Tape tension contour wrapping method and apparatus for busbar production

Abstract

The application is suitable for the technical field of electrical insulation process and automatic equipment, and particularly relates to a mica tape tension contour wrapping method and equipment for busbar production, which comprises the following steps: obtaining contour point set data of a target data area of a busbar to be wrapped; dividing the busbar to be wrapped into a plurality of measurement sub-areas, and determining contour geometric parameters of the busbar to be wrapped along a wrapping path based on the region characteristic variation intensity of each measurement sub-area in the contour point set data; generating a target tension curve associated with the wrapping path position based on the contour geometric parameters, preset mica tape material characteristic parameters and wrapping process parameters; obtaining a current path position of a wrapping point in real time, indexing a target tension value corresponding to the current path position from the target tension curve, and generating a control instruction based on at least the target tension value. The method can solve the tension-deformation mismatch problem of existing busbar wrapping equipment at the bending and R-angle of the busbar.

Description

Technical Field

[0001] This application belongs to the field of electrical insulation technology and automation equipment technology, and in particular relates to a method and equipment for tension conformal wrapping of mica tape for busbar production. Background Technology

[0002] As a core component for power transmission and distribution, the insulation quality of busbars directly affects the safety of power systems and new energy vehicles. Mica tape wrapping is a key process for achieving the main insulation of high-voltage busbars.

[0003] Existing wrapping equipment mostly adopts constant tension or simple taper tension control methods based on changes in unwinding diameter. However, for irregularly shaped busbars with geometric contour changes such as bends and radius angles on the surface, the existing constant tension control methods have serious technical defects, specifically manifested as tension-deformation mismatch problems at the bends and radius angles of the busbars. Summary of the Invention

[0004] This application provides a method and equipment for tension conformal wrapping of mica tape in busbar production, which can solve the tension-deformation mismatch problem at busbar bends and R-angles in existing busbar wrapping equipment.

[0005] In a first aspect, embodiments of this application provide a method for conformal tension wrapping of mica tape in busbar production, applied to a mica tape conformal tension wrapping device, the method comprising: Obtain the contour point set data of the target data region of the busbar to be wrapped; wherein, the contour point set data refers to the discrete spatial coordinate point sequence distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped. The busbar to be wrapped is divided into several measurement sub-regions. Based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the busbar to be wrapped along the wrapping path are determined. The intensity of regional feature changes is used to reflect the degree of abrupt change in the structural features of data points between adjacent sub-regions. The contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position and the cross-sectional dimension parameters of the busbar to be wrapped. Based on the aforementioned contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, a target tension curve associated with the wrapping path position is generated using a preset tension calculation model. The current path position of the wrapping point is obtained in real time, the target tension value corresponding to the current path position is indexed from the target tension curve, and a control command is generated based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

[0006] The technical solutions described in this application embodiment have at least the following technical effects: The mica tape tension conformal wrapping method for bus production provided in this application firstly acquires the contour point set data of the target data region of the bus to be wrapped. In this step, the target data region of the bus is scanned to obtain the contour point set data, and analysis of the contour point set data reflects the contour shape of the bus. Secondly, the bus to be wrapped is divided into several measurement sub-regions. Based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the bus distributed along the wrapping path are determined. In this step, the contour point set data is analyzed to obtain the locations of abrupt changes in regional features on the bus, thereby resolving the contour of the bus. Then, based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, a target tension curve associated with the wrapping path position is generated using a preset tension calculation model. In this step, after knowing the bus contour, the wrapping tension at different positions is calculated, and the target tension curve associated with the wrapping path position is obtained. Finally, the current path position of the wrapping point is acquired in real time, the target tension value corresponding to the current path position is indexed from the target tension curve, and a control command is generated based on at least the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape. In this step, the unwinding actuator is controlled to wrap with different wrapping tensions at different wrapping positions. In this method, a target tension curve associated with the wrapping path position is generated based on the contour geometry parameters of the busbar to be wrapped. When the wrapping point passes through the outer arc of the bend, the target tension curve automatically reduces the tension value, reducing the tensile stress on the mica tape, thereby preventing the mica tape from being overstretched and thinned or broken. When the wrapping point passes through the inner arc of the bend, the target tension curve automatically increases the tension value, increasing the traction force on the mica tape, overcoming the stacking tendency of the mica tape, thereby preventing wrinkling and delamination. Thus, this method achieves conformal matching between the wrapping tension and the contour geometry deformation of the busbar, solving the tension-deformation mismatch problem of existing constant tension control at bends and radius angles.

