A high-efficiency winding device and winding method for transformer production

Abstract

This invention discloses a high-efficiency winding equipment and method for transformer production. The high-efficiency winding equipment includes a foil unwinding mechanism and an auxiliary foil unwinding mechanism. The foil unwinding mechanism has multiple first rolls, and the auxiliary foil unwinding mechanism has multiple second rolls. It also includes an adaptive processing mechanism, a self-cleaning mechanism, a scratch removal mechanism, and a machine vision online inspection system. The adaptive processing mechanism is located between the auxiliary foil unwinding mechanism and the foil unwinding mechanism. The self-cleaning mechanism is connected to one end face of the adaptive processing mechanism. This invention includes a self-cleaning mechanism between the auxiliary foil unwinding mechanism and the foil unwinding mechanism to remove dust from the fed foil. Simultaneously, a burr removal mechanism is included to clean edge burrs, preventing dust and burrs from affecting the final production quality.

Description

Technical Field

[0001] This invention belongs to the technical field of high-efficiency winding equipment and winding method for transformer production, specifically relating to a high-efficiency winding equipment and winding method for transformer production. Background Technology

[0002] Features: Widely used in the manufacturing of power transformers, dry-type reactors, new energy transformers, and high-end power transmission and transformation equipment, it is a key production equipment for ensuring the quality and operational reliability of transformer windings. However, in the actual production winding process, existing foil winding equipment still faces a series of prominent problems affecting product quality and production stability due to various factors such as incoming material condition, equipment structure, environmental factors, and process control. These are as follows: 1. During the entire process of unwinding, conveying, and cutting, foil materials are susceptible to contamination from dust, metal shavings, insulating paper fibers, and other impurities in the workshop environment, resulting in dust and other foreign matter adhering to the foil surface. During the winding process, impurities trapped between the foil and the interlayer insulating paper can form localized hard spots, causing defects such as coil bulging and insulation layer wrinkling. This not only significantly increases the product scrap rate and rework costs but also causes uneven stress in the overall coil structure. At the same time, if the edge burrs generated during the foil cutting process are not effectively cleaned, they can easily pierce the interlayer insulation layer during the winding and compaction process, forming a conductive path and ultimately causing inter-turn short circuit faults in the transformer, seriously threatening the safe operation of the equipment.

[0003] 2. During production, transportation, storage, and equipment processing, foil materials are easily contaminated with various oil stains such as guide rail lubricating oil, hydraulic oil, and fingerprints and grease from operators. Furthermore, existing equipment lacks targeted online cleaning control, resulting in oil residue remaining on the foil surface. On one hand, oil stains can damage the metallurgical bonding properties of the foil's welding surfaces, causing problems such as incomplete welding, detachment, and insufficient weld strength at the foil's ends, leading to strip breakage and coil structural failure during winding. On the other hand, oil stains can form an isolation layer between the foil and the insulating paper, resulting in loose insulation, voids, and delamination, significantly reducing the coil's insulation withstand voltage performance and partial discharge level, ultimately causing transformer insulation performance failure and failing to meet factory testing and long-term operation requirements.

[0004] 3. During the unwinding, conveying, rolling, and cutting processes, foil materials are prone to surface scratches due to factors such as foreign objects in the equipment roller system, mechanical friction, and improper operation. Scratched areas will form significant stress concentration points. Under continuous tension during the winding process, these areas are highly susceptible to foil breakage, causing production interruptions and coil scrapping. At the same time, scratches reduce the effective current-carrying cross-sectional area of ​​the foil material, leading to uneven current density distribution during coil operation. This can cause localized overheating in the scratched areas, which will accelerate insulation aging over long-term operation and even cause thermal breakdown failures, severely reducing the service life and operational reliability of the transformer.

[0005] Therefore, in view of the above-mentioned technical problems, it is necessary to provide a high-efficiency winding equipment and winding method for transformer production.

[0006] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0007] The purpose of this invention is to provide a high-efficiency winding device and winding method for transformer production, which can solve the above-mentioned problems.

[0008] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution: A high-efficiency winding device for transformer production includes a foil unwinding mechanism and an auxiliary foil unwinding mechanism. The foil unwinding mechanism has multiple first rolls, and the auxiliary foil unwinding mechanism has multiple second rolls. The device also includes an adaptive processing mechanism, a self-cleaning mechanism, a scratch removal mechanism, and a machine vision online inspection system. The adaptive processing mechanism is located between the auxiliary foil unwinding mechanism and the foil unwinding mechanism. A self-cleaning mechanism is connected to one end face of the adaptive processing mechanism. This mechanism includes an oil stain cleaning mechanism, a burr polishing mechanism, an intelligent brush roller cleaning box, and a dust cleaning mechanism. The oil stain cleaning mechanism and the dust cleaning mechanism clamp the foil material located between a pair of second rolls using an automatic lifting device, cleaning the surface oil stains or dust. Both the oil stain cleaning mechanism and the dust cleaning mechanism include multiple soft-bristled brush rollers, with multiple alcohol and cleaning agent inlets within each pair of soft-bristled brush rollers. The burr polishing mechanism is located on a pair of opposite end faces of the adaptive processing mechanism. The intelligent brush roller cleaning box is located on the bottom end face of the auxiliary foil unwinding mechanism, and includes a movable cleaning mechanism and a lower cleaning mechanism. A scratch treatment mechanism is connected to one end face of the adaptive processing mechanism. This mechanism includes a pair of scratch treatment mechanisms and a pair of polishing components, which are respectively located on both end faces of the pair of second rolls. A machine vision online inspection system is located on multiple end faces of the foil unwinding mechanism and the auxiliary foil unwinding mechanism.

[0009] In one or more embodiments of the present invention, the adaptive processing mechanism includes a support frame, a base, and a storage mechanism. The support frame is disposed on one end face of the auxiliary foil unwinding mechanism, and the storage mechanism and the base are fixedly connected to the bottom end face of the support frame in sequence. The support frame is a hollow structure.

[0010] In one or more embodiments of the present invention, the oil stain cleaning mechanism further includes a first reinforced cleaning component and a second reinforced cleaning component, the first reinforced cleaning component and the second reinforced cleaning component being disposed on the inner wall of the support frame at opposite end faces between a pair of second rollers, and the dust removal mechanism includes a cleaning component and a second cleaning component, the cleaning component and the second cleaning component being respectively disposed on the support frame at opposite end faces of the first reinforced cleaning component and the second reinforced cleaning component.

[0011] In one or more embodiments of the present invention, the first enhanced cleaning component, the second enhanced cleaning component, the cleaning component, and the second cleaning component all include an automatic lifting device, a connecting frame, and a soft brush roller. The automatic lifting device is fixedly connected to the inner wall end face of the support frame, the connecting frame is fixedly connected to the bottom of the automatic lifting device, and the soft brush roller is rotatably connected to the inner wall end face of the connecting frame. The first enhanced cleaning component and the second enhanced cleaning component are both connected to a first supply box and a second supply box. The first supply box and the second supply box are connected to the alcohol delivery port and the cleaning agent delivery port of the soft brush roller through a replenishment pipe. The first supply box stores alcohol, and the second supply box stores hydrocarbon cleaning agent.

[0012] In one or more embodiments of the present invention, the burr removal mechanism includes a drive motor and a grinding wheel. The drive motor is fixedly connected to one end face of the inner wall of the support frame located between a pair of second rollers. The grinding wheel is disposed on one side of the drive motor. An ion fan is disposed on one side of the support frame located on either the cleaning component or the second cleaning component.

[0013] In one or more embodiments of the present invention, the lower cleaning mechanism includes a lower cleaning box, which is fixedly connected to the bottom of the support frame and located on one side of the first reinforced cleaning component. The lower cleaning box is provided with a plurality of drainage holes, and a drainage groove is provided on one side of the lower cleaning box. A plurality of cleaning nozzles and alcohol cleaning nozzles are provided on one side of the lower cleaning box located on the inner wall of the drainage groove. The cleaning nozzles and alcohol cleaning nozzles are respectively connected to an alcohol supply tank and a water tank. The alcohol supply tank and the water tank are located on the inner wall end face of the storage mechanism. The alcohol supply tank and the water tank are connected to the plurality of cleaning nozzles and alcohol cleaning nozzles through a second supply pipe.

[0014] In one or more embodiments of the present invention, the movable cleaning mechanism includes a movable box and a shielding curtain. The top end face of the movable box has a groove matching the second reinforced cleaning component and the cleaning component. The shielding curtain is disposed on the end face of the support frame located in the groove. A conveying pipe is disposed on the side of the movable box away from the groove. Multiple upper cleaning nozzles and upper alcohol cleaning nozzles are disposed at the bottom of the conveying pipe. A third supply pipe is disposed on the alcohol supply tank and the water tank. The multiple upper cleaning nozzles and upper alcohol cleaning nozzles are respectively connected to the third supply pipe via supply branch pipes. A portion of the end face of the third supply pipe is located on the inner wall of the conveying pipe. The moving box and the lower cleaning box are equipped with drying troughs on multiple sides. The drying troughs are connected to a hot air blower through hot air delivery pipes. An automatic telescopic door is provided on one end face of the moving box. A limiting groove matching the automatic telescopic door is provided on one side of the lower cleaning box. A baffle plate is fixedly connected to the support frame on one side of the second cleaning component. A pair of opposite end faces of the moving box are connected to a leverless cylinder through a connecting seat. The leverless cylinder is fixedly connected to the upper end face of the support frame on the moving box. A dryer is provided on one side of the scratch treatment mechanism of the adaptive processing mechanism. Multiple drying nozzles are provided on the bottom end face of the dryer.

[0015] In one or more embodiments of the present invention, the scratch treatment mechanism includes a soldering head, a solder feeder, and a moving mechanism. The solder feeder is connected to the bottom of the solder feeder and to one side of the moving mechanism. The solder feeder is slidably connected to the side wall end face of the support frame. A pair of soldering heads are arranged opposite to each other. The polishing assembly includes a second lifting mechanism and a second polishing wheel. The second lifting mechanism is fixedly connected to one side end face of the solder feeder. A mounting plate is fixedly connected to the bottom of the second lifting mechanism. A second drive motor is fixedly connected to the bottom of the mounting plate. The second drive motor is connected to the second polishing wheel.

[0016] In one or more embodiments of the present invention, the foil unwinding mechanism is provided with a pair of dust cleaning components between a pair of first rolls, the pair of dust cleaning components being arranged opposite to each other and having a gap between them.

[0017] The winding method of high-efficiency winding equipment for transformer production includes the following steps; S1. Foil material conveying: The foil material is sequentially introduced into the auxiliary foil material unwinding mechanism and the foil material unwinding mechanism to start the winding operation. During the winding process, the dust, burrs and scratches on the surface of the foil material are monitored by the machine vision online detection system. S2. Dust removal: Depending on the workshop environment, if there is a lot of dust, during the production process, the automatic lifting device controls a pair of cleaning components and a second cleaning component to clean the dust from the upper and lower surfaces of the foil. If the workshop is clean, the dust removal mechanism will be activated to clean the dust from the foil surface when the machine vision online detection system detects dust. S3. Oil stain cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects whether there is oil stain on the surface of the foil. If so, the oil stain cleaning mechanism is activated, and the first or second reinforced cleaning component is controlled to clean the upper and lower surfaces of the foil by spraying alcohol. After cleaning, the dust cleaning mechanism is activated to wipe it again. S4. Scratch cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects scratches on the foil surface. First, the first and second reinforced cleaning components spray alcohol to clean the surface. Then, the scratch treatment mechanism is activated to perform soldering. After soldering, the polishing component is used to smooth the surface and restore it to a smooth state.

