storage ring 4 at each sampling moment and the output torque current. To improve the stability of the reference sequence, three to ten complete rotation cycles can be continuously collected, and the current values ​​within the same angle range can be averaged to obtain an angle-indexed reference resistance torque feedforward sequence. The sequence can be stored in the form of an angle lookup table or an array discrete at fixed angle intervals. In this embodiment, if the storage ring 4 is divided into 360 angle intervals, each interval corresponds to an average reference current value. The industrial control computer 1 directly calls the reference current value of the interval according to the real-time angle during subsequent winding to eliminate the interference of the inherent resistance of the storage ring 4 body on the tension conversion result. The wire storage ring 4 is provided with a wire passage hole 14; the total output torque current of the main drive motor 5 in the wound state, the reference resistance torque feedforward sequence, and the inertial compensation parameters used to overcome the rotational inertia of the wire storage ring are obtained to determine the real-time dynamic tension of the enameled wire, including: Subtract the reference current value in the reference resistance torque feedforward sequence corresponding to the current rotation angle from the total output torque current, and subtract the inertial compensation current used to overcome the angular acceleration generated by the rotational inertia of the storage ring 4, to obtain the reverse load current generated by the enameled wire acting on the wire passage hole 14 of the storage ring 4. Multiply the reverse load current by the conversion factor to obtain the real-time dynamic tension of the enameled wire; where the conversion factor is related to the motor torque coefficient and the radial distance from the wire passage hole 14 to the rotation center of the wire storage ring 4; the real-time dynamic tension is the equivalent tension value obtained by the load conversion of the main drive motor 5 under the winding state, which means the instantaneous reverse force generated by the enameled wire on the wire storage ring 4 at the wire passage hole 14. In practice, after the enameled wire passes through the wire passage hole 14 of the wire storage ring 4 and is fixed to the surface of the iron core, the main drive motor 5 drives the wire storage ring 4 to rotate at a set angular velocity. The industrial control computer 1 obtains the total output torque current of the main drive motor 5 in real time, and reads the encoder or absolute position feedback of the main drive motor 5 to obtain the current rotation angle and angular velocity change. Based on the current rotation angle, the industrial computer 1 reads the corresponding reference current value from the reference resistance torque feedforward sequence and subtracts the reference current value from the total output torque current to eliminate the influence of mechanical friction resistance torque and eccentric torque. When the main drive motor 5 is in the acceleration and deceleration phase, the industrial control computer 1 calculates the inertial compensation current to overcome the rotational inertia based on the total rotational inertia of the storage ring 4, the real-time angular acceleration and the motor torque coefficient, and then subtracts the inertial compensation current from the aforementioned difference to obtain the reverse load current caused by the enameled wire tension. If the torque coefficient of the main drive motor is denoted as Let r be the radial distance from the wire hole 14 to the rotation center of the wire storage ring 4. Then, the reverse load current multiplied by... The equivalent reverse load torque is then obtained, and dividing it by r yields the real-time dynamic tension. Therefore, the conversion factor can be calculated as follows: Divide by the r setting; taking the torque coefficient of the main drive motor 5 as 0.64 N·m / A and the radial distance of the wire hole 14 as 0.09 meters as an example, the conversion factor is approximately 7.11 N per ampere; The key to this implementation is that the main drive gear 6 directly meshes with the spur gear ring 13 of the wire storage ring 4, so that the load change formed by the enameled wire at the wire passage hole 14 can be directly transmitted to the main drive motor 5, reducing the masking of small load fluctuations by the elastic deformation of the transmission chain; the industrial control computer 1 continuously outputs real-time dynamic tension values ​​for the stepper drive motor 10 speed compensation module to call, thereby realizing timely response to tension peaks and troughs. The logical function of the inertia compensation current is to deduct the current component caused by the acceleration or deceleration of the storage ring 4 itself from the total output torque current, so as to avoid misjudging the acceleration or deceleration load of the equipment body as the change of enameled wire tension. The processing flow can be as follows: the industrial control computer 1 continuously reads the angular velocity data of the main drive motor 5 at adjacent sampling times; the current angular acceleration is obtained based on the angular velocity difference between adjacent sampling times and the sampling period; the specific angular acceleration... The calculation logic is as follows:

[0019] in, The current angular acceleration, The angular velocity at the current sampling moment. The angular velocity at the previous sampling time. The sampling period is used to convert the pre-calibrated total moment of inertia of the storage loop 4 into inertial torque corresponding to the current angular acceleration, and then convert it into inertial compensation current according to the motor torque coefficient; the corresponding inertial compensation current... The calculation formula is:

[0020] in, For inertial compensation current, The total moment of inertia of the storage loop. This is the motor torque coefficient; the inertia compensation current is subtracted from the total output torque current with the same sign as the acceleration direction; the total moment of inertia of the storage loop 4 can be obtained through no-load acceleration and deceleration tests after the equipment is assembled. Specifically, a known acceleration command can be applied without wiring, the output current of the servo driver can be recorded, and the result can be back-calculated using the established reference resistance torque feedforward sequence; the back-calculation formula is:

[0021] in, The current rotation angle, To apply a known angular acceleration The total torque current output by the driver, This is the reference current corresponding to the current rotation angle in the reference sequence. The test angular acceleration is known. After replacing the wire storage ring (size 4), the wire passage hole (position 14), or the main drive transmission component, recalibration can be performed once. Real-time dynamic tension serves not only as a numerical display quantity but also as a direct input for subsequent speed compensation modules: when the tension is higher than the current process target value for multiple consecutive sampling periods, it indicates that the wire suction speed at the receiving end is too fast or the path length is too fast; when the tension is lower than the current process target value for multiple consecutive sampling periods, it indicates that the wire suction speed at the receiving end is too slow or there is a tendency for the wire to loosen. Thus, real-time dynamic tension simultaneously assumes the dual role of load characterization quantity and speed regulation trigger quantity in the control logic. To avoid sudden jumps in tension estimation caused by sampling noise, the industrial control computer 1 can perform a 3-point to 8-point sliding average of the reverse load current before performing tension conversion; if the averaged reverse load current is less than zero, the real-time dynamic tension can be limited to zero or treated as a small tension near zero to indicate that the enameled wire is in a state of not being obviously taut. The processing logic for determining the real-time dynamic tension of the enameled wire can be clearly defined as a sequential data stream: the torque current output by the main drive motor 5 is used as the raw input, the reference resistance torque feedforward sequence provides the inherent resistance reference quantity corresponding to the current angle, and the angular velocity change quantity is used to generate the inertia compensation quantity. After the corresponding subtraction of the three within the same sampling period is completed in the industrial control computer 1, the reverse load current caused only by the action of the enameled wire is obtained, and then the torque to tension under the fixed lever arm condition is converted to obtain the real-time dynamic tension. This logic breaks down the total load into mechanical inherent resistance components, rotational inertia components, and wire action components according to their physical sources. The remaining components after the first two are filtered out are used to characterize the actual force on the wire. Since the position of the wire-passing hole 14, the rotation center of the wire storage ring 4, and the motor torque coefficient are all known after equipment calibration, this tension value actually characterizes the relationship between the enameled wire tension acting on the wire storage ring 4 through a fixed lever arm and its mapping to the motor current; specifically, real-time dynamic tension. The calculation formula is as follows:

[0022] in, For real-time dynamic tension, This is the total output torque current. For corresponding angles The reference current, The radial distance from the wire-passing circular hole 14 to the rotation center of the wire storage ring 4. This is the current rotation angle; Based on the real-time dynamic tension, the speed compensation strategy for the stepper drive motor 10 is determined, including: When the real-time dynamic tension exceeds the preset safety upper limit threshold, the stepper drive motor 10 is controlled by the industrial control computer 1 to reduce the speed, so as to reduce the rotational displacement of the iron core in the circumferential direction. When the real-time dynamic tension is less than the preset lower limit threshold, the stepper drive motor 10 is controlled by the industrial control computer 1 to increase the speed, so as to accelerate the rotational displacement of the iron core. When the real-time dynamic tension is between the preset lower tension threshold and the preset upper safety threshold and includes the endpoint value, the current speed of the stepper drive motor 10 is maintained; The speed compensation strategy of the stepper drive motor 10 is used to change the wire receiving speed of the iron core according to the real-time dynamic tension, so as to adapt to the difference in path length formed by the wire storage ring 4 through the wire hole 14 when passing through the inner hole of the iron core and around the outer circle of the iron core; during implementation, the industrial control computer 1 presets the safety upper limit threshold and the tension lower limit threshold, which are determined based on the enameled wire diameter, the enamel layer tolerance value, the target winding cycle and the iron core size; Taking enameled wire with a diameter of 0.08mm to 0.20mm as an example, the upper limit threshold of dynamic tension safety can be set to 0.9N to 2.5N, and the lower limit threshold of tension can be set to 0.2N to 0.8N. When the real-time dynamic tension obtained by the industrial control computer 1 according to the algorithm is greater than the upper limit threshold of safety, it is determined that the current outgoing wire path is growing too fast. If the original wire receiving speed is maintained, the tension of the enameled wire will be further increased. Therefore, the industrial control computer 1 sends a deceleration command to the stepper drive motor 10. The deceleration amplitude can be a fixed percentage or proportional to the amplitude exceeding the threshold. Preferably, the current speed of the stepper motor 10 is reduced by 5% to 20% each time to reduce the circumferential rotational displacement of the iron core per unit time and reduce the rate at which the enameled wire is pulled; when the real-time dynamic tension is less than the lower limit threshold of tension, it is determined that the shortening of the wire path has caused the enameled wire to have a loosening trend, and the industrial control computer 1 sends an acceleration command to the stepper motor 10, the acceleration amplitude of which is preferably 5% to 15% of the current speed, so that the iron core absorbs more enameled wire length per unit time; When the real-time dynamic tension is between two thresholds, the industrial control computer 1 maintains the current speed without applying additional compensation. To avoid the stepper drive motor 10 frequently changing speed near the threshold, the shortest holding time can be set in the industrial control computer 1, for example, from 5ms to 20ms, and the real-time dynamic tension can be processed by a 3-point to 10-point moving average. This implementation method makes the speed change at the receiving end correspond to the load change at the releasing end, thereby reducing the periodic peak value of dynamic tension and increasing the tension trough value, and keeping the wire tightness within a set range during the wire laying process. The physical meaning of the upper limit threshold of safety is the upper boundary of the tension that the enameled wire can withstand under current process conditions without easily breaking, scratching the enamel layer, or being excessively thinned. The physical meaning of the lower limit threshold of tension is the lower boundary of the minimum effective tension required to ensure that the enameled wire continues to adhere to the iron core surface and to avoid loose coils, wire stacking, or wire drift. Together, these two factors constitute a tension working window that allows for stable winding. When the real-time dynamic tension falls within this window, it indicates that the speeds of the wire feeding end and the wire receiving end are basically matched; when it exceeds this window, it indicates an increased tension risk; when it falls below this window, it indicates an increased risk of wire slack. The two thresholds can be determined by trial winding calibration: first select the target wire diameter, core outer diameter, wire storage ring speed 4 and target cycle time, and try winding several turns at a low speed and gradually increase the speed; record the tension fluctuation range corresponding to the absence of wire breakage, scratches, obvious loose turns and pitch instability; Then, the upper boundary of the interval is lowered by 5% to 15% as the safety upper limit threshold, and the lower boundary of the interval is raised by 5% to 20% as the tightening lower limit threshold, so as to reserve process margin for mass production. When processing iron cores of different specifications on the same equipment, the industrial control computer 1 can store the corresponding thresholds according to the process formula, and automatically match them according to wire diameter, iron core outer diameter and winding speed when calling them. The processing flow of the speed compensation strategy can be clearly defined as follows: the industrial computer 1 first receives the filtered real-time dynamic tension; then compares the tension with two thresholds; if it is higher than the upper safety threshold, it enters the deceleration branch; if it is lower than the lower tension threshold, it enters the speed increase branch; if it is between the two, it enters the holding branch; the deceleration branch and the speed increase branch can both be set with a single compensation upper limit and a continuous compensation interval to prevent the stepper drive motor 10 from accumulating excessive adjustment in a short period of time. The compensated new speed serves as the theoretical linear velocity input for the next control cycle and continues to participate in slippage determination, thus forming a closed-loop processing link where tension speed regulation and slippage correction complement each other. Furthermore, the quantitative calculation logic in the speed compensation strategy regarding the proportionality to the magnitude exceeding the threshold is as follows:

[0023] in, To the target rotational speed after compensation, The current rotational speed,

[0024] This corresponds to the upper safety threshold or the lower safety threshold. This is the proportional compensation coefficient, and its value range is... to This formula enables the industrial computer 1 to dynamically determine the adjustment intensity of the stepper drive motor 10 based on the degree to which the tension deviates from the preset window, thereby maintaining constant tension under complex winding paths. The actual linear velocity collected by the core encoder 11 and the theoretical linear velocity output by the stepper motor 10 are obtained. Based on the actual and theoretical linear velocities, a slippage compensation strategy for the stepper motor 10 is determined, including: Calculate the velocity difference between the theoretical linear velocity and the actual linear velocity; When the theoretical linear velocity is greater than the actual linear velocity and the speed difference is greater than the preset judgment threshold, the speed difference is integrated over time to calculate the lost circumferential arc length. In the step instruction of the next winding cycle, the rotation angle corresponding to the lost circumferential arc length is superimposed on the stepper drive motor 10. No slippage compensation is performed when the theoretical linear velocity is not greater than the actual linear velocity or the velocity difference is not greater than the preset judgment threshold. The slippage compensation strategy targets the minute slippage between the active floating clamping wheel 9 and the outer surface of the iron core caused by surface tolerance, pressure fluctuation, or local deposits. During implementation, the industrial control computer 1 calculates the theoretical linear velocity based on the pulse command frequency of the stepper drive motor 10, the electronic gear ratio, and the effective radius of the active floating clamping wheel 9; at the same time, the iron core encoder 11 feeds back the actual rotation speed of the driven floating clamping wheel 9, and the actual linear velocity is obtained by combining the effective radius of the driven floating clamping wheel 9. The theoretical linear velocity and the actual linear velocity should be approximately equal under ideal slip-free conditions. When the theoretical linear velocity is greater than the actual linear velocity and the speed difference exceeds the preset judgment threshold, it indicates that there is positive slippage on the surface of the active floating clamping wheel 9 relative to the outer periphery of the iron core. The preset judgment threshold can be set to 1% to 5% of the theoretical linear velocity to avoid misjudgment caused by measurement noise. The industrial control computer 1 integrates the speed difference exceeding the threshold according to the sampling period. The integration result is the circumferential arc length loss that is not actually transmitted to the iron core per unit time. The integration continues until the end of the current winding cycle or the speed difference falls back to within the threshold. The industrial control computer 1 then converts the lost arc length into an additional rotation angle based on the effective radius of the outer circumference of the iron core, and adds the rotation angle to the step command of the next winding cycle, thereby compensating for the insufficient wire spacing caused by slippage in the previous cycle. If the theoretical linear velocity is not greater than the actual linear velocity, or the speed difference is not greater than the preset judgment threshold, the industrial control computer 1 will not perform slippage compensation to prevent overcompensation. Since the floating clamping wheel 9 is covered with a polyurethane friction layer 19, the slippage usually manifests as a continuous small change rather than an instantaneous loss of steps. The speed difference integral method can obtain a stable arc length error estimation result. Through this implementation method, the local dimensional error of the outer surface of the iron core will not be directly amplified into wire overlap, and the cumulative error of the winding pitch can be kept within the set tolerance. The theoretical linear velocity is the circumferential linear velocity that should be transmitted to the iron core based on the motion command issued by the stepper drive motor 10, the transmission connection relationship, and the effective radius of the active floating clamping wheel 9; the actual linear velocity is the circumferential linear velocity actually obtained by the iron core by the iron core encoder 11 through the driven floating clamping wheel 9. The comparison results of the two are used to determine whether the displacement command issued by the active drive side is actually transmitted to the iron core body. Therefore, the speed difference essentially represents the degree of slippage of the contact interface between the drive chain and the iron core. The preset judgment threshold is not simply to distinguish whether there is a speed error, but to filter out the encoder quantization error, the elastic compression and rebound of the floating clamping wheel 9, and the small false differences caused by short-term mechanical vibration. The determination method can be adopted by two-stage calibration: unloaded clamping and low-speed trial winding. First, clamp the standard iron core without threading and run it at multiple fixed speeds to record the natural fluctuation range between the theoretical linear speed and the actual linear speed. Then, record the fluctuation range of the speed difference when in stable contact under low-tension trial winding conditions. The larger of the two values, with a safety margin, is used as the preset judgment threshold. With this setting, only speed differences that continuously exceed the normal fluctuation range are considered valid slippage signals. The processing flow of the speed difference integral can be clearly defined as follows: In each sampling period, the industrial control computer 1 first calculates the current theoretical linear velocity and the actual linear velocity; then calculates the difference between the two; and determines whether the difference simultaneously satisfies that the theoretical linear velocity is greater than the actual linear velocity and exceeds the preset judgment threshold. If the condition is met, the portion of the speed difference exceeding the threshold will be multiplied by the current sampling period and added to the lost circumferential arc length register; if the condition is not met, the register will remain unchanged. When the current winding cycle ends, the industrial control computer 1 reads the registered value, converts it into the additional rotation angle that needs to be compensated for in the next winding cycle, and clears the registered value to zero or updates it according to the remaining uncompensated value after the angle is superimposed. The final output of this process is the additional rotation angle, which is directly sent to the next cycle position command generation module of the stepper drive motor 10. To avoid excessive compensation, the industrial computer 1 can also set an upper limit for the additional rotation angle of a single cycle, for example, not exceeding 2% to 10% of the theoretical rotation angle of the current winding cycle; when the theoretical linear velocity is not greater than the actual linear velocity, this embodiment considers it as no positive lost arc length that needs to be compensated. The reason is that this situation may be caused by the measurement phase difference, a small change in the contact radius, or the instantaneous advance of the driven measurement side. If reverse compensation is not performed under the condition, it is easy to cause the wiring to be too dense. Therefore, slippage compensation is not performed according to the limit. The slippage compensation strategy can be logically divided into four consecutive stages: speed measurement and value acquisition, difference determination, arc length accumulation, and angle correction for the next cycle. The speed measurement and value acquisition stage is responsible for generating two types of speed data at the same moment from the drive command side and the encoding feedback side, respectively. The difference judgment stage is responsible for eliminating normal fluctuations and retaining only the effective slip amount that meets the judgment conditions; the arc length accumulation stage is responsible for converting the instantaneous speed difference into a circumferential length error with geometric meaning; the next cycle angle correction stage is responsible for converting the length error into an additional displacement command for the stepper drive motor 10. The physical relationship represented by this strategy is as follows: Since the circumferential displacement between the active floating clamping wheel 9 and the iron core is transmitted through friction, when friction is insufficient, the theoretical displacement output by the drive side will not be fully transmitted to the iron core body, resulting in the actual linear velocity being lower than the theoretical linear velocity. Accumulating this velocity difference over time essentially restores the untransmitted circumferential length. Specifically, an additional rotation angle is added. The calculation formula is as follows:

[0025] in, To add rotation angle, and The first The theoretical linear velocity and the actual linear velocity of the next sample. For sampling sequence number, This represents the total number of samples taken within the current winding cycle. The outer radius of the iron core; The summation operator represents the summation of values ​​within a single winding cycle. The angle corresponding to the lost arc length of each sample is accumulated and integrated; Pi; The winding head frame 3 is internally supported by evenly distributed deep groove ball bearings 12 for the wire storage ring 4; The inner diameter of the wire storage ring 4 is larger than the outer diameter of the iron core to be processed; The outer circumferential surface of the wire storage ring 4 is machined with a straight toothed ring 13 of a preset module; the ring body of the wire storage ring 4 is provided with a wire-passing circular hole 14 of a preset diameter for guiding the enameled wire out. The winding head frame 3 is equipped with evenly distributed deep groove ball bearings 12 to support the rotation of the wire storage ring 4. Even distribution means that multiple deep groove ball bearings 12 are distributed at angular intervals along the outer periphery of the wire storage ring 4 so that the wire storage ring 4 obtains stable radial support when rotating. Preferably, three deep groove ball bearings 12 are used with an angular interval of 120°. This arrangement achieves a balance between structural compactness and support rigidity. The inner diameter of the wire storage ring 4 is larger than the outer diameter of the iron core to be processed, so that the wire storage ring 4 can pass around the outer circumference of the iron core without mechanical interference during rotation. The radial gap between the inner diameter and the outer diameter of the iron core is preferably 5mm to 30mm to balance the winding passage and structural dimensions. The outer circumferential surface of the wire storage ring 4 is machined with a spur gear ring 13 of a preset module. The preset module is preferably module two, but it can also be selected in the range of module one to module three according to the diameter of the wire storage ring 4 and the output torque of the main drive motor 5. The use of a spur gear ring 13 facilitates direct meshing with the main drive gear 6, reducing axial force and improving the correspondence between angular position information and load information; a wire passage hole 14 of a preset diameter is opened on the wire storage ring 4 to guide the enameled wire out from the inside of the wire storage ring 4. The diameter of the wire passage hole 14 is preferably 2mm to 5mm, and 3mm can be selected for fine-diameter enameled wire, so as to ensure the wire can pass through while controlling the radial distance of the wire passage position relative to the rotation center of the wire storage ring 4 to be stable; This structure allows the enameled wire tension to form an approximately fixed lever arm on the wire storage ring 4 at the wire passage hole 14, which facilitates the conversion of the reverse load current into real-time dynamic tension in the algorithm by using a fixed conversion factor; the support of the deep groove ball bearing 12, the dimensional relationship of the wire storage ring 4, the gear module, and the dimensions of the wire passage hole 14 together ensure the stability of the mechanical transmission and the repeatability of the tension conversion calculation; The main drive motor 5 is an absolute value servo motor; The output shaft of the main drive motor 5 is connected to the main drive gear 6 via a key 16; The main drive gear 6 directly meshes with the spur gear ring 13 of the wire storage ring 4; The main drive motor 5 is an absolute value servo motor. Its output shaft angular position can be read directly without returning to zero after power-on. Therefore, the industrial control computer 1 can obtain a unified absolute angle coordinate in both the no-load reference sampling and winding operation stages. This angle coordinate is used to index the reference current value in the reference resistance torque feedforward sequence, thereby ensuring that the same mechanical angular position corresponds to the same sequence data in different operating cycles. The output shaft of the main drive motor 5 is connected to the main drive gear 6 via a key 16. The key 16 is used to transmit torque within a set range between the motor shaft and the gear hub and to suppress relative angular offset. The main drive gear 6 directly meshes with the spur gear ring 13 of the wire storage ring 4. Direct meshing means that there are no belt drive pairs, chain drive pairs, or multi-stage reduction gear pairs between the motor and the wire storage ring 4, thereby reducing elastic hysteresis and backlash error in the transmission chain. For implementations requiring higher speeds and higher load identification accuracy, the main drive gear 6 can have 20 to 40 teeth, a tooth width of 15 mm to 30 mm, and the tooth surface material can be tempered steel with surface hardening treatment to control meshing wear. Since the absolute value servo motor has a high current sampling bandwidth and position feedback resolution, and the flat key 16 connection and direct engagement shorten the load fluctuation transmission path, the reverse tension of the enameled wire received by the wire storage ring 4 at the wire passage hole 14 can be more directly mapped to the torque current change of the main drive motor 5. Therefore, this embodiment is beneficial to improving the resolution of dynamic tension conversion. The self-centering chuck 8 has jaws 17 that move synchronously in the radial direction; The top of each chuck 17 is connected to a corresponding floating clamping wheel 9 via a rotating shaft 18; The main body of the floating clamping wheel 9 is made of aluminum alloy; The outer circumference of the floating clamping wheel 9 is covered with a polyurethane friction layer 19 of a preset thickness; the Shore hardness of the polyurethane friction layer 19 is the preset hardness. The self-centering chuck 8 is used to position toroidal iron cores of different outer diameters at the winding center and provide uniform clamping force; its interior can adopt a planar threaded disc structure, which drives multiple jaws 17 to move synchronously in the radial direction, so that the geometric center of the iron core coincides with the rotation center of the chuck as much as possible; preferably, three jaws 17 are used to achieve a balance between structural simplification and circumferential support uniformity. Each claw 17 has its top end connected to a corresponding floating clamping wheel 9 via a rotating shaft 18. The rotating shaft 18 enables the floating clamping wheel 9 to rotate freely around its own axis and roll with the outer circumference of the iron core. The main body of the floating clamping wheel 9 is made of aluminum alloy, preferably 6061 or 7075 aluminum alloy, to reduce rotational inertia and reduce the additional load when the stepper drive motor 10 starts and adjusts its speed. The outer circumference of the floating clamping wheel 9 is covered with a polyurethane friction layer 19 of a preset thickness. The preset thickness is preferably 5 mm, but can also be selected in the range of 3 mm to 8 mm. When the thickness is smaller, the contact stiffness is higher, and when the thickness is larger, the surface conformability is enhanced. The Shore hardness of the polyurethane friction layer 19 is preferably 80 A, but can also be selected in the range of 70 A to 90 A. This hardness range provides a sufficient coefficient of friction while elastically accommodating minor irregularities and local dimensional deviations on the outer surface of the iron core. The chuck 17, which moves synchronously with the self-centering chuck 8, ensures that the three floating clamping wheels 9 always contact the outer periphery of the iron core with approximately uniform radial pressure. The polyurethane friction layer 19 increases the contact area and alleviates local stress concentration, thereby providing a stable and continuous friction transmission basis for speed difference integral compensation and avoiding the sudden slippage common in rigid pressure wheels. A stepper drive motor 10 is fixedly connected to the claw 17 on one side via a flange 20; Stepper motor 10 is a servo motor; The output shaft of the stepper drive motor 10 is directly connected to the corresponding floating clamping wheel 9 via a flexible coupling 22. The iron core encoder 11 is fixedly connected to the claw 17 on the other side; The resolution of the iron core encoder 11 is the preset resolution; The input shaft of the iron core encoder 11 is connected to the corresponding floating clamping wheel 9 through the cross slider coupling 24; A stepper drive motor 10 is fixedly connected to the jaw 17 on one side via a flange 20. In this embodiment, the stepper drive motor 10 is a servo motor with position closed-loop and speed closed-loop capabilities. The rated power can be selected from 100W to 750W according to the outer diameter of the iron core and the winding tension. The output shaft of the stepper drive motor 10 is directly connected to the corresponding floating clamping wheel 9 via a plum blossom flexible coupling 22. The plum blossom flexible coupling 22 can compensate for the slight coaxiality deviation between the motor shaft and the floating clamping wheel 9 shaft, and retains high torsional stiffness when transmitting torque. Therefore, it is suitable for quickly transmitting the speed compensation command output by the industrial control computer 1 to the active floating clamping wheel 9. A core encoder 11 is fixedly connected to the jaw 17 on the other side. The core encoder 11 is used to collect the actual rotation speed and displacement of the corresponding driven floating clamping wheel 9. The preferred resolution is seventeen bits, but fifteen to twenty-three bits can also be used according to the accuracy requirements of the cable pitch. The input shaft of the iron core encoder 11 is connected to the corresponding floating clamping wheel 9 through the cross slider coupling 24. The cross slider coupling 24 is suitable for compensating for the axial offset caused by the slight radial movement of the chuck 17, ensuring that the iron core encoder 11 can still stably read the rotation angle of the driven floating clamping wheel 9 after the self-centering chuck 8 adjusts the clamping diameter. In this embodiment, the stepper drive motor 10 on one side is responsible for applying the theoretical circumferential displacement, while the iron core encoder 11 on the other side is responsible for providing the actual circumferential displacement reference. The two act on different floating clamping wheels 9 respectively, which can reduce the error of a single measuring point affected by the local elastic deformation of the drive shaft. The combination of the plum blossom elastic coupling 22 and the cross slider coupling 24 allows the active drive and the driven measurement to adapt to different mechanical deviation forms, thereby improving the stability and repeatability of slippage compensation calculation. In this embodiment, the drive unit that executes the displacement command of the receiving end adopts a stepper drive motor 10; in terms of hardware selection, the stepper drive motor 10 can be a servo motor with coded feedback or a closed-loop stepper servo integrated machine to obtain higher speed response and position following accuracy. Since the stepper drive motor 10 is responsible for the rapid increase and decrease after tension triggering and the additional angle compensation for the next winding cycle, it is directly connected to the active floating clamping wheel 9 and supplemented with a high torsional stiffness coupling, so that the control command can be more directly converted into the circumferential displacement of the iron core. Furthermore, since the actual displacement is acquired by an independent encoder on the other side, the drive execution chain and the measurement feedback chain are set up separately, providing an independent data source for slippage identification; To verify the technical effect of the present invention, an outer diameter of [missing information] was used. The iron core and wire diameter are A comparative winding experiment was conducted on the enameled wire. The experiment was divided into two groups: the control group used a conventional open-loop speed regulation winding device without tension compensation, and the experimental group used the winding device of the present invention, which includes a reference resistance torque feedforward sequence and a slippage compensation strategy. Set the main drive speed to Continuous processing The results of the test on the sample are recorded as follows: the breakage rate of the enameled wire in the control group is... The insulation layer scratch defect rate is The maximum cumulative error in the cable spacing reached After implementing dynamic tension compensation and slippage integral correction, the breakage rate of the enameled wire in the experimental group decreased to [a lower percentage]. The insulation layer scratch defect rate decreased to The maximum cumulative error of the cable spacing was stably controlled within within; The experimental data above show that the method of the present invention smooths out the periodic fluctuations of tension and improves the uniformity and insulation safety of high-speed winding.