[0007] Secondly, embodiments of this application provide a mica tape tension conformal wrapping device, applied to a mica tape tension conformal wrapping equipment, the device comprising: The scanning unit is used to acquire the contour point set data of the target data area of ​​the busbar to be wrapped; wherein, the contour point set data refers to the discrete spatial coordinate point sequence distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped. The geometric analysis unit is used to divide the busbar to be wrapped into several measurement sub-regions, and then determine the contour geometric parameters of the busbar to be wrapped along the wrapping path based on the intensity of regional feature changes in each measurement sub-region in the contour point set data; wherein, the intensity of regional feature changes is used to reflect the degree of abrupt change in the structural features of data points between adjacent sub-regions, and the contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position, and the cross-sectional dimension parameters of the busbar to be wrapped; The tension analysis unit is used to generate a target tension curve associated with the position of the wrapping path based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, using a preset tension calculation model. The control unit is used to acquire the current path position of the wrapping point in real time, index the target tension value corresponding to the current path position from the target tension curve, and generate control commands based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

[0008] Thirdly, embodiments of this application provide a mica tape tension conformal wrapping device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that the processor executes the computer program to implement the method described in any of the first aspects above.

[0009] Fourthly, embodiments of this application provide a computer-readable storage medium storing a computer program that, when executed by a processor, implements the method described in any of the first aspects above.

[0010] Fifthly, embodiments of this application provide a computer program product that, when running on a mica tape tension conformal wrapping device, causes the mica tape tension conformal wrapping device to perform the mica tape tension conformal wrapping method for busbar production as described in any of the first aspects above.

[0011] It is understood that the beneficial effects of the second to fifth aspects mentioned above can be found in the relevant descriptions in the first aspect mentioned above, and will not be repeated here. Attached Figure Description

[0012] To more clearly illustrate the technical solutions in the embodiments of this application, 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 of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0013] Figure 1This is a schematic flowchart of a method for tension conformal wrapping of mica tape for busbar production provided in an embodiment of this application; Figure 2 This is a schematic diagram of the structure of the mica tape tension conformal wrapping device provided in the embodiments of this application; Figure 3 This is a schematic diagram of the structure of the mica tape tension conformal wrapping device provided in the embodiments of this application. Detailed Implementation

[0014] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, apparatuses, circuits, and methods have been omitted so as not to obscure the description of this application with unnecessary detail.

[0015] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.

[0016] In related technologies, existing wrapping equipment mostly adopts constant tension or simple taper tension control methods based on changes in unwinding diameter. However, for irregularly shaped busbars with geometric contour changes such as bends and radius angles on the surface, the existing constant tension control methods have serious technical defects, specifically manifested as tension-deformation mismatch problems at the bends and radius angles of the busbars.

[0017] To address the aforementioned issues, this application provides a method for contour wrapping mica tape tension in busbar production. The method first involves acquiring the contour point set data of the target data region of the busbar to be wrapped. This step involves scanning the target data region of the busbar to obtain the contour point set data, which, after analysis, reflects the contour shape of the busbar. Next, the busbar to be wrapped is divided into several measurement sub-regions. Based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the busbar distributed along the wrapping path are determined. This step involves analyzing the contour point set data to identify the locations of abrupt changes in regional features on the busbar, thereby resolving the busbar's contour. Then, based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, a preset tension calculation model is used to generate a target tension curve associated with the wrapping path position. In this step, after knowing the busbar contour, the wrapping tension at different positions is calculated, and the target tension curve associated with the wrapping path position is obtained. Finally, the current path position of the wrapping point is obtained in real time, the target tension value corresponding to the current path position is indexed from the target tension curve, and a control command is generated based on at least the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape. In this step, the unwinding actuator is controlled to wrap with different wrapping tensions at different wrapping positions, which can solve the tension-deformation mismatch problem at the bends and R-angles of the existing busbar wrapping equipment.

[0018] The mica tape tension conformal wrapping method for busbar production provided in this application embodiment can be applied to a mica tape tension conformal wrapping device. In this case, the mica tape tension conformal wrapping device is the execution subject of the mica tape tension conformal wrapping method for busbar production provided in this application embodiment. This application embodiment does not impose any restrictions on the specific type of mica tape tension conformal wrapping device.

[0019] For example, a mica tape tension conformal wrapping device may include a sensing layer, a position feedback layer, a tension feedback layer, an execution layer, and a decision layer, wherein the decision layer is communicatively connected to the sensing layer, position feedback layer, tension feedback layer, and execution layer. The sensing layer may be a laser displacement sensor, used to scan along the length of the busbar to acquire a two-dimensional contour point set on the busbar surface. It can be fixed in front of the wrapping head to pre-scan the busbar contour before wrapping. The position feedback layer may be a rotary encoder, used to measure the angular position of the wrapping rotation spindle in real time and convert it into the current path position of the wrapping point along the busbar path. It can be coaxially mounted on the wrapping rotation spindle and rotate synchronously with the wrapping head. The tension feedback layer may be a tension sensor, used to detect the tension experienced by the mica tape during wrapping. It can be installed on the mica tape path between the unwinding wheel and the wrapping point, and a guide roller applies a stable wrap angle to the sensor measuring wheel, thereby detecting stable tension data. The execution layer can include servo motors and servo drivers to receive control commands from the controller and precisely adjust the output torque / speed of the unwinding motor, thereby controlling the real-time tension of the mica tape. The servo motor can be connected to the mica tape unwinding shaft via a coupling or reducer. The decision layer can control the sensing layer to collect the contour point set data of the busbar, control the position feedback layer to provide feedback on the angle and position of the wrapping point, control the tension feedback layer to provide feedback on the real-time wrapping tension on the mica tape, and control the execution layer to adjust the real-time tension of the mica tape.