[0018] S5. Winding operation: Start the winding operation and begin the winding of the foil material until the final product is generated.

[0019] Compared with the prior art, the high-efficiency winding equipment and winding method for transformer production of the present invention have the following advantages; A self-cleaning mechanism is set between the auxiliary foil unwinding mechanism and the foil unwinding mechanism to remove dust from the foil being fed. At the same time, a burr grinding mechanism is set to clean the edge burrs to prevent dust and burrs from affecting the final production quality. The self-cleaning mechanism cleans the oil stains on the surface of the foil to prevent them from becoming oily before entering the welding mechanism and affecting the welding quality. The scratch treatment mechanism temporarily repairs scratches on the foil surface to prevent production interruptions and coil scrapping, thereby improving production efficiency. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1 This is a front view of the high-efficiency winding equipment for transformer production in Embodiment 1 of the present invention; Figure 2 This is a schematic diagram of the high-efficiency winding equipment for transformer production in Embodiment 1 of the present invention; Figure 3 This is a partial structural schematic diagram of the high-efficiency winding equipment for transformer production in Embodiment 1 of the present invention; Figure 4 This is a partial structural diagram of the high-efficiency winding equipment for transformer production in Embodiment 1 of the present invention. Figure 2 ; Figure 5 for Figure 4 A schematic diagram of the structure at point A; Figure 6 This is a schematic diagram of the adaptive processing mechanism structure in Embodiment 1 of the present invention. Figure 1 ; Figure 7 for Figure 6 A schematic diagram of the structure at point B; Figure 8 This is a schematic diagram of the adaptive processing mechanism structure in Embodiment 1 of the present invention. Figure 2 ; Figure 9 for Figure 8 A schematic diagram of the structure at point C; Figure 10 This is a schematic diagram showing the usage state of the adaptive processing mechanism in Embodiment 1 of the present invention; Figure 11 This is a schematic diagram of the intelligent brush roller cleaning box in Embodiment 1 of the present invention. Figure 1 ; Figure 12 This is a schematic diagram of the intelligent brush roller cleaning box in Embodiment 1 of the present invention. Figure 2 .

[0022] Figure 13 This is a schematic diagram of the high-efficiency winding equipment for transformer production in Embodiment 2 of the present invention; Explanation of key figure labels: 1-Foil unwinding mechanism, 101-First roll, 2-Auxiliary foil unwinding mechanism, 201-Second roll, 3-Adaptive processing mechanism, 301-Support frame, 302-Base, 303-Storage mechanism, 4-Layer insulation unwinding device, 5-Feeding mechanism, 6-Intelligent brush roller cleaning box, 601-Moving box, 602-Lower cleaning box, 6021-Limiting groove, 603-Shielding curtain, 604-Drain hole, 605-Draining trough, 606-Cleaning nozzle, 6061-Alcohol cleaning nozzle, 607-Leverless cylinder, 608-Connecting seat, 609-Conveying pipe, 610-Upper cleaning nozzle, 611-Upper alcohol cleaning nozzle, 612-Drying tank, 613-Automatic extension Shrink plate, 7-burr grinding mechanism, 701-drive motor, 702-grinding wheel, 8-scratching mechanism, 801-soldering head, 802-mounting plate, 803-solder feeder, 804-moving mechanism, 805-second lifting mechanism, 806-second drive motor, 807-second grinding wheel, 9-automatic telescopic door, 10-first supply box, 11-second supply box, 12-first reinforced cleaning assembly, 1201-automatic lifting device, 1202-connecting frame, 1203-soft brush roller, 13-shielding plate, 14-second reinforced cleaning assembly, 15-cleaning assembly, 16-dryer, 1601-drying nozzle, 17-ion fan, 18-dust cleaning assembly. Detailed Implementation

[0023] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0024] like Figure 1 As shown in the figure, an embodiment of the present invention discloses a high-efficiency winding device and method for transformer production. The high-efficiency winding device includes a foil unwinding mechanism 1, an auxiliary foil unwinding mechanism 2, a layer insulation unwinding device 4, and a feeding mechanism 5. The foil unwinding mechanism 1 is equipped with multiple first rolls 101, and the auxiliary foil unwinding mechanism 2 is equipped with multiple second rolls 201. During winding, the foil is sequentially fed between a pair of first rolls 101 and a pair of second rolls 201, and then sequentially enters a welding mechanism for welding before being wound. During winding, the foil strip position is adjusted in real time by a correction system to maintain alignment. This is common knowledge in the art and will not be elaborated further here. The high-efficiency winding equipment for transformer production also includes an adaptive processing mechanism 3, a self-cleaning mechanism, a scratch removal mechanism, and a machine vision online inspection system. The adaptive processing mechanism 3 is located between the auxiliary foil unwinding mechanism 2 and the foil unwinding mechanism 1. The self-cleaning mechanism and the scratch removal mechanism are both connected to one end face of the adaptive processing mechanism 3. The self-cleaning mechanism automatically removes dust, burrs, and oil stains from the foil before winding, preventing them from affecting subsequent normal production, reducing the occurrence of defective products, saving production costs, and improving production efficiency.

[0025] like Figure 1-4 As shown, the adaptive processing mechanism 3 includes a support frame 301, a base 302, and a storage mechanism 303. The support frame 301 is disposed on one side end face of the auxiliary foil unwinding mechanism 2. The storage mechanism 303 and the base 302 are fixedly connected to the bottom end face of the support frame 301 in sequence. The support frame 301 has a hollow structure. The self-processing cleaning mechanism and the scratch treatment mechanism are both disposed inside the adaptive processing mechanism 3, and the overall support is provided by the adaptive processing mechanism 3.

