Electrical control method and system for a coil wire bar taping machine

Abstract

This invention discloses an electrical control method and system for a coil bar wrapping machine, belonging to the field of electrical control technology. The method includes the following steps: acquiring the rotation and position of the coil bar to obtain its real-time motion state; controlling the wrapping tension based on the real-time motion state to obtain a stable tension state; performing synchronous rotation and axial control based on the stable tension state to obtain a spiral wrapping trajectory; performing interlayer compression based on the spiral wrapping trajectory to obtain a uniform insulation layer; adjusting the wrapping in multiple segments based on the uniform insulation layer to obtain a local pitch variation structure; and performing full-process closed-loop control based on the local pitch variation structure to obtain the final wrapped state. This invention establishes a spiral wrapping geometric path through synchronous rotation and axial control, maintaining a stable trajectory relationship for the insulation tape, achieving full surface coverage, uniform interlayer coverage, and consistent wrapping pitch, thus improving the overall insulation quality of the coil bar and enhancing the stability and consistency of the wrapping trajectory.

Description

Technical Field

[0001] This invention relates to the field of electrical control technology, specifically to an electrical control method and system for a coil bar wrapping machine. Background Technology

[0002] Coil bar wrapping machines are mainly used for insulation wrapping of motor coils, generator bars, and high-voltage winding conductors. By driving the coil bar to rotate and controlling the continuous axial movement of the insulation tape, the tape is spirally wound onto the surface of the coil bar, forming a multi-layered insulation structure that meets electrical insulation requirements. During the coil bar wrapping process, the insulation tape needs to complete processes such as tape release, tension maintenance, trajectory formation, interlayer bonding, and multi-layer covering while in continuous motion.

[0003] In the existing technology, there is a lack of synchronization between rotational motion and axial motion: In the existing coil bar wrapping process, the spiral wrapping trajectory is formed by a fixed ratio between the preset rotational speed and axial speed. It is difficult to maintain a stable synchronous relationship between rotational motion and axial motion under conditions of continuous change in insulation layer thickness and local pitch switching. As a result, the spiral wrapping trajectory is prone to cumulative deviation, which affects the consistency of the final insulation layer wrapping trajectory and the overall insulation quality of the coil bar. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an electrical control method and system for a coil bar wrapping machine, thereby resolving the problems mentioned in the background section.

[0005] To achieve the above objectives, the present invention provides the following technical solution: In a first aspect, the present invention provides an electrical control method for a coil bar wrapping machine, comprising the following steps: S1. The coil bar rotation and position acquisition are used to obtain the real-time motion state; S2. Control the strap tension based on the real-time motion state to obtain a stable tension state; S3. Based on the stable tension state, perform synchronous control of rotation and axial direction to obtain the spiral wrapping trajectory; S4. Compact the layers according to the spiral tape trajectory to obtain a uniform insulation layer; S5. Adjust the wrapping tape in multiple segments according to the uniform insulation layer to obtain a structure with local pitch variation. S6. Perform closed-loop control throughout the entire process based on the local pitch change structure to obtain the final tape completion state.

[0006] To further optimize this technical solution, the coil bar rotation and position acquisition in step S1 include: By installing a rotary encoder and a position detection device, rotation and displacement signals are synchronously acquired, establishing a correspondence between rotation and displacement states. The acquired signals are then filtered to obtain the real-time motion state.

[0007] To further optimize this technical solution, the tape tension control in step S2 includes: Based on the obtained real-time motion state, the correspondence between motion state and tension is established through the tension detection structure. The tension deviation is calculated based on the current actual tension and the target tension, and the belt pulley speed is corrected based on the tension deviation result, ultimately forming a stable tension state.

[0008] To further optimize this technical solution, the rotational and axial synchronization control in step S3 includes: Based on the stable tension state, the target pitch is set according to the width of the insulating tape and the interlayer overlap requirements. The synchronous correspondence between the rotational motion and the axial motion is established. The axial movement speed is calculated based on the current rotational state. Rotation and axial synchronous control are executed. The axial motor output is corrected by calculating the synchronization error to form a continuous spiral wrapping trajectory.

[0009] To further optimize this technical solution, the target pitch includes: in: Target pitch; : Width of insulating tape; Overlap ratio; The target pitch is obtained based on the width and overlap ratio of the insulating tape.

[0010] To further optimize this technical solution, the synchronization correspondence includes: in: : Axial velocity; : Rotational angular velocity; Based on the target pitch and the current rotational angular velocity, the corresponding axial velocity is calculated.

[0011] To further optimize this technical solution, the synchronization error includes: in: Synchronization error; In time The axial position at any given moment; In time The cumulative rotation angle at any given time; The synchronization error is obtained by comparing the theoretical axial position calculated from the target pitch and cumulative rotation angle with the actual axial position at the current moment.

[0012] To further optimize this technical solution, the interlayer compaction in step S4 includes: Based on the obtained spiral wrapping tape trajectory, the target pressure is set for interlayer compression, and the current compression status is continuously monitored and the pressure is adjusted accordingly to continuously compress each layer of insulation tape and form a uniform insulation layer.

[0013] To further optimize this technical solution, the multi-segment packing adjustment in step S5 includes: Based on a uniform insulation layer, multiple wrapping areas are divided, and a correspondence between different segmented areas and local pitch is established. Under the control of local pitch, the newly added insulation tape layer is wrapped and compressed in multiple segments to form a structure with varying local pitch.

