A transformer winding method and system based on tension and speed cooperative compensation

Abstract

This invention discloses a transformer winding method and system based on tension and speed collaborative compensation, belonging to the field of transformer manufacturing technology. After determining the current effective winding radius and the current number of turns per layer, this invention generates a paper feeding speed command for the insulating paper based on the equivalent axial strain corresponding to the tension of the stranded conductors. It generates a differential correction torque based on the tension differences among the strands to balance the tension of each strand. It determines the deceleration timing for layer switching based on the rotational inertia corresponding to the winding state and decomposes the deceleration and wire reversal into independent commands for collaborative execution. The aforementioned compensation commands are then issued in a coordinated manner based on a unified state benchmark. This invention helps to suppress the accumulation of deviations in the length of the conductors and insulating paper, improves the consistency of tension among multiple conductors, reduces the dynamic tension impact during layer switching, and enables each compensation link to form a coordinated control relationship, thereby improving the winding quality and structural reliability.

Description

Technical Field

[0001] This invention belongs to the field of transformer manufacturing technology, and in particular relates to a transformer winding method and system based on tension and speed collaborative compensation. Background Technology

[0002] Transformer winding equipment typically includes a pay-off device, a main winding shaft, a wire laying device, a tension detection device, and a controller. The industry generally employs tension and speed control schemes based on coil diameter identification, tension closed-loop control, and inertia feedforward compensation for this type of equipment. Coil diameter identification is often achieved by using the ratio of linear velocity to spindle angular velocity or by accumulating the number of turns and layer thickness. Tension closed-loop control, based on the coil diameter identification result, superimposes proportional-integral-derivative control to eliminate tension deviations. Inertia feedforward compensation superimposes a compensation torque related to rotational inertia during acceleration and deceleration. These schemes are widely used in continuous winding and unwinding equipment for materials such as steel strip, film, and single conductors, and are considered standard techniques in this field. The winding process of transformer windings differs from the above-mentioned conventional winding and unwinding scenarios. During winding, the conductor and inter-turn or inter-layer insulation paper are usually laid simultaneously. The low-voltage portion of the winding often uses multiple strands of conductor wound in parallel to meet high current carrying requirements. Furthermore, the winding is layered according to the design drawings, with the number of turns in each layer determined before winding. A commutation transition is required when changing layers.

[0003] Existing tension and speed control schemes are designed for continuous winding scenarios using a single material. They fail to consider the difference between the elastic elongation of the conductor under tension and the minimal elongation of the insulating paper. If the paper feed speed is set solely based on the nominal winding speed of the conductor, deviations between the actual length of the insulating paper and the conductor can easily occur as the winding process progresses. In cases of multi-strand winding, existing schemes typically only implement closed-loop control for the combined tension or a sampled single-strand tension, without actively balancing the tension differences between individual strands. This can easily lead to tension inconsistencies during winding operation. The commutation deceleration stages in existing schemes often employ fixed deceleration times or passive responses after detection, failing to consider the change in moment of inertia with the number of winding layers. This makes it prone to uncontrollable tension shocks during the commutation transition. Furthermore, the various compensation stages in existing schemes are usually set independently, lacking a coordination mechanism based on a unified state benchmark. This can easily lead to incoordination between compensation stages during periods of rapid change in winding conditions.

[0004] Therefore, given that existing technologies cannot simultaneously address the challenges of synchronously laying conductors and insulating paper, achieving tension balance among multiple conductors, and ensuring dynamic stability during layer transitions, it is of great significance to propose a transformer winding method that provides synergistic compensation for the aforementioned operating conditions. Summary of the Invention

[0005] The technical solution of this invention is as follows: A transformer winding method based on tension and speed co-compensation includes the following steps: S1: Control the rotation of the main winding shaft, wind the multiple strands of wires with a set tension onto the skeleton, and simultaneously collect the tension of the stranded wires, the tension of each individual wire, the rotation angle of the main winding shaft and the angular velocity of the main winding shaft. Determine the current layer number, the number of turns wound in the current layer and calculate the current effective winding radius based on the rotation angle. S2: Based on the equivalent axial strain corresponding to the tension of the stranded conductor, the current effective winding radius and the angular velocity of the main winding shaft, a paper feeding speed command for insulating paper is generated in coordination, and the insulating paper drive roller is controlled to lay the insulating paper synchronously with the conductor according to the paper feeding speed command. S3: Calculate the tension deviation between strands based on the tension of each strand of conductor, generate the target output resistance torque command for each strand pay-off device, control each strand pay-off device to output according to the target output resistance torque command, and balance the tension of each strand of conductor. S4: Based on the number of turns wound in the current layer, the number of turns designed for each layer, the moment of inertia corresponding to the current effective winding radius, and the allowable tension deviation, determine the number of turns to decelerate in advance, generate the main shaft deceleration command and the wire reversal command, control the main winding shaft to decelerate according to the main shaft deceleration command, and synchronously control the wire laying device to run in the reverse direction according to the wire reversal command to complete the layer change and reversal transition; S5: Based on the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft, which are latched in the same control cycle, the insulating paper feeding speed command, the target output resistance torque command, the main shaft deceleration command, and the wiring reverse command are respectively limited and synchronously sent to the corresponding execution unit according to a unified timestamp.

[0006] Furthermore, step S1 includes: S11: A conductor tension detection unit is set on the conductor path before the multi-strand conductor is wound together to the main winding axis. The conductor tension after the strand is combined is detected in real time. After removing tension mutation values ​​that exceed a preset multiple of the average of adjacent samples, a moving average filter is performed to obtain the tension of the combined conductor. S12: A tension detection unit is set at the outlet of the wire feeding device of each wire to detect the tension of each wire in real time. After removing tension mutation values ​​that exceed a preset multiple of the average value of adjacent samples, a moving average filter is performed to obtain the tension of each wire. S13: An encoder is installed on the main winding shaft to detect the rotation angle of the main winding shaft in real time. The angular velocity of the main winding shaft is obtained based on the change of the rotation angle per unit time or through the rotational speed feedback of the servo driver of the main winding shaft. S14: Based on the cumulative count of the number of turns wound on the main winding shaft according to the aforementioned turning angle, determine the current layer number and the number of turns wound on the current layer using the following formula: ; ; In the formula, The cumulative number of turns wound on the main winding shaft; The preset number of turns per layer; This indicates the floor function; The current layer number; The current layer has been wound with a certain number of turns; S15: Calculate the current effective winding radius using the following formula: ; In the formula, The initial radius of the preset skeleton; The current layer number determined in step S14; The single-layer equivalent thickness is a preset value, which is pre-calibrated based on the radial equivalent thickness of the conductor, the radial equivalent thickness of the insulating paper, and the compaction correction amount. The current effective winding radius is denoted as .

[0007] Furthermore, step S2 includes: S21: Based on the current effective winding radius and the angular velocity of the main winding shaft, calculate the surface linear velocity of the main winding shaft using the following formula: ; In the formula, The current effective winding radius is calculated according to step S15; The angular velocity of the main winding shaft; The linear velocity of the main winding shaft surface; S22: Calculate the equivalent axial strain of the stranded conductor used for paper feed compensation using the following formula: ; In the formula, The tension of the stranded conductor is obtained directly by the conductor tension detection unit or calculated from the sum of the tensions of each strand. This represents the equivalent axial stiffness of the stranded conductor. It is the sum of the products of the elastic modulus and the cross-sectional area of ​​each strand of conductor, assuming that the materials and specifications of each strand of conductor are consistent. , The elastic modulus of a single-strand conductor. This represents the cross-sectional area of ​​a single-strand conductor. The number of strands in the parallel-wound conductor; The equivalent axial strain of the stranded conductor; S23: Calculate the paper feeding speed command for the insulating paper according to the following formula: ; In the formula, The linear velocity of the main winding shaft surface calculated according to step S21; The pre-calibrated directional coefficient is a dimensionless number. Its positive or negative values ​​correspond to two calibration conditions, namely, the increase or decrease of the paper feeding speed of the insulating paper as the equivalent axial strain increases. The equivalent axial strain of the stranded conductor calculated according to step S22; This refers to the paper feed speed command for the insulating paper; S24: Limit the paper feeding speed command of the insulating paper to the preset allowable speed range of the insulating paper drive roller, and send it to the servo driver of the insulating paper drive roller set on the insulating paper supply path. The insulating paper supply path merges with the multi-strand wire laying path upstream of the wiring device. S25: The actual paper feeding speed of the insulating paper drive roller is obtained through the insulating paper feeding speed detection unit. The insulating paper feeding speed command is corrected in a closed loop according to the deviation between the actual paper feeding speed and the insulating paper feeding speed command. The insulating paper drive roller is controlled to feed paper at the corrected paper feeding speed so that the insulating paper and the conductor are laid synchronously on the main winding shaft, and a winding with the conductor and insulating paper laid synchronously is obtained.

[0008] Furthermore, step S3 includes: S31: According to the The initial radius of the wire feeding device's feed reel and the diameter of a single strand of wire, combined with the cumulative feeding length, are used to estimate the first strand's length using the following formula. Instantaneous radius of the wire feeding device's feed reel: ; In the formula, For the first The initial radius of the wire feeding device of the wire feeding device; For the first The diameter of the conductor strand; For the first The cumulative length of the wire strands is calculated by the sum of the angle of the wire feeding reel of the wire feeding device and the initial radius of the wire feeding reel; For the first Instantaneous radius of the wire feeding device's feed reel; S32: Calculation Arithmetic mean of the tension of a strand of wire The arithmetic mean is the first to the second... Sum of tensions in the conductor strands divided by ; S33: Calculate the tension deviation of each conductor using the following formula: ; In the formula, For the first The tension of the conductor strand, For stock serial number and ; The result calculated according to step S32 The arithmetic mean of the tension in a strand of conductor; For the first Tension deviation of the conductor strand; S34: Taking the direction that increases the wire-feeding resistance torque of the wire-feeding device as the positive direction, calculate the differential correction torque of the wire-feeding device for each strand of conductor according to the following formula: ; In the formula, The pre-calibrated proportional gain coefficient is a dimensionless number. The first one calculated according to step S33 Tension deviation of the conductor strand; The first one calculated according to step S31 Instantaneous radius of the wire feeding device's feed reel; For the first Differential correction torque of the wire feeding device.

[0009] Furthermore, step S3 also includes: S35: When the absolute value of the tension deviation is less than the preset dead zone threshold, the first... The differential correction torque of the wire feeding device is set to zero; S36: Calculate the following formula The target output resistance torque of the wire feeding device: ; In the formula, For the first The foundation resistance torque of the wire feeding device; The differential correction torque is calculated according to steps S34 and S35; Indicates when Less than Time to take ,when Greater than Time to take In other cases, take itself; The preset minimum holding torque, Greater than zero; This is the preset maximum allowable resistance torque; For the first The target output resistance torque of the wire feeding device; S37: Convert the target output resistance torque into the target excitation current according to the pre-calibrated torque-current curve and limit it within the allowable current range of the magnetic powder brake, controlling the first... The magnetic powder brake of the wire feeding device outputs excitation current according to the target excitation current, equalizes the tension of each wire, and obtains a multi-strand wire with improved tension consistency.

[0010] Furthermore, step S4 includes: S41: Update the equivalent moment of inertia referred to the main winding axis according to the following formula: ; In the formula, The pre-calibrated moment of inertia of the skeleton and main winding shaft foundation; The equivalent inertia coefficient of the pre-calibrated winding material is determined based on the linear density of the conductor and insulating paper and the axial length of the winding. The current effective winding radius is calculated according to step S15; The initial radius of the preset skeleton; The equivalent moment of inertia referred to the main winding axis; S42: Calculate the time required to complete deceleration using the following formula: ; In the formula, The equivalent moment of inertia obtained in step S41 is updated accordingly; The steady-state angular velocity before deceleration; This refers to the commutation transition angular velocity; The current effective winding radius; This is the preset allowable dynamic tension deviation; The time required to complete deceleration; S43: Calculate the number of pre-deceleration turns using the following formula, and round the result up to the integer number of pre-deceleration turns: ; In the formula, The steady-state angular velocity before deceleration; This refers to the commutation transition angular velocity; The time required to complete deceleration, calculated according to step S42; To reduce the number of turns in advance; Round up to get the integer number of turns for early deceleration. ; S44: When the number of pre-deceleration integer turns is not less than the preset number of turns per layer, control the main winding shaft and the wire laying device to complete the winding of the current layer in a preset low-speed winding mode.

[0011] Furthermore, step S4 also includes: S45: When the number of turns wound in the current layer reaches the difference between the designed number of turns per layer and the integer number of turns for advance deceleration, the spindle deceleration command and the cable reversal command are generated; S46: Control the main winding shaft to decelerate from the steady-state angular velocity to the reversing transition angular velocity according to the main shaft deceleration command and the duration calculated in step S42, without the main winding shaft performing reverse rotation; control the wire laying device to run in the opposite direction relative to the original axial arrangement direction according to the wire laying reverse command, and execute synchronously with the main shaft deceleration command at the same trigger time to complete the layer changing and reversing transition; S47: During deceleration, the deceleration of the main winding shaft is corrected based on the real-time feedback of the tension of the stranded conductor. After the transition, the main winding shaft is controlled to recover to the steady-state angular velocity, so that the theoretical dynamic tension deviation calculated according to the main shaft deceleration command does not exceed the allowable dynamic tension deviation.

[0012] Furthermore, step S5 includes: S51: In the same control cycle, latch the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding axis; S52: Limit the speed command for the insulating paper feed, the target output resistance torque command, the spindle deceleration command, and the cable reversal command respectively; S53: Within the deceleration window corresponding to the integer number of deceleration turns in advance, reduce the value of the directional coefficient in the paper feeding speed command of the insulating paper, and mitigate the sudden change in the differential correction torque in the target output resistance torque command. S54: The paper feeding speed command of the insulating paper, the target output resistance torque command, the spindle deceleration command and the cable reversal command, after being limited by step S52 and adjusted by step S53, are synchronously sent to the corresponding execution components according to a unified timestamp.

[0013] The present invention also provides a transformer winding system based on tension and speed co-compensation, comprising: The system comprises a main winding shaft, a main shaft servo motor, a multi-strand pay-off array, a conductor tension detection unit, an insulating paper feeding unit, an insulating paper feeding speed detection unit, a wire laying device, a wire laying servo motor, an encoder, and a main controller. The main winding shaft, driven by the main shaft servo motor, clamps the bobbin and drives the conductor winding. The control input of the main shaft servo motor is connected to the corresponding output of the main controller. The multi-strand pay-off array includes... A wire feeding device, For integers greater than or equal to 2, each of the wire feeding sub-devices feeds a strand of wire to the main winding shaft. Each wire feeding sub-device includes a wire feeding reel and an actuator coaxially connected to the wire feeding reel. A strand tension detection unit is provided at the wire outlet. The wire tension detection unit is provided on the path where the multiple strands of wire are wound onto the main winding shaft after converging. The insulating paper feeding unit includes an insulating paper drive roller and a matching servo driver, and is located on the insulating paper supply path. The insulating paper supply path converges with the multiple strands of wire laying path upstream of the wire laying device. The insulating paper feeding speed detection unit is located on the insulating paper drive roller. The wire laying device is located on the laying path where the multiple strands of wire and insulating paper converge, and is driven by the wire laying servo motor. The encoder is mounted on the main winding shaft. The main controller is connected to the strand tension detection unit, the conductor tension detection unit, the servo driver of the insulating paper drive roller, the insulating paper feed speed detection unit, the actuators of each of the wire feeding sub-devices, the wire laying servo motor, the main shaft servo motor, and the encoder. It includes a strain calculation and paper feed speed collaborative compensation module, a multi-strand tension differential equalization calculation module, and a forward-looking planning module, which are used to generate insulating paper feed speed commands and control the servo driver of the insulating paper drive roller, generate target output resistance torque commands and control the actuators of each of the wire feeding sub-devices, and generate main shaft deceleration commands and wire laying reverse commands and control the main shaft servo motor and the wire laying servo motor, respectively.

[0014] Furthermore, the strain calculation and paper feed speed collaborative compensation module is used to generate the insulating paper feed speed command based on the strand tension detected by the conductor tension detection unit, combined with the current effective winding radius and main winding shaft angular velocity calculated by the angle detected by the encoder; the multi-strand tension differential balancing calculation module is used to generate the target output resistance torque command for each of the wire feeding sub-devices based on the tension of each strand detected by each strand tension detection unit, and output it to the actuator of the corresponding wire feeding sub-device after torque-current conversion; the shift forward planning module is used to generate the main shaft deceleration command and the wire reversal command based on the current number of turns wound in the current layer and the current effective winding radius determined by the angle detected by the encoder; the main controller coordinates the commands calculated by the strain calculation and paper feed speed collaborative compensation module, the multi-strand tension differential balancing calculation module and the shift forward planning module according to a unified control cycle and timestamp before issuing them.

[0015] The beneficial effects of this invention are as follows: This invention includes step S2, which generates an insulating paper feeding speed command based on the equivalent axial strain corresponding to the tension of the stranded conductor, combined with the current effective winding radius and the angular velocity of the main winding shaft. This allows the insulating paper feeding speed to be dynamically adjusted according to the change in conductor tension, changing the previous practice of setting the insulating paper feeding speed only according to the surface velocity of the main winding shaft without considering the elastic elongation of the conductor. This ensures that the feeding length of the insulating paper corresponds to the actual path length of the conductor under tension, suppressing the phenomenon that the actual laying length of the insulating paper and the conductor continues to widen during the winding process. It also reduces the occurrence of defects such as uneven insulation paper edges, local exposure, or wrinkles, and improves the integrity and reliability of the winding insulation structure.

[0016] In step S3 of this invention, the tension deviation between strands is calculated based on the tension of each strand of conductor, and a target output resistance torque command for each strand pay-off device is generated accordingly to perform differential correction on the tension of each strand. This overcomes the problem that previous multi-strand wires relied solely on a uniform tension setting and did not actively adjust for differences between strands. This allows the tension of each strand of conductor to approach the overall average value, alleviating the problem of inconsistent tension between strands caused by differences in the mechanical characteristics of the pay-off device or different remaining diameters of the pay-off reel. It is beneficial to reduce the additional circulating current loss caused by differences in tension and position between strands when the winding is energized, and improve the uniformity of preload and structural stability of the winding when subjected to short-circuit electrodynamic impact.

[0017] This invention designs step S4, which determines the number of turns to be decelerated in advance based on the number of turns already wound in the current layer, the designed number of turns per layer, the moment of inertia corresponding to the current effective winding radius, and the allowable tension deviation. The commutation process is decomposed into a spindle deceleration command and a wire reversal command, which are executed separately. This solves the problem that previous commutation deceleration relied on a fixed duration or passive response after detection, and did not consider the impact of changes in the number of winding layers on the moment of inertia. This allows the deceleration duration and advance amount to be adjusted accordingly with the increase of the number of winding layers, suppressing the phenomenon that the dynamic tension impact caused by the increase in the moment of inertia during the layer change transition stage continues to expand with the increase of the number of layers. This reduces the possibility of defects such as wire damage and interlayer misalignment, and improves the stability of the winding layer change transition.

[0018] Step S5 of this invention, based on the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft latched in the same control cycle, limits the amplitude of the insulating paper feeding speed command, the target output resistance torque command, the main shaft deceleration command, and the wire reversal command, and issues them in a coordinated manner according to a unified timestamp. This establishes the three links of insulating paper feeding speed collaborative compensation, multi-strand tension balancing, and layer-change deceleration suppression on a unified state benchmark, avoiding the command incoordination problem caused by inconsistent sampling times. Furthermore, it suppresses the amplification of tension fluctuations caused by the mutual coupling of various compensation links during the rapid change of state variables in the layer-change deceleration stage. This makes the whole method present an organically connected collaborative control whole, improving the overall stability and consistency of the winding process. Attached Figure Description

[0019] Figure 1 This is a comparison chart of the cumulative deviation of the wire-insulating paper laying length between Example 1 and Comparative Example 1.