[0026] The self-cleaning mechanism includes an oil stain cleaning mechanism, a burr polishing mechanism 7, an intelligent brush roller cleaning box 6, and a dust cleaning mechanism. The oil stain cleaning mechanism and the dust cleaning mechanism use an automatic lifting device 1201 to clamp and adhere the foil material located between a pair of second rollers 201 to clean the surface of oil stains or dust. Both the oil stain cleaning mechanism and the dust cleaning mechanism include multiple soft brush rollers 1203. Each pair of soft brush rollers 1203 is equipped with multiple alcohol delivery ports and cleaning agent delivery ports. The alcohol delivery ports and cleaning agent delivery ports deliver cleaning agent or alcohol. Initial cleaning of oil stains is performed by delivering alcohol. If the oil stains are not cleaned properly, stubborn oil stains are cleaned by delivering cleaning agent.

[0027] The burr removal mechanism 7 is located on a pair of opposite end faces of the adaptive processing mechanism 3 to clean the edge burrs on the sides of the foil. The intelligent brush roller cleaning box 6 is located on the bottom end face of the auxiliary foil unwinding mechanism 2. The intelligent brush roller cleaning box 6 includes a movable cleaning mechanism and a lower cleaning mechanism. The intelligent brush roller cleaning box 6 automatically cleans the multiple soft brush rollers of the oil and dust cleaning mechanisms, eliminating the need for frequent manual replacement and allowing for repeated use.

[0028] like Figure 3-10 As shown, the oil stain cleaning mechanism also includes a first reinforced cleaning component 12 and a second reinforced cleaning component 14. The first reinforced cleaning component 12 and the second reinforced cleaning component 14 are disposed on the inner wall of the support frame 301 at the opposite end face between a pair of second drums 201. That is, the first reinforced cleaning component 12 is disposed on the inner wall of the support frame 301 at the lower end face of the second drum 201, and the second reinforced cleaning component 14 is disposed on the inner wall of the support frame 301 at the lower end face of the second drum 201. The dust removal mechanism includes a cleaning component 15 and a second cleaning component, which are respectively disposed on the opposite end faces of the first reinforced cleaning component 12 and the second reinforced cleaning component 14 on the support frame 301. That is, the cleaning component 15 is disposed on the adjacent end face of the second reinforced cleaning component 14, and the second cleaning component is disposed on the adjacent end face of the first reinforced cleaning component 12. The cleaning component 15 and the second cleaning component are used to clean dust from the surface of the foil.

[0029] Furthermore, the first reinforced cleaning component 12, the second reinforced cleaning component 14, the cleaning component 15, and the second cleaning component all include an automatic lifting device 1201, a connecting frame 1202, and a soft brush roller 1203. The automatic lifting device 1201 is fixedly connected to the inner wall end face of the support frame 301, the connecting frame 1202 is fixedly connected to the bottom of the automatic lifting device 1201, and the soft brush roller 1203 is rotatably connected to the inner wall end face of the connecting frame 1202. The automatic lifting device 1201 controls the lifting of the connecting frame 1202 and the soft brush roller 1203.

[0030] Specifically, after the foil is introduced between a pair of second rolls 201, a pair of automatic lifting devices 1201 control a pair of soft brush rollers 1203 to rise and fall to the upper and lower ends of the foil. Although the pair of soft brush rollers 1203 are in contact with the foil, they do not cause significant friction. As the foil moves and is conveyed to the foil unwinding mechanism 1, the soft brush rollers 1203 on both sides can perform a rolling cleaning of dust and oil on the surface. That is, while the second rolls 201 are conveying the foil forward, the soft brush rollers 1203 are rolling to clean the dust or oil on its surface.

[0031] The first reinforced cleaning component 12 and the second reinforced cleaning component 14 are both connected to the first supply box 10 and the second supply box 11. The first supply box 10 and the second supply box 11 are located on the top end face of the support frame 301. The soft brush roller 1203 is provided with multiple alcohol delivery ports and cleaning agent delivery ports. The alcohol delivery ports and cleaning agent delivery ports are respectively connected to the replenishment delivery main pipe. The first supply box 10 and the second supply box 11 are connected to the replenishment delivery main pipe through the replenishment pipe to replenish the alcohol delivery ports and cleaning agent delivery ports of the soft brush roller 1203.

[0032] The first supply tank 10 contains alcohol, and the second supply tank 11 contains hydrocarbon cleaning agent. The alcohol in the first supply tank 10 is sequentially supplied through the supply pipe and the supply conveying main pipe to the alcohol supply port of the soft brush roller 1203 for spraying to clean the surface of the foil. The hydrocarbon cleaning agent in the second supply tank 11 is sequentially supplied through the supply pipe and the supply conveying main pipe to the cleaning agent supply port of the soft brush roller 1203 for spraying to clean the surface of the foil.

[0033] like Figure 11-12As shown, the lower cleaning mechanism includes a lower cleaning box 602, which is fixedly connected to the bottom of the support frame 301 and located on one side of the first reinforced cleaning assembly 12. The height of the movable box 601 and the lower cleaning box 602 does not affect the normal conveying of the foil. The lower cleaning box 602 is provided with multiple drainage holes 604, and a drainage groove 605 is provided on one side of the lower cleaning box 602 to guide the wastewater after cleaning out. A drain outlet is provided on the side of the lower cleaning box 602 located at the bottom of the drainage holes 604, and the drain outlet is connected to an external drain pipe to discharge the wastewater to the outside.

[0034] Furthermore, an automatic telescopic plate 613 is provided on the bottom end face of the movable box 601. Part of the end face of the automatic telescopic plate 613 is fixed to one side of the movable box 601. The bottom of the automatic telescopic plate 613 matches the bottom of the first reinforced cleaning component 12 and the second cleaning component. A drainage groove is provided on the automatic telescopic plate 613 so that when the movable box 601 moves to the upper part of the first reinforced cleaning component 12 and the second cleaning component, the automatic telescopic plate 613 extends forward to one side to insert into the bottom of the first reinforced cleaning component 12 and the second cleaning component, covering their bottoms. The other side is located on the upper side of the drain trough 605. When the upper cleaning nozzle 610 and the upper alcohol cleaning nozzle 611 deliver alcohol or hydrocarbon cleaning agent, wastewater can enter the automatic telescopic plate 613. The drainage groove of the automatic telescopic plate 613 leads the wastewater into the drain trough 605 for discharge. Preferably, the automatic telescopic plate 613 is inclined to facilitate the drainage of wastewater. Of course, after cleaning is completed, the automatic telescopic plate 613 is reset. It does not extend when cleaning the second reinforced cleaning component 14 and the cleaning component 15, so it does not affect the normal cleaning operation.

[0035] In another embodiment, the storage mechanism 303 is provided with a plurality of second drain holes at the bottom of the first reinforced cleaning assembly 12 and the second cleaning assembly. The second drain holes are connected to second drain pipes, which are connected to a wastewater tank located inside the storage mechanism 303. When cleaning the first reinforced cleaning assembly 12 and the second cleaning assembly, wastewater flows from the second drain holes into the wastewater tank for storage.

[0036] The lower cleaning box 602, located on one side of the inner wall of the drain tank 605, is equipped with multiple cleaning nozzles 606 and alcohol cleaning nozzles 6061. The cleaning nozzles 606 and 6061 are connected to an alcohol supply tank and a water tank, respectively. The alcohol supply tank and water tank are located on the inner wall end face of the storage mechanism 303. The alcohol supply tank and water tank are connected to the multiple cleaning nozzles 606 and 6061 via a second supply main pipe for supplying alcohol or water.

[0037] The movable box 601 and the lower cleaning box 602 are equipped with drying troughs 612 on multiple sides. The drying troughs 612 are connected to a hot air blower through a hot air delivery pipe. The hot air blower is located on one side of the inner wall of the movable box 601.

[0038] Specifically, when cleaning the soft brush roller 1203 on the second reinforced cleaning component 14 and cleaning component 15, the automatic lifting device 1201 controls the soft brush roller 1203 to descend into the upper movable box 601 of the lower cleaning box 602. Water is sprayed through multiple cleaning nozzles 606 to clean the dust adhering to the cleaning component 15. After cleaning, the dryer is started and hot air is delivered through the drying tank 612 for drying, after which it can be reused. When cleaning oil stains and hydrocarbon cleaning agents on the cleaning component 15, alcohol is delivered through multiple alcohol cleaning nozzles 6061 to clean the residual oil stains or hydrocarbon cleaning agents on the cleaning component 15. Under the cleaning of high-pressure water, the soft brush roller 1203 can rotate on the connecting frame 1202 to achieve a full cleaning of the surface of the soft brush roller 1203. After cleaning for 6-10 seconds, the dryer can be started for drying.

[0039] The mobile cleaning mechanism includes a movable box 601 and a shielding curtain 603. The top end face of the movable box 601 has a groove that matches the second reinforced cleaning component 14 and the cleaning component 15. The shielding curtain 603 is set on the end face of the support frame 301 located in the groove. The shielding curtain 603 blocks and seals the groove, and at the same time, it can prevent water from overflowing during the cleaning operation.

[0040] A conveying pipe 609 is provided on the side of the movable box 601 away from the groove. Multiple upper cleaning nozzles 610 and upper alcohol cleaning nozzles 611 are provided at the bottom of the conveying pipe 609. A third supply pipe is provided on the alcohol supply tank and the water tank. The multiple upper cleaning nozzles 610 and upper alcohol cleaning nozzles 611 are connected to the third supply pipe through supply branch pipes. Part of the end face of the third supply pipe is located on the inner wall of the conveying pipe 609. Alcohol and water are supplied into the conveying pipe 609 through the third supply pipe and sprayed through the upper cleaning nozzles 610 and upper alcohol cleaning nozzles 611 for cleaning.

[0041] An automatic telescopic door 9 is provided on one end face of the movable box 601, and a limiting groove 6021 matching the automatic telescopic door 9 is provided on one side of the lower cleaning box 602. During the cleaning operation, the automatic telescopic door 9 can be controlled to descend into the limiting groove 6021 to form a closed space for cleaning the soft brush roller 1203.

[0042] The support frame 301 is fixedly connected to a shield 13 on one side of the second cleaning component. The shield is used to prevent water leakage when the first reinforced cleaning component 12 and the second cleaning component are cleaning.

[0043] A pair of opposite end faces of the movable box 601 are connected to a leverless cylinder 607 via a connecting seat 608. The leverless cylinder 607 is fixedly connected to the upper end face of the support frame 301 located on the movable box 601. Activation of the leverless cylinder 607 drives the connecting seat 608, thereby causing the movable box 601 to slide to the first reinforced cleaning component 12 and the second cleaning component for shielding and cleaning operations. Furthermore, a second sliding groove is provided on the lower cleaning box 602, and a sliding plate matching the second sliding groove is provided at the bottom of the movable box 601. When the leverless cylinder 607 drives the movable box 601 to slide, the movable box 601 slides within the second sliding groove of the lower cleaning box 602 via the sliding plate, thus limiting its movement.

[0044] Specifically, when the first enhanced cleaning component 12 and the second cleaning component need cleaning, the leverless cylinder 607 is controlled to move the movable box 601 above the first enhanced cleaning component 12 and the second cleaning component. At this time, the movable box 601 and the baffle plate 13 are in contact, forming a semi-enclosed space. The upper cleaning nozzle 610 and the upper alcohol cleaning nozzle 611 are activated. The upper cleaning nozzle 610 sprays water to clean the dust adhering to the second cleaning component. After cleaning, the dryer is activated and hot air is delivered through the drying tank 612 for drying, after which it can be reused. When it is necessary to clean the oil stains or hydrocarbon cleaning agents on the first enhanced cleaning component 12, alcohol is delivered through multiple upper alcohol cleaning nozzles 611 to clean the residual oil stains or hydrocarbon cleaning agents on the first enhanced cleaning component 12. After cleaning for 6-10 seconds, the dryer can be activated for drying.

[0045] The adaptive processing mechanism 3 is located on one side of the scratch processing mechanism 8 and is equipped with a dryer 16. Multiple drying nozzles 1601 are installed on the bottom end face of the dryer 16. Specifically, when cleaning oil stains from the foil surface, alcohol or hydrocarbon cleaning agent is supplied through the first enhanced cleaning component 12 or the second enhanced cleaning component 14 to clean the oil stains from the foil surface by rolling. After wiping the foil surface again through the cleaning component 15 or the second cleaning component, the dryer 16 is activated to turn on the hot air. Hot air is then sprayed through the drying nozzles 1601 for drying, after which the foil is transported normally.

[0046] The deburring mechanism 7 includes a drive motor 701 and a grinding wheel 702. The drive motor 701 is fixedly connected to one end face of the inner wall of the support frame 301 located between a pair of second rolls 201. The grinding wheel 702 is located on one side of the drive motor 701. An automatic telescopic device is fixedly connected between the drive motor 701 and the support frame 301. The automatic telescopic device drives the drive motor 701 to extend and retract, thereby driving the grinding wheel 702 to move forward to both sides of the foil for bonding. The grinding wheel 702 is then activated to grind the burrs on both sides of the foil and remove the burrs.

[0047] An ion fan 17 is installed on one side of either the cleaning assembly 15 or the second cleaning assembly. After the cleaning assembly 15 and the second cleaning assembly have finished cleaning the larger particulate contaminants attached to both ends of the foil, the nozzle of the ion fan 17 is activated to blow away the fine dust, keeping the surface clean before proceeding to the next step.

[0048] like Figure 1-5 As shown, the scratch treatment mechanism is connected to one side end face of the adaptive treatment mechanism 3. The scratch treatment mechanism includes a pair of scratch treatment mechanisms 8 and a pair of polishing components. The pair of scratch treatment mechanisms 8 and polishing components are respectively disposed on the two side end faces of a pair of second rolls 201. That is, the pair of scratch treatment mechanisms 8 and polishing components are respectively fixedly connected to the upper and lower end faces of the support frame 301, and can remove the scratches on the upper and lower end faces of the foil material passing between the pair of second rolls 201.

[0049] The scratch treatment mechanism 8 includes a welding lifting mechanism, a soldering head 801, a solder feeder 803, and a moving mechanism 804. The solder feeder 803 is connected to the soldering head 801 at its bottom, and the moving mechanism 804 is connected to one side of the solder feeder 803. The solder feeder 803 is slidably connected to the side wall end face of the support frame 301. The moving mechanism 804 can move the solder feeder 803 and the soldering head 801 to the position to be repaired. The welding lifting mechanism drives the soldering head 801 down to the optimal position for repair to perform the repair operation.

[0050] Furthermore, a pair of soldering heads 801 are positioned opposite each other to repair the target location by adhering to the upper and lower ends of the foil, achieving all-round repair. During repair, the foil can be moved back and forth by the second roll 201 to cover and repair the scratches.

[0051] The polishing assembly includes a second lifting mechanism 805 and a second polishing wheel 807. The second lifting mechanism 805 is fixedly connected to one end face of the solder feeder 803. A mounting plate 802 is fixedly connected to the bottom of the second lifting mechanism 805. A second drive motor 806 is fixedly connected to the bottom of the mounting plate 802. The second drive motor 806 is connected to the second polishing wheel 807. The second lifting mechanism 805 controls the lifting and lowering of the second drive motor 806 and the second polishing wheel 807 to polish scratches and smooth out solder-filled areas, restoring a smooth surface.

[0052] Specifically, when the machine vision online inspection system detects scratches on the surface of the foil transported between a pair of second rolls 201, it first activates the corresponding first reinforced cleaning component 12 or the second reinforced cleaning component 14 to spray alcohol to clean the scratched area. Then, it controls the scratch treatment mechanism 8 to start cleaning the scratches. The moving mechanism 804 moves the solder feeder 803 and the soldering head 801 to the location requiring repair. The soldering head 801 feeds solder wire, melts the solder, and smoothly fills the scratch pit. Finally, the second grinding wheel 807 is activated to smooth the surface and restore its flatness. It should be noted that if the scratches are extensive and deep, repair should be abandoned, and new foil should be used for processing.

[0053] Preferably, when oxidation is detected on the foil surface, the control moving mechanism 804 drives the second grinding wheel 807 to the oxidation position, starts the second grinding wheel 807 to grind away the oxidation, and then starts the first enhanced cleaning component 12 or the second enhanced cleaning component 14 to spray alcohol to clean the polished area.

[0054] The machine vision online inspection system is installed on multiple end faces of the foil unwinding mechanism 1 and the auxiliary foil unwinding mechanism 2. The machine vision online inspection system includes industrial cameras. Through the installation of multiple industrial cameras, visual inspection can be performed to detect minute defects such as dust, burrs, and scratches with a diameter of less than 0.1mm. When a defect is detected, an automatic alarm is triggered, and the defect category is automatically determined based on the model, controlling the corresponding cleaning program to perform the cleaning.

[0055] The winding method of high-efficiency winding equipment for transformer production includes the following steps; S1. Foil material conveying: The foil material is sequentially introduced into the auxiliary foil material unwinding mechanism 2 and the foil material unwinding mechanism 1 to start the winding operation. During the winding process, the dust, burrs and scratches on the surface of the foil material are monitored by the machine vision online detection system. S2. Dust removal: Depending on the workshop environment and the presence of a lot of dust, during the production process, the automatic lifting device 1201 controls a pair of cleaning components 15 and a second cleaning component to clean the large dust particles on the upper and lower surfaces of the foil material. Then, the ion fan 17 is started to blow away the fine dust particles on the surface.

[0056] If the workshop is clean, the dust cleaning mechanism will be activated to clean the dust off the foil surface when the machine vision online inspection system detects dust.

[0057] S3. Oil stain cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects whether there is oil stain on the surface of the foil. If so, the oil stain cleaning mechanism is activated, and the first reinforced cleaning component 12 or the second reinforced cleaning component 14 is controlled to perform a rolling cleaning of the upper and lower surfaces of the foil by spraying alcohol. After cleaning, the dust cleaning mechanism is activated to wipe again, that is, the cleaning component 15 or the second cleaning component is activated to wipe away the residual stains to keep it clean. After wiping, the dryer 16 is activated to dry the foil before normal foil conveying.

[0058] If the alcohol does not completely remove the oil stains, the second supply box 11 connected to the first enhanced cleaning component 12 or the second enhanced cleaning component 14 is activated to deliver hydrocarbon cleaning agent and spray it onto the areas where the oil stains have not been completely removed. After enhanced wiping and cleaning, the cleaning component 15 or the second cleaning component is activated to clean the hydrocarbon cleaning agent adhering to the foil surface. After wiping, the dryer 16 is activated to dry the foil before normal foil conveying is resumed.

[0059] S4. Scratch cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects scratches on the surface of the foil. The second roll 201 moves the foil to the underside of the first reinforced cleaning component 12 and the second reinforced cleaning component 14. After the first reinforced cleaning component 12 and the second reinforced cleaning component 14 spray alcohol to clean the scratched surface, the scratch treatment mechanism 8 is activated to perform soldering operation. After soldering, the polishing component is used to smooth the surface and restore it to a smooth surface.

[0060] S5. Winding operation: Start the winding operation and begin the winding of the foil material until the final product is generated. Example

[0061] like Figure 13 As shown, a pair of dust cleaning components 18 are arranged between a pair of first rolls 101 in the foil unwinding mechanism 1. The pair of dust cleaning components 18 are arranged opposite each other with a gap. The pair of dust cleaning components 18 can adhere the upper and lower surfaces of the foil. When the foil enters the pair of first rolls 101, the machine vision online inspection system detects residual dust on its surface and then activates the dust cleaning components 18 to perform rolling cleaning of the foil surface, keeping its surface clean at all times and ensuring the normal operation of the next process.

[0062] The difference between Example 2 and Example 1 is that Example 2 adds a dust cleaning component 18 to strengthen the supervision of the foil material in subsequent processes. When dust appears, the dust cleaning component 18 can be used for cleaning.

[0063] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0064] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-efficiency winding device for transformer production, comprising a foil unwinding mechanism and an auxiliary foil unwinding mechanism, wherein the foil unwinding mechanism is provided with a plurality of first rolls, and the auxiliary foil unwinding mechanism is provided with a plurality of second rolls, characterized in that, It also includes: An adaptive processing mechanism is positioned between the auxiliary foil unwinding mechanism and the foil unwinding mechanism; A self-cleaning mechanism is connected to one end face of the adaptive processing mechanism. The self-cleaning mechanism includes an oil stain cleaning mechanism, a burr polishing mechanism, an intelligent brush roller cleaning box, and a dust cleaning mechanism. The oil stain cleaning mechanism and the dust cleaning mechanism clamp the foil material located between a pair of second rolls through an automatic lifting device to clean the oil stains or dust on the surface. The oil stain cleaning mechanism and the dust cleaning mechanism both include multiple soft brush rollers, and a pair of soft brush rollers are provided with multiple alcohol delivery ports and cleaning agent delivery ports. The burr polishing mechanism is located on a pair of opposite end faces of the adaptive processing mechanism. The intelligent brush roller cleaning box is located on the bottom end face of the auxiliary foil unwinding mechanism. The intelligent brush roller cleaning box includes a movable cleaning mechanism and a lower cleaning mechanism. A scratch treatment mechanism is connected to one end face of the adaptive treatment mechanism. The scratch treatment mechanism includes a pair of scratch treatment mechanisms and a pair of polishing components. The pair of scratch treatment mechanisms and polishing components are respectively disposed on the two end faces of a pair of second rolls. The machine vision online inspection system is installed on multiple end faces of the foil unwinding mechanism and the auxiliary foil unwinding mechanism.

2. The high-efficiency winding equipment for transformer production according to claim 1, characterized in that, The adaptive processing mechanism includes a support frame, a base, and a storage mechanism. The support frame is disposed on one end face of the auxiliary foil unwinding mechanism. The storage mechanism and the base are fixedly connected to the bottom end face of the support frame in sequence. The support frame is a hollow structure.

3. The high-efficiency winding equipment for transformer production according to claim 2, characterized in that, The oil stain cleaning mechanism further includes a first reinforced cleaning component and a second reinforced cleaning component. The first reinforced cleaning component and the second reinforced cleaning component are disposed on the inner wall of the support frame at opposite end faces between a pair of second drums. The dust removal mechanism includes a cleaning component and a second cleaning component. The cleaning component and the second cleaning component are respectively disposed on the support frame at opposite end faces of the first reinforced cleaning component and the second reinforced cleaning component.