[0020] The decision-making layer can be a microcontroller, microprocessor, mobile phone, tablet computer, laptop computer, netbook, desktop computer, computer, laptop computer, etc.

[0021] To better understand the mica tape tension conformal wrapping method for busbar production provided in this application embodiment, the specific implementation process of the mica tape tension conformal wrapping method for busbar production provided in this application embodiment will be described by way of example below.

[0022] Figure 1 This illustration shows a schematic flowchart of a mica tape tension conformal wrapping method for busbar production provided in an embodiment of this application. The mica tape tension conformal wrapping method for busbar production includes: S100, acquire the contour point set data of the target data area of ​​the busbar to be wrapped. The contour point set data refers to the sequence of discrete spatial coordinate points distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped.

[0023] It is understood that the busbar to be wrapped is a copper or aluminum conductive busbar that is about to undergo mica tape insulation wrapping. In the application scenario targeted by this invention, the busbar to be wrapped usually has at least one bending area, rather than being a straight line, so its surface contour has geometric abrupt changes. The target data area refers to the effective data interval that is precisely located from the raw data collected by the sensor after spatial registration and standardization calibration, containing only the contour information of the busbar itself, excluding interference from irrelevant information such as background and fixtures. The contour point set data is a set of discrete spatial coordinate points arranged sequentially along the length of the busbar. Each point contains at least the position coordinates along the length direction and the height coordinates perpendicular to the surface. The contour point set data is essentially a digital sampling of the surface contour of the busbar and is the original input for all subsequent geometric analysis work. It is particularly important to emphasize that the contour point set data is only a collection of values; it does not contain structured geometric semantic information such as "where the bend starts" or "what the bend radius is."

[0024] The contour point set data is obtained by scanning the busbar of the package to be wrapped by the perception layer. This step is the entry point for data acquisition and preprocessing in this method.

[0025] Optionally, in S100, when determining the target data region, the method further includes: S110, acquire initial test data and reference template data. The initial test data refers to the uncalibrated contour point set data of the busbar to be wrapped, and the reference template data includes the regional positioning information of the busbar to be wrapped.

[0026] It is understandable that the initial test data refers to the raw contour point set data directly collected by the laser displacement sensor in the current measurement, without any spatial correction processing. Since the actual placement and orientation of the bus will deviate from the standard position each time the bus is clamped, the initial test data not only contains the geometric information of the bus itself, but also superimposed the spatial offset and rotation caused by the clamping deviation. The reference template data refers to a set of reference contour point set data collected and saved by the sensor when a standard bus is installed in a standard clamping manner during the initial system debugging. The reference template data presets the area positioning information, that is, the coordinate range of the region of interest that is precisely surrounded by the bus contour by the operator manually selected on the HMI interface, the reference corner point position and other spatial reference information.

[0027] S120: Based on the reference template data, spatial registration and normalization calibration are performed on the initial test data to obtain calibrated test data. Here, calibrated test data refers to the calibrated contour point set data of the busbar to be wrapped.

[0028] It can be understood that the spatial transformation relationship (including translation Δx, Δy and rotation angle Δθ) between the initial test data and the reference template data is calculated using an algorithm. Then, a rigid body transformation is performed on the initial test data to precisely align it with the reference template data in space. This is spatial registration and standardization calibration. Commonly used registration algorithms include the iterative nearest point algorithm. The calibrated test data is the contour point set data obtained after spatial registration and standardization calibration. Its data point coordinates have been corrected, eliminating the influence of clamping deviations, and it is in a unified spatial coordinate system with the reference template data.

[0029] S130, map the area positioning information to the calibrated test data to locate the target data area corresponding to the busbar to be wrapped.

[0030] It is understandable that after calibration, the regional positioning information can be directly applied to the calibrated test data. Therefore, the preset regional positioning information in the reference template is directly mapped to the calibrated test data to accurately cut out the target data area containing only the busbar outline.

[0031] This setup ensures that the target data area obtained from each measurement is highly consistent in space, and the coordinate system reference for subsequent contour analysis remains unified, enabling this method to operate stably in mass production.

[0032] S200: The busbar to be wrapped is divided into several measurement sub-regions. Then, based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the busbar distributed along the wrapping path are determined. The intensity of regional feature changes reflects the degree of abrupt change in the structural features of data points between adjacent sub-regions. The contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position, and the cross-sectional dimension parameters of the busbar to be wrapped.

[0033] It can be understood that dividing the target data area into several measurement sub-regions refers to dividing the target data area into several continuous data segments at equal intervals along the length of the busbar. The intensity of regional feature variation is a quantitative numerical indicator used to measure the degree of difference in the structural features of data points between two adjacent measurement sub-regions. Structural features can be linearity (high linearity in straight segments, low linearity in bent segments). Profile geometric parameters refer to the structured geometric information required for a complete engineering description of the busbar profile. It includes two types of data: the first type is the radius of curvature mapping relationship, i.e., the inner diameter R(s) of the bend at each position s along the wrapping path—R tends to infinity in straight segments, is positive in outer arc segments, and negative in inner arc segments; the second type is the cross-sectional dimension parameters, i.e., the cross-sectional thickness H and width W of the busbar.

[0034] In one possible implementation, in S200, based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the distribution of the busbar to be wrapped along the wrapping path are determined, including: S210, perform feature aggregation processing on the structural characteristics of data points in each measurement sub-region of the contour point set data to obtain the regional feature values ​​of the corresponding measurement sub-region.

[0035] It can be understood that data point structural characteristics refer to the spatial distribution characteristics of data points within a measurement sub-region, such as whether they are linearly distributed. Feature aggregation processing refers to performing statistical analysis on all data points within the measurement sub-region, using a representative value to describe the structural characteristics of the entire sub-region. For example, principal component analysis is used to calculate the eigenvalues ​​of the covariance matrix of data points within the sub-region, and the ratio of the largest eigenvalue to the second largest eigenvalue is used as a linearity index. Regional eigenvalues ​​are the numerical results output after feature aggregation processing, and are also a single quantitative index representing the overall structural characteristics of the measurement sub-region. For example, the regional eigenvalue of a straight segment of a busbar is close to the upper limit (e.g., linearity close to 1).

[0036] S220, based on the characteristic values ​​of each region, calculates the intensity of regional characteristic changes in each measurement sub-region.

[0037] It is understandable that within a straight line segment, the structures of adjacent sub-regions are similar, and the intensity of change is close to zero; in the bending transition zone, the structure abruptly changes from a straight line to a curve, and the intensity of change increases sharply.

[0038] S230, select the measurement sub-regions whose regional feature change intensity is greater than a preset threshold as target sub-regions, and determine the boundary features of the busbar to be wrapped based on the data points in the target sub-regions.

[0039] It can be understood that the boundary feature refers to the precise geometric boundary between the bend area of ​​the busbar and the straight segments on both sides. First, the target sub-regions whose change intensity exceeds the preset threshold are marked; then, based on the distribution information of the target sub-regions, data points of the stable regions on both sides (the straight segments with the least change intensity) are extracted. After fitting the data points to straight lines, two boundary lines L1 and L2 are obtained. The two boundary lines L1 and L2 can represent the boundary feature.

[0040] S240, based on the relative positional relationship of the boundary features, calculate the profile geometric parameters of the busbar to be wrapped.

[0041] It is understandable that the bending angle is calculated based on the spatial angle between L1 and L2, and the bending inner diameter R and arc length s are calculated based on the data points of their intersection and transition zone. At the same time, the busbar section thickness H and width W are obtained, which together form the profile geometric parameters.

[0042] This setting solves the problem of automatic and robust extraction of contour parameters.

[0043] S300, based on contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, uses a preset tension calculation model to generate a target tension curve associated with the wrapping path position.

[0044] It can be understood that the material property parameters of mica tape refer to the set of parameters characterizing the physical properties of mica tape that are pre-acquired and stored in the system before the wrapping process begins. These parameters include at least the elastic modulus, thickness, bandwidth, and friction coefficient between the mica tape and the busbar. The wrapping process parameters refer to the parameters preset according to process requirements during the wrapping production task. These parameters include at least the target number of wrapping layers, and in more preferred implementations, may also include the overlap ratio and wrapping helix angle. The tension calculation model is a deterministic calculation framework built based on the mechanism of additional bending traction. Its physical logic is as follows: at the bend, the mica tape needs to deflect and twist to adapt to the contour change. This process requires overcoming the bending stiffness and interfacial friction of the mica tape itself, thus requiring additional traction. Based on the radius of curvature and cross-sectional width in the contour geometry parameters, and the elastic modulus and thickness in the mica tape material property parameters, the additional bending traction is calculated. Based on the additional bending traction and the basic tension value, a target tension curve associated with the wrapping path position is generated. The target tension curve is the final result output by the tension calculation model. It is in the form of a sequence of target tension values ​​that correspond one-to-one with the position s of the wrapping path.

[0045] In one possible implementation, in S300, based on contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, a preset tension calculation model is used to generate a target tension curve associated with the wrapping path position, including: S310: Based on the target number of wrapping layers in the wrapping process parameters, obtain the basic tension value from the preset basic tension table of layers.

[0046] It can be understood that the target number of wrapping layers refers to the total number of mica tape layers that need to be wrapped around the busbar surface as specified in the process requirements. Since the bottom layer of mica tape will be compressed during subsequent wrapping, different numbers of layers usually require different base tensions, generally showing a decreasing trend layer by layer. The layer base tension table is a preset lookup table that stores the base tension value corresponding to each number of wrapping layers. The layer base tension table is set and stored in the system once by the process engineer based on the mica tape specifications and process experience. The method execution entity directly looks up the base tension value in the table based on the current number of wrapping layers N. The base tension value refers to the steady-state tension value that needs to be applied when wrapping the busbar on a straight section.

[0047] S320, based on the radius of curvature and cross-sectional width in the profile geometry parameters, and the elastic modulus and thickness in the mica tape material property parameters, calculates the additional bending traction force required to overcome the deflection and twisting of the mica tape in the bending section.

[0048] It is understandable that, based on the profile geometry parameters (radius of curvature R, cross-sectional width W) and mica tape material properties (elastic modulus E, thickness t), the additional traction force required to overcome the deflection and twisting of the mica tape at the bend is calculated. The physical logic of the calculation model is based on the following: the bending stiffness of the mica tape (positively correlated with the elastic modulus E and thickness t³, i.e., bending stiffness metric D = E × t³ / 12) determines the force required to cause its deflection; the severity of the bend (W / R) determines the magnitude of the deflection; and the profile geometry parameters and mica tape material properties together determine the magnitude of the additional traction force.

[0049] In one possible implementation, in S320, based on the radius of curvature and cross-sectional width in the profile geometry parameters, and the elastic modulus and thickness in the mica tape material property parameters, the additional bending traction force required to overcome the deflection and twisting of the mica tape in the bending section is calculated, including: S321, for the outer arc segment, based on the bending stiffness measurement of the mica strip, the ratio of the cross-sectional width to the radius of curvature, and the friction coefficient between the mica strip and the busbar, combined with the preset outer arc correction coefficient, the required reduction in tension compensation for the outer arc segment is obtained.

[0050] It's understandable that at the same bend, the tension requirements for the outer and inner arcs are diametrically opposed: the outer arc requires reduced tension to prevent the mica tape from being overstretched, thinning, or breaking, while the inner arc requires increased tension to compact the mica tape and prevent wrinkling and delamination. For the outer arc segment, the method calculates the required reduction in tension compensation based on four physical factors: the bending stiffness metric of the mica tape (determining its resistance to deformation), the ratio of cross-sectional width to radius of curvature (determining the degree of geometric severity), the coefficient of friction (determining interfacial resistance), and the outer arc correction factor (correcting for deviations between theory and practice). These four factors together determine how much compensation needs to be subtracted from the base tension for the outer arc segment.

[0051] That is, for the outer arc segment, the tension compensation amount ΔT_outer=K_outer×D×(W / R)×μ, where K_outer is the outer arc correction coefficient, D is the bending stiffness measure, W is the cross-sectional width, R is the radius of curvature, and μ is the friction coefficient; the target tension value of the outer arc segment T_outer=T_base-ΔT_outer.

[0052] S322, for the inner arc segment, based on the bending stiffness measurement of the mica strip, the ratio of the absolute value of the cross-sectional width to the radius of curvature, and the friction coefficient between the mica strip and the busbar, combined with the preset inner arc correction coefficient, the amount of tension compensation required to be added to the inner arc segment is obtained.

[0053] It is understandable that for the inner arc segment, the method calculates the amount of tension compensation that needs to be increased based on the same four physical factors. The difference is that the value of the inner arc correction coefficient is usually greater than that of the outer arc correction coefficient, because the accumulation problem of the inner arc is usually more difficult to overcome than the stretching problem of the outer arc, requiring a relatively larger amount of compensation.

[0054] That is, for the inner arc segment, the tension compensation amount ΔT_inner=K_inner×D×(W / R)×μ, where K_inner is the inner arc correction coefficient, D is the bending stiffness measure, W is the cross-sectional width, R is the radius of curvature, μ is the friction coefficient, and K_inner>K_outer; the target tension value of the inner arc segment T_inner=T_base+ΔT_inner.

[0055] This setup can solve the problem of differentiated tension compensation for the completely opposite physical requirements of the inner and outer arcs within the bending area.

[0056] S330 determines the target tension value corresponding to each path position in the target tension curve based on the basic tension value and the additional traction force during bending.

[0057] It is understandable that in the inner arc segment, a greater traction force is needed to overcome the tendency of mica tape to accumulate, so an additional traction force is added to the base value; in the outer arc segment, the tension needs to be reduced to prevent the mica tape from being overstretched, so the additional traction force is subtracted from the base value, ultimately generating a continuous target tension curve that corresponds one-to-one with the path position.

[0058] This setup can solve the problem of rapid changeover in flexible production with multiple specifications.

[0059] Optionally, determining the target tension value corresponding to each path position in the target tension curve further includes: S331, based on the tensile strength of mica tape, preset upper and lower limits of safe tension.

[0060] It can be understood that the upper limit of safe tension is the maximum allowable tension value acting on the mica tape after multiplying its tensile strength by a safety factor less than 1. Similarly, the lower limit of safe tension is the minimum allowable tension value that ensures the mica tape remains taut and does not loosen during the wrapping process.

[0061] S332 limits the calculated target tension values ​​corresponding to each path position to the range between the upper and lower limits of the safe tension.

[0062] It is understandable that, in order to keep the target tension value within a safe range that is physically tolerable and process-acceptable for the mica tape material, the following steps are performed: if the calculated value is greater than the upper limit of the safe tension, the upper limit of the safe tension is forcibly taken; if it is less than the lower limit of the safe tension, the lower limit of the safe tension is forcibly taken; and if it is within the range, the original value is maintained.

[0063] This design prevents the safety risks of belt breakage and loosening, ensuring the stability and reliability of the production process.

[0064] S400 acquires the current path position of the wrapping point in real time, indexes the target tension value corresponding to the current path position from the target tension curve, and generates control commands based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

[0065] It can be understood that the current path position of the wrapping point refers to the spatial position where the mica tape actually contacts and wraps around the busbar at the current moment, which is obtained by measuring and calculating in real time through a rotary encoder installed on the wrapping rotating spindle. The unwinding actuator is the actuator that receives control commands and drives the mica tape roll to perform unwinding actions. It is usually composed of a servo driver and a servo motor, and its output torque or speed directly determines the real-time tension of the mica tape.

[0066] When the wrapping point actually moves to a certain position on the busbar, a control command is sent to the unwinding actuator according to the target tension value at the corresponding position in the target tension curve, so that the real-time tension approaches the target tension value.

[0067] This setup forms a method chain from perception to analysis and then to control, which can solve the tension-deformation mismatch problem at the bends and radius angles of existing busbar wrapping equipment.

[0068] In one possible implementation, in S400, control commands are generated at least based on the target tension value, including: S410 uses the target tension value as the feedforward control variable.

[0069] It can be understood that feedforward control quantity refers to the control command component calculated directly based on the preset target tension value, without relying on the actual tension feedback. Essentially, it means that once the target tension value corresponding to the current path position is known, the control command is adjusted to be close to the required tension in advance, without waiting for the tension deviation to occur before responding.

[0070] S420 acquires the measured tension value from the tension sensor in real time, and then calculates the feedback control quantity from the measured tension value using the feedback controller.

[0071] As can be understood, the tension sensor is a real-time tension measurement device installed on the mica tape path between the unwinding reel and the wrapping point. After obtaining the target tension value and the measured tension value, the feedback controller calculates the deviation between the measured value and the target value, and generates a feedback control quantity based on the deviation.

[0072] S430 superimposes the feedforward control quantity and the feedback control quantity to generate a control command.

[0073] It is understandable that the feedforward control quantity and the feedback control quantity are superimposed to generate the final control command, which drives the unwinding servo motor to adjust the output torque. Under ideal conditions, the feedforward quantity undertakes most of the control output, and the feedback quantity only needs to be slightly corrected.

[0074] This configuration, with its feedforward and feedback composite control architecture, enables the tension control system to act in advance at geometrically abrupt changes such as bending, suppressing dynamic deviations to a minimum. At the same time, it can eliminate static error and maintain constant tension accuracy under steady-state conditions such as straight sections. Compared with static control, this configuration has significant performance advantages.

[0075] Optionally, the method also includes: S510 identifies the inner arc region as the area in the contour geometry parameters where the radius of curvature is negative and the absolute value is less than a preset threshold.

[0076] It is understandable that the contour geometry parameters include the radius of curvature R. A negative R value represents an inner arc. To prevent misjudgment, the absolute value of the radius of curvature is limited. That is, the area where the radius of curvature is negative and the absolute value is less than a preset threshold is defined as the inner arc region. The preset threshold can be a value between 5mm and 50mm. The inner arc region is the path segment that simultaneously satisfies both the conditions of "negative radius of curvature" and "absolute value less than the threshold". The inner arc region is the location with the highest risk of mica tape accumulation and wrinkling, and the steady-state tension may not be sufficient to completely overcome the accumulation trend.

[0077] S520, when the wrapping point reaches the inner arc area, superimposes a positive torque pulse of a preset waveform onto the unwinding actuator to instantly increase the tension.

[0078] This is understandable, as the inner arc region is where the risk of mica tape wrinkling and buildup is highest. Therefore, it is necessary to apply a positive torque pulse with a preset waveform (which can be a half-sine wave) to the unwinding actuator when the wrapping point reaches the inner arc region to instantaneously increase the tension and prevent wrinkling. Instantaneous tension increase refers to raising the tension to a level exceeding the steady-state target value for a brief instant (usually on the order of tens of milliseconds), after which the tension quickly returns to the normal target value.

[0079] This design effectively prevents the mica tape from wrinkling in the inner arc area.

[0080] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of this application.

[0081] Corresponding to the mica tape tension conformal wrapping method for busbar production described in the above embodiments, this application also provides a mica tape tension conformal wrapping device, the various units of which can implement the various steps of the mica tape tension conformal wrapping method for busbar production. Figure 2 The diagram shows a structural block diagram of the mica tape tension conformal wrapping device provided in an embodiment of this application. For ease of explanation, only the parts related to the embodiment of this application are shown.

[0082] Reference Figure 2 The device includes: The scanning unit is used to acquire the contour point set data of the target data area of ​​the busbar to be wrapped; wherein, the contour point set data refers to the discrete spatial coordinate point sequence distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped. The geometric analysis unit is used to divide the busbar to be wrapped into several measurement sub-regions, and then determine the contour geometric parameters of the busbar to be wrapped along the wrapping path based on the intensity of regional feature changes in each measurement sub-region in the contour point set data; wherein, the intensity of regional feature changes is used to reflect the degree of abrupt change in the structural features of data points between adjacent sub-regions, and the contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position, and the cross-sectional dimension parameters of the busbar to be wrapped; The tension analysis unit is used to generate a target tension curve associated with the position of the wrapping path based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, using a preset tension calculation model. The control unit is used to acquire the current path position of the wrapping point in real time, index the target tension value corresponding to the current path position from the target tension curve, and generate control commands based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

[0083] It should be noted that the information interaction and execution process between the above-mentioned units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, which will not be repeated here.

[0084] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units is used as an example. In practical applications, the above functions can be assigned to different functional units as needed, that is, the internal structure of the device can be divided into different functional units to complete all or part of the functions described above. The functional units in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.

[0085] This application also provides a mica tape tension conformal wrapping device. Figure 3 This is a schematic diagram of the structure of a mica tape tension conformal wrapping device provided in one embodiment of this application. Figure 3 As shown, the decision layer 4 of the mica tape tension conformal wrapping device in this embodiment includes: at least one processor 40 ( Figure 3 Only one is shown in the image), at least one memory 41 ( Figure 3 (Only one is shown in the image) and a computer program 42 stored in the at least one memory 41 and executable on the at least one processor 40, wherein when the processor 40 executes the computer program 42, it causes the decision layer 4 of the mica tape tension conformal wrapping device to implement the steps in any of the above embodiments of the mica tape tension conformal wrapping method for busbar production, or causes the decision layer 4 of the mica tape tension conformal wrapping device to implement the functions of each unit in the above embodiments of the apparatus.

[0086] For example, the computer program 42 may be divided into one or more units, which are stored in the memory 41 and executed by the processor 40 to complete this application. The one or more units may be a series of computer program instruction segments capable of performing a specific function, which describe the execution process of the computer program 42 in the decision layer 4 of the mica tape tension conformal wrapping device.

[0087] The decision layer 4 of the mica tape tension conformal wrapping device can be a microcontroller, microprocessor, mobile phone, tablet computer, wearable device, vehicle-mounted device, laptop computer, ultra-mobile personal computer (UMPC), netbook, personal digital assistant (PDA), desktop computer, smart screen, smart TV, or handheld device with wireless communication capabilities. The decision layer 4 of the mica tape tension conformal wrapping device may include, but is not limited to, a processor 40 and a memory 41. Those skilled in the art will understand that... Figure 3 This is merely an example of the decision layer 4 of the mica tape tension conformal wrapping device, and does not constitute a limitation on the decision layer 4 of the mica tape tension conformal wrapping device. It may include more or fewer components than shown in the figure, or combine certain components, or different components, such as input / output devices, network access devices, buses, etc.

[0088] The processor 40 can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. The general-purpose processor can be a microprocessor or any conventional processor.

[0089] In some embodiments, the memory 41 may be an internal storage unit of the decision layer 4 of the mica tape tension conformal wrapping device, such as a hard disk or memory of the decision layer 4. In other embodiments, the memory 41 may be an external storage device of the decision layer 4 of the mica tape tension conformal wrapping device, such as a plug-in hard disk, smart media card (SMC), secure digital (SD) card, flash card, etc., equipped on the decision layer 4 of the mica tape tension conformal wrapping device. Further, the memory 41 may include both internal storage units and external storage devices of the decision layer 4 of the mica tape tension conformal wrapping device. The memory 41 is used to store operating systems, applications, bootloaders, data, and other programs, such as the program code of computer programs. The memory 41 can also be used to temporarily store data that has been output or will be output.

[0090] This application also provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps in any of the above method embodiments.

[0091] This application provides a computer program product that, when running on a mica tape tension conformal wrapping device, enables the mica tape tension conformal wrapping device to perform the steps in any of the above method embodiments.

[0092] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying the computer program code to a mica tape tension conformal wrapping device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks.

[0093] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0094] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

[0095] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A method for tension conformal wrapping of mica tape in busbar production, characterized in that, The method, applied to a mica tape tension conformal wrapping device, includes: Obtain the contour point set data of the target data region of the busbar to be wrapped; wherein, the contour point set data refers to the discrete spatial coordinate point sequence distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped. The busbar to be wrapped is divided into several measurement sub-regions. Based on the intensity of regional feature changes in each measurement sub-region in the contour point set data, the contour geometric parameters of the busbar to be wrapped along the wrapping path are determined. The intensity of regional feature changes is used to reflect the degree of abrupt change in the structural features of data points between adjacent sub-regions. The contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position and the cross-sectional dimension parameters of the busbar to be wrapped. Based on the contour geometry parameters, preset mica tape material property parameters, and wrapping process parameters, a target tension curve associated with the wrapping path position is generated using a preset tension calculation model. The current path position of the wrapping point is obtained in real time, the target tension value corresponding to the current path position is indexed from the target tension curve, and a control command is generated based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

2. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, When determining the target data region, the method further includes: Acquire initial test data and reference template data; wherein, the initial test data refers to the uncalibrated contour point set data of the busbar to be wrapped, and the reference template data includes the regional positioning information of the busbar to be wrapped; Spatial registration and normalization calibration are performed on the initial test data based on the reference template data to obtain calibrated test data; wherein, the calibrated test data refers to the profile point set data of the busbar to be wrapped after calibration; The regional positioning information is mapped to the calibrated test data to locate the target data region corresponding to the busbar to be wrapped.

3. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, The determination of the contour geometric parameters of the busbar to be wrapped along the wrapping path based on the intensity of regional feature changes in each measurement sub-region of the contour point set data includes: The structural characteristics of data points within each measurement sub-region in the contour point set data are subjected to feature aggregation processing to obtain the regional feature values ​​of the corresponding measurement sub-region. Based on the regional feature values, the intensity of regional feature change in each measurement sub-region is calculated; The measurement sub-regions with a feature change intensity greater than a preset threshold are selected as target sub-regions, and the boundary features of the busbar to be wrapped are determined based on the data points within the target sub-regions. Based on the relative positional relationship of the boundary features, the contour geometric parameters of the busbar to be wrapped are calculated.

4. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, Based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, a target tension curve associated with the wrapping path position is generated using a preset tension calculation model, including: Based on the target number of wrapping layers in the wrapping process parameters, the basic tension value is obtained from the preset basic tension table of layers; Based on the radius of curvature and cross-sectional width in the contour geometry parameters, and the elastic modulus and thickness in the mica tape material property parameters, the additional bending traction force required to overcome the deflection and twisting of the mica tape in the bending section is calculated. Based on the basic tension value and the additional traction force during bending, the target tension value corresponding to each path position in the target tension curve is determined.

5. The method for tension conformal wrapping of mica tape for busbar production as described in claim 4, characterized in that, The additional bending traction force required to overcome the deflection and twisting of the mica tape in the bending section is calculated based on the radius of curvature and cross-sectional width in the contour geometry parameters and the elastic modulus and thickness in the mica tape material property parameters, including: For the outer arc segment, based on the bending stiffness measurement of the mica strip, the ratio of the cross-sectional width to the radius of curvature, and the friction coefficient between the mica strip and the busbar, combined with the preset outer arc correction coefficient, the required reduction in tension compensation for the outer arc segment is obtained. For the inner arc segment, the required increase in tension compensation for the inner arc segment is obtained based on the bending stiffness measurement of the mica strip, the ratio of the cross-sectional width to the absolute value of the radius of curvature, and the friction coefficient between the mica strip and the busbar, combined with a preset inner arc correction coefficient.

6. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, Determining the target tension value corresponding to each path position in the target tension curve further includes: Based on the tensile strength of mica tape, a preset upper and lower limit of safe tension are established; The calculated target tension values ​​corresponding to each path position are limited to the range between the upper limit and the lower limit of the safe tension.

7. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, The generation of control commands based at least on the target tension value includes: The target tension value is used as the feedforward control variable; The measured tension value fed back by the tension sensor is acquired in real time, and then the measured tension value is used by the feedback controller to calculate the feedback control quantity. The control command is generated by superimposing the feedforward control quantity and the feedback control quantity.

8. The method for tension conformal wrapping of mica tape for busbar production as described in claim 1, characterized in that, The method further includes: The region in the contour geometry parameters where the radius of curvature is negative and the absolute value is less than a preset threshold is identified as the inner arc region; When the wrapping point reaches the inner arc area, a positive torque pulse with a preset waveform is superimposed on the unwinding actuator to instantly increase the tension.

9. A mica tape tension conformal wrapping device, characterized in that, An apparatus for conformal wrapping of mica tape under tension, comprising: The scanning unit is used to acquire the contour point set data of the target data area of ​​the busbar to be wrapped; wherein, the contour point set data refers to the discrete spatial coordinate point sequence distributed along the length direction of the busbar to be wrapped, which is used to reflect the surface contour morphology of the busbar to be wrapped. The geometric analysis unit is used to divide the busbar to be wrapped into several measurement sub-regions, and then determine the contour geometric parameters of the busbar to be wrapped along the wrapping path based on the intensity of regional feature changes in each measurement sub-region in the contour point set data; wherein, the intensity of regional feature changes is used to reflect the degree of abrupt change in the structural features of data points between adjacent sub-regions, and the contour geometric parameters include the curvature radius mapping relationship associated with the wrapping path position, and the cross-sectional dimension parameters of the busbar to be wrapped; The tension analysis unit is used to generate a target tension curve associated with the position of the wrapping path based on the contour geometric parameters, preset mica tape material property parameters, and wrapping process parameters, using a preset tension calculation model. The control unit is used to acquire the current path position of the wrapping point in real time, index the target tension value corresponding to the current path position from the target tension curve, and generate control commands based at least on the target tension value to drive the unwinding actuator to adjust the real-time tension of the mica tape.

10. A mica tape tension conformal wrapping device, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method as described in any one of claims 1 to 8.

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