[0026] Example 2: Combination Figures 1 to 4 As shown, a winding device for manufacturing a current transformer core includes: 1. Industrial control computer; 2. Base; 3. Winding head frame; 4. Wire storage ring; 5. Main drive motor; 6. Main drive gear; 7. Iron core support frame; 8. Self-centering chuck; 9. Floating clamping wheel; 10. Stepper drive motor; and 11. Iron core encoder. The upper surface of the base 2 is fixedly connected to the winding head frame 3; the inside of the winding head frame 3 is supported by the wire storage ring 4 through the deep groove ball bearing 12; the outer circumferential surface of the wire storage ring 4 is machined with a straight tooth ring 13; the ring body of the wire storage ring 4 is provided with a wire passage hole 14. The top of the winding head frame 3 is fixedly connected to the main drive motor 5; the output shaft of the main drive motor 5 is connected to the main drive gear 6; the main drive gear 6 meshes with the spur gear ring 13; the front side of the base 2 is fixedly connected to the iron core support frame 7; the top surface of the iron core support frame 7 is fixedly connected to the self-centering chuck 8; the self-centering chuck 8 has a chuck claw 17 that moves synchronously in the radial direction. The top of each jaw 17 is connected to a floating clamping wheel 9 via a rotating shaft 18; the floating clamping wheel 9 is used to press and support the iron core from the outside; a stepper drive motor 10 is fixedly connected to the jaw 17 on one side; the output shaft of the stepper drive motor 10 is connected to the corresponding floating clamping wheel 9; an iron core encoder 11 is fixedly connected to the jaw 17 on the other side. The input shaft of the iron core encoder 11 is connected to the corresponding floating clamping wheel 9; the industrial control computer 1 is communicatively connected to the main drive motor 5, the stepper drive motor 10 and the iron core encoder 11. The iron core winding device for manufacturing current transformers consists of a mechanical execution part and an electrical control processing part. The mechanical execution part includes a base 2, a winding head frame 3, a wire storage ring 4, a main drive motor 5, a main drive gear 6, an iron core support frame 7, a self-centering chuck 8, a floating clamping wheel 9, a stepper drive motor 10, and an iron core encoder 11. The electrical control processing part includes an industrial control computer 1 and its communication links with each actuator and sensor. The upper surface of the base 2 is fixedly connected to the winding head frame 3, and the front side of the base 2 is fixedly connected to the iron core support frame 7. The two maintain a fixed relative position in space to ensure that the rotation trajectory of the wire storage ring 4 corresponds to the iron core clamping position. The winding head frame 3 is supported by a deep groove ball bearing 12 inside the winding head frame 3. The wire storage ring 4 is provided with a straight toothed ring 13 on the outer circumference of the wire storage ring 4. A wire passage hole 14 is opened on the ring body. The main drive motor 5 is installed on the top of the winding head frame 3. Its output shaft is connected to the main drive gear 6. After the main drive gear 6 meshes with the straight toothed ring 13, it drives the wire storage ring 4 to rotate, realizing the wire feeding movement of the enameled wire through the inner and outer circumferences of the iron core. A self-centering chuck 8 is fixedly connected to the top surface of the iron core support frame 7. Multiple jaws 17 of the self-centering chuck 8 move synchronously in the radial direction. The top of each jaw 17 is connected to a floating clamping wheel 9 through a rotating shaft 18. Multiple floating clamping wheels 9 press and support the iron core from the outside. A stepper drive motor 10 is fixedly connected to the jaw 17 on one side. The output shaft of the stepper drive motor 10 is connected to the corresponding floating clamping wheel 9 to drive the iron core to rotate. An iron core encoder 11 is fixedly connected to the jaw 17 on the other side. The input shaft of the iron core encoder 11 is connected to the corresponding floating clamping wheel 9 to provide feedback on the actual motion state. The industrial control computer 1 is communicatively connected to the main drive motor 5, the stepper drive motor 10, and the iron core encoder 11. In this device, the main drive motor 5 and its directly meshing wire storage ring 4 are responsible for load sensing, the stepper drive motor 10 and its floating clamping wheel 9 are responsible for adjusting the displacement of the wire end, and the iron core encoder 11 and its connected driven floating clamping wheel 9 are responsible for real displacement feedback. The correspondence between the various structures is formed through the data processing relationship of the industrial control computer 1. In practical use, the industrial control computer 1 performs no-load torque current sampling and establishes a reference resistance torque feedforward sequence during the power-on preparation stage. During the winding operation stage, it performs real-time dynamic tension conversion, step speed compensation, and slippage integral correction, so that the device has both the ability to complete mechanical winding actions and the ability to adjust the winding process parameters in real time according to changes in mechanical load.