4. The high-efficiency winding equipment for transformer production according to claim 1 or 3, characterized in that, The first enhanced cleaning component, the second enhanced cleaning component, the cleaning component, and the second cleaning component all include an automatic lifting device, a connecting frame, and a soft brush roller. The automatic lifting device is fixedly connected to the inner wall end face of the support frame, and the connecting frame is fixedly connected to the bottom of the automatic lifting device. The soft brush roller is rotatably connected to the inner wall end face of the connecting frame. The first enhanced cleaning component and the second enhanced cleaning component are both connected to a first supply box and a second supply box. The first supply box and the second supply box are connected to the alcohol delivery port and the cleaning agent delivery port of the soft brush roller through a replenishment pipe. The first supply box stores alcohol, and the second supply box stores hydrocarbon cleaning agent.

5. The high-efficiency winding equipment for transformer production according to claim 3, characterized in that, The deburring mechanism includes a drive motor and a grinding wheel. The drive motor is fixedly connected to one end face of the inner wall of the support frame located between a pair of second rollers. The grinding wheel is located on one side of the drive motor. An ion fan is provided on one side of the support frame located on either the cleaning component or the second cleaning component.

6. The high-efficiency winding equipment for transformer production according to claim 5, characterized in that, The lower cleaning mechanism includes a lower cleaning box, which is fixedly connected to the bottom of the support frame and located on one side of the first reinforced cleaning component. The lower cleaning box has multiple drainage holes and a drainage groove on one side. Multiple cleaning nozzles and alcohol cleaning nozzles are provided on the inner wall of the lower cleaning box located in the drainage groove. The cleaning nozzles and alcohol cleaning nozzles are respectively connected to an alcohol supply tank and a water tank. The alcohol supply tank and water tank are located on the inner wall of the storage mechanism. The alcohol supply tank and water tank are connected to the multiple cleaning nozzles and alcohol cleaning nozzles through a second supply pipe.

7. The high-efficiency winding equipment for transformer production according to claim 6, characterized in that, The movable cleaning mechanism includes a movable box and a shielding curtain. The top end face of the movable box has a groove matching the second reinforced cleaning component and the cleaning component. The shielding curtain is located on the end face of the support frame at the groove. A conveying pipe is provided on the side of the movable box away from the groove. Multiple upper cleaning nozzles and upper alcohol cleaning nozzles are provided at the bottom of the conveying pipe. A third supply pipe is provided on the alcohol supply tank and water tank. The multiple upper cleaning nozzles and upper alcohol cleaning nozzles are respectively connected to the third supply pipe through supply branch pipes. A portion of the end face of the third supply pipe is located on the inner wall of the conveying pipe. The movable box and the lower... The cleaning box has drying troughs on multiple sides, which are connected to a hot air blower via hot air delivery pipes. One end face of the movable box is provided with an automatic telescopic door, and one side of the lower cleaning box is provided with a limiting groove that matches the automatic telescopic door. A baffle plate is fixedly connected to one side of the support frame located on the second cleaning component. A pair of opposite end faces of the movable box are connected to a leverless cylinder via a connecting seat. The leverless cylinder is fixedly connected to the upper end face of the support frame located on the movable box. A dryer is provided on one side of the scratch treatment mechanism located on the self-adaptive processing mechanism, and multiple drying nozzles are provided on the bottom end face of the dryer.

8. The high-efficiency winding equipment for transformer production according to claim 7, characterized in that, The scratch treatment mechanism includes a soldering head, a solder feeder, and a moving mechanism. The solder feeder is connected to the bottom of the solder feeder and to one side of the moving mechanism. The solder feeder is slidably connected to the side wall end face of the support frame. A pair of soldering heads are arranged opposite each other. The polishing assembly includes a second lifting mechanism and a second polishing wheel. The second lifting mechanism is fixedly connected to one side end face of the solder feeder. A mounting plate is fixedly connected to the bottom of the second lifting mechanism. A second drive motor is fixedly connected to the bottom of the mounting plate. The second drive motor is connected to the second polishing wheel.

9. The high-efficiency winding equipment for transformer production according to claim 1, characterized in that, The foil unwinding mechanism is provided with a pair of dust cleaning components between a pair of first rolls. The pair of dust cleaning components are arranged opposite each other and have a gap.

10. A winding method for a high-efficiency winding device for transformer production, applied to the high-efficiency winding device for transformer production as described in any one of claims 1-9, characterized in that, Includes the following steps; S1. Foil material conveying: The foil material is sequentially introduced into the auxiliary foil material unwinding mechanism and the foil material unwinding mechanism to start the winding operation. During the winding process, the dust, burrs and scratches on the surface of the foil material are monitored by the machine vision online detection system. S2. Dust removal: Depending on the workshop environment, if there is a lot of dust, during the production process, the automatic lifting device controls a pair of cleaning components and a second cleaning component to clean the dust from the upper and lower surfaces of the foil. If the workshop is clean, the dust removal mechanism will be activated to clean the dust from the foil surface when the machine vision online detection system detects dust. S3. Oil stain cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects whether there is oil stain on the surface of the foil. If so, the oil stain cleaning mechanism is activated, and the first or second reinforced cleaning component is controlled to clean the upper and lower surfaces of the foil by spraying alcohol. After cleaning, the dust cleaning mechanism is activated to wipe again. For stubborn oil stains, the first or second reinforced cleaning component is activated to spray hydrocarbon cleaning agent for wiping and cleaning. S4. Scratch cleaning: Before the foil enters the welding mechanism, the machine vision online inspection system detects scratches on the foil surface. First, the first and second reinforced cleaning components spray alcohol to clean the surface. Then, the scratch treatment mechanism is activated to perform soldering. After soldering, the polishing component is used to smooth the surface and restore it to a smooth state. 11.S5, Winding operation: Start the winding operation and begin the winding of the foil material until the final product is generated.

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