A coupling capacitor core packing and synchronous measurement feedback control method and system

Abstract

The application discloses a kind of coupling capacitor core packing and synchronous measurement feedback control method and system, belong to coupling capacitor manufacturing technical field.The method includes: in the state that capacitor core keeps constant pressing force, the actual capacitance and actual height of capacitor core in the state of pressing are obtained;When actual capacitance or actual height exceeds corresponding target interval, the capacitance deviation interval of single element is calculated according to capacitance deviation and element quantity, and then the packing parameter adjustment interval is determined;In the adjustment interval, the value is taken according to preset adjustment step, the capacitance value and height value of adjusted capacitor core corresponding to each value are predicted, and multiple groups of candidate arrays are generated;From candidate array, the scheme that adjusted capacitance value and height value both fall into target interval is filtered out, a group that capacitance value is closest to target interval center value is selected, and the corresponding packing parameter adjustment amount is obtained.The application guarantees the consistency of pressing with constant pressure pressing, realizes real-time quality determination with online synchronous measurement in the state of pressing, quantitatively adjusts the suggestion by optimization output from candidate array, reduces rework, and improves production efficiency.

Description

Technical Field

[0001] This invention relates to the field of capacitor manufacturing technology, specifically to a method and system for packaging and synchronously measuring feedback control of coupled capacitor cores. Background Technology

[0002] The coupling capacitor core is the core component of a capacitive voltage transformer, composed of several capacitor elements assembled through pressing, lead connection, and packaging. Capacitance is a key technical parameter of the capacitor and must be controlled within a specified tolerance range. During the element winding process, microscopic air gaps inevitably remain between the dielectric material layers, resulting in the actual thickness after winding being greater than the sum of the pure thicknesses of each dielectric layer. The ratio of these two is the compression factor. This factor reflects the tightness of the bonding between the dielectric layers, directly affecting the equivalent dielectric constant of the core, and thus determining the final capacitance. If the compression factor is too low, the core structure is loose, making it difficult to guarantee the stability and consistency of the capacitance; if the compression factor is too high, the interlayer bonding is too tight, hindering the penetration of the impregnating agent into the micro-gaps, affecting the impregnation effect and long-term reliability. Therefore, the compression factor must be controlled within a reasonable range.

[0003] Traditional core packing methods target a fixed height, relying on manual judgment of compression. Operators determine core tightness by feel or visual inspection, leading to inconsistencies between operators and even between different batches by the same operator. This results in significant variations in the core compression coefficient for products of the same specification. Furthermore, the fixed height control method cannot overcome the influence of raw material thickness variations: the dielectric film thickness itself exhibits manufacturing variations, resulting in over-compression of thicker cores and under-compression of thinner cores. Additionally, capacity testing can only be performed after core packing, creating a delay in the testing process and hindering online synchronous measurement and timely feedback, leading to rework and inefficiency. When a capacity defect is detected, it's impossible to determine whether the deviation stems from compression or winding parameters, requiring adjustments based solely on the experience of highly skilled operators or technicians.

[0004] Therefore, there is an urgent need for a control system and method that can simultaneously measure capacitance and height online under the packaging and pressing state, and automatically provide suggestions for adjusting winding parameters based on the measurement results, so as to achieve consistent control of the pressing degree and closed-loop regulation of capacitance. Summary of the Invention

[0005] To address the problems existing in the prior art, this invention provides a method and system for the synchronous measurement feedback control of coupled capacitor core packaging. The method achieves constant pressure packaging through pressure closed-loop control, and synchronously measures the capacitance and height of the core under the compressed state. The measured values ​​are automatically compared with the preset target value range, and adjustment suggestions for winding parameters are output in stages according to the deviation amount. This achieves consistent control of the capacitor core compression quality and closed-loop regulation of the capacitance.

[0006] This invention is achieved through the following technical solution: In a first aspect, this application provides a method for packaging and synchronously measuring feedback control of coupled capacitor cores, comprising the following steps: Step 1: Under the condition that the capacitor core is kept under constant clamping force, obtain the actual capacitance and actual height of the capacitor core under the clamping state; Step 2: When the actual capacitance or the actual height exceeds the corresponding target range, calculate the capacitance deviation range of a single element based on the capacitance deviation and the number of elements in the capacitor core, and determine the packing parameter adjustment range based on the capacitance deviation range. Step 3: Within the packaging parameter adjustment range, take values ​​according to a preset adjustment step size, predict the adjusted capacitor core capacitance value and adjusted capacitor core height value corresponding to each value, and generate multiple candidate arrays; Step 4: Select candidate arrays from the multiple candidate arrays where both the adjusted capacitance value and the adjusted height value fall within the corresponding target interval. Select the candidate array whose adjusted capacitance value is closest to the center value of the target interval to obtain the corresponding packaging parameters.

[0007] Preferably, the packaging parameters are winding parameters or the number of components; the winding parameters are electrode length or the number of component turns.

[0008] Preferably, in step 1, the constant clamping force is obtained as follows: Obtain the actual clamping force of the capacitor core, and adjust the actual clamping force according to the deviation between the actual clamping force and the preset pressure value, so that the actual clamping force is maintained within the allowable fluctuation range of the preset pressure value.

[0009] Preferably, the preset pressure value is calibrated according to the given clamping coefficient and process data for the corresponding allowable fluctuation range; The compression coefficient is the ratio of the arithmetic sum of the thicknesses of all dielectric material layers inside the capacitor core to the measured height of the core as a whole under pressure.

[0010] Preferably, in step 2, the method for calculating the capacitance deviation range of the individual element is as follows: Based on the difference between the lower and upper boundaries of the actual capacitance and the target capacitance value range, the total capacitance deviation range of the capacitor core is determined. Then, combined with the number of series connections of the components in the capacitor core, the total capacitance deviation range is converted into the capacitance deviation range of a single component.

[0011] Preferably, determining the packing parameter adjustment range based on the capacitance deviation range includes: The packing parameter adjustment range is determined based on the capacitance deviation range of the individual component and the capacitance change of the component corresponding to the unit packing parameter.

[0012] Preferably, in step 3, the predicted values ​​of the adjusted capacitor core capacitance and the adjusted capacitor core height corresponding to each value include: Based on the adjustment amount of the packaging parameters corresponding to the values, combined with the dielectric thickness, compression coefficient, and electrode thickness, the adjusted capacitor core capacitance and capacitor core height are predicted.

[0013] Preferably, when the capacitor core cannot be made to meet the target range by adjusting the packing parameters based on the capacitance deviation and height deviation; First, adjust the number of components, then recalculate the capacitor deviation range and the packing parameter adjustment range, generate a candidate array, and output the best one that includes both the component quantity adjustment and the packing parameter adjustment.

[0014] Secondly, this application also provides a coupled capacitor core packing and synchronous measurement feedback control system, including a measuring device and a control unit; The measuring device is integrated into the packaging device and is used to measure the actual capacitance, actual height and number of components of the capacitor core under compressed conditions. The control unit is signal-connected to the measuring device and is used to compare the actual capacitance and actual height with the preset target capacitance value and preset target height value, respectively. When the comparison result does not meet the error requirements, the control unit calculates the packing parameters based on the capacitance deviation, height deviation and number of components.

[0015] Preferably, the capacitance measurement unit includes at least two measuring electrodes and a capacitance measurement circuit; When the at least two measuring electrodes are pressed together, they respectively form electrical contact with the corresponding leads or plates of the capacitor core, and the capacitance measuring circuit obtains the capacitance value through the measuring electrodes. The height measuring unit is a displacement sensor, located at the follow-up position of the pressure head of the packaging device, and obtains the actual height value by detecting the amount of travel displacement of the pressure head relative to the reference surface.

[0016] Compared with the prior art, the present invention has the following beneficial technical effects: This application provides a feedback control method for packaging and synchronous measurement of coupled capacitor cores. It obtains the actual capacitance and height of the capacitor cores while maintaining a constant clamping force, replacing traditional fixed-height clamping with constant pressure. This eliminates the impact of raw material thickness dispersion on the consistency of clamping, while ensuring the measurement state matches the final usage state of the cores. When the measured value exceeds the target range, the capacitance deviation range of a single component is calculated based on the capacitance deviation and the number of components. The packaging parameter adjustment range is then determined based on the capacitance deviation range, converting the overall core deviation into component-level adjustment. Within the adjustment range, values ​​are taken at preset steps, predicting the adjusted core capacitance and height values ​​corresponding to each value, generating multiple candidate arrays. The adjustment effect is verified through prediction calculations. Step four selects the scheme that simultaneously satisfies the target capacitance and height ranges from the candidate arrays, choosing the set with the capacitance value closest to the center value of the target range as the optimal output. This method can detect deviations and provide quantitative parameter adjustment suggestions during the packaging stage, eliminating reliance on the experience judgment of highly skilled personnel and reducing rework and process waste.

[0017] This application also proposes a coupled capacitor core packing and synchronous measurement feedback control system, an electronic device, and a computer storage medium, which possess all the advantages of the above-mentioned coupled capacitor core packing and synchronous measurement feedback control method. Attached Figure Description

[0018] To more clearly illustrate the technical solutions of the embodiments of this application, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this application and should not be regarded as a limitation of the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1 This is a schematic diagram of the coupling capacitor core packaging and synchronous measurement feedback control system of the present invention; Figure 2 This is a flowchart of the coupling capacitor core packaging and synchronous measurement feedback control method of the present invention. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. The components of the embodiments of this application described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of this application provided in the accompanying drawings is not intended to limit the scope of the claimed application, but merely to illustrate selected embodiments of the application. All other embodiments obtained by those skilled in the art based on the embodiments of this application without inventive effort are within the scope of protection of this application.

[0022] See Figure 1 In a first aspect, this embodiment provides a coupling capacitor core packaging and synchronous measurement feedback control system, including an automatic clamping device, a measuring device, and a control unit; The automatic clamping device is used to apply a preset constant pressure value to the stacked capacitor cores for clamping. The measuring device is integrated into the station of the automatic clamping device and is used to measure the actual capacitance and actual height of the capacitor core under the clamping state. The control unit is signal-connected to the automatic clamping device and the measuring device, and is used to compare the measured capacitance and measured height with the preset target capacitance value and preset target height value, respectively. When the comparison result does not meet the error requirements, the control unit outputs adjustment suggestions for the automatic clamping device based on the deviation.

[0023] The system's automatic clamping device detects the clamping force in real time through a measuring device and feeds it back to the control unit, dynamically adjusting the output of the clamping drive mechanism. This ensures that the core is always subjected to a preset constant pressure during the packaging process, replacing the traditional packaging method that uses a fixed height as the control target. This eliminates the impact of raw material thickness dispersion on the consistency of clamping. The measuring device is integrated into the station of the automatic clamping device, simultaneously measuring the actual capacitance and actual height of the core under clamping conditions. The measurement status is consistent with the final working state of the core, avoiding capacitance value deviation caused by the rebound of the dielectric layer after the clamping force is released. The control unit automatically compares the measured values ​​with the preset target range. When the deviation exceeds the limit, it outputs adjustment suggestions for winding parameters according to the capacitance deviation and height deviation, transforming quality control from post-event sampling to in-process intervention. Deviations are detected and corrected in time during the packaging stage, reducing rework and process waste, and reducing reliance on highly skilled operators.

[0024] In some embodiments, the automatic clamping device includes a clamping drive mechanism, a pressure sensor, and a pressure closed-loop controller; The pressure sensor detects the pressure applied to the capacitor core in real time and feeds the detection result back to the pressure closed-loop controller. The pressure closed-loop controller dynamically adjusts the output of the clamping drive mechanism based on the feedback signal from the pressure sensor, so that the actual pressure value is maintained within the allowable fluctuation range of the preset pressure value.

[0025] The automatic clamping device achieves constant pressure packaging through closed-loop pressure control. Pressure sensors provide real-time feedback of the actual pressure value, and the closed-loop pressure controller dynamically compensates for the output of the clamping drive mechanism, ensuring that the core is always subjected to a stable and consistent clamping force during the packaging process. This replaces the traditional packaging method that uses a fixed height as the control target, eliminating the impact of raw material thickness dispersion on the consistency of clamping at the source.

[0026] Furthermore, the preset pressure value and allowable fluctuation range are calibrated based on the clamping coefficient given in the design process and combined with the process data; in actual use, different preset pressure values ​​can also be set according to the differences in the geometric dimensions of capacitor elements of different specifications.

[0027] The clamping drive mechanism is one of a hydraulic cylinder, a pneumatic cylinder, a servo electric cylinder, or a screw drive mechanism. The pressure sensor is one of a piezoelectric pressure sensor, a strain gauge pressure sensor, or a capacitive pressure sensor.

[0028] As a specific example, the pressure sensor is a strain gauge pressure sensor, installed on the pressure-bearing surface between the pressure head of the clamping drive mechanism and the capacitor core. When the clamping drive mechanism drives the pressure head downward to press the capacitor core, the clamping force is transmitted to the strain gauge pressure sensor through the pressure head. The strain gauge undergoes elastic deformation and outputs a voltage signal proportional to the pressure value. The pressure closed-loop controller reads this voltage signal in real time, obtains the current actual pressure value after calibration and conversion, compares it with the preset pressure value, and dynamically adjusts the output of the clamping drive mechanism to keep the clamping force within the allowable fluctuation range of the preset pressure value.

[0029] In some embodiments, the preset pressure value of the automatic clamping device is calibrated based on the clamping coefficient given in the design process and combined with process data.

[0030] The compression coefficient is defined as the ratio of the arithmetic sum of the thicknesses of all dielectric material layers inside the capacitor core to the measured height of the core under pressure. The calibration process for the preset pressure value is as follows: During the process testing phase, different pressure values ​​are applied to capacitor cores of different specifications for compression, and the compression coefficient corresponding to each pressure value is measured to establish the correspondence between the pressure value and the compression coefficient. Based on the target value of the compression coefficient required by the design, the preset pressure value and its allowable fluctuation range for that specification of core are determined from the correspondence curve.

[0031] Based on the differences in the geometric dimensions of capacitor elements of different specifications, different preset pressure values ​​are calibrated and set to avoid inconsistent compression levels between products of different specifications due to size differences.

[0032] The allowable fluctuation range is determined based on the pressure stability data in the process test, and is preferably controlled within ±2% of the preset pressure value.

[0033] In some embodiments, the measurement device includes a capacitance measurement unit and a height measurement unit.

[0034] The capacitance measurement unit includes at least two measurement electrodes and a capacitance measurement circuit; the at least two measurement electrodes are respectively in electrical contact with the corresponding leading-out terminals or plates of the capacitor core; the capacitance measurement circuit obtains the capacitance value of the capacitor core through the measurement electrodes.

[0035] The height measurement unit is a displacement sensor, which is disposed at the follow-up position of the pressing head of the automatic pressing device, and obtains the actual height value of the capacitor core by detecting the stroke displacement of the pressing head relative to the reference plane; or is a laser displacement sensor disposed at the side of the capacitor core, and obtains the actual height value by directly measuring the distance between the top end of the core and the reference plane.

[0036] The capacitance measurement unit performs capacitance measurement when the capacitor core is in the packed and pressed state and the pressing force has not been released, so as to ensure that the measurement state is consistent with the final use state.

[0037] Further, the measurement electrode adopts an elastic telescopic probe structure to ensure the reliability of contact with the capacitor core; the capacitance measurement circuit is an LCR bridge or a resonant capacitance measurement circuit.

[0038] The measurement device is integrated on the station of the automatic pressing device, and the on-line measurement of capacitance and height can be completed synchronously without displacing the capacitor core in the pressed state. The capacitance measurement unit performs measurement when the pressed state is not released, the measurement state is consistent with the final working state of the capacitor core, and the capacitance value deviation caused by the rebound of the dielectric layer after the pressing force is released is avoided. The height measurement unit synchronously obtains the actual height of the capacitor core in the pressed state, and provides the measured height value for the control unit. This system eliminates the independent test station and transfer link, effectively shortens the detection cycle and improves production efficiency.

[0039] In some embodiments, the measurement device further includes an element quantity measurement unit, which collects image information of capacitor elements or capacitor cores through an industrial camera, and realizes automatic identification and statistics of the element quantity in combination with image processing and target detection algorithms.

[0040] Preferably, the industrial camera is a CCD industrial camera; The CCD industrial camera collects image information of capacitor elements or capacitor cores during the element assembly process, and realizes automatic identification and statistics of the element quantity in combination with image processing and target detection algorithms.

[0041] Preferably, the target detection algorithm is one of the following: YOLO target detection algorithm based on convolutional neural network, region-based fully convolutional network target detection algorithm, single-frame detector target detection algorithm, or instance segmentation algorithm based on image segmentation.

[0042] The image processing algorithm includes two stages: image preprocessing and target counting. The image preprocessing stage performs grayscale conversion, filtering and noise reduction, and edge enhancement on the images acquired by the industrial camera. The target counting stage identifies the closed contour of each capacitor element through a contour extraction algorithm, and the number of closed contours is counted to obtain the number of elements.

[0043] As a specific example, the object detection algorithm is the YOLO object detection algorithm based on a convolutional neural network. An industrial camera in the component quantity measurement unit acquires images from the side of the capacitor core and inputs these images into a pre-trained YOLO object detection model. The YOLO object detection model locates the outer contour of each capacitor component in the image and outputs the corresponding detection box and confidence score for each component. The number of detection boxes is then counted to obtain the component quantity. The YOLO object detection model is trained using an image dataset labeled with capacitor component contours, enabling high-precision counting even when the boundaries between component layers are clear.

[0044] The component quantity measurement unit uses an industrial camera to acquire image information in real time during component assembly, and automatically identifies and counts the number of components using image processing and target detection algorithms. The acquired component quantity serves as one of the input parameters for the subsequent feedback output module to calculate winding parameter adjustment suggestions. It is also used to compare with the preset quantity to promptly detect problems such as missing, over-assembly, or abnormal arrangement, avoiding misjudgment of capacitance values ​​and rework due to component quantity deviations.

[0045] In some embodiments, the control unit has a built-in data comparison and analysis module, a feedback output module, and a data storage module.

[0046] The data comparison and analysis module is used to compare the measured capacitance with the preset target capacitance value, and to compare the measured height with the preset target height value, to determine whether both meet the preset error requirements.

[0047] The feedback output module is used to calculate and output the adjustment parameters of the winding parameters based on the capacitance deviation, height deviation and number of components when the data comparison and analysis module determines that the error requirements are not met.

[0048] The data storage module is used to associate and store the product specifications, compression parameters, measured capacitance value, measured height value, judgment results and feedback output of each capacitor core to form a quality traceability file.

[0049] The proposed adjustments to the winding parameters include at least one of the following: adjustment amount for electrode length and adjustment amount for element number of turns.

[0050] The adjustment parameters are transmitted to the winding machine control interface or host computer system via industrial communication protocol. The winding machine automatically receives and executes parameter corrections to achieve closed-loop automatic adjustment of winding parameters.

[0051] As an optional solution, different specifications of capacitor cores correspond to different combinations of design parameters. The preset parameters of commonly used design schemes are stored through a data storage module. When in use, the corresponding parameter formula can be called to achieve quick switching between different specifications.

[0052] As a specific example, the target capacitance value is expressed in the form of a range, including the rated value and the allowable deviation range; the measured capacitance value is considered qualified if it falls within the target range, and triggers feedback if it exceeds the range. For example, the preset allowable deviation of capacitance is ±3%, and the capacitor is considered qualified when the measured capacitance value is within ±3% of the rated value.

[0053] In some embodiments, the feedback output module attempts to adjust the strategy sequentially according to the following three priority levels until an adjustment scheme that meets the error requirements is found or an anomaly is confirmed: Level 1, meets requirements, no adjustment needed: When the measured capacitance value falls within the target capacitance value range and the measured height value falls within the target height value range, it is judged as qualified, and the output is "Meets requirements, no parameter adjustment needed"; The second stage involves adjusting the electrode length or the number of component turns: When the measured capacitance or height value exceeds the allowable deviation range, the capacitance deviation range of a single component is calculated to determine the electrode length or the number of component turns that needs to be increased or decreased. Within the adjustable range, combined with the preset minimum adjustment step size, the adjusted core capacitance and core height values ​​are calculated, generating multiple candidate arrays. The scheme with the adjusted capacitance value closest to the center value of the target range is selected from the candidate arrays that meet the target range as the output. The third level involves adjusting the number of components before adjusting the plate length or the number of component turns: If the second-level strategy fails to meet the requirements, first add or remove one component, and then determine whether the adjusted number of components meets the allowable deviation requirements. If the adjusted capacitance and height values ​​both fall within the target range, then the output only suggests adjusting the number of components. If the requirements are still not met, then the adjustable range and candidate array are recalculated, and the optimal output is a suggestion that includes both component quantity adjustment and winding parameter adjustment.

[0054] Furthermore, if the third-level strategy still cannot find an adjustment scheme that meets the requirements, the feedback output module outputs an abnormal alarm signal, indicating that there may be problems such as the medium thickness deviating from the design value, abnormal winding tension, or incorrect number and order of components, and outputs the current measured value, target value, and candidate calculation data of each level of strategy.

[0055] The three-tiered adjustment strategy proceeds step-by-step, prioritizing the smallest possible adjustment. The first tier prioritizes confirming the acceptable state, avoiding unnecessary adjustments. The second tier adjusts only the winding parameters without changing the number of components, resulting in small adjustments and simple operation. The third tier introduces component quantity adjustments when winding parameter adjustments fail to meet requirements, expanding the adjustment capability. Each tier verifies the adjustment effect through predictive calculations, ensuring the output solution simultaneously meets capacitance and height deviation requirements, avoiding the drawbacks of traditional methods relying on blind adjustments based on manual experience.

[0056] Furthermore, the data storage module associates and stores the product specifications, clamping parameters, measured capacