A transformer stay device

Abstract

This invention relates to the field of transformer manufacturing technology and provides a transformer wire pulling device. A pneumatic pull rod is provided on one side of a fixed base, and a guide seat is fixedly provided between the fixed base and the pneumatic pull rod. A pneumatic telescopic rod is fixedly provided above the guide seat via a fixed frame. The telescopic end of the pneumatic telescopic rod is rotatably connected to a pressure guide wheel. The device also includes a control system comprising: a parameter acquisition module for real-time acquisition of the operating status parameters of the winding conductor during the wire pulling process and the mechanical execution parameters of the transformer wire pulling equipment; and an index evaluation module for fusing and extracting the operating status parameters and fitting them to generate a conductor status evaluation index. In this invention, the pressure force control module, based on the adjusted tension force and operating status parameters, simultaneously considers the static longitudinal component and the dynamic centrifugal force effect through a physical space decoupling formula, achieving coordinated dynamic adjustment of the pressure force and tension force under the pressure guide wheel.

Description

Technical Field

[0001] This invention belongs to the field of transformer manufacturing technology, and in particular relates to a transformer pull wire device. Background Technology

[0002] In the transformer winding manufacturing process, the conductor pulling device plays a core role in winding the electromagnetic wire evenly onto the iron core or mold with stable tension. The precise coordination of its tension and compression forces directly determines the tightness of the winding structure, the integrity of the inter-turn insulation, and the electrical performance stability of the final product.

[0003] Traditional wire pulling devices typically use mechanical springs or fixed pneumatic sources as the tensioning force, and rely on manual intervention to adjust the downward pressure of the clamping rollers to maintain the wire's position within the guide groove. This open-loop control architecture has inherent limitations and struggles to cope with dynamic changes in actual production.

[0004] Specifically, existing devices lack the ability to monitor the conductor's operating status in real time. When the pneumatic pull rod's operating speed fluctuates, the conductor's lateral vibration amplitude increases abnormally, or an angular deviation occurs at the clamping guide wheel, the system still mechanically executes preset parameters. This can easily cause sudden changes in tension, resulting not only in scratches on the conductor surface and damage to the insulation layer, but also, in severe cases, loosening of the winding structure or even the risk of inter-turn short circuits. Furthermore, conductors from different production batches exhibit significant differences in inherent properties such as material yield strength and surface friction characteristics. Fixed control parameters cannot adaptively match material fluctuations, further exacerbating process instability.

[0005] Furthermore, the control of tension and clamping forces has long been disconnected. Most equipment only considers the downward pressure of the clamping guide wheel as an independent means of preventing deviation, neglecting the additional normal load generated by the combined action of the longitudinal component of the tension force and the inertia of the conductor. When the tension force is increased or the conductor speed is accelerated, if the clamping force is not increased synchronously, the conductor is prone to jumping or lateral slippage in the contact arc, compromising the winding accuracy.

[0006] To address the aforementioned issues, existing technologies urgently need improvement. Summary of the Invention

[0007] The purpose of this invention is to provide a transformer pull wire device to solve the above-mentioned problems.

[0008] This invention is implemented as follows: a transformer wire pulling device includes a fixed base, on which a positioning wheel for positioning the winding is rotatably mounted; a pneumatic pull rod for tightening the winding wire is fixedly mounted on one side of the fixed base; a guide seat is fixedly mounted between the fixed base and the pneumatic pull rod; a pneumatic telescopic rod is fixedly mounted above the guide seat via a fixed frame; the telescopic end of the pneumatic telescopic rod is rotatably connected to a pressure guide wheel; and a control system is also included, comprising:

[0009] The parameter acquisition module is used to collect the operating status parameters of the winding conductors and the mechanical execution parameters of the transformer pulling equipment in real time.

[0010] The index evaluation module is used to fuse and extract the operating status parameters and fit them to generate a conductor status evaluation index.

[0011] The tension control module is used to fit the conductor state evaluation index with the preset winding conductor inherent parameters to generate a tension demand index, and dynamically adjust the tension of the pneumatic tie rod accordingly.

[0012] The clamping force control module is used to perform decoupling analysis of lateral and longitudinal forces based on the adjusted tension force and the operating status parameters, and to dynamically adjust the downward clamping force of the clamping guide wheel.

[0013] A further technical solution involves specifying that the operating state parameters include the instantaneous velocity of the pneumatic connecting rod, the lateral vibration amplitude of the conductor, and the deflection angle of the conductor at the clamping guide wheel; before fitting the conductor state evaluation index, the index evaluation module standardizes each parameter:

[0014] The instantaneous velocity normalized value is equal to the measured velocity divided by the upper limit of the process velocity; the transverse vibration amplitude normalized value is equal to the measured amplitude divided by the maximum safe amplitude; and the deflection angle normalized value is equal to the measured deflection angle divided by the maximum mechanical limit deflection angle.

[0015] A further technical solution is that the fitting formula for the conductor condition evaluation index generated by the index evaluation module is as follows:

[0016] The conductor condition assessment index is equal to the velocity disturbance weighting coefficient multiplied by the square of the velocity normalization value, plus the vibration nonlinearity weighting coefficient multiplied by the natural logarithm of (1 plus the amplitude normalization value), plus the deflection angle weighting coefficient multiplied by the hyperbolic tangent function value of the deflection angle normalization value; where each weighting coefficient is positive and the sum is 1.

[0017] A further technical solution is that the inherent parameters of the winding conductor include the per-unit yield stress and the per-unit surface friction coefficient of the conductor, which are respectively defined as the actual yield stress divided by the reference yield stress and the actual friction coefficient divided by the reference friction coefficient.

[0018] The fitting formula for the tension demand index generated by the tension control module is as follows: the tension demand index is equal to the material stiffness compensation coefficient multiplied by the conductor condition evaluation index divided by the per-unit yield stress, plus the friction damping gain coefficient multiplied by the exponential function value with (per-unit friction coefficient multiplied by the normalized deflection angle) as the exponent; wherein the material stiffness compensation coefficient ranges from 0.8 to 1.5, and the friction damping gain coefficient ranges from 0.1 to 0.8.

[0019] A further technical solution is that the formula for the tension control module to adjust the tension of the pneumatic tie rod is as follows:

[0020] The target tension force is equal to the tension demand index multiplied by the initial reference tension force; the initial reference tension force is set according to the wire diameter, specifically equal to the wire diameter minus the tension coefficient multiplied by the square of the wire diameter. For copper wire, the wire diameter minus the tension coefficient is 12 to 25 N / mm².

[0021] A further technical solution is that the clamping force control module calculates and adjusts the downward clamping force of the clamping guide wheel using the following physical space decoupling formula:

[0022] The target pressing force is equal to the static mapping coefficient multiplied by the target tension force multiplied by the sine of the deflection angle, plus the dynamic damping coefficient multiplied by (the equivalent mass of the arc segment of the conductor in contact with the pressing guide wheel multiplied by the square of the instantaneous velocity divided by the actual radius of the guide wheel).

[0023] Among them, the static mapping coefficient ranges from 0.3 to 0.9, and the dynamic damping coefficient ranges from 0.05 to 0.4; the equivalent mass of the contact arc segment between the conductor and the clamping guide wheel is equal to the linear density of the conductor multiplied by the contact arc length.

[0024] A further technical solution, considering the inherent response delay of the clamping guide wheel actuator, includes an anti-overshoot correction unit in the clamping force control module; the anti-overshoot correction unit extracts the longitudinal vector component of the clamping force and introduces a differential feedforward term in conjunction with the response delay time to smoothly correct the target downward clamping force, generating the final execution clamping force:

[0025] The final clamping force is equal to the target downward clamping force minus (the inherent response delay of the actuator multiplied by the differential overshoot suppression coefficient, and then multiplied by the derivative of (the target clamping force multiplied by the sine of the deflection angle) with respect to time).

[0026] The inherent response delay time ranges from 0.01 to 0.02 seconds, and the differential overshoot suppression coefficient ranges from 0.05 to 0.3. In the discrete control system, the derivative is approximated by backward difference, that is, by dividing the difference between adjacent sampling periods by the sampling period. When the longitudinal jump force of the conductor increases sharply, the differential feedforward term provides negative compensation to reduce the instantaneous clamping deformation caused by command overshoot. When the longitudinal force of the conductor drops sharply, the differential feedforward term provides positive compensation to slow down the attenuation rate of the clamping force and maintain conductor adhesion.

[0027] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0028] The present invention provides a transformer pull wire device that acquires real-time operating status parameters such as the instantaneous speed of the pneumatic pull rod, the lateral vibration amplitude of the conductor, and the deflection angle through a parameter acquisition module, and combines them with an index evaluation module to generate a conductor status evaluation index. This achieves dynamic adaptive adjustment of the tension force, effectively avoiding sudden tension changes and conductor insulation layer damage caused by speed fluctuations, abnormal vibrations, or angle deviations under traditional fixed parameter control.

[0029] This invention provides a transformer pull wire device. The tension control module incorporates inherent parameters such as the per-unit yield stress and per-unit surface friction coefficient of the winding conductor, and performs nonlinear fitting with the conductor condition assessment index to generate a tension demand index. This mechanism enables the tension force to accurately match the material stiffness and frictional characteristics of different batches of conductors, significantly enhancing the equipment's adaptability to material fluctuations and improving the stability of the winding process.

[0030] The present invention provides a transformer wire pulling device. The clamping force control module, based on the adjusted clamping force and operating status parameters, simultaneously considers the static longitudinal component and the dynamic centrifugal force effect through a physical space decoupling formula. This achieves coordinated dynamic adjustment of the clamping force and the tensioning force under the clamping guide wheel, effectively preventing the conductor from jumping and lateral slipping during high-speed movement or deflection, and ensuring the winding accuracy.

[0031] The present invention provides a transformer pull wire device, which adds an overshoot correction unit. It uses a differential feedforward term to compensate for the inherent response delay of the actuator and corrects the clamping force command in real time according to the rate of change of the longitudinal jump force of the conductor. When the force increases sharply, negative compensation suppresses overshoot and pinching, and positive compensation slows down the attenuation when the force drops sharply, ensuring a smooth transition of clamping force. It is especially suitable for high-speed and high-dynamic pull wire scenarios and further reduces the risk of conductor deformation and damage. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the structure of the present invention;

[0033] Figure 2 Here is a logic block diagram for parameter acquisition and per-unit processing;

[0034] Figure 3 Generate a logic block diagram for the conductor condition assessment index;

[0035] Figure 4 This is a block diagram of the dynamic tension control logic.

[0036] Figure 5 The logic block diagram for decoupling the clamping force and preventing overshoot is shown.

[0037] In the attached diagram: 1. Fixed base; 2. Positioning wheel; 3. Pneumatic pull rod; 4. Guide seat; 5. Pneumatic telescopic rod; 6. Pressing guide wheel. Detailed Implementation

[0038] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0039] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0040] like Figures 1-5 As shown, a transformer wire pulling device according to an embodiment of the present invention includes a fixed base 1, a positioning wheel 2 for positioning the winding is rotatably mounted on the fixed base 1, a pneumatic pull rod 3 for tightening the winding wire is fixedly mounted on one side of the fixed base 1, a guide seat 4 is fixedly mounted between the fixed base 1 and the pneumatic pull rod 3, and a pneumatic telescopic rod 5 is fixedly mounted above the guide seat 4 by a fixing frame. The telescopic end of the pneumatic telescopic rod 5 is rotatably connected to a pressure guide wheel 6. The device also includes a control system, which comprises:

[0041] The parameter acquisition module is used to collect the operating status parameters of the winding conductors and the mechanical execution parameters of the transformer pulling equipment in real time.

[0042] The index evaluation module is used to fuse and extract the operating status parameters and fit them to generate a conductor status evaluation index.

[0043] The tension control module is used to fit the conductor state evaluation index with the preset winding conductor inherent parameters to generate a tension demand index, and dynamically adjust the tension of the pneumatic tie rod 3 accordingly.

[0044] The clamping force control module is used to perform decoupling analysis of lateral and longitudinal forces based on the adjusted tension force and the operating state parameters, and to dynamically adjust the downward clamping force of the clamping guide wheel 6.

[0045] In this embodiment, the fixed base 1 serves as the supporting foundation for the entire device, and a positioning wheel 2 for positioning the winding can be mounted on it. The positioning wheel 2 provides initial path guidance to the winding conductor by contacting it. A pneumatic pull rod 3 for tightening the winding conductor is fixedly mounted on one side of the fixed base 1. The pneumatic pull rod 3 can be a standard single-acting or double-acting cylinder, which provides tension force on the conductor by controlling the air source pressure. In some implementations, the tension force of the pneumatic pull rod 3 can be preset to a fixed value, or it can be coarsely adjusted by manually adjusting the air source pressure. This fixed or manually adjustable method is difficult to provide precise and adaptable tension force when faced with differences in conductor material or changes in operating conditions.

[0046] A guide seat 4 is fixedly installed between the fixed base 1 and the pneumatic pull rod 3 to further constrain the movement trajectory of the conductor and reduce its degrees of freedom during the pulling process. A pneumatic telescopic rod 5 is fixedly connected above the guide seat 4. This pneumatic telescopic rod 5 can be a small cylinder used to provide the vertical lifting and lowering movement of the clamping guide wheel 6. The telescopic end of the pneumatic telescopic rod 5 is rotatably connected to the clamping guide wheel 6. The clamping guide wheel 6 can be a roller with a rubber or polyurethane coating, which applies a vertical clamping force to the conductor through the downward pressure of the pneumatic telescopic rod 5. In some implementations, the downward clamping force of the clamping guide wheel 6 can be determined by the fixed air pressure of the pneumatic telescopic rod 5, or provided by a simple mechanical spring mechanism. This fixed clamping force method may not be able to adapt to changes in tension, conductor speed, or deflection angle, resulting in excessive clamping force causing conductor damage, or insufficient clamping force causing conductor jumping.

[0047] Furthermore, this device also includes a control system, which is crucial for achieving intelligent control. The control system includes a parameter acquisition module, which is used to acquire in real time the operating status parameters of the winding conductors during the pulling process, as well as the mechanical execution parameters of the transformer pulling equipment. The parameter acquisition module can employ a combination of various sensors; for example, it can acquire the instantaneous velocity using a displacement sensor or encoder mounted on the pneumatic pull rod 3, monitor the lateral vibration amplitude of the conductor using a laser displacement sensor or vision system, and measure the deflection angle of the conductor at the clamping guide wheel 6 using an angle sensor or image recognition technology. In some simpler implementations, parameter acquisition may be limited to acquiring only a few easily obtainable parameters, such as the average speed of the pull rod, while ignoring more subtle dynamic changes, which may lead to an incomplete assessment of the conductor's condition.

[0048] The control system also includes an index evaluation module, which integrates and extracts the operating status parameters acquired by the parameter acquisition module to generate a conductor status evaluation index. Furthermore, the control system includes a tension control module, which fits the conductor status evaluation index generated by the index evaluation module with preset inherent parameters of the winding conductor to generate a tension demand index, and dynamically adjusts the tension force of the pneumatic tie rod 3 accordingly. Finally, the control system also includes a clamping force control module, which performs decoupling analysis of lateral and longitudinal forces based on the adjusted tension force and operating status parameters, and dynamically adjusts the downward clamping force of the clamping guide wheel 6.

[0049] In a preferred embodiment of the present invention, the operating state parameters include the instantaneous speed of the pneumatic lever 3. Horizontal vibration amplitude of conductor and the deflection angle of the wire at the clamping guide wheel 6 ;

[0050] Before fitting the conductor state evaluation index, the index evaluation module normalizes each parameter using the following formula:

[0051] , , ;

[0052] in Normalized value of instantaneous velocity The normalized value of the transverse vibration amplitude. This is the normalized value of the deflection angle. This is the upper limit of the process speed. For the maximum permissible safe amplitude, This is the maximum allowable deflection angle for the mechanical limit switch.

[0053] In this embodiment, the operating state parameters are key indicators that describe the dynamic behavior of the winding conductor during the pulling process. They reflect the real-time state of the conductor in terms of motion, vibration and force deflection, and their accurate acquisition is the basis for achieving fine control.

[0054] Instantaneous speed of pneumatic lever 3 This refers to the speed of the pneumatic rod 3 that drives the conductor to stretch at a certain moment. This speed directly affects the motion state and inertial force of the conductor. The instantaneous speed can be obtained in real time by combining the linear displacement sensor or encoder installed on the pneumatic rod 3 with time information; or the instantaneous speed of the conductor can be directly measured by a non-contact laser velocimeter.

[0055] transverse vibration amplitude of conductor This refers to the amplitude of the conductor's vibration perpendicular to the direction of the pull during the pulling process. Excessive lateral vibration may cause conductor wear, insulation damage, or misalignment of the windings. This amplitude can be obtained by monitoring the conductor's lateral displacement in real time and calculating its vibration amplitude using a non-contact laser displacement sensor or a visual recognition system; or by integrating the displacement information using an accelerometer installed near the conductor, and then calculating the vibration amplitude.

[0056] The deflection angle of the line at the clamping guide wheel 6 This refers to the deflection angle of the conductor relative to the axis of the guide wheel 6 as it passes the clamping guide wheel. This angle reflects the force and fit of the conductor at the guide wheel. The deflection angle can be calculated in real time by measuring the incident and exit angles of the conductor using an optical angle sensor or image recognition system installed near the guide wheel; or by installing force sensors on both sides of the guide wheel and inferring the deflection angle based on the direction and magnitude of the force.

[0057] The index evaluation module is a core processing unit in the control system. It receives raw operating state parameters, preprocesses and fuses them to generate a unified evaluation index. This module can be implemented by an embedded controller running a pre-defined algorithm program; or it can be composed of an industrial PC or a dedicated data processing unit with stronger computing and data processing capabilities. Perimeter standardization is a data standardization method that aims to eliminate differences in dimensions and orders of magnitude between different physical quantities, mapping them uniformly to a dimensionless range of 0 to 1 (or -1 to 1).

[0058] , , These formulas define specific per-unit calculation methods, which will convert instantaneous velocity... Lateral vibration amplitude and deflection angle The ratios are calculated with their corresponding maximum allowed values ​​to obtain dimensionless normalized values. These calculations can be performed in the processor of the exponent evaluation module using floating-point or fixed-point arithmetic instructions. The upper limit of the process speed refers to the highest operating speed that the conductor can reach under a specific winding process. This value is usually preset according to the equipment design, conductor material characteristics and process requirements, and stored in the parameter database of the control system. The maximum permissible safe amplitude refers to the maximum amplitude of lateral vibration that a conductor is allowed to reach during the pulling process. This value is also set according to the conductor type, insulation material, and process standards, and is stored as a safety threshold. The maximum deflection angle allowed by the mechanical limit refers to the maximum deflection angle of the conductor that the clamping guide wheel 6 mechanism can withstand. This value is determined by the mechanical structure design and stored in the system as a physical constraint.

[0059] In a preferred embodiment of the present invention, the fitting formula for the conductor condition evaluation index generated by the index evaluation module is as follows:

[0060]

[0061] in, For velocity disturbance weighting coefficients, For vibration nonlinearity weighting coefficients, This is the deflection angle weighting coefficient. , It is a dimensionless conductor condition assessment index.

[0062] In this embodiment, the fitting formula is the core function of the index evaluation module, aiming to quantify multiple operating state parameters into a single, dimensionless conductor state evaluation index. This formula can be implemented by hard-coding a preset mathematical expression in the index evaluation module's software program, or dynamically generated through a regression model trained on historical data. The structure of the formula represents the nonlinear relationship learned by the model. (Velocity perturbation weight coefficient) Vibration nonlinearity weighting coefficient and deflection angle weighting coefficient These are adjustment factors used to adjust the contribution of various parameters to the conductor condition assessment index. These weighting coefficients can be calibrated and optimized offline using expert experience combined with a large amount of experimental data to ensure that they accurately reflect the actual impact of different disturbance sources; alternatively, they can be adjusted in real time using online adaptive algorithms based on feedback information during the actual wire pulling process to adapt to different conductor materials and process conditions.

[0063] The formula provides a normalized value for instantaneous velocity. Squaring the values ​​effectively amplifies the impact of velocity fluctuations on the evaluation index, ensuring higher sensitivity to dynamic disturbances in high-speed cable-stayed scenarios. This squaring operation can be implemented through the arithmetic logic unit within the index evaluation module or through software functions. The normalized value of the lateral vibration amplitude is then applied. Using logarithmic functions The processing aims to simulate the nonlinear characteristics of the impact of vibration on conductor mass, i.e., high sensitivity at small amplitudes, while the marginal effect tends to flatten as the amplitude increases, which is more consistent with physical reality. This logarithmic function can be calculated using a lookup table, Taylor series expansion, or floating-point arithmetic. The deflection angle is normalized. Using hyperbolic tangent function This processing method limits the influence of the deflection angle to a specific range, effectively smoothing out the abrupt changes near the mechanical limit and preventing drastic jumps in the evaluation index when the deflection angle approaches its limit. This hyperbolic tangent function can also be implemented using a lookup table or numerical calculation method.

[0064] The index evaluation module receives the normalized instantaneous velocity value after it has been standardized. , normalized value of lateral vibration amplitude and the normalized value of the deflection angle Then, it will initiate its core nonlinear fitting operation. This module first... The squared value is applied to highlight the effect of velocity fluctuations; then, the... Logarithmic functions are applied to capture the nonlinear characteristics of vibration effects; simultaneously, [the following is also discussed]... A hyperbolic tangent function is applied to smooth the effect of the deflection angle near the limit. Subsequently, the exponential evaluation module multiplies these nonlinearly processed parameters by their corresponding weighting coefficients. , , These weighting coefficients are pre-defined and optimized, and together they determine the relative importance of each parameter in the conductor condition assessment index. Finally, summing these three weighted nonlinear terms yields the dimensionless conductor condition assessment index. This index comprehensively reflects the overall risk level of the conductor in three dimensions: velocity, vibration, and deflection. It provides a precise and comprehensive quantitative basis for the subsequent tension control module, enabling the entire control system to respond promptly and accurately to the complex dynamic changes in the conductor's operating status.

[0065] In a preferred embodiment of the present invention, the inherent parameters of the winding conductor include the per-unit yield stress of the conductor. with the per-unit surface friction coefficient Their definitions are as follows: , ,in This represents the actual yield stress of the conductor material. As the reference yield stress, This is the actual coefficient of friction. The reference friction coefficient;

[0066] The fitting formula for the tension demand index generated by the tension control module is as follows:

[0067]

[0068] in It is a dimensionless tensile demand index. This is the material stiffness compensation coefficient. ; This is the friction damping gain coefficient. .

[0069] In this embodiment, the present application further proposes the following technical features: Inherent parameters of the winding conductor, including the per-unit yield stress of the conductor. with the per-unit surface friction coefficient Perimeter yield stress It is the actual yield stress of the conductor material. Compared with the reference yield stress The ratio of these values ​​is used to quantify the conductor's resistance to plastic deformation and is standardized for application in control models. (Perimeter-scaled surface friction coefficient) It is the actual coefficient of friction of the conductor. Friction coefficient with reference The ratio, used to characterize the frictional properties between the conductor surface and contact components such as the clamping guide wheel 6, is also standardized. These inherent parameters can be obtained in various ways, for example, by consulting the technical specifications or material data sheets provided by the conductor material supplier, or by accurately determining them through offline material mechanics tests (such as tensile tests) and tribological tests (such as sliding friction tests) on different batches of conductors.

[0070] The tension control module's main function is to calculate the required tension index based on the conductor's operating status and inherent properties. This allows for the dynamic adjustment of the tension force of the pneumatic lever 3. This module can be implemented using an embedded controller, such as a high-performance microcontroller or digital signal processor, or via an industrial programmable logic controller or an industrial computer equipped with corresponding control algorithm software. Its core function lies in its ability to receive data in real time, perform complex mathematical calculations, and output precise control commands.

[0071] The fitting formula for the tension demand index generated by the tension control module is as follows: This formula measures the dynamic operating status of the conductor (through the conductor status assessment index). and deflection angle (reflected) and the inherent material properties of the conductor (through per-unit yield stress) and per-unit surface friction coefficient (Embody) the organic combination. Among them, the first item The aim is to compensate for tensile stress based on the dynamic state of the conductor and its own resistance to deformation, ensuring that appropriate tension is maintained under different material strengths. (Second item) It is used to compensate for the nonlinear tension loss of the wire caused by friction at the pressure guide wheel 6, especially when the deflection angle is large or the friction coefficient is high, it can provide more accurate compensation.

[0072] This is the material stiffness compensation coefficient, with a value range of [0.8, 1.5]. This coefficient is used to adjust the weight of the influence of conductor material stiffness on the tensile force demand index. For example, for conductors with high elastic modulus and resistance to deformation, It can be adjusted downwards appropriately to avoid overcompensation; however, for softer, more easily deformed wires, This coefficient can be appropriately increased to provide stronger stiffness compensation. It can be adaptively optimized through experimental calibration, expert experience setting, or based on machine learning algorithms.

[0073] This is the friction damping gain coefficient, with a value range of [0.1, 0.8]. This coefficient is used to adjust the weight of the influence of the friction between the conductor and the clamping guide wheel 6 on the tensile force demand index. For example, when the conductor surface is smooth or well lubricated, It can be adjusted downwards appropriately; however, when the conductor surface is rough or there is significant friction, It can be appropriately increased to more effectively compensate for frictional losses. This coefficient can also be adaptively optimized through experimental calibration, expert experience setting, or based on machine learning algorithms.

[0074] The proposed solution optimizes tension control by introducing inherent parameters of the winding conductor. This solution uses a parameter acquisition module to acquire the instantaneous velocity of the pneumatic linkage 3 in real time. Horizontal vibration amplitude of conductor and the deflection angle of the wire at the clamping guide wheel 6 The operating status parameters are processed by the index evaluation module, which standardizes and fits them to generate the conductor status evaluation index. Building upon this foundation, the inherent physical properties of the conductor are further taken into consideration. Specifically, the tension control module generates the tension demand index. At the same time, it not only takes into account the current dynamic operating state of the conductor (through...) and (Reflection), and also incorporates the per-unit yield stress of the conductor. and per-unit surface friction coefficient By fitting the formula The system can determine the material stiffness characteristics of the conductor itself (through...). Correction ) and its frictional characteristics at the guide wheel (through and (Revised), dynamically calculating a more accurate tensile demand index. Among these, the material stiffness compensation coefficient... and friction damping gain coefficient As an adjustable parameter, this further enhances the system's adaptability to different conductor materials and processing conditions. Ultimately, the tension control module bases its decisions on this comprehensive tension demand index. The tension force of the pneumatic lever 3 is precisely and dynamically adjusted to ensure that the tension force accurately matches the actual physical properties and dynamic operating state of the conductor. This mechanism makes the tension force adjustment no longer a simple response to the conductor's operating state, but a personalized adjustment combined with the conductor's own "constitution," significantly improving the precision and adaptability of tension control.

[0075] In a preferred embodiment of the present invention, the formula for the tension control module to adjust the tension of the pneumatic lever 3 is as follows:

[0076]

[0077] in, The adjusted target tension;

[0078] The initial reference tension force is set based on the wire diameter. The value of is determined by the following formula: , The diameter of the wire. This is the wire diameter-tensile strength coefficient, which is 12-25 N / mm for copper wire. 2

[0079] In this embodiment, the adjusted target tension force This refers to the actual tension force that the pneumatic pull rod 3 ultimately needs to apply to the winding conductor during the wire pulling process, after dynamic calculation and adjustment by the control system. This force is an instantaneous target value set by the transformer wire pulling device under specific operating conditions to ensure stable conductor tension and avoid damage. It can be achieved by precisely controlling the air pressure through a servo cylinder, or by using a force sensor to provide real-time feedback and closed-loop adjustment of the output force of the pneumatic pull rod 3. Tension Demand Index It is a dimensionless comprehensive index, which is evaluated by the tension control module based on the conductor condition. Per-unit yield stress of conductors and per-unit surface friction coefficient It is generated through parameter fitting. It reflects the relative demand for tension in the conductor under current wire pulling conditions. The calculation of this index is usually performed in a digital controller or embedded system, using a preset mathematical model and real-time acquired data.

[0080] Initial reference tension This is a pre-set basic tension value based on the diameter of the winding conductor. It represents the minimum or average tension force that a conductor of a specific diameter should withstand under ideal or standard operating conditions. The setting of this value takes into account the physical properties of the conductor material and process requirements, providing a stable benchmark for dynamic adjustment. It can be determined by consulting process manuals, fitting experimental data, or through pre-calibration.

[0081] wire diameter These are the geometric dimensions of the winding conductors, typically measured in millimeters. They are used to calculate the initial reference tension force. The key input parameter directly reflects the cross-sectional area of ​​the conductor, thus affecting its tensile strength capacity. The conductor diameter can be measured online using a laser diameter gauge, or manually measured and input into the system before drawing the conductor.

[0082] Wire diameter - tensile strength coefficient This is an empirical coefficient used to correlate wire diameter with an initial reference tension force. It reflects the reasonable range of tensile force that a unit cross-sectional area can withstand under specific process requirements for different materials (such as copper wire). For copper wire, this coefficient is typically taken as 12-25 N / mm². 2 The specific value can be adjusted according to the conductor grade, insulation type, and winding process requirements. This coefficient can be determined through extensive experimental data analysis, expert experience, or industry standards.

[0083] This solution achieves a precise mapping from abstract control indices to specific physical execution forces by introducing an initial baseline tension force calculation model. The tension control module first receives the tension demand index. This index has been based on real-time operating parameters (such as the instantaneous speed of pneumatic lever 3). Horizontal vibration amplitude of conductor and the deflection angle of the wire at the clamping guide wheel 6 ) and the conductor's inherent parameters (such as per-unit yield stress) and per-unit surface friction coefficient The dynamic generation reflects the relative tension requirement of the conductor under the current guy wire operating conditions. Simultaneously, to provide a physical basis for dynamic adjustment, the system calculates an initial reference tension force. This calculation uses the wire diameter. wire diameter-tensile strength coefficient Through formula The influence of conductor cross-sectional area on its tensile strength was directly considered, ensuring that the reference tension force always matched the physical properties of the conductor of a specific specification, avoiding excessively high or low reference settings. Ultimately, the adjusted target tension force... By using the pull demand index Compared with the initial reference tension force The result is obtained by multiplication. This multiplicative relationship ensures that the final applied tension force not only dynamically responds to instantaneous changes in operating conditions but also is always proportionally adjusted based on a safety benchmark determined by the physical characteristics of the conductor. This mechanism is closely integrated with the aforementioned parameter acquisition, index evaluation, and tension demand index generation processes, ensuring the scientific rigor, accuracy, and safety of the entire control chain from real-time state perception to final physical execution, thereby significantly improving the control precision and reliability of the entire transformer pull-wire device.

[0084] In a preferred embodiment of the present invention, the clamping force control module calculates and adjusts the downward clamping force of the clamping guide wheel 6 using the following physical space decoupling formula:

[0085]

[0086] in, The clamping force applied to the guide wheel 6 is measured in N.

[0087] For dimensionless static mapping coefficients, ;

[0088] The dimensionless dynamic damping coefficient is... ;

[0089] The equivalent mass of the contact arc segment between the conductor and the clamping guide wheel 6, in kg. ,in The linear density of the conductor. It is the contact arc length;

[0090] The instantaneous velocity of the pneumatic lever 3 is collected in real time, in m / s;

[0091] The actual radius of the clamping guide wheel 6, in meters.

[0092] In this embodiment, the clamping force control module is an important component of the control system. Its function is to calculate and output a pressing force command on the clamping guide wheel 6 based on the real-time operating status and tension force. Its implementation can include, but is not limited to: a microcontroller-based embedded system that receives data from the parameter acquisition module, executes a preset algorithm, and outputs an analog signal via a digital-to-analog converter or controls the actuator of the clamping guide wheel 6 via a pulse width modulation signal; or, the module can be a programmable logic controller (PLC) that implements complex logic operations and control outputs through programming.

[0093] The physical space decoupling formula is used to calculate the target downward clamping force of the clamping guide wheel 6. The core mathematical model of this system separates and combines multiple physical factors affecting the clamping force (such as tension, conductor deflection angle, conductor speed, and conductor mass) to achieve precise control of the clamping force. This formula can be established based on methods such as mechanical analysis, experimental data fitting, or finite element simulation. This refers to the normal force that the clamping guide wheel 6 needs to apply to the winding conductor to ensure that the conductor is stably attached to the guide wheel during the pulling process, preventing jumping or slippage. This force is dynamically changing and is calculated in real time by the physical space decoupling formula.

[0094] It is a dimensionless adjustment parameter used to adjust the tension. The contribution of the longitudinal component generated at the clamping guide wheel 6 to the clamping force. This coefficient ranges from [0.3, 0.9] and can be determined experimentally or empirically based on the elastic modulus of the conductor material, the surface friction characteristics of the guide wheel, and actual process requirements. For example, for softer or more easily deformable conductors... A smaller value can be used to avoid excessive compression; for stiffer or smooth-surfaced wires, A larger value can be selected to enhance the adhesion.

[0095] This is a dimensionless adjustment parameter used to adjust the degree of compensation of the clamping force by the centrifugal force generated during the high-speed movement of the conductor. The value of this coefficient ranges from [0.05, 0.4], and its specific value can be determined through experimental analysis and optimization of the conductor's vibration trend under different wire diameters and speeds. For example, when the conductor speed changes frequently or there is significant inertia, It can be appropriately increased to provide stronger dynamic compensation; conversely, under low-speed stable operating conditions, This can be reduced to decrease unnecessary clamping force.

[0096] This refers to the effective mass of the conductor within the arc-shaped area where the clamping guide wheel 6 contacts the conductor. This parameter is used to calculate the centrifugal force generated when the conductor moves at high speed. It is calculated using the linear density of the conductor. Multiply by the contact arc length Linear density It can be calculated from the density of the conductor material and the cross-sectional area of ​​the conductor, or obtained by weighing a conductor of known length;

[0097] Contact arc length This depends on the geometry of the clamping guide wheel 6 and the wrap angle of the wire on the guide wheel. v refers to the instantaneous speed of the wire as it passes the clamping guide wheel 6 during the wire pulling process of the pneumatic rod 3. This speed is dynamically changing and is acquired in real time through a parameter acquisition module. For example, the instantaneous speed of the wire can be measured in real time using a linear encoder, laser speed sensor, or vision system mounted on the pneumatic rod 3.

[0098] This refers to the geometric dimensional parameter of the pressure guide wheel 6, specifically its outer radius. This parameter is a fixed value and is determined during the device design.

[0099] The solution in this application uses a clamping force control module and a physical space decoupling formula to control the downward clamping force of the clamping guide wheel 6. Tensioning force of pneumatic lever 3 The deflection angle of the wire at the clamping guide wheel 6 Instantaneous speed of pneumatic lever 3 And the physical properties of the conductor itself (such as linear density) Contact arc length 6-radius clamping guide wheel This involves performing a deep coupling analysis. The formula comprises two main components: a static mapping term. and dynamic damping term Static mapping term Designed to compensate for tension The influence of the longitudinal component generated at point 6 of the clamping guide wheel on the normal pressure of the conductor. When the tension force... Increase or deflection angle When changes occur, this term can dynamically adjust the clamping force to ensure that the conductor always maintains a stable fit. Dynamic damping term. This is used to counteract the centrifugal force generated when the conductor moves at high speed. When the conductor moves at an instantaneous speed... Through radius When the clamping guide wheel 6 is engaged, an outward centrifugal force is generated, which may cause the conductor to jump or slip. The equivalent mass of the contact arc segment between the conductor and the clamping guide wheel 6 is calculated. (Based on conductor linear density) and contact arc length (Confirmed) This feature can compensate for centrifugal force in real time, thereby effectively preventing the conductor from slipping or detaching in the contact arc segment.

[0100] By introducing dimensionless static mapping coefficients and dynamic damping coefficient This solution provides the system with the flexibility to adjust for different mechanical structures, conductor material properties, and process requirements. These coefficients can be experimentally calibrated or empirically set during the system commissioning phase, allowing the clamping force to be adaptively adjusted according to real-time working conditions. Combined with the aforementioned tension control mechanism, this solution forms a more complete collaborative control system. The tension control module evaluates the conductor condition index. Based on the inherent parameters of the winding conductors, the tension force of the pneumatic tie rod 3 is dynamically adjusted. Subsequently, the clamping force control module utilizes this adjusted... Combined with real-time acquisition of instantaneous speed and deflection angle The precise clamping force is calculated using the above physical space decoupling formula. This linkage mechanism means that tension and compressive forces are no longer independent control quantities, but are instead optimized collaboratively based on the conductor's operating state and physical model.

[0101] As a preferred embodiment of the present invention, considering the inherent response delay of the clamping guide wheel 6 actuator, the clamping force control module further includes an overshoot correction unit;

[0102] The anti-overshoot correction unit extracts the longitudinal vector component of the tension force and introduces a differential feedforward term in conjunction with the response delay time to smoothly correct the target downward pressing force, generating the final execution pressing force. The correction formula is as follows:

[0103]

[0104] in, The final applied clamping force after correction, in N;

[0105] The inherent response delay time preset for the actuator, in seconds; ;

[0106] This is a dimensionless differential overshoot suppression coefficient. ;

[0107] The instantaneous rate of change of the longitudinal runout component of the conductor over time, in N / s, is approximated using the backward difference method in discrete control systems. , The sampling period is defined as follows: when the longitudinal force of the conductor increases sharply, the differential feedforward term provides negative compensation to reduce the instantaneous clamping deformation caused by command overshoot; when the longitudinal force of the conductor decreases sharply, the differential feedforward term provides positive compensation to slow down the attenuation rate of the clamping force and maintain conductor adhesion.

[0108] In this embodiment, the overshoot correction unit is a component of the clamping force control module. Its main function is to dynamically adjust the downward clamping force command of the clamping guide wheel 6 to cope with the inherent response delay of the actuator. This unit can be an independent hardware module, such as an embedded controller or digital signal processor, specifically responsible for executing the correction algorithm; or it can be part of the internal software algorithm of the clamping force control module, implementing real-time correction of the clamping force command through programming. Its core function is to predict and compensate for the hysteresis effect of the actuator, ensuring that the clamping force can respond to changes in the conductor state in a timely and stable manner.

[0109] Extracting the longitudinal vector component of the tension force refers to obtaining the wire tension force. The component of the force perpendicular to the direction of the conductor's motion, i.e. This component directly reflects the change in the clamping force required by the conductor at clamping guide wheel 6, and is the core disturbance source that necessitates correction of the clamping force command. This extraction process can be obtained in real time through the control system, for example, by measuring the tension force in real time using sensors. and deflection angle Then, the processor performs multiplication to obtain the result; or, in some simplified scenarios, it can be approximated by looking up a table or a preset model. Introducing a differential feedforward term in conjunction with the response delay time means that when calculating the final clamping force, not only the current static or dynamic requirements are considered, but also the response lag of the actuator is compensated in advance.

[0110] Response latency This is the time required for the actuator to take action from receiving a command to actually producing the corresponding action; its value typically ranges from 0.01 seconds to 0.02 seconds. The introduction of the differential feedforward term means that the system will adjust the feedforward based on the instantaneous rate of change of the longitudinal runout component of the conductor over time. This allows for advance adjustment of the clamping force command. This feedforward mechanism can effectively predict future trends, thus incorporating corrections into the command before the actuator has fully responded.

[0111] The calculation of the differential feedforward term can be achieved by... Perform real-time differentiation (e.g., using backward difference approximation in digital systems). ,in This is achieved by (using a sampling period). The target pressing force is smoothly corrected to generate the final pressing force. The goal is to avoid abrupt changes in the pressing force command and ensure the smooth operation of the pressing guide wheel 6, thereby preventing impact or damage to the wire.

[0112] Final clamping force Based on the target pressing force (Calculated from the aforementioned physical space decoupling formula) minus the correction amount of the differential feedforward term. This correction method allows the clamping force command to more accurately track changes in the conductor state, while suppressing overshoot or undershoot caused by actuator inertia or delay. The corrected command It is then sent to the actuator of the clamping guide wheel 6 to drive it to perform the corresponding action.

[0113] Differential overshoot suppression coefficient η is a dimensionless parameter, ranging from 0.05 to 0.3. This coefficient is used to adjust the correction strength of the differential feedforward term. By adjusting the value of η, the magnitude of the correction can be controlled, thereby achieving a balance between suppressing overshoot and maintaining the system response speed. For example, when η is larger, the correction effect is stronger, and the suppression of overshoot is more obvious, but it may increase the sensitivity of the system; when η is smaller, the correction effect is relatively mild, suitable for operating conditions with minimal changes. The setting of this coefficient usually needs to be empirically adjusted or optimized based on the dynamic characteristics of the actual equipment and process requirements.

[0114] The solution proposed in this application effectively solves the control accuracy problem caused by the inherent response delay of the clamping guide wheel 6 actuator by adding an anti-overshoot correction unit to the clamping force control module. Specifically, the anti-overshoot correction unit first extracts the longitudinal vector component of the clamping force in real time. This longitudinal component is a key component in generating the normal force on the conductor at the clamping guide wheel 6, and its instantaneous changes directly affect the contact state between the conductor and the clamping guide wheel 6. Given that the clamping guide wheel 6 actuator has a preset inherent response delay time... If only the target downward clamping force calculated instantaneously is considered... Control is performed when the longitudinal component of the conductor... When drastic changes occur, the actuator will be unable to respond in time, resulting in excessive or insufficient clamping force.

[0115] To overcome this problem, the overshoot correction unit introduces a differential feedforward term. This feedforward term calculates the instantaneous rate of change of the longitudinal runout component of the conductor over time. In conjunction with the differential overshoot suppression coefficient η, the clamping force applied to the target is... Pre-correction is performed. When the longitudinal force on the conductor increases sharply, it means that the conductor has a tendency to jump upwards. If the clamping force is not increased in time, it may cause the conductor to detach or jump. At this time, the differential feedforward term shows negative compensation, that is, from Subtracting a correction term from the input aims to mitigate command overshoot. This is because actuator delays cause the actual clamping force to lag behind the command. If the command is too large, the actual clamping force may overshoot after the delayed response, instantly flattening the conductor. Negative compensation smooths the command and avoids excessive peaks in the actual clamping force after the delay. Conversely, when the longitudinal component of the conductor drops sharply, it means the conductor has a downward slack tendency. If the clamping force is not reduced in time, the conductor may be over-clamped. In this case, the differential feedforward term provides positive compensation, i.e., it shifts towards... An adjustment is added to slow down the rate of clamping force decay and maintain wire adhesion. This is because if the clamping force command drops abruptly, the delay in the actuator may cause the actual clamping force to drop too quickly, thus loosening the wire. Positive compensation allows the command to decrease more gradually, ensuring that the actual clamping force can still maintain wire adhesion after the delay.

[0116] Through this rate-of-change-based differential feedforward correction mechanism, the system can predict and compensate for the response delay of the actuator, thereby ensuring the final clamping force is applied. It can track the dynamic changes in the conductor's state more smoothly and accurately. This is consistent with the aforementioned calculation of the target's compressive force using a decoupling formula based on physical space. The combination of these solutions forms a more complete closed-loop control system. The theoretical clamping force requirements are provided based on a physical model, and the overshoot correction unit is further optimized for the dynamic characteristics of the actuator, ensuring that the theoretical commands can be efficiently and stably implemented by the actual actuator. This synergistic effect enables the transformer wire pulling device to maintain precise control over conductor tension and position even when facing high-speed, highly dynamic wire pulling conditions, significantly improving the stability of the wire pulling process and product quality.

[0117] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A transformer wire pulling device, comprising a fixed base, a positioning wheel for positioning a winding rotatably mounted on the fixed base, a pneumatic pull rod for tightening the winding wire fixedly mounted on one side of the fixed base, a guide seat fixedly mounted between the fixed base and the pneumatic pull rod, a pneumatic telescopic rod fixedly mounted above the guide seat via a fixed frame, and a pressure guide wheel rotatably connected to the telescopic end of the pneumatic telescopic rod, characterized in that... It also includes a control system, which includes: The parameter acquisition module is used to collect the operating status parameters of the winding conductors and the mechanical execution parameters of the transformer pulling equipment in real time. The index evaluation module is used to fuse and extract the operating status parameters and fit them to generate a conductor status evaluation index. The tension control module is used to fit the conductor state evaluation index with the preset winding conductor inherent parameters to generate a tension demand index, and dynamically adjust the tension of the pneumatic tie rod accordingly. The clamping force control module is used to perform decoupling analysis of lateral and longitudinal forces based on the adjusted tension force and the operating state parameters, and to dynamically adjust the downward clamping force of the clamping guide wheel.

2. The transformer pull wire device according to claim 1, characterized in that, The operating status parameters include the instantaneous velocity of the pneumatic connecting rod, the lateral vibration amplitude of the conductor, and the deflection angle of the conductor at the clamping guide wheel; before fitting the conductor status evaluation index, the index evaluation module normalizes each parameter: The instantaneous velocity normalized value is equal to the measured velocity divided by the upper limit of the process velocity; the transverse vibration amplitude normalized value is equal to the measured amplitude divided by the maximum safe amplitude; and the deflection angle normalized value is equal to the measured deflection angle divided by the maximum mechanical limit deflection angle.

3. The transformer pull wire device according to claim 2, characterized in that, The fitting formula for the conductor condition evaluation index generated by the index evaluation module is as follows: The conductor condition assessment index is equal to the velocity disturbance weighting coefficient multiplied by the square of the velocity normalization value, plus the vibration nonlinearity weighting coefficient multiplied by the natural logarithm of (1 plus the amplitude normalization value), plus the deflection angle weighting coefficient multiplied by the hyperbolic tangent function value of the deflection angle normalization value; where each weighting coefficient is positive and the sum is 1.

4. The transformer puller device of claim 3, wherein, The inherent parameters of the winding conductor include the per-unit yield stress and the per-unit surface friction coefficient of the conductor, which are defined as the actual yield stress divided by the reference yield stress and the actual friction coefficient divided by the reference friction coefficient, respectively. The fitting formula for the tension demand index generated by the tension control module is as follows: the tension demand index is equal to the material stiffness compensation coefficient multiplied by the conductor condition evaluation index divided by the per-unit yield stress, plus the friction damping gain coefficient multiplied by the exponential function value with (per-unit friction coefficient multiplied by the normalized deflection angle) as the exponent; wherein the material stiffness compensation coefficient ranges from 0.8 to 1.5, and the friction damping gain coefficient ranges from 0.1 to 0.

8.

5. The transformer puller device of claim 3, wherein, The formula used by the tension control module to adjust the tension of the pneumatic tie rod is as follows: The target tension force is equal to the tension demand index multiplied by the initial reference tension force; the initial reference tension force is set according to the wire diameter, specifically equal to the wire diameter minus the tension coefficient multiplied by the square of the wire diameter. For copper wire, the wire diameter minus the tension coefficient is 12 to 25 N / mm².

6. The transformer puller device of claim 5, wherein, The clamping force control module calculates and adjusts the downward clamping force of the clamping guide wheel using the following physical space decoupling formula: The target pressing force is equal to the static mapping coefficient multiplied by the target tension force multiplied by the sine of the deflection angle, plus the dynamic damping coefficient multiplied by (the equivalent mass of the arc segment of the conductor in contact with the pressing guide wheel multiplied by the square of the instantaneous velocity divided by the actual radius of the guide wheel). Among them, the static mapping coefficient ranges from 0.3 to 0.9, and the dynamic damping coefficient ranges from 0.05 to 0.4; the equivalent mass of the contact arc segment between the conductor and the clamping guide wheel is equal to the linear density of the conductor multiplied by the contact arc length.

7. The transformer puller device of claim 5, wherein, Considering the inherent response delay of the clamping guide wheel actuator, the clamping force control module also includes an overshoot correction unit; the overshoot correction unit extracts the longitudinal vector component of the clamping force and, in conjunction with the response delay time, introduces a differential feedforward term to smoothly correct the target downward clamping force, generating the final execution clamping force: The final clamping force is equal to the target downward clamping force minus (the inherent response delay of the actuator multiplied by the differential overshoot suppression coefficient, and then multiplied by the derivative of (the target clamping force multiplied by the sine of the deflection angle) with respect to time). The inherent response delay time ranges from 0.01 to 0.02 seconds, and the differential overshoot suppression coefficient ranges from 0.05 to 0.

3. In the discrete control system, the derivative is approximated by backward difference, that is, by dividing the difference between adjacent sampling periods by the sampling period. When the longitudinal jump force of the conductor increases sharply, the differential feedforward term provides negative compensation to reduce the instantaneous clamping deformation caused by command overshoot. When the longitudinal force of the conductor drops sharply, the differential feedforward term provides positive compensation to slow down the attenuation rate of the clamping force and maintain conductor adhesion.

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