[0020] Figure 2 The diagrams show a comparison of the tension convergence process of each strand of the conductor in Example 2 and Comparative Example 2. (a) is a diagram showing the change of tension of each strand over time after differential equilibrium in Example 2, and (b) is a diagram showing the change of tension of each strand over time under a fixed resistance torque in Comparative Example 2.

[0021] Figure 3 The diagram shows the difference between the reversing peak dynamic tension of Example 3 and Comparative Example 3. (a) is a diagram showing the change of equivalent moment of inertia with the floor number, and (b) is a diagram showing the change of peak dynamic tension difference between Example 3 and Comparative Example 3 with the floor number.

[0022] Figure 4 This is a comparison diagram of the tension fluctuation of the stranded conductor during the layer replacement transition period in Example 4 and Comparative Example 4.

[0023] Figure 5 This is a schematic diagram of the composition structure of a transformer winding system based on tension and speed collaborative compensation according to the present invention. Detailed Implementation

[0024] The technical solutions of this invention will be clearly and completely described below. In addition, the forms of the various structures described in the following embodiments are merely illustrative. This invention is not limited to the structures described in the following embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0025] The transformer winding system based on tension and speed coordinated compensation described in this embodiment is as follows: Figure 5 As shown, the system includes a main winding shaft, a main spindle servo motor, a wire laying device, a wire laying servo motor, a multi-strand wire feeding array, an insulating paper feeding unit, an insulating paper feeding speed detection unit, a wire tension detection unit, several strand tension detection units, an encoder, and a main controller. The main winding shaft is used to clamp the transformer winding frame and is driven to rotate by the main spindle servo motor, winding the parallel multi-strand wires onto the frame at a set tension to form the transformer winding. The control input terminal of the main spindle servo motor is connected to the corresponding output terminal of the main controller, receiving spindle deceleration commands from the main controller.

[0026] Multi-strand wire feeding device array includes A wire feeding device, The number is an integer greater than or equal to 2. Each wire-laying sub-device lays out a strand of wire along the wire-laying direction towards the main winding shaft. Multiple strands of wire converge on their path before reaching the main winding shaft, forming a combined strand. Each wire-laying sub-device includes a wire-laying reel and an actuator coaxially connected to the reel. The actuator is used to adjust the output resistance torque of the wire-laying reel for that strand. In this embodiment, the actuator is preferably a magnetic powder brake. The magnetic powder inside the magnetic powder brake generates resistance torque under the action of the magnetic field formed by the excitation current. The larger the excitation current, the larger the output resistance torque of the magnetic powder brake. The excitation current input terminal of the magnetic powder brake is connected to the corresponding output terminal of the main controller. By adjusting the magnitude of the excitation current, the output resistance torque of the corresponding wire-laying reel is changed, thereby adjusting the tension of that strand of wire.

[0027] Each wire feeding sub-device is equipped with a strand tension detection unit at its outlet to detect the tension of the corresponding strand of conductor in real time and upload the detection signal to the main controller. A conductor tension detection unit is also installed on the conductor path before the stranded conductor is wound onto the main winding shaft to detect the tension of the stranded conductor and upload the detection signal to the main controller.

[0028] The insulating paper feeding unit includes an insulating paper drive roller and a matching servo driver. The insulating paper drive roller is positioned on the insulating paper supply path, which merges with the multi-strand conductor laying path upstream of the wiring device. After being conveyed by the insulating paper drive roller, the insulating paper merges with the multi-strand conductor upstream of the wiring device and is then laid synchronously with the conductor onto the main winding shaft. The servo driver of the insulating paper drive roller is signal-connected to the main controller, receiving the insulating paper feeding speed command from the main controller and driving the insulating paper drive roller to rotate according to the speed command. An insulating paper feeding speed detection unit is located on the insulating paper drive roller to detect the actual feeding speed of the insulating paper drive roller and feed this speed back to the main controller for closed-loop correction of the insulating paper feeding speed command.

[0029] The winding device is positioned on the laying path after the multi-strand wires and insulating paper converge. It guides the wires and insulating paper along the axial direction of the main winding shaft and reverses the axial direction upon completion of each layer, achieving layer transition. The winding device is driven by a winding servo motor, whose control input is connected to the corresponding output of the main controller, receiving reverse winding commands from the main controller. An encoder is mounted on the main winding shaft to detect its rotation angle in real time and uploads the detection signal to the main controller.

[0030] The main controller is connected to the conductor tension detection unit, the individual strand tension detection units, the servo driver of the insulating paper drive roller, the insulating paper feed speed detection unit, the actuators of each pay-off sub-device, the wire laying servo motor, the spindle servo motor, and the encoder signal. Internally, the main controller includes a strain calculation and paper feed speed collaborative compensation module, a multi-strand tension differential balancing calculation module, and a forward-looking planning module. The strain calculation and paper feed speed collaborative compensation module generates an insulating paper feed speed command based on the strand tension detected by the conductor tension detection unit, combined with the current effective winding radius and main winding spindle angular velocity calculated from the angle detected by the encoder, and outputs it to the servo driver of the insulating paper drive roller. The multi-strand tension differential balancing calculation module generates a target output resistance torque command for each pay-off sub-device based on the individual strand tension detected by the individual strand tension detection units, and outputs it to the actuator of the corresponding pay-off sub-device after torque-current conversion. The forward-looking planning module generates spindle deceleration commands and cable reversal commands based on the current layer's number of turns and the current effective winding radius, determined by the rotation angle detected by the encoder. These commands are then output to the spindle servo motor and the cable servo motor, respectively. The commands calculated by these three modules are coordinated and issued by the main controller according to a unified control cycle and timestamp, ensuring that tension and speed compensation are implemented under the same state reference.

[0031] The following describes each step of the winding method of the present invention in conjunction with the above-mentioned winding equipment.

[0032] The winding method of this embodiment first executes step S1, which controls the rotation of the main winding shaft and winds the multi-strand wires with a set tension onto the skeleton. At the same time, the tension of the stranded wires, the tension of each strand of wires, the rotation angle of the main winding shaft and the angular velocity of the main winding shaft are collected. Based on the rotation angle, the current layer number, the number of turns wound in the current layer are determined and the current effective winding radius is calculated.

[0033] Step S1 includes steps S11 to S15. In step S11, the tension of the stranded conductor is detected in real time by a conductor tension detection unit along the conductor path before the multi-strand conductor is wound to the main winding shaft. The output signal of the tension sensor usually contains occasional sudden interference caused by factors such as conductor vibration and sensor installation gaps. To avoid such interference being mistakenly transmitted as real tension changes to subsequent compensation calculations, this step first compares the current sampled value with the average of several adjacent sampled values, removes tension sudden values ​​exceeding a preset multiple of the average, and then performs a moving average filter on the remaining sampled values ​​to obtain the stranded conductor tension used for subsequent calculations. The window length and multiple threshold of the moving average filter can be pre-calibrated according to the sensor noise level and the response speed of the tension control loop. If the window length is too large, it will affect the following speed of tension changes; if the window length is too small, the filtering effect will be limited. Both need to be determined comprehensively based on the specific equipment, and specific values ​​are not provided here.

[0034] Step S12 is based on the same principle as step S11, except that the detection object is each strand of wire. A strand tension detection unit is installed at the outlet of the wire feeding device for each strand to detect the tension of each strand in real time. Similarly, sudden tension changes are first eliminated, and then a moving average filter is applied to obtain the tension of each strand, providing input for the inter-strand tension balancing in the subsequent step S3.

[0035] In step S13, the rotation angle of the main winding shaft is detected in real time by an encoder installed on the main winding shaft. The angular velocity of the main winding shaft can be calculated by measuring the change in rotation angle per unit time, or it can be obtained directly from the speed feedback signal inside the servo driver of the main winding shaft; both methods are feasible. In applications requiring high encoder resolution and short sampling periods, the differential rotation angle method is preferred, as it reduces reliance on the internal communication interface of the servo driver.

[0036] In step S14, the transformer windings are wound layer by layer according to the design drawings. The number of turns in each layer is determined before winding. There is a definite correspondence between the rotation angle of the main winding shaft and the number of turns. Therefore, this step counts the cumulative number of turns wound on the main winding shaft based on the rotation angle, and records it as follows. Combined with the preset number of turns per layer The current layer number and the number of turns already wound on the current layer are determined by the following formula.

[0037] ; ; In the formula, The cumulative number of turns (turns) wound on the main winding shaft; The preset number of turns per layer; INT(·) indicates the floor function; The current layer number; This represents the number of turns wound in the current layer. The meaning of the above formula is that the cumulative number of turns is divided by the designed number of turns for each layer, and the quotient plus 1 is the current layer number of the winding. The remainder is the number of turns wound in that layer. Compared with the method of setting independent counters for each layer and then resetting them layer by layer, this method only requires one cumulative counter to determine the layer number and the number of turns in the layer. The structure is simple and will not cause layer number confusion due to the accumulation of errors in the resetting time.

[0038] In step S15, the transformer windings are stacked layer by layer along the radial direction of the frame. After each layer is wound, the winding radius increases by an equivalent layer thickness. Therefore, the current effective winding radius is calculated by the following formula.

[0039] ; In the formula, The initial radius of the skeleton is preset (m); The current layer number determined in step S14; The preset single-layer equivalent thickness (m) is a combination of the radial equivalent thickness of the conductor itself, the radial equivalent thickness of the insulating paper, and the radial shrinkage correction caused by the compaction during the winding process. It can be pre-calibrated by trial winding and actual measurement of the layer thickness. Let be the current effective winding radius (m). The above formula shows that the winding radius is equal to the initial radius of the skeleton when the first layer is wound. For each additional layer, the winding radius is the equivalent layer thickness of the corresponding number of layers added to the initial radius of the skeleton. The current effective winding radius obtained in this way serves as a common reference for the linear velocity calculation and moment of inertia update in subsequent steps S2 and S4, avoiding the problem of key state quantities such as winding diameter and layer number being repeatedly collected or having inconsistent sources in different compensation stages.

[0040] Step S2 generates an insulating paper feeding speed command based on the equivalent axial strain corresponding to the tension of the stranded conductor, the current effective winding radius, and the angular velocity of the main winding shaft. The insulating paper drive roller is then controlled to lay the insulating paper synchronously with the conductor according to the speed command.

[0041] During transformer winding, the conductors and insulating paper are usually laid simultaneously. Under tension, the conductors undergo axial elastic elongation, while the axial stiffness of the insulating paper is much higher than that of the conductors, and the laying tension is relatively small, so its elongation is negligible. If the insulating paper feeding speed is set only according to the surface speed of the main winding shaft, without considering the elastic elongation of the conductors, the actual laid lengths of the conductors and insulating paper will gradually accumulate as the winding progresses, leading to uneven edges, localized exposure, or wrinkles in the insulating paper. Step S2 addresses this phenomenon by implementing the following speed compensation mechanism.

[0042] In step S21, the surface linear velocity of the main winding shaft is calculated according to the current effective winding radius and the angular velocity of the main winding shaft using the following formula.

[0043] ; In the formula, The current effective winding radius (m) is calculated according to step S15; The angular velocity of the main winding shaft (rad / s); Let be the linear velocity (m / s) of the surface of the main winding axis. The above formula is the basic relationship between linear velocity, angular velocity, and radius in circular motion, that is, the linear velocity is equal to the product of the radius and the angular velocity.

[0044] In step S22, the equivalent axial strain of the stranded conductor used for paper feed compensation is calculated using the following formula.

[0045] ; In the formula, The tension of the stranded conductor (N) can be obtained either directly by the conductor tension detection unit or by the sum of the tensions of each strand. Let N be the equivalent axial stiffness of the stranded conductor. Since each strand has the same axial strain due to synchronous laying during winding, according to Hooke's Law, the first... The tension of a strand of conductor is equal to the product of its elastic modulus and cross-sectional area, multiplied by its strain. The summation of the tensions in the strands of a conductor yields the result: the total tension of the strands equals the sum of the products of the elastic modulus and cross-sectional area of ​​each strand, multiplied by the strain. This is the definition of... It is the sum of the products of the elastic modulus and the cross-sectional area of ​​each strand of the conductor, assuming that the materials and specifications of each strand of the conductor are consistent. Degenerate into , This represents the elastic modulus (Pa) of a single-strand conductor. The cross-sectional area (m²) of a single-strand conductor 2 ), The number of strands in the parallel-wound conductor; This represents the equivalent axial strain of the stranded conductor.

[0046] In step S23, the paper feeding speed command for the insulating paper is calculated using the following formula.

[0047] ; In the formula, The linear velocity (m / s) on the surface of the main winding shaft is calculated according to step S21; The pre-calibrated direction coefficient is a dimensionless number used to characterize the direction and magnitude of the change in the paper feed speed of the insulating paper with the equivalent axial strain of the conductor. Its value can be obtained by reverse calibration after trial winding and measuring the alignment deviation between the edge of the insulating paper and the edge of the conductor. If, during calibration, it is found that the paper feed speed of the insulating paper needs to increase with the increase of the equivalent axial strain of the conductor to maintain alignment, then... Take a positive value; if it is found that a corresponding decrease is needed to maintain alignment, then... Take the negative value; The equivalent axial strain of the stranded conductor calculated according to step S22; This is the instruction for the paper feeding speed of the insulating paper (m / s). Compared to the method of setting the paper feeding speed of the insulating paper only according to the surface speed of the main winding shaft, the correction introduced in this step can adjust the paper feeding speed of the insulating paper synchronously when the conductor tension changes, so that the actual laying length of the insulating paper and the conductor remains in correspondence.

[0048] In step S24, the paper feeding speed command obtained in step S23 is limited to a preset allowable speed range for the insulating paper drive roller to prevent the command from exceeding the mechanical or servo capability range of the drive roller. The limited speed command is then sent to the servo driver of the insulating paper drive roller located on the insulating paper supply path. The insulating paper supply path merges with the multi-strand conductor laying path upstream of the wiring device. The insulating paper and the multi-strand conductor have already merged upstream of the wiring device and are then guided together by the wiring device to be laid onto the main winding shaft.

[0049] In step S25, the actual paper feeding speed of the insulating paper drive roller is obtained through the insulating paper feeding speed detection unit. This actual paper feeding speed is compared with the insulating paper feeding speed command issued in step S24. Based on the deviation between the two, a closed-loop correction is performed on the insulating paper feeding speed command. The insulating paper drive roller is then controlled to feed paper at the corrected speed, so that the insulating paper and the conductor are laid synchronously onto the main winding shaft, resulting in a winding with the conductor and insulating paper laid synchronously. The closed-loop correction can compensate for the deviation between the actual paper feeding speed and the command value caused by factors such as the transmission gap of the insulating paper drive roller and load disturbances, thereby improving the execution accuracy of the insulating paper feeding speed command.

[0050] Step S3 calculates the tension deviation between strands based on the tension of each strand of conductor, and generates the target output resistance torque command for each strand pay-off device accordingly. The device is then controlled to output the command to balance the tension of each strand of conductor.

[0051] Transformer low-voltage windings typically use multiple strands of wire wound in parallel to meet high current carrying requirements, with each strand released by an independent release device. If each release device uses a uniform tension setting without differentiated adjustment between strands, the actual tension of each strand can easily deviate due to differences in the mechanical characteristics of the release devices, varying remaining diameter of the release reel, and other factors. This results in inconsistent actual path lengths and preload states for each strand after winding, potentially causing additional inter-strand circulating current losses during winding operation and localized loosening due to uneven preload when the winding is subjected to short-circuit electrodynamic impacts. Step S3 is used to suppress the aforementioned inter-strand tension deviation.

[0052] In step S31, the instantaneous radius of the pay-off reel of each pay-off sub-device is... This is a necessary parameter in the subsequent differential correction torque calculation, and the radius of the pay-off reel continuously decreases during the pay-off process. This step is based on the first... The instantaneous radius of the pay-off reel of the wire-paying device is estimated by the following formula, taking into account the initial radius of the pay-off reel and the diameter of a single strand of wire, combined with the cumulative pay-off length.

[0053] ; In the formula, For the first The initial radius (m) of the wire feeding device of the wire feeding device; For the first The diameter (m) of the conductor strand; For the first The cumulative length (m) of the wire laid out is calculated by the sum of the angle of the wire laying disc and the initial radius of the wire laying disc; sqrt(·) represents the square root operation; For the first The instantaneous radius (m) of the wire feeding device's feed reel. The above formula is derived based on the conservation relationship of the feed reel's winding cross-sectional area. The feed reel is considered as a coil with an approximately circular cross-section, and the initial cross-sectional area of ​​the coil is... Each release length is Diameter is The conductor is equivalent to removing an area of ​​[area] from the cross-section of the coil. The annular region, the remaining cross-sectional area of ​​the roll is Let the remaining cross-sectional area equal to ,Right now Divide both sides by Then, by taking the square root, we obtain the above formula.

[0054] In step S32, calculate Arithmetic mean of the tension of a strand of wire The arithmetic mean is the first to the second... Sum of tensions in the conductor strands divided by This serves as a benchmark for measuring the overall tension level of each conductor strand.

[0055] In step S33, the tension deviation of each conductor is calculated using the following formula.

[0056] ; In the formula, For the first The tension (N) of a strand of wire. For stock serial number and ; The result calculated according to step S32 The arithmetic mean (N) of the tension of the conductor strands; For the first Tension deviation (N) of the conductor strand.

[0057] In step S34, taking the direction of increasing the wire feeding resistance torque of the wire feeding device as the positive direction, the differential correction torque of the wire feeding device for each strand of conductor is calculated according to the following formula.

[0058] ; In the formula, The pre-calibrated proportional gain coefficient is a dimensionless number. Its value can be calibrated according to the response bandwidth of the servo circuit of the wire feeding device. During calibration, the response speed and stability of the differential correction torque can be observed and gradually adjusted through a step tension deviation test. The first one calculated according to step S33 Tension deviation (N) of the conductor strand; The first one calculated according to step S31 Instantaneous radius (m) of the wire feeding device of the wire feeding device; For the first The differential correction torque (N·m) of the wire feeding device. The negative sign in the above formula indicates that the differential correction torque is in the opposite direction to the tension deviation adjustment. The principle is that the resistance torque of each wire feeding device is positively correlated with the tension of that wire strand. That is, if the resistance torque increases, the tension of that strand increases. Therefore, when the tension of a certain wire strand is higher than the average value, that is, the tension deviation is positive, the resistance torque of the wire feeding device should be reduced to reduce the tension, and the corresponding differential correction torque should be negative. Similarly, when the tension of a certain wire strand is lower than the average value, the resistance torque should be increased. This forms a negative feedback adjustment relationship, causing the tension of each wire strand to converge towards the average value.

[0059] In step S35, when the absolute value of the tension deviation is less than the preset dead zone threshold, the differential correction torque of the wire feeding device is set to zero to avoid the repeated adjustment of the differential correction torque when the tension deviation is near the sensor noise level, which would cause the wire feeding device actuator to operate frequently.

[0060] In step S36, the following formula is used to calculate the first... The target output resistance torque of the wire feeding device.

[0061] ; In the formula, For the first The basic resistance torque (N·m) of the wire feeding device for each strand of conductor is calculated by a conventional common-mode tension closed loop based on the set tension and the instantaneous radius of the current wire feeding reel, and is used to maintain the overall tension level of each strand of conductor. The differential correction torque (N·m) calculated according to steps S34 and S35; amplitude limiting ( ) indicates when Less than Time to take ,when Greater than Time to take In other cases, take itself; The preset minimum holding torque (N·m) Greater than zero; This is the preset maximum allowable resistance torque (N·m); For the first The target output resistance torque (N·m) of the wire feeding device. This step limits the minimum holding resistance torque to be greater than zero because actuators such as magnetic powder brakes can only apply resistance torque to the wire and cannot output active driving torque. If the negative adjustment range of the differential correction torque exceeds the basic resistance torque, the target output resistance torque will become zero or negative and cannot be achieved by the actuator. By setting a minimum holding resistance torque greater than zero, it can be ensured that the target output resistance torque is always within the range achievable by the actuator.

[0062] In step S37, the target output resistance torque is converted into the target excitation current according to the pre-calibrated torque-current curve, and this current is limited within the allowable current range of the magnetic powder brake, thus controlling the first... The magnetic powder brake of the conductor winding device outputs excitation current according to the target excitation current. Through the aforementioned torque-current curve, the torque-dimensional control quantity can be converted into a current-dimensional control quantity that the magnetic powder brake can directly execute. The torque-current curve can be obtained in advance through the calibration test of the magnetic powder brake. After the above adjustments, the tension of each conductor tends to be balanced, resulting in a multi-strand wound conductor with improved tension consistency.

[0063] Step S4 determines the number of turns to be decelerated in advance based on the number of turns already wound in the current layer, the number of turns designed for each layer, the moment of inertia corresponding to the current effective winding radius, and the allowable tension deviation. It then generates a main shaft deceleration command and a wire reversal command, controls the main winding shaft to decelerate according to the main shaft deceleration command, and synchronously controls the wire laying device to run in the reverse direction according to the wire reversal command, thus completing the layer change and reversal transition.

[0064] When the transformer winding reaches the end of each layer, a layer transition is required. A wire arrangement device changes the arrangement direction of the conductors and insulation paper along the axial direction of the main winding shaft. Simultaneously, the main winding shaft typically needs to reduce its rotational speed to avoid dynamic impacts on conductor tension caused by sudden speed changes during layer transition. It should be noted that in this embodiment, the main winding shaft only decelerates during the layer transition; its rotation direction is not reversed. The actual reversal along the axial direction is achieved by the wire arrangement device. The control commands for both are generated independently and executed synchronously at the same trigger moment.

[0065] In step S41, as the number of winding layers increases, the equivalent moment of inertia referred to the main winding axis will increase due to the continuous accumulation of winding material. If the deceleration time is still calculated based on a fixed initial moment of inertia, the deviation between the calculation result and the actual situation will increase as the winding process progresses. Therefore, this step updates the equivalent moment of inertia according to the following formula.

[0066] ; In the formula, The pre-calibrated moment of inertia (kg·m) of the skeleton and main winding shaft foundation. 2 The moment of inertia can be obtained through a test under no-load conditions. The equivalent inertia coefficient of the pre-calibrated wound material (kg / m) 2 The calibration is based on the linear density of the conductor and insulating paper and the axial length of the winding. The current effective winding radius (m) is calculated according to step S15; The initial radius of the skeleton is preset (m); The equivalent moment of inertia (kg·m) referred to the principal winding axis 2 The engineering basis of the above formula is that the winding material approximately forms an inner diameter of... Outer diameter is For annular rolls, assuming approximately constant axial length and material linear density, the mass of the annular roll is directly proportional to the increase in its cross-sectional area, i.e., it is proportional to... The increase in moment of inertia caused by the increase in mass distribution radius can be approximated as being proportional to the mass increase when the layer thickness is relatively small compared to the radius. Therefore, the increase in moment of inertia is related to... They are approximately proportional, and the proportionality constant is... This coefficient can be obtained by fitting and calibrating measured data of rotational inertia at several typical winding stages. For applications requiring high accuracy, a more precise result can be obtained by accumulating the rotational inertia components of each layer of winding material. This implementation method adopts the above formula as a preferred method that balances solution efficiency and accuracy.

[0067] In step S42, the main winding shaft needs to decelerate from its steady-state angular velocity to the commutation transition angular velocity within a finite time during the layer transition. This deceleration process essentially applies an additional deceleration torque to the main winding shaft, which is transmitted through the stranded wire as an additional dynamic tension disturbance. According to the rotational form of Newton's second law, torque equals the product of moment of inertia and angular acceleration. Assuming the deceleration process is a uniform deceleration process with constant angular acceleration, where angular acceleration equals the change in angular velocity divided by the deceleration duration, the additional deceleration torque is the product of moment of inertia and change in angular velocity divided by the deceleration duration. Since there is a relationship between torque and tension where torque equals the product of tension and radius of action, dividing the additional deceleration torque by the current effective winding radius yields the dynamic tension disturbance corresponding to this deceleration process. Setting this dynamic tension disturbance equal to the preset allowable dynamic tension deviation, the minimum deceleration duration that satisfies the allowable tension deviation requirement can be obtained, leading to the following formula.

[0068] ; In the formula, The equivalent moment of inertia (kg·m) obtained in step S41 is updated accordingly. 2 ); The steady-state angular velocity (rad / s) before deceleration; The angular velocity during the reversal (rad / s); The current effective winding radius (m); The preset allowable dynamic tension deviation (N) is set in advance according to the winding tension process tolerance requirements; The time (s) required to complete the deceleration.

[0069] In step S43, in order to allow time for completing the above deceleration process before the number of turns for layer switching is reached, the duration needs to be... This is converted to the corresponding number of advance deceleration turns. Assume the angular velocity during deceleration is... Uniform change to According to the laws of uniformly accelerated motion, the average angular velocity during this process is equal to half the sum of the initial and final angular velocities. The angle swept by the deceleration process is equal to the product of the average angular velocity and the deceleration time. Dividing this angle by... That is, we can obtain the corresponding number of laps, from which we get the following formula.

[0070] ; In the formula, The steady-state angular velocity (rad / s) before deceleration; The angular velocity during the reversal (rad / s); The time (s) required to complete the deceleration, calculated according to step S42; To reduce the number of turns (turns) in advance. Due to It is usually not an integer, but the actual triggering time can only be judged in whole turns. This step will... Round the calculation result up to obtain the integer number of turns for early deceleration. Rounding up ensures that the actual lead time is not less than the minimum value required by theoretical calculation, avoiding insufficient deceleration time due to improper rounding direction.

[0071] In step S44, when the number of turns designed for each layer is small or the deceleration time is long, there may be extreme cases where the number of turns decelerated in advance reaches or even exceeds the number of turns designed for each layer. If the trigger time is determined in the conventional way, sufficient deceleration margin will not be reserved in this layer. Therefore, this step sets up corresponding boundary treatment. When the number of turns decelerated in advance is not less than the preset number of turns designed for each layer, the main winding shaft and the winding device are controlled to complete the winding of the current layer in the preset low-speed winding mode. That is, the layer runs at a low steady-state angular velocity throughout the entire process, which fundamentally reduces the dynamic tension disturbance corresponding to the deceleration process and avoids the situation where the predetermined deceleration process cannot be completed in the layer.

[0072] In step S45, when the number of turns wound in the current layer reaches the difference between the designed number of turns per layer and the integer number of turns for advance deceleration, a spindle deceleration command and a wiring reversal command are generated. These two commands are independent of each other and correspond to different execution objects.

[0073] In step S46, the main winding shaft is controlled to decelerate from its steady-state angular velocity to the commutation transition angular velocity according to the main shaft deceleration command, based on the time calculated in step S42. During this process, the main winding shaft does not perform reverse rotation, and its rotation direction remains unchanged. Simultaneously, the wiring device is controlled to reverse its direction relative to the original axial arrangement direction according to the wiring reverse command. This reverse operation is executed synchronously with the main shaft deceleration command at the same trigger moment. Together, they complete the layer-changing and commutation transition. That is, the main winding shaft is responsible for the smooth transition of rotation speed, and the wiring device is responsible for switching the laying direction of the conductor and the insulating paper. The execution subjects and physical meanings of the two actions are independent of each other, but they are synchronized in timing.

[0074] In step S47, the deceleration time in step S42 is calculated based on the theoretical moment of inertia and theoretical angular acceleration model. However, during actual deceleration, factors such as the servo system's response characteristics, mechanical friction, and lag in tension detection and execution may cause differences between the actual dynamic tension deviation and the theoretically calculated value. This step corrects the deceleration of the main winding shaft based on real-time feedback of the stranded conductor tension during deceleration. Specifically, the stranded conductor tension is continuously monitored during deceleration. When the measured tension deviates from the set tension by a greater margin than expected, the instantaneous deceleration of the main winding shaft is adjusted accordingly. After the deceleration transition is complete, the main winding shaft is controlled to return to its steady-state angular velocity. Through this combination of theoretical calculation and real-time feedback, the theoretical dynamic tension deviation calculated according to the main shaft deceleration command is ensured to not exceed the allowable dynamic tension deviation.

[0075] Step S5, based on the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft latched in the same control cycle, limits the insulating paper feeding speed command, the target output resistance torque command, the main shaft deceleration command, and the wiring reverse command, and then synchronously sends them to the corresponding execution units according to a unified timestamp.

[0076] Although steps S2, S3, and S4 respectively compensate for three different aspects—insulating paper feeding speed, inter-strand tension balancing, and layer-changing deceleration—they all use state variables such as the current effective winding radius and the number of turns wound in the current layer as a common calculation basis. If the three calculation steps sample the above state variables independently, the inconsistent sampling times may cause deviations in the state references on which the three types of commands are based, resulting in command inconsistencies during phases where state variables change rapidly, such as layer changes. Step S5 is designed to solve this problem.

[0077] In step S51, the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft are latched in the same control cycle. That is, at the beginning of each control cycle, the above three state variables are read and fixed at the same time, so that they can be used together for the calculation of the insulation paper feeding speed, the calculation of the tension difference between strands, and the calculation of the forward planning of the changeover in that cycle, so as to avoid the use of inconsistent state variables in the three calculation links in the same cycle.

[0078] In step S52, the paper feeding speed command, target output resistance torque command, spindle deceleration command, and cable reversal command are limited respectively to ensure that each command is within the allowable range of the corresponding execution component. This limiting process is performed separately for each execution object, and the commands between different execution objects do not have numerical superposition or conversion.

[0079] In step S53, within the deceleration window corresponding to the integer number of turns of advance deceleration, the value of the directional coefficient in the insulating paper feed speed command is reduced, and the sudden change in the differential correction torque in the target output resistance torque command is mitigated. This is because the main winding shaft speed changes during the layer-changing deceleration stage, and the conductor tension itself is in a fluctuating state. If the same feed speed compensation gain and differential torque response speed as the steady-state winding stage are maintained during this stage, the tension fluctuation during the deceleration stage is easily amplified excessively and transmitted to the insulating paper feed speed and inter-strand torque adjustment links. By appropriately reducing the relevant compensation gain and limiting the rate of change of the differential correction torque within this window, the amplification of fluctuations by multiple compensation links can be avoided.

[0080] In step S54, the insulating paper feeding speed command, target output resistance torque command, spindle deceleration command, and wire reversal command, which were limited by step S52 and adjusted by step S53, are synchronously sent to the corresponding execution components according to a unified timestamp. That is, the servo driver of the insulating paper drive roller, the actuators of each wire feeding sub-device, the spindle servo motor, and the wire feeding servo motor receive and execute their respective commands at the same time, so that the coordinated compensation of tension and speed remains consistent in the time dimension.

[0081] Example 1: This example uses the winding of the low-voltage winding of a 10kV oil-immersed distribution transformer as an example. The winding is constructed from... It is made of four strands of copper wire wound together, with insulating paper laid on top. Each strand of wire is a round electrical copper wire with a diameter of... It is 2.0mm, cross-sectional area Approximately 3.14mm 2 elastic modulus The tensile strength and elongation of the conductor are determined based on the relevant standards for electrical round copper wire, and the test method is based on the requirements for tensile strength and elongation of winding wire. The tensile properties of the insulating paper are determined based on the tensile strength of paper and paperboard. Its tensile modulus is much higher than that of the conductor, and the elongation of the insulating paper under laying tension is negligible.

[0082] This embodiment controls the rotation of the main winding shaft according to the method described in this invention, executing step S1. Step S11 detects the tension of the stranded conductor; step S12 detects the tension of each strand of conductor; step S13 detects the rotation angle and angular velocity of the main winding shaft; step S14 determines the current layer number and the number of turns wound in the current layer; step S15 calculates the current effective winding radius, and the tension of the stranded conductor is set to 30N. Based on this, step S2 is executed. Step S21 calculates the surface linear velocity of the main winding shaft according to the current effective winding radius and the angular velocity of the main winding shaft; step S22 calculates... Calculate the equivalent axial strain of the stranded conductor, step S23 as follows A paper feeding speed command for insulating paper is generated. Step S24 limits the width of the command and then sends it out. Step S25 performs closed-loop correction based on the actual paper feeding speed feedback of the insulating paper drive roller to ensure that the insulating paper and the conductor are laid synchronously.

[0083] Example 2: This example, based on the winding device described in Example 1, expands the number of parallel strands to... This method, used to cover larger winding scales, highlights the multi-strand tension balancing scheme described in step S3. The initial tension of each strand of conductor varies due to differences in the mechanical characteristics of the pay-off device; the average tension is set to 25N. This embodiment executes step S3. Step S31 estimates the instantaneous radius of each pay-off reel based on the initial radius of the pay-off reel and the conductor diameter. Step S32 calculates the arithmetic mean of the tension of the eight conductors. Step S33 calculates the tension deviation of each conductor. Step S34... Calculate the differential correction torque for each strand. In step S35, no correction is made for tension deviations less than the dead zone threshold. In step S36, proceed as follows... Determine the target output resistance torque, and in step S37 convert the target resistance torque into excitation current and control the output of the magnetic powder brake to make the tension of the 8 wires tend to be balanced.

[0084] Example 3: This example covers multi-layer winding, with the number of turns designed for each layer of the winding. It has 40 turns, with a total of 15 layers, and the initial radius of the skeleton is... The equivalent thickness of a single layer is 0.10m. It is 2.5mm. This embodiment executes step S4, step S41 according to... Update the equivalent moment of inertia referred to the principal winding axis, and the fundamental moment of inertia. Take 0.03 kg·m 2 Equivalent inertia coefficient Take 6kg / m 2 Step S42 calculates the time required for deceleration and the steady-state angular velocity according to the corresponding formula. Take 6 rad / s as the commutation transition angular velocity. Take 2 rad / s as the allowable dynamic tension deviation Take 5N, in step S43 calculate the number of turns for advance deceleration and round up, in step S44 set a low-speed winding mode for cases where the integer number of turns for advance deceleration is not less than the design number of turns per layer, in steps S45 to S47 generate spindle deceleration command and wiring reverse command respectively, control the two to be executed synchronously, and correct the deceleration according to tension feedback during the deceleration process, so that the dynamic tension deviation of each layer commutation transition is maintained within the allowable range.

[0085] Example 4 combines the scenarios of Examples 2 and 3, taking and winding the number of strands. The strand, with 15 winding layers, is used to verify the effectiveness of the collaborative arbitration mechanism described in step S5. In this embodiment, step S5 is executed. Step S51 latches the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft within the same control cycle. Step S52 limits the insulating paper feed speed command, the target output resistance torque command, the main shaft deceleration command, and the wire reversal command, respectively. Step S53 reduces the value of the direction coefficient in the insulating paper feed speed command within the deceleration window corresponding to the integer number of turns of advance deceleration and mitigates the sudden change in differential correction torque. Step S54 synchronously issues the above commands according to a unified timestamp.

[0086] Comparative Example 1 uses the same winding equipment, wire, and insulating paper parameters as Example 1, except that strain compensation is not performed in step S2, and the insulating paper feeding speed command is always executed according to... Setting, i.e., in the formula This correction term is always zero, and the remaining steps are the same as in Example 1.

[0087] Comparative Example 2 uses the same winding equipment and winding scale as Example 2, but the differential tension balancing described in steps S33 to S37 is not performed. The actuators of each pay-off sub-device operate at a fixed base resistance torque. The output does not include the differential correction torque; the remaining steps are the same as in Example 2.

[0088] Comparative Example 3 uses the same winding layering parameters and rotational inertia update relationship as Example 3. The difference is that the layer-by-layer deceleration time calculation described in steps S42 and S43 is not performed. Instead, a fixed deceleration time of 0.3s is used. This time is set according to the empirical value under the first layer winding conditions. The commutation transition of each subsequent layer follows this fixed time. The remaining steps are the same as in Example 3.

[0089] Comparative Example 4 uses the same winding scale and layering parameters as Example 4. The difference is that the process of reducing the value of the directional coefficient and slowing down the differential correction torque mutation in the layer-changing window described in step S53 is not performed. The insulation paper feeding speed compensation and differential tension correction maintain the same response speed as the steady-state winding stage in the layer-changing deceleration window. The remaining steps are the same as in Example 4.

[0090] Experimental Example 1: Using the methods of Example 1 and Comparative Example 1, a winding of 200m of stranded conductor was wound. During the winding process, the alignment deviation between the edge of the insulating paper and the edge of the conductor was measured every 20m. The cumulative change of this deviation with the winding length was recorded. The experimental results are as follows: Figure 1 As shown. Figure 1 The vertical axis represents the cumulative deviation of the wire-insulating paper laying length in mm, and the horizontal axis represents the winding length in m. The curves of Comparative Example 1 and Example 1 are marked with legends in the figure.

[0091] from Figure 1 It can be seen that the cumulative deviation of Comparative Example 1 increases linearly with the winding length, reaching approximately 4.3 mm at 200 m. In contrast, the cumulative deviation of Example 1 remains at a very low level throughout the entire winding length, reaching approximately 0.15 mm at 200 m, which is about 96.5% lower than that of Comparative Example 1. This indicates that the method described in this invention can keep the actual laying length of the insulating paper and the conductor basically consistent during the winding process in which the tension of the stranded conductor is continuous, thus avoiding the continuous accumulation of deviation with the winding length.

[0092] Under tension, the conductor will undergo axial elastic elongation, while the tensile modulus of the insulating paper is much higher than that of the conductor, and the corresponding elongation can be ignored. If the paper feeding speed of the insulating paper is set only according to the surface speed of the main winding shaft without considering the elastic elongation of the conductor, the actual laying length of the insulating paper and the conductor will continue to widen with the winding length. This invention calculates the equivalent axial strain based on the real-time tension of the stranded conductor, and accordingly adds a correction amount related to the strain to the surface speed of the main winding shaft to generate the paper feeding speed command of the insulating paper, so that the paper feeding length of the insulating paper corresponds to the actual path length of the conductor under tension, thereby suppressing the accumulation of deviation.

[0093] Experimental Example 2 follows the methods of Example 2 and Comparative Example 2. Under the same initial tension conditions of 8 strands of wire, the initial tension of each strand is distributed around a mean of 25N with a standard deviation of approximately 3.7N. The change of the standard deviation of the tension of each strand over time from 0 to 3 seconds is recorded. The experimental results are as follows: Figure 2 As shown. Figure 2In Example 2, (a) shows the change of tension of each conductor over time, and in Comparative Example 2, (b) shows the change of tension of each conductor over time. The vertical axis represents the tension of each conductor in N, and the horizontal axis represents time in s. In both figures, different colored curves represent the tension of the eight conductors from strand 1 to strand 8, and the strand number corresponding to each curve is marked with a legend.

[0094] from Figure 2 It can be seen that the tension of each strand of conductor in Example 2 gradually converges within 3 seconds, and the standard deviation decreases from about 3.7N to about 0.1N. In contrast, the tension of each strand of conductor in Comparative Example 2 basically remains at the initial distribution level throughout the observation time, without any convergence trend. This indicates that the method described in this invention can make the tension of multi-stranded conductors tend to be consistent, and the tension deviation between strands will continue to be retained without differential correction.

[0095] The resistance torque of each wire feeding device is positively correlated with the tension of that strand. When the tension of a strand is higher than the average, the resistance torque of that strand decreases; when it is lower than the average, the resistance torque of that strand increases. This creates negative feedback regulation, gradually bringing the tension of each strand closer to the average. In contrast, the resistance torque of each wire feeding device in Comparative Example 2 remains constant, and the tension deviation of each strand lacks a spontaneous decay mechanism. Improving the consistency of tension among each strand is related to the dynamic stability of the winding under short-circuit electrodynamic forces. Relevant standards impose corresponding requirements on the short-circuit withstand capability for the winding's dynamic stability under short-circuit conditions. Excessive tension deviation between strands will cause uneven winding preload, which is detrimental to meeting this requirement.

[0096] Experimental Example 3: Using the methods of Example 3 and Comparative Example 3, a 15-layer winding was wound, and the equivalent moment of inertia and peak dynamic tension deviation at the commutation transition time of each layer were recorded. The experimental results are as follows: Figure 3 As shown. Figure 3 (a) in the figure represents the change of equivalent moment of inertia with the layer number. This curve represents the physical inertia experienced by Example 3 and Comparative Example 3 when winding the same winding. It is independent of the specific control algorithm used. Example 3 actively reads and updates this inertia according to step S41 of the present invention to calculate the deceleration time. Comparative Example 3 does not read this inertia and still executes according to the fixed deceleration time, but the actual physical inertia of the winding still increases according to this curve. The vertical axis represents the equivalent moment of inertia, and the unit is kg·m. 2 The horizontal axis represents the floor number; Figure 3 Figure (b) shows the variation of the reversing peak dynamic tension deviation with the layer number for Example 3 and Comparative Example 3. The vertical axis represents the reversing peak dynamic tension deviation in N, and the horizontal axis represents the layer number. The allowable tension deviation is also plotted in the figure. The corresponding horizontal lines are marked with legends for the curves of Comparative Example 3, Example 3, and the allowable tension deviation horizontal line, respectively.

[0097] from Figure 3As can be seen from (a) in the figure, the equivalent moment of inertia experienced by Example 3 and Comparative Example 3 when the same winding is wound increases with the increase of the layer number, and is about 0.030 kg·m for the first layer. 2 The 15th layer weighs approximately 0.079 kg·m. 2 This increase in inertia is a physical property of the winding itself and is not changed by the type of deceleration control method used. Figure 3 As shown in (b), the peak dynamic tension deviation of Comparative Example 3 increases with the layer number, reaching approximately 4.0 N for the first layer and approximately 7.8 N for the 15th layer, exceeding the allowable tension deviation of 5 N by approximately 57%. In contrast, the peak dynamic tension deviation of each layer in Example 3 remains within the allowable tension deviation of 5 N, indicating that the controller of Comparative Example 3 did not read the data. Figure 3 The inertia growth process shown in (a) is still executed according to a fixed deceleration time, which causes the dynamic tension deviation of the reversal peak to gradually exceed the allowable range as the number of winding layers increases. However, the controller of Example 3 actively reads the inertia and recalculates the deceleration time layer by layer accordingly, so that the dynamic tension deviation does not continue to increase as the number of winding layers increases.

[0098] During the deceleration process of layer switching, the additional dynamic tension disturbance experienced by the main winding shaft is directly proportional to the equivalent moment of inertia referred to the main winding shaft and inversely proportional to the deceleration time. The equivalent moment of inertia of the winding will continue to increase with the increase of the number of winding layers and the increase of the winding radius. If the deceleration time remains unchanged, the dynamic tension disturbance will increase with the increase of the number of layers. This invention updates the equivalent moment of inertia layer by layer according to the current effective winding radius and recalculates the deceleration time accordingly, so that the dynamic tension disturbance is always kept within the allowable range.

[0099] Experimental Example 4: Experimental Example 4 uses the methods of Example 4 and Comparative Example 4 to record the time history of the tension in the stranded conductor near the trigger moment of the commutation deceleration at the 8th layer. The experimental results are as follows: Figure 4 As shown. Figure 4 The vertical axis represents the tension of the stranded conductor in N, and the horizontal axis represents the time of the relative reversal trigger moment in s. The figure also shows the horizontal line corresponding to the set tension, and the curve of Example 4, the curve of Comparative Example 4, and the set tension horizontal line are marked with legends.

[0100] from Figure 4 It can be seen that in Example 4, the tension peak overshoot after the layer change trigger is about 2.8N, and it falls back and remains within 1N of the set tension after about 0.3s. In contrast, the tension peak overshoot in Comparative Example 4 is about 9.0N, and it takes about 2.2s to fall back and remain within 1N of the set tension. During the fallback process, about 1 to 2 observable oscillations occur. This shows that the method described in this invention can suppress the fluctuation amplitude of the stranded conductor tension and accelerate its recovery speed during the layer change deceleration disturbance. Without window processing, the tension fluctuation amplitude is larger, the recovery is slower, and oscillations are accompanied.

[0101] During the deceleration phase of layer change, the rotational speed of the main winding shaft changes, and the tension of the conductor itself is in a fluctuating state. If the paper feed speed compensation and differential torque correction maintain the same response speed as the steady-state winding phase during this phase, the two compensation links will further amplify the tension fluctuations in this phase and couple with each other, forming reciprocating oscillations. This invention reduces the response amplitude of the paper feed speed compensation within the layer change window and slows down the sudden change in the differential correction torque, avoiding the above-mentioned coupling amplification, so that the tension fluctuations can recover to near the set level more quickly.

[0102] Although embodiments of this application have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting this application. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of this application.

Claims

1. A transformer winding method based on tension and speed co-compensation, characterized in that, Includes the following steps: S1: Control the rotation of the main winding shaft, wind the multiple strands of wires with a set tension onto the skeleton, and simultaneously collect the tension of the stranded wires, the tension of each individual wire, the rotation angle of the main winding shaft and the angular velocity of the main winding shaft. Determine the current layer number, the number of turns wound in the current layer and calculate the current effective winding radius based on the rotation angle. S2: Based on the equivalent axial strain corresponding to the tension of the stranded conductor, the current effective winding radius and the angular velocity of the main winding shaft, a paper feeding speed command for insulating paper is generated in coordination, and the insulating paper drive roller is controlled to lay the insulating paper synchronously with the conductor according to the paper feeding speed command. S3: Calculate the tension deviation between strands based on the tension of each strand of conductor, generate the target output resistance torque command for each strand pay-off device, control each strand pay-off device to output according to the target output resistance torque command, and balance the tension of each strand of conductor. S4: Based on the number of turns wound in the current layer, the number of turns designed for each layer, the moment of inertia corresponding to the current effective winding radius, and the allowable tension deviation, determine the number of turns to decelerate in advance, generate the main shaft deceleration command and the wire reversal command, control the main winding shaft to decelerate according to the main shaft deceleration command, and synchronously control the wire laying device to run in the reverse direction according to the wire reversal command to complete the layer change and reversal transition; S5: Based on the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding shaft, which are latched in the same control cycle, the insulating paper feeding speed command, the target output resistance torque command, the main shaft deceleration command, and the wiring reverse command are respectively limited and synchronously sent to the corresponding execution unit according to a unified timestamp.

2. The method according to claim 1, characterized in that, Step S1 includes: S11: A conductor tension detection unit is set on the conductor path before the multi-strand conductor is wound together to the main winding axis. The conductor tension after the strand is combined is detected in real time. After removing tension mutation values ​​that exceed a preset multiple of the average of adjacent samples, a moving average filter is performed to obtain the tension of the combined conductor. S12: A tension detection unit is set at the outlet of the wire feeding device of each wire to detect the tension of each wire in real time. After removing tension mutation values ​​that exceed a preset multiple of the average value of adjacent samples, a moving average filter is performed to obtain the tension of each wire. S13: An encoder is installed on the main winding shaft to detect the rotation angle of the main winding shaft in real time. The angular velocity of the main winding shaft is obtained based on the change of the rotation angle per unit time or through the rotational speed feedback of the servo driver of the main winding shaft. S14: Based on the cumulative count of the number of turns wound on the main winding shaft according to the aforementioned turning angle, determine the current layer number and the number of turns wound on the current layer using the following formula: ； ； In the formula, The cumulative number of turns wound on the main winding shaft; The preset number of turns per layer; This indicates the floor function; The current layer number; The current layer has been wound with a certain number of turns; S15: Calculate the current effective winding radius using the following formula: ； In the formula, The initial radius of the preset skeleton; The current layer number determined in step S14; The single-layer equivalent thickness is a preset value, which is pre-calibrated based on the radial equivalent thickness of the conductor, the radial equivalent thickness of the insulating paper, and the compaction correction amount. The current effective winding radius is denoted as .

3. The method according to claim 2, characterized in that, Step S2 includes: S21: Based on the current effective winding radius and the angular velocity of the main winding shaft, calculate the surface linear velocity of the main winding shaft using the following formula: ； In the formula, The current effective winding radius is calculated according to step S15; The angular velocity of the main winding shaft; The linear velocity of the main winding shaft surface; S22: Calculate the equivalent axial strain of the stranded conductor used for paper feed compensation using the following formula: ； In the formula, The tension of the stranded conductor is obtained directly by the conductor tension detection unit or calculated from the sum of the tensions of each strand. This represents the equivalent axial stiffness of the stranded conductor. It is the sum of the products of the elastic modulus and the cross-sectional area of ​​each strand of conductor, assuming that the materials and specifications of each strand of conductor are consistent. , The elastic modulus of a single-strand conductor. This represents the cross-sectional area of ​​a single-strand conductor. The number of strands in the parallel-wound conductor; The equivalent axial strain of the stranded conductor; S23: Calculate the paper feeding speed command for the insulating paper according to the following formula: ； In the formula, The linear velocity of the main winding shaft surface calculated according to step S21; The pre-calibrated directional coefficient is a dimensionless number. Its positive or negative values ​​correspond to two calibration conditions, namely, the increase or decrease of the paper feeding speed of the insulating paper as the equivalent axial strain increases. The equivalent axial strain of the stranded conductor calculated according to step S22; This refers to the paper feed speed command for the insulating paper; S24: Limit the paper feeding speed command of the insulating paper to the preset allowable speed range of the insulating paper drive roller, and send it to the servo driver of the insulating paper drive roller set on the insulating paper supply path. The insulating paper supply path merges with the multi-strand wire laying path upstream of the wiring device. S25: The actual paper feeding speed of the insulating paper drive roller is obtained through the insulating paper feeding speed detection unit. The insulating paper feeding speed command is corrected in a closed loop according to the deviation between the actual paper feeding speed and the insulating paper feeding speed command. The insulating paper drive roller is controlled to feed paper at the corrected paper feeding speed so that the insulating paper and the conductor are laid synchronously on the main winding shaft, and a winding with the conductor and insulating paper laid synchronously is obtained.

4. The method according to claim 2, characterized in that, Step S3 includes: S31: According to the The initial radius of the wire feeding device's feed reel and the diameter of a single strand of wire, combined with the cumulative feeding length, are used to estimate the first strand's length using the following formula. Instantaneous radius of the wire feeding device's feed reel: ； In the formula, For the first The initial radius of the wire feeding device of the wire feeding device; For the first The diameter of the conductor strand; For the first The cumulative length of the wire strands is calculated by the sum of the angle of the wire feeding reel of the wire feeding device and the initial radius of the wire feeding reel; For the first Instantaneous radius of the wire feeding device's feed reel; S32: Calculation Arithmetic mean of the tension of a strand of wire The arithmetic mean is the first to the second... Sum of tensions in the conductor strands divided by ; S33: Calculate the tension deviation of each conductor using the following formula: ； In the formula, For the first The tension of the conductor strand, For stock serial number and ; The result calculated according to step S32 The arithmetic mean of the tension in a strand of conductor; For the first Tension deviation of the conductor strand; S34: Taking the direction that increases the wire-feeding resistance torque of the wire-feeding device as the positive direction, calculate the differential correction torque of the wire-feeding device for each strand of conductor according to the following formula: ； In the formula, The pre-calibrated proportional gain coefficient is a dimensionless number. The first one calculated according to step S33 Tension deviation of the conductor strand; The first one calculated according to step S31 Instantaneous radius of the wire feeding device's feed reel; For the first Differential correction torque of the wire feeding device.

5. The method according to claim 4, characterized in that, Step S3 further includes: S35: When the absolute value of the tension deviation is less than the preset dead zone threshold, the first... The differential correction torque of the wire feeding device is set to zero; S36: Calculate the following formula The target output resistance torque of the wire feeding device: ； In the formula, For the first The foundation resistance torque of the wire feeding device; The differential correction torque is calculated according to steps S34 and S35; Indicates when Less than Time to take ,when Greater than Time to take In other cases, take itself; The preset minimum holding torque, Greater than zero; This is the preset maximum allowable resistance torque; For the first The target output resistance torque of the wire feeding device; S37: Convert the target output resistance torque into the target excitation current according to the pre-calibrated torque-current curve and limit it within the allowable current range of the magnetic powder brake, controlling the first... The magnetic powder brake of the wire feeding device outputs excitation current according to the target excitation current, equalizes the tension of each wire, and obtains a multi-strand wire with improved tension consistency.

6. The method according to claim 2, characterized in that, Step S4 includes: S41: Update the equivalent moment of inertia referred to the main winding axis according to the following formula: ； In the formula, The pre-calibrated moment of inertia of the skeleton and main winding shaft foundation; The equivalent inertia coefficient of the pre-calibrated winding material is determined based on the linear density of the conductor and insulating paper and the axial length of the winding. The current effective winding radius is calculated according to step S15; The initial radius of the preset skeleton; The equivalent moment of inertia referred to the main winding axis; S42: Calculate the time required to complete deceleration using the following formula: ； In the formula, The equivalent moment of inertia obtained in step S41 is updated accordingly; The steady-state angular velocity before deceleration; This refers to the commutation transition angular velocity; The current effective winding radius; This is the preset allowable dynamic tension deviation; The time required to complete deceleration; S43: Calculate the number of pre-deceleration turns using the following formula, and round the result up to the integer number of pre-deceleration turns: ； In the formula, The steady-state angular velocity before deceleration; This refers to the commutation transition angular velocity; The time required to complete deceleration, calculated according to step S42; To reduce the number of turns in advance; Round up to get the integer number of turns for early deceleration. ; S44: When the number of pre-deceleration integer turns is not less than the preset number of turns per layer, control the main winding shaft and the wire laying device to complete the winding of the current layer in a preset low-speed winding mode.

7. The method according to claim 6, characterized in that, Step S4 further includes: S45: When the number of turns wound in the current layer reaches the difference between the designed number of turns per layer and the integer number of turns for advance deceleration, the spindle deceleration command and the cable reversal command are generated; S46: Control the main winding shaft to decelerate from the steady-state angular velocity to the reversing transition angular velocity according to the main shaft deceleration command and the duration calculated in step S42, without the main winding shaft performing reverse rotation; control the wire laying device to run in the opposite direction relative to the original axial arrangement direction according to the wire laying reverse command, and execute synchronously with the main shaft deceleration command at the same trigger time to complete the layer changing and reversing transition; S47: During deceleration, the deceleration of the main winding shaft is corrected based on the real-time feedback of the tension of the stranded conductor. After the transition, the main winding shaft is controlled to recover to the steady-state angular velocity, so that the theoretical dynamic tension deviation calculated according to the main shaft deceleration command does not exceed the allowable dynamic tension deviation.

8. The method according to claim 1, characterized in that, Step S5 includes: S51: In the same control cycle, latch the current effective winding radius, the number of turns wound in the current layer, and the angular velocity of the main winding axis; S52: Limit the speed command for the insulating paper feed, the target output resistance torque command, the spindle deceleration command, and the cable reversal command respectively; S53: Within the deceleration window corresponding to the integer number of deceleration turns in advance, reduce the value of the directional coefficient in the paper feeding speed command of the insulating paper, and mitigate the sudden change in the differential correction torque in the target output resistance torque command. S54: The paper feeding speed command of the insulating paper, the target output resistance torque command, the spindle deceleration command and the cable reversal command, after being limited by step S52 and adjusted by step S53, are synchronously sent to the corresponding execution components according to a unified timestamp.

9. A transformer winding system based on tension and speed coordinated compensation for implementing the method according to any one of claims 1-8, characterized in that, include: The system comprises a main winding shaft, a main shaft servo motor, a multi-strand pay-off array, a conductor tension detection unit, an insulating paper feeding unit, an insulating paper feeding speed detection unit, a wire laying device, a wire laying servo motor, an encoder, and a main controller. The main winding shaft, driven by the main shaft servo motor, clamps the bobbin and drives the conductor winding. The control input of the main shaft servo motor is connected to the corresponding output of the main controller. The multi-strand pay-off array includes... A wire feeding device, For integers greater than or equal to 2, each of the wire feeding sub-devices feeds a strand of wire to the main winding shaft. Each wire feeding sub-device includes a wire feeding reel and an actuator coaxially connected to the wire feeding reel. A strand tension detection unit is provided at the wire outlet. The wire tension detection unit is provided on the path where the multiple strands of wire are wound onto the main winding shaft after converging. The insulating paper feeding unit includes an insulating paper drive roller and a matching servo driver, and is located on the insulating paper supply path. The insulating paper supply path converges with the multiple strands of wire laying path upstream of the wire laying device. The insulating paper feeding speed detection unit is located on the insulating paper drive roller. The wire laying device is located on the laying path where the multiple strands of wire and insulating paper converge, and is driven by the wire laying servo motor. The encoder is mounted on the main winding shaft. The main controller is connected to the strand tension detection unit, the conductor tension detection unit, the servo driver of the insulating paper drive roller, the insulating paper feed speed detection unit, the actuators of each of the wire feeding sub-devices, the wire laying servo motor, the main shaft servo motor, and the encoder. It includes a strain calculation and paper feed speed collaborative compensation module, a multi-strand tension differential equalization calculation module, and a forward-looking planning module, which are used to generate insulating paper feed speed commands and control the servo driver of the insulating paper drive roller, generate target output resistance torque commands and control the actuators of each of the wire feeding sub-devices, and generate main shaft deceleration commands and wire laying reverse commands and control the main shaft servo motor and the wire laying servo motor, respectively.

10. The system according to claim 9, characterized in that, The strain calculation and paper feed speed collaborative compensation module is used to generate the insulating paper feed speed command based on the stranded wire tension detected by the wire tension detection unit, combined with the current effective winding radius and main winding shaft angular velocity calculated by the rotation angle detected by the encoder. The multi-strand tension differential equalization calculation module is used to generate a target output resistance torque command for each wire feeding sub-device based on the tension of each strand of wire detected by each strand tension detection unit, and output the command to the actuator of the corresponding wire feeding sub-device after torque-current conversion. The forward-looking planning module is used to generate the spindle deceleration command and the cable reversal command based on the number of turns wound on the current layer and the current effective winding radius determined by the rotation angle detected by the encoder. The main controller coordinates the commands calculated by the strain calculation and paper feed speed collaborative compensation module, the multi-strand tension differential equalization calculation module and the forward-looking planning module according to a unified control cycle and timestamp before issuing them.

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