[0027] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention.

Claims

1. A winding method for a winding device for manufacturing the core of a current transformer, characterized in that, Applied to a core winding device, the device includes: Industrial computer (1), base (2), winding head frame (3) set on base (2), wire storage ring (4) set inside winding head frame (3) and main drive motor (5) on top, iron core support frame (7) set on the front side of base (2), self-centering chuck (8) set on iron core support frame (7), floating clamping wheel (9) connected to self-centering chuck (8), and stepper drive motor (10) and iron core encoder (11) respectively connected to floating clamping wheel (9); The floating clamping wheels (9) press and support the annular iron core from the outside; The floating clamping wheel (9) connected to the stepper drive motor (10) is the active floating clamping wheel, and the floating clamping wheel (9) connected to the iron core encoder (11) is the driven floating clamping wheel; The winding methods executed by the industrial computer (1) include: Obtain the output torque current of the main drive motor (5) under no-load conditions, and determine the reference resistance torque feedforward sequence accordingly; Obtain the total output torque current of the main drive motor (5) in the winding state, and determine the real-time dynamic tension of the enameled wire based on the total current, the reference resistance torque feedforward sequence and the inertial compensation parameter to overcome the rotational inertia of the storage ring. Based on the real-time dynamic tension, the speed compensation strategy of the stepper drive motor (10) is determined; The actual linear velocity collected by the iron core encoder (11) and the theoretical linear velocity output by the stepper motor (10) are obtained, and the slippage compensation strategy for the stepper motor (10) is determined accordingly.

2. The winding method according to claim 1, characterized in that, The step of obtaining the output torque current of the main drive motor (5) under no-load conditions and determining the reference resistance torque feedforward sequence based on the output torque current includes: In the unloaded state where the wire storage ring (4) is not inserted with enameled wire, the main drive motor (5) drives the wire storage ring (4) to rotate at a preset rated speed. The output torque current of the main drive motor (5) is continuously recorded at a preset period; wherein the output torque current reflects the mechanical frictional resistance torque of the wire storage ring (4) at different rotation angles and the eccentric torque caused by the center of gravity shift; The curve of the output torque current changing with the rotation angle during the complete rotation cycle is stored as the reference resistance torque feedforward sequence.

3. The winding method according to claim 1, characterized in that, The wire storage ring (4) is provided with a wire passage hole (14); the step of obtaining the total output torque current of the main drive motor (5) in the winding state, and determining the real-time dynamic tension of the enameled wire based on the total output torque current, the reference resistance torque feedforward sequence, and the inertial compensation parameter used to overcome the rotational inertia of the wire storage ring, includes: Subtract the reference current value in the reference resistance torque feedforward sequence corresponding to the current rotation angle from the total output torque current, and subtract the inertial compensation current used to overcome the angular acceleration generated by the rotational inertia of the wire storage ring (4) to obtain the reverse load current generated by the enameled wire acting on the wire passage hole (14) of the wire storage ring (4). The real-time dynamic tension of the enameled wire is obtained by multiplying the reverse load current by a conversion factor; wherein the conversion factor is related to the motor torque coefficient and the radial distance from the wire passage hole (14) to the rotation center of the wire storage ring (4).

4. The winding method according to claim 1, characterized in that, The stepper motor (10) speed compensation strategy determined based on the real-time dynamic tension includes: When the real-time dynamic tension is greater than the preset safety upper limit threshold, the stepper drive motor (10) is controlled by the industrial control computer (1) to reduce the speed, so as to reduce the rotational displacement of the iron core in the circumferential direction; When the real-time dynamic tension is less than the preset lower limit threshold, the industrial control computer (1) controls the stepper drive motor (10) to increase the speed to accelerate the rotational displacement of the iron core. When the real-time dynamic tension is between the preset lower tension threshold and the preset upper safety threshold and includes the endpoint value, the current speed of the stepper drive motor (10) is maintained.

5. The winding method according to claim 1, characterized in that, The process of acquiring the actual linear velocity collected by the core encoder (11) and the theoretical linear velocity output by the stepper motor (10), and determining a slippage compensation strategy for the stepper motor (10) based on the actual linear velocity and the theoretical linear velocity, includes: Calculate the velocity difference between the theoretical linear velocity and the actual linear velocity; When the theoretical linear velocity is greater than the actual linear velocity and the speed difference is greater than the preset judgment threshold, the speed difference is integrated over time to calculate the lost circumferential arc length, and in the stepping instruction of the next winding cycle, the rotation angle corresponding to the lost circumferential arc length is superimposed on the stepper drive motor (10). No slippage compensation is performed when the theoretical linear velocity is not greater than the actual linear velocity or the velocity difference is not greater than the preset judgment threshold.

6. The winding method according to claim 1, characterized in that, The winding head frame (3) is internally supported by evenly distributed deep groove ball bearings (12) for the wire storage ring (4); The inner diameter of the wire storage ring (4) is larger than the outer diameter of the iron core to be processed; The outer circumferential surface of the wire storage ring (4) is machined with a straight toothed ring (13) of a preset module; The wire storage ring (4) has a wire-passing hole (14) of a preset diameter on its ring body for guiding the enameled wire out.

7. The winding method according to claim 6, characterized in that, The main drive motor (5) is an absolute value servo motor; The output shaft (15) of the main drive motor (5) is connected to the main drive gear (6) via a key (16); The main drive gear (6) directly meshes with the spur gear ring (13) of the wire storage ring (4).

8. The winding method according to claim 1, characterized in that, The self-centering chuck (8) has jaws (17) that move synchronously in the radial direction; The top of each of the claws (17) is connected to the corresponding floating clamping wheel (9) via a rotating shaft (18); The main body of the floating clamping wheel (9) is made of aluminum alloy; The outer circumference of the floating clamping wheel (9) is covered with a polyurethane friction layer (19) of a predetermined thickness; The Shore hardness of the polyurethane friction layer (19) is a preset hardness.

9. The winding method according to claim 8, characterized in that, The stepper drive motor (10) is fixedly connected to the claw (17) located on one side via a flange (20); The stepper motor (10) is a servo motor; The output shaft (21) of the stepper drive motor (10) is directly connected to the corresponding floating clamping wheel (9) through a plum blossom flexible coupling (22); The iron core encoder (11) is fixedly connected to the claw (17) located on the other side; The resolution of the iron core encoder (11) is a preset resolution; The input shaft (23) of the core encoder (11) is connected to the corresponding floating clamping wheel (9) via a cross slider coupling (24).

10. A winding apparatus for manufacturing a current transformer core, used to implement the method according to any one of claims 1-9, characterized in that, include: Industrial computer (1), base (2), winding head frame (3), wire storage ring (4), main drive motor (5), main drive gear (6), iron core support frame (7), self-centering chuck (8), floating clamping wheel (9), stepper drive motor (10) and iron core encoder (11); The upper surface of the base (2) is fixedly connected to the winding head frame (3); the inside of the winding head frame (3) is supported by a deep groove ball bearing (12) for the wire storage ring (4); the outer circumferential surface of the wire storage ring (4) is machined with a straight tooth ring (13); The wire storage ring (4) has a wire-passing circular hole (14) on its ring body; the top of the winding head frame (3) is fixedly connected to the main drive motor (5); the output shaft (15) of the main drive motor (5) is connected to the main drive gear (6); the main drive gear (6) meshes with the spur gear ring (13); The base (2) is fixedly connected to the iron core support frame (7) on the front side; the iron core support frame (7) is fixedly connected to the self-centering chuck (8) on the top surface; the self-centering chuck (8) has a jaw (17) that moves synchronously in the radial direction; the top of the jaw (17) is connected to the floating clamping wheel (9) through a rotating shaft (18). The floating clamping wheels (9) are used to press and support the iron core from the outside together; the stepper drive motor (10) is fixedly connected to the jaw (17) on one side; the output shaft (21) of the stepper drive motor (10) is connected to the corresponding floating clamping wheel (9); the iron core encoder (11) is fixedly connected to the jaw (17) on the other side. The input shaft (23) of the core encoder (11) is connected to the corresponding floating clamping wheel (9); The industrial control computer (1) is communicatively connected to the main drive motor (5), the stepper drive motor (10) and the iron core encoder (11) and is used to execute the winding method as described in any one of claims 1 to 9.

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