[0014] The electrical control system for the coil bar wrapping machine is constructed based on the aforementioned electrical control method for the coil bar wrapping machine, and includes the following functional modules: The system includes a motion state detection module, a strap tension control module, a rotation axis synchronization control module, an interlayer compression control module, a multi-segment strap adjustment module, and a closed-loop control module.

[0015] In a second aspect, the present invention provides a computer device, including a memory and a processor, wherein the memory stores a computer program, wherein the computer program instructions, when executed by the processor, implement the steps of the electrical control method and system for coil bar wrapping machine as described in the first aspect of the present invention.

[0016] Thirdly, the present invention provides a computer-readable storage medium having a computer program stored thereon, wherein: when the computer program instructions are executed by a processor, the steps of the electrical control method and system for coil bar wrapping machine as described in the first aspect of the present invention are implemented.

[0017] Compared with the prior art, the present invention provides an electrical control method and system for a coil bar wrapping machine, which has the following beneficial effects: The electrical control method and system for the coil bar wrapping machine establishes a spiral wrapping geometric path through synchronous control of rotation and axial direction, so that the insulation tape maintains a stable trajectory relationship, achieves full surface coverage, uniform interlayer coverage, and consistent wrapping pitch, thereby improving the overall insulation quality of the coil bar and enhancing the stability and consistency of the wrapping trajectory. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a flowchart illustrating the electrical control method for the coil bar wrapping machine proposed in this invention. Figure 2 This is a schematic diagram of the electrical control system module of the coil bar wrapping machine proposed in this invention. Detailed Implementation

[0020] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0021] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0022] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places throughout this specification does not necessarily refer to the same embodiment, nor is it a single embodiment or an embodiment selectively excluded from other embodiments.

[0023] Example 1: Reference Figure 1 This is the first embodiment of the present invention, which provides an electrical control method for a coil bar wrapping machine, including the following steps: S1. The coil bar rotates and its position is acquired to obtain the real-time motion status.

[0024] In this embodiment, the rotation and position acquisition of the coil bar includes: In coil and bar wrapping machines, the core of wrapping accuracy lies in the coordination of rotational motion, axial feed, and wrapping tension. Because the coil or bar rotates at high speed, any angular deviation or axial position error directly affects the uniformity of the insulation layer. If the rotation angle and axial position cannot be accurately acquired, subsequent tension control and spiral trajectory synchronization cannot be executed accurately, easily leading to problems such as loose insulation tape, wrinkling, or uneven interlayer overlap. Therefore, it is necessary to acquire accurate signals of coil and bar rotation and axial position in real time as the input basis for subsequent closed-loop control and multi-axis coordination.

[0025] By installing a rotary encoder and a position detection device, rotation and displacement signals are synchronously acquired, establishing a correspondence between rotation and displacement states. The acquired signals are then filtered to obtain the real-time motion state, which serves as the unified motion basis for the subsequent electrical control of the tape machine and provides a basis for subsequent steps.

[0026] The coil bar rotation and position acquisition steps include: A rotary encoder is installed on the rotating shaft of the coil bar: An incremental rotary encoder is installed at the end of the main shaft that drives the coil bar to rotate. The encoder and the rotating shaft are coaxially connected, so that the motion of the rotating shaft can be synchronously transmitted to the encoder. When the main shaft rotates, the grating disk inside the encoder rotates synchronously and outputs continuous pulse signals. Each pulse indicates that the rotating shaft has rotated through a fixed angle. The controller calculates the current rotation speed based on the number of pulses per unit time. At the same time, it calculates the current rotation angle based on the cumulative number of pulses. In this way, the current rotation direction, current rotation angular velocity and current cumulative rotation angle can be obtained in real time, and the slippage error problem existing in traditional mechanical speed measurement structures can be avoided.

[0027] A position detection device is installed in the wrapping head moving mechanism: During the wrapping process of the coil bar, the wrapping head needs to move continuously along the axial direction. Therefore, a linear displacement detection device is installed at the position of the wrapping head guide rail. The displacement detection device moves synchronously with the wrapping head. When the wrapping head moves, the position detection device outputs the current position signal. The controller calculates the current axial position, current axial movement speed and current movement direction based on the current position change. Thus, through continuous detection, the current coverage area of ​​the insulation tape can be determined in real time, avoiding the problem that traditional mechanical limit methods cannot continuously measure.

[0028] Synchronize the timing of rotation and displacement signals: Since a correspondence needs to be established between rotational motion and axial motion, a unified time mark is applied to the two types of signals. By establishing a fixed sampling period, the current number of rotational pulses and the current change in axial displacement are read simultaneously in each sampling period to establish a correspondence between the rotational state and the displacement state. For example, when the rotation angle increases, the corresponding axial movement distance is recorded synchronously, thus forming a continuous spiral motion relationship.

[0029] Motion signal filtering: Due to mechanical vibration during the operation of the tape machine, the acquired signal may contain fluctuation interference. To avoid misjudgment, multiple sample values ​​are continuously read and smoothed to remove abrupt outliers. The rotation and displacement signals are filtered, and the acquired rotation speed is more stable, the displacement change is more continuous, and the instantaneous fluctuation is significantly reduced, thereby avoiding mechanical vibration from affecting subsequent control.

[0030] Establish real-time motion state: After signal processing is completed, the current real-time motion state is established, including the current rotation speed and angle, the current axial position and moving speed, the current direction of motion, and the current relationship between rotation and displacement, which serves as the unified motion basis for the subsequent electrical control of the entire tape machine.

[0031] S2. Control the strap tension based on the real-time motion state to obtain a stable tension state.

[0032] In this embodiment, the strap tension control includes: During the coil bar wrapping process, the insulation tape needs to be continuously wound around the coil surface under stable stress. If the tension is too high, the insulation tape will be stretched and deformed, resulting in problems such as insufficient local insulation layer thickness, reduced interlayer coverage, and reduced withstand voltage. If the tension is too low, the insulation tape will be loose, causing it to fail to adhere tightly to the coil surface, easily resulting in gaps and wrinkles. Moreover, the tension fluctuation is more obvious when running at high speed, which will cause the insulation tape to experience continuous stress fluctuation. Traditional fixed tension methods cannot adapt to this dynamic change, so a real-time dynamic tension control mechanism must be established.

[0033] Based on the obtained real-time motion state, the correspondence between motion state and tension is established through the tension detection structure. The tension deviation is calculated based on the current actual tension and the target tension, and the speed of the wrapping wheel is corrected based on the tension deviation result, so as to form a stable tension state. This ensures that the insulating tape maintains a stable stress state throughout the wrapping process, reduces the impact of mechanical vibration, improves the wrapping quality, and provides a stable foundation for subsequent steps.

[0034] Methods for controlling the tension of the strapping tape include: Establish a tension detection structure: Install a tension detection wheel on the transmission path of the insulating tape. The tension detection wheel is in continuous contact with the surface of the insulating tape. When the tension of the insulating tape changes, the force on the detection wheel changes synchronously. The tension sensor converts this force change into an electrical signal. By continuously reading this tension signal, the current stress state of the insulating tape can be obtained in real time.

[0035] Read real-time motion status: Read the real-time motion status established by S1, including the current rotation speed and angle, current axial position and moving speed, and establish the correspondence between the current motion status and tension. For example, when the rotation speed increases, the traction speed of the insulating tape increases synchronously. At this time, it is necessary to increase the tape release speed, otherwise the insulating tape will be tightened and the tension will increase, thus providing a basis for subsequent dynamic correction.

[0036] Determine the target tension value: Since different insulating tape materials have different mechanical properties, the allowable tension range during the wrapping process is not the same. It is necessary to set the target tension value according to the current process conditions, including the thickness of the insulating tape material, the width of the insulating tape, the current number of wrapping layers, and the current rotation speed. For example, when the number of wrapping layers increases, the thickness of the insulating layer increases, and the friction between the insulating tape and the workpiece surface increases. If the initial tension value is still used, it may cause difficulty in moving the insulating tape, and the target tension needs to be increased.

[0037] Perform tension deviation calculation: continuously calculate the deviation between the current tension and the target tension. If the difference is small, it indicates that the current tension is stable. When the deviation increases, it indicates that the force on the insulating tape has changed. Further combine the current rotation state and the current axial movement state to determine the source of the tension change. For example, if the rotation speed increases and the tension increases at the same time, it is determined that it is caused by the change in traction speed. It is necessary to increase the tape release speed, thereby realizing the analysis of the cause of tension deviation and avoiding incorrect correction.

[0038] Generate tape pulley speed correction: Based on the tension deviation results, calculate the speed correction of the tape pulley drive motor, and adjust the tape release speed of the tape pulley drive motor in conjunction with the real-time motion status. If the current tension is too high, it means that the insulating tape is pulled too tight, so increase the tape release speed; if the current tension is too low, decrease the tape release speed. After receiving the correction signal, the drive motor adjusts the tape pulley speed, thereby changing the insulating tape release speed to maintain a matching relationship with the rotation and axial movement.

[0039] Forming a tension closed-loop control: After completing the speed correction, continue to read the new tension state, cycle the tension control process, form a complete tension closed loop under a stable tension state, and ultimately keep the insulation tape under stable stress throughout the entire wrapping process, without significant stretching or loosening, and without large-scale slippage or instantaneous shaking.

[0040] Furthermore, the belt pulley speed correction includes: in: : The tape pulley speed correction amount represents the speed adjustment amount generated in response to the current tension deviation. It is used to correct the output speed of the tape pulley. The actual range is related to the motor response capability and the insulation tape material. Usually, a maximum correction limit is set to prevent problems such as motor oscillation or tape impact. Tension deviation is obtained by subtracting the actual tension from the current target tension. It represents the amount of deviation between the current target tension and the actual tension, and is used to reflect the difference between the current stress state of the insulation tape and the target state. The magnitude and direction of the deviation determine the adjustment direction and magnitude of the subsequent tape pulley speed. A deviation greater than 0 indicates that the insulation tape is over-tightened, and a deviation less than 0 indicates that the insulation tape has a tendency to loosen, and the tape release speed needs to be reduced. Tension correction coefficient represents the proportional relationship between tension deviation and speed correction, i.e., the speed adjustment amount corresponding to a unit tension deviation. It is used to control the tension correction sensitivity and is determined through equipment debugging experiments. If it is too large, the adjustment will be too sensitive and prone to oscillation. If it is too small, the response will be slow and the tension will recover slowly. Based on the tension deviation and the tension correction coefficient, the speed correction amount of the belt pulley is calculated.

[0041] S3. Based on the stable tension state, perform synchronous control of rotation and axial movement to obtain the spiral wrapping trajectory.

[0042] In this embodiment, the rotation and axial synchronization control includes: During the coil bar wrapping process, the insulation tape needs to be continuously covered on the coil surface in a spiral manner. The spiral wrapping is essentially a spatial motion trajectory formed by the superposition of the coil bar rotational motion and the axial motion of the wrapping head. If only rotational motion exists, the insulation tape will only be repeatedly superimposed on the same cross section and cannot form axial coverage. If only axial motion exists, the insulation tape cannot wrap around the coil surface. Therefore, it is necessary to establish a synchronous relationship between rotation and axial motion so that the insulation tape is continuously laid along the spatial spiral path. If the synchronous relationship is not established, problems such as inconsistent pitch, changes in interlayer overlap, and wrapping tape skew will occur. Therefore, it is necessary to establish a real-time correctable synchronous control relationship between rotation and axial motion based on stable tension.

[0043] Based on a stable tension state, the target pitch is set according to the insulation tape width and interlayer overlap requirements. A synchronous correspondence between rotational and axial motion is established. The axial movement speed is calculated based on the current rotational state, and rotational and axial synchronous control is executed. By calculating the synchronization error, the axial motor output is corrected to form a continuous spiral wrapping trajectory, thereby establishing a spiral wrapping geometric path. This ensures that the insulation tape maintains a stable trajectory relationship, achieves full surface coverage, guarantees uniform interlayer coverage and consistent wrapping pitch, avoids local accumulation or sparseness, improves the overall insulation quality of the coil bar, and enhances the stability and consistency of the wrapping trajectory, providing a stable structure for subsequent pressing.

[0044] Methods for achieving rotational and axial synchronization control include: Obtain stable tension state: Read the tension state output by S2 to confirm that the current tension is within the set range, the tension fluctuation is within the allowable range, and the tension change trend is stable. Only under the premise of stable tension is it allowed to enter the synchronization control process, thereby avoiding the generation of unstable trajectory under tension fluctuation state.

[0045] Obtain real-time motion status: Obtain the real-time motion status of step S1, including the current rotation speed and angle, current axial position and movement speed, and establish the current motion reference.

[0046] Set target pitch parameters: Set the target pitch according to process requirements to determine the distance the wrapping head needs to move in the axial direction when rotating one revolution. The pitch is determined by multiple process factors, including the width of the insulation tape (the smaller the width, the smaller the pitch), the overlap ratio requirement (the higher the overlap rate, the smaller the pitch), and the number of wrapping layers requirement (multi-layer wrapping usually requires improving the uniformity between layers, and the pitch control is more stringent), etc., to establish a clear spatial motion target for subsequent synchronous control.

[0047] Establish a synchronous relationship between rotation and axial motion: Based on the target pitch, establish a correspondence between rotational motion and axial motion. That is, when the rotating shaft rotates through a certain angle, the axial mechanism must move the corresponding distance synchronously. When the rotation angle changes, the distance that the axial mechanism should move is calculated synchronously. When the axial position changes, the matching of the rotation angle is checked synchronously. Through bidirectional constraints, the rotation and axial motion are kept consistent, forming a stable helical trajectory.

[0048] Generate axial movement control signal: Since the rotational speed of the coil bar may change during operation, the axial feed speed cannot be kept at a fixed value. Otherwise, when the rotational speed increases, the pitch will decrease, and when the rotational speed decreases, the pitch will increase. Therefore, the axial movement speed is calculated with the rotational motion as the reference. That is, when the rotational speed changes, the axial movement speed is adjusted synchronously to ensure that a fixed axial displacement corresponds to a unit rotation.

[0049] Rotational and axial synchronous control is implemented: the rotary motor and the axial motor operate simultaneously in a synchronous relationship. The rotary motor maintains a set angular velocity, and the axial motor moves proportionally. During operation, the actual rotation angle and actual axial position are continuously detected to determine the synchronization error, that is, the difference between the actual axial position and the theoretical axial position. Based on the error result, the output of the axial motor is increased or decreased, thereby dynamically eliminating the error and ensuring that the rotational motion and axial motion always remain synchronized.

[0050] Forming a continuous spiral wrapping track: Under synchronous control, the insulation tape forms a continuous spiral path along the coil surface. The spacing between each turn of this path is consistent, the interlayer overlap is uniform, and there is no obvious offset or discontinuity, thus forming a spiral wrapping track that meets the process requirements.

[0051] Furthermore, the target pitch includes: in: The target pitch, the axial distance that corresponds to one revolution of the coil, determines the geometry of the helical wrapping structure. Insulating tape width: The physical width of a single insulating tape determines the covering capacity and minimum pitch of the tape, and is determined by the material specifications; Overlap ratio: The overlap ratio between adjacent wrapping layers affects the density and electrical performance of the insulation layer. It is set according to process requirements and is usually in the range of 0 to 0.8. The target pitch is obtained based on the width and overlap ratio of the insulating tape.

[0052] Furthermore, the synchronization correspondence includes: in: Axial velocity, which is the speed at which the tape head moves along the axis of the coil, represents the theoretically target axial velocity that should be achieved under the current rotational speed conditions; Rotational angular velocity, i.e., the instantaneous angular velocity of the coil bar rotating around the axis, determines the circumferential unfolding speed of the helical trajectory, and is obtained through the real-time motion state of S1; Based on the target pitch and the current rotational angular velocity, the corresponding axial velocity is calculated.

[0053] Furthermore, the synchronization error includes: in: Synchronization error represents the deviation between the actual axial position and the theoretical position, and is used to measure the accuracy of rotational and axial synchronization. In time The axial position at any given moment represents the real-time position of the tape head in the axial direction, used to determine the current tape coverage area and trajectory integrity. It is calculated by accumulating the real-time motion state or axial velocity of S1. In time The cumulative rotation angle at any given time is used to determine the current winding position of the insulating tape, and is calculated by accumulating the rotational angular velocity. The synchronization error is obtained by comparing the theoretical axial position calculated from the target pitch and cumulative rotation angle with the actual axial position at the current moment.

[0054] S4. Compact the layers according to the spiral tape trajectory to obtain a uniform insulation layer.

[0055] In this embodiment, the interlayer compression includes: During the coil bar wrapping process, relying solely on the tension of the insulation tape itself cannot fully guarantee the stability of the interlayer structure. The main reasons include the material springback characteristics of the insulation tape, the easy formation of air gaps between layers, which reduces thermal conductivity and electrical withstand voltage performance, the tendency for interlayer slippage to occur during high-speed wrapping, leading to cumulative errors, and uneven thickness after multiple layers are stacked, affecting the assembly accuracy and insulation consistency of the motor. Therefore, it is necessary to eliminate the influence of material springback through external compression, reduce errors, achieve interlayer homogenization, and make the insulation layer form a stable, uniform, and dense structure.

[0056] Based on the obtained spiral wrapping tape trajectory, a target pressing pressure is set to perform interlayer pressing, and the current pressing status is continuously monitored and the pressure is adjusted accordingly. Each layer of insulation tape is continuously pressed to form a uniform insulation layer, thereby improving the interlayer adhesion, reducing interlayer gaps, maintaining uniform insulation layer thickness, improving the stability of the wrapping tape structure, and enhancing the adaptability to subsequent processes.

[0057] The steps to achieve interlayer compaction include: Read the spiral tape trajectory: Read the trajectory status information output by S3, such as the current rotation angle, current axial position, current pitch status and current tape coverage area, to determine the current pressing position of the pressing wheel. Since the pressing process must be carried out continuously along the spiral trajectory, the movement path of the pressing wheel needs to be synchronized with the tape trajectory in S3.

[0058] Set the target clamping pressure: Set the target clamping pressure according to the current process parameters. The target pressure is related to factors such as the thickness of the insulation tape, the current number of layers, the material hardness, and the wrapping speed. Send an initial clamping command to the clamping mechanism to make the clamping roller contact the surface of the insulation layer and apply continuous pressure to the insulation tape so that the insulation tape gradually adheres to the surface of the coil.

[0059] Detecting the current compaction status: During the compaction process, the sensor continuously detects the force state of the compaction wheel, and reads the current pressure, pressure change trend and compaction position status in real time. If a sudden increase in pressure is detected, it indicates that there may be thickness accumulation in a local area. If the pressure suddenly decreases, it indicates that there may be insufficient compaction or voids in a local area, thus reflecting the interlayer structure status in real time.

[0060] Generate a clamping correction control signal: compare the current clamping force with the target pressure, calculate the clamping deviation. If the current clamping force is too large, reduce the downward pressure of the clamping wheel; if the current clamping force is too small, increase the downward pressure of the clamping wheel. At the same time, combined with the current spiral trajectory position, synchronously adjust the axial position of the clamping wheel so that the clamping wheel is always located in the area corresponding to the current wrapping layer, thereby realizing the joint control of pressure regulation and trajectory synchronization.

[0061] Perform continuous interlayer pressing: The pressing wheel moves continuously along the axial direction under the drive of the servo mechanism, while the coil bar rotates continuously, so that the pressing wheel continuously presses each layer of insulation tape along the spiral trajectory. Throughout the process, pressure detection, pressure correction and position synchronization are continuously performed to ensure that the entire insulation layer is continuously and stably pressed.

[0062] Forming a uniform insulation layer structure: After continuous compression, the insulation layer gradually forms a stable and dense structure with uniform interlayer bonding, smooth surface, consistent thickness, no obvious gaps and no local bulges, ultimately forming a uniform insulation layer that meets the process requirements.

[0063] S5. Adjust the wrapping tape in multiple segments according to the uniform insulation layer to obtain a structure with local pitch variation.

[0064] In this embodiment, the multi-segment strap adjustment includes: During the coil wrapping process, the requirements for insulation layer thickness and coverage density are not entirely consistent across different regions. If a fixed pitch is used for wrapping the entire coil, problems such as insufficient insulation capacity or excessive material accumulation in local areas can easily occur. For example, the local electric field intensity is usually higher at coil ends, corner areas, and interlayer transition areas, making partial discharge and insulation aging more likely. It is necessary to increase the local insulation layer coverage density in these areas. Areas with curvature changes are prone to interlayer gaps, requiring a reduction in the local pitch to increase the interlayer overlap ratio and enhance bonding ability. Furthermore, a fixed pitch can easily lead to uneven material distribution and error accumulation. Therefore, it is necessary to locally change the pitch to create insulation structures with different coverage densities in different areas.

[0065] Based on a uniform insulation layer, multiple wrapping areas are divided, and a correspondence between different segmented areas and local pitch is established. Under the control of local pitch, the newly added insulation tape layer is wrapped and pressed in multiple segments to form a structure with varying local pitch. This improves the local insulation coverage, enhances the bonding stability of curved areas, and makes the distribution of insulation material in different areas more balanced, providing a stable structure for subsequent steps.

[0066] Methods for adjusting multi-segment straps include: Read the uniform insulation layer status: Read the insulation layer status information output by S4, including the current insulation layer thickness (to determine whether the subsequent addition of the wrapping layer will exceed the allowable thickness of the process), the current number of wrapping layers (to determine which wrapping stage it is currently in), the current axial position, and the current spiral trajectory position, etc., to determine that the current insulation layer has met the conditions for continued laying, and to determine the starting position of the subsequent addition of the insulation tape layer.

[0067] Divide the wrapping area into multiple segments: The wrapping area is divided into segments according to the coil structure characteristics. Different segments correspond to different wrapping requirements, such as the middle straight area, the end area, the curvature change area, and the interlayer transition area. Set corresponding pitches for different areas. For example, use a smaller pitch for areas with higher insulation requirements, a medium pitch for areas with curvature changes, and a larger pitch for areas with stable structures, thereby establishing a segmented wrapping structure.

[0068] Establish local pitch correspondence: For different segmented regions, based on the target pitch corresponding to the region, re-establish the correspondence between rotational speed and axial speed. When entering a certain region, switch the current target pitch. Based on the synchronous control steps of rotation and axial movement, adjust the axial movement speed so that the newly added insulation tape layer forms a new local spiral coverage trajectory. For example, when the target pitch decreases, the axial movement distance corresponding to a unit rotation decreases synchronously, thereby increasing the insulation tape overlap ratio.

[0069] Generate local pitch switching control signal: continuously detect the current axial position, and generate the corresponding pitch switching control signal when a new segment area is detected. The axial servo driver receives the new speed command and maintains stable tension, continuous wrapping tape and continuous trajectory throughout the switching process to avoid wrapping tape jump, local stretching or interlayer error during the switching moment.

[0070] Execute continuous wrapping of the new insulating tape layer: Under the action of local pitch control, the new insulating tape layer continues to be laid along the surface of the stable insulating layer formed by S4. As the coil continues to rotate, the insulating tape forms different overlap densities in different areas. Throughout the process, position synchronization, tension control and pitch switching control are continuously performed to ensure the continuous and stable laying of the new insulating tape layer.

[0071] The newly added insulating tape layer is track-following and compacted: The current local pitch status and the current tape trajectory position are read. Since different areas use different pitches, the compaction wheel cannot continue to run at a fixed axial speed. Otherwise, it is easy to miss or repeat the compaction. It is necessary to re-establish the movement path of the compaction wheel according to the current local pitch relationship. For example, when entering the small pitch area, the axial movement speed of the compaction wheel is reduced synchronously to increase the local compaction coverage density. When entering the large pitch area, the axial movement speed of the compaction wheel is increased synchronously to prevent repeated compaction. During the compaction process, the current pressure is continuously detected and the pressure is adjusted to re-compact the newly formed local pitch variation insulation layer in S5, so that the newly added insulating tape layer forms a stable bonding structure. Forming a locally pitch-variable insulation structure: After multiple wrapping and compression, the entire insulation layer forms a locally pitch-variable structure. Different areas have different coverage densities, the insulation layer is thicker in the locally reinforced areas, the interlayer bonding is tighter in the curvature areas, and the overall structure transitions continuously, ultimately forming a multi-layer wrapping structure that meets the insulation requirements of different areas.

[0072] S6. Perform closed-loop control throughout the entire process based on the local pitch change structure to obtain the final tape completion state.

[0073] In this embodiment, the full closed-loop control includes: In the process of multi-layer and multi-segment wrapping, relying solely on local control cannot guarantee the consistency of the final overall quality. The main reasons include cumulative errors caused by multi-segment pitch switching, dynamic deviations caused by tension and motion coupling, and nonlinear thickness changes caused by multi-layer stacking. Without full closed-loop constraints, the final wrapping state may deviate from the target.

[0074] Based on the obtained local pitch change structure, the current multi-segment wrapping state is obtained. Combined with the whole-process target reference relationship, the current global deviation is analyzed, and comprehensive correction control is carried out to achieve full-process closed-loop adjustment, forming the final wrapping state. This eliminates the cumulative error of the multi-segment structure, ensures the overall consistency of the final spiral trajectory, controls the overall thickness of the insulation layer to be uniform, and improves the stability of the final wrapping quality.

[0075] The steps of the entire closed-loop control process include: Tape status acquisition: Based on the local pitch change structure, the current multi-segment tape status is acquired, including the current axial position, current rotation angle, current pitch of each region, current number of tape layers, current insulation layer thickness, and current tension status. This constitutes the status description of the entire tape process and establishes a unified status basis required for global control.

[0076] Establish a complete target reference relationship: Based on the process settings, establish a complete target relationship from the start point to the end point of the wrapping tape, including the target pitch corresponding to each axial position, the target thickness corresponding to each wrapping tape layer, the tension range corresponding to each operating stage, and the synchronous motion relationship corresponding to different regions. This target relationship changes with the axial position. In this way, the corresponding target state can be obtained at any position, providing a dynamic target benchmark for subsequent deviation calculation.

[0077] Calculate the current global deviation: Compare the real-time motion state with the target reference to obtain the deviation, including pitch deviation, thickness deviation, tension deviation and synchronization error. By calculating the deviation of multiple parameters at the same time, the overall operation error state is obtained.

[0078] Generate comprehensive correction control signals: Based on various deviations, correction signals are generated and distributed to different actuators. For tension deviations, the speed of the belt pulley is adjusted; for pitch deviations, the axial speed is adjusted; for thickness deviations, the pressure of the clamping wheel is adjusted; and for synchronization errors, the axial position is corrected. When generating correction signals, the coordination relationship between variables is maintained to avoid new deviations caused by single adjustments, thereby achieving multi-variable coordinated control.

[0079] Full-process closed-loop regulation: During operation, real-time detection, deviation calculation, control correction and status update are continuously performed in cycles. Each actuator (rotary motor, axial motor, wrapping wheel, clamping mechanism) responds synchronously to control commands until the wrapping process ends, thereby achieving continuous closed-loop regulation and eliminating instantaneous disturbances and cumulative errors.

[0080] The final wrapped tape is completed: Under the closed-loop control throughout the process, a stable and complete insulation wrapped tape structure is obtained, forming the final wrapped tape completion state. The pitch of each area meets the set requirements, the interlayer coverage is uniform, the insulation layer thickness is consistent, the multi-layer structure transitions smoothly and there is no obvious deviation or local abnormality.

[0081] Example 2: Reference Figure 2 This is a second embodiment of the present invention, which provides an electrical control system for a coil bar wrapping machine, including the following functional modules: Motion status detection module: used to detect the running status of the coil bar in real time during the wrapping process, providing basic motion parameters for subsequent tension control, trajectory control and synchronization control.

[0082] The wrapping tape tension control module is used to control the stress state of the insulating tape during the unwrapping process, so that the insulating tape maintains a stable tension during continuous wrapping.

[0083] Rotational Axial Synchronization Control Module: Used to establish a synchronous relationship between the rotational motion of the coil and the axial movement of the wrapping head, so that the insulating tape forms a stable spiral wrapping trajectory.

[0084] Interlayer compression control module: used to continuously compress the insulating tape layers to form a stable bonding structure between the insulating tape layers.

[0085] Multi-segment wrapping adjustment module: used to adjust the wrapping tape pitch in segments according to the insulation requirements of different areas, so that different areas can form different coverage densities.

[0086] Closed-loop control module: Used to coordinate and control the entire wrapping process, ensuring that the multi-layer wrapping structure remains consistent throughout the entire process.

[0087] Example 3: In practical applications, this invention can be applied to the production of high-voltage motor coil insulation tape, and is used to continuously spirally wrap the outer surface of the coil bar with multiple layers of insulation tape. The following is an illustration using a 6kV high-voltage motor stator bar insulation tape production line as a typical scenario.

[0088] After the wire bar enters the wrapping station, the clamping and rotating mechanism first clamps both ends of the wire bar synchronously. A rotary servo motor drives the wire bar to rotate continuously around its own axis, and a rotary encoder detects the current rotation angle and speed in real time. An axial servo mechanism synchronously drives the wrapping head to move along the length of the wire bar, and a position encoder detects the current axial position in real time. The controller establishes a real-time motion state based on the current rotation angle and axial displacement, ensuring that the wrapping head always runs along a preset trajectory during rotation.

[0089] During the tape unwinding process, a tension sensor continuously monitors the current tension of the insulating tape. When the detected tension exceeds the target tension, the controller increases the speed of the wrapping wheel drive motor, increasing the tape unwinding speed and reducing the stretching of the tape. When the detected tension falls below the target tension, the controller reduces the wrapping wheel speed, maintaining a stable and close fit of the insulating tape. Throughout the continuous rotation of the wire rod, the insulating tape tension remains within the set range, preventing tape slack, edge lifting, and localized stretching deformation during the wrapping process.

[0090] When forming the spiral wrapping trajectory, the controller establishes a correspondence between rotational speed and axial movement speed based on the target pitch. For example, when the bar rotates once, the wrapping head moves 4mm axially, and the insulation tape forms a corresponding spiral covering trajectory. During operation, the controller continuously monitors the synchronization status between the current rotational speed and axial speed. When the actual axial movement distance is detected to be too large, the axial servo motor speed is reduced; when the actual axial movement distance is detected to be too small, the axial movement speed is increased, thereby ensuring that the overlap ratio of the insulation tape remains consistent, resulting in a continuous and stable spiral wrapping structure on the bar surface.

[0091] After the insulating tape completes one spiral wrap, the clamping mechanism operates synchronously along the current spiral trajectory, with the clamping rollers applying continuous pressure to the surface of the insulating tape. A pressure sensor monitors the current clamping force in real time. When the clamping force in a local area exceeds the set value, the controller reduces the pressure of the clamping rollers; when the clamping force is below the set value, the pressure of the clamping rollers is increased, ensuring stable adhesion between the insulating tape and the wire bar surface, as well as the interlayer structure. After continuous clamping, a uniform and dense structure is formed on the surface of the insulation layer, eliminating interlayer gaps and localized suspended areas.

[0092] When the wrapping tape reaches the end region of the bar, due to the curvature change at the bar end, the current target pitch needs to be switched, adjusting the axial movement distance from 4mm per revolution to 2.5mm per revolution, resulting in a higher overlap ratio of the insulation tape in the end region. After entering the middle straight region, the original pitch parameters are restored to improve the overall wrapping efficiency. During the switching between different regions, the controller synchronously adjusts the ratio between axial speed and rotational speed to keep the local pitch change process continuous, avoiding interlayer misalignment and trajectory jumps.

[0093] After the new insulating tape layer is formed, the clamping roller readjusts its movement path according to the current local pitch. In the small pitch area, the axial movement speed of the clamping roller is reduced synchronously to increase the clamping coverage density; in the large pitch area, the clamping roller resumes its normal movement speed and continuously monitors the surface thickness of the new insulating layer and the clamping status to avoid local material accumulation or interlayer bulging in the small pitch area.

[0094] Throughout the wrapping process, the global closed-loop control module continuously monitors the current pitch, insulation thickness, tension, and rotational synchronization error. When an increase in insulation thickness is detected in a certain area, the controller synchronously corrects the pressure of the clamping rollers and the axial movement speed; when an increase in pitch deviation is detected, the synchronization ratio between rotational speed and axial speed is readjusted. Through continuous closed-loop adjustment throughout the entire process, the multi-layer insulation structure maintains a consistent coverage state along the entire length of the wire rod.

[0095] The resulting high-voltage line bar insulation layer has a continuous spiral covering structure, uniform bonding between insulation tape layers, coverage density in different areas meets the set requirements, and the overall thickness of the insulation layer remains consistent, thus meeting the requirements for subsequent impregnation, hot pressing curing, and assembly and operation of the high-voltage motor line bar.

[0096] Example 4: This embodiment also provides a computer device applicable to the electrical control method and system of a coil bar wrapping machine, including a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to realize the electrical control method and system of the coil bar wrapping machine as proposed in the above embodiment.

[0097] This embodiment also provides a storage medium storing a computer program, which, when executed by a processor, implements the electrical control method and system for the coil bar wrapping machine as proposed in the above embodiments.

[0098] The computer device can be a terminal, comprising a processor, memory, communication interface, display screen, and input devices connected via a system bus. The processor provides computing and control capabilities. The memory includes non-volatile storage media and internal memory. The non-volatile storage media stores the operating system and computer programs. The internal memory provides an environment for the operation of the operating system and computer programs stored in the non-volatile storage media. The communication interface is used for wired or wireless communication with external terminals; wireless communication can be achieved through Wi-Fi, carrier networks, NFC (Near Field Communication), or other technologies. The display screen can be an LCD screen or an e-ink screen. The input devices can be a touch layer covering the display screen, buttons, a trackball, or a touchpad on the computer device's casing, or an external keyboard, touchpad, or mouse.

[0099] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0100] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequenced list of executable instructions for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, an instruction execution system, apparatus, or device (such as a computer-based system, a processor-including system, or other system that can fetch and execute instructions from, an instruction execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can be any means that can contain, store, communicate, propagate, or transmit programs for use by, or in conjunction with, an instruction execution system, apparatus, or device.

[0101] More specific examples (a non-exhaustive list) of computer-readable media include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which programs can be printed, because programs can be obtained electronically, for example, by optically scanning the paper or other media, followed by editing, interpreting, or otherwise processing as necessary, and then stored in computer memory.

[0102] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable instruction execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0103] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. An electrical control method for a coil bar wrapping machine, characterized in that, Includes the following steps: S1. The coil bar rotation and position acquisition are used to obtain the real-time motion state; S2. Control the strap tension based on the real-time motion state to obtain a stable tension state; S3. Based on the stable tension state, perform synchronous control of rotation and axial direction to obtain the spiral wrapping trajectory; S4. Compact the layers according to the spiral tape trajectory to obtain a uniform insulation layer; S5. Adjust the wrapping tape in multiple segments according to the uniform insulation layer to obtain a structure with local pitch variation. S6. Perform closed-loop control throughout the entire process based on the local pitch change structure to obtain the final tape completion state.

2. The coil taping machine electrical control method of claim 1, wherein, The coil bar rotation and position acquisition in step S1 include: By installing a rotary encoder and a position detection device, rotation and displacement signals are synchronously acquired, establishing a correspondence between rotation and displacement states. The acquired signals are then filtered to obtain the real-time motion state.

3. The coil taping machine electrical control method of claim 1, wherein, The tape tension control in step S2 includes: Based on the obtained real-time motion state, the correspondence between motion state and tension is established through the tension detection structure. The tension deviation is calculated based on the current actual tension and the target tension, and the belt pulley speed is corrected based on the tension deviation result, ultimately forming a stable tension state.

4. The coil taping machine electrical control method of claim 1, wherein, The rotational and axial synchronization control in step S3 includes: Based on the stable tension state, the target pitch is set according to the width of the insulating tape and the interlayer overlap requirements. The synchronous correspondence between the rotational motion and the axial motion is established. The axial movement speed is calculated based on the current rotational state. Rotation and axial synchronous control are executed. The axial motor output is corrected by calculating the synchronization error to form a continuous spiral wrapping trajectory.

5. The electrical control method for a coil bar wrapping machine according to claim 4, characterized in that, The target pitch includes: in: : target pitch; : width of insulation band; : overlap ratio; The target pitch is obtained based on the width and overlap ratio of the insulating tape.

6. The electrical control method of a coil taping machine as defined in claim 4, wherein, The synchronization correspondence includes: in: : axial velocity; : rotational angular velocity; Based on the target pitch and the current rotational angular velocity, the corresponding axial velocity is calculated.

7. The electrical control method of a coil taping machine as defined in claim 4, wherein, The synchronization error includes: in: : synchronization error; : at the time axial position at the time : at time cumulative rotation angle at the time The synchronization error is obtained by comparing the theoretical axial position calculated from the target pitch and cumulative rotation angle with the actual axial position at the current moment.

8. The method of claim 1, wherein, The interlayer compaction in step S4 includes: Based on the obtained spiral wrapping tape trajectory, the target pressure is set for interlayer compression, and the current compression status is continuously monitored and the pressure is adjusted accordingly to continuously compress each layer of insulation tape and form a uniform insulation layer.

9. The method of claim 1, wherein, The multi-segment strap adjustment in step S5 includes: Based on a uniform insulation layer, multiple wrapping areas are divided, and a correspondence between different segmented areas and local pitch is established. Under the control of local pitch, the newly added insulation tape layer is wrapped and compressed in multiple segments to form a structure with varying local pitch.

10. An electrical control system for a coil bar wrapping machine, constructed based on the electrical control method for a coil bar wrapping machine according to any one of claims 1-9, characterized in that, Includes the following functional modules: The system includes a motion state detection module, a strap tension control module, a rotation axis synchronization control module, an interlayer compression control module, a multi-segment strap adjustment module, and a closed-loop control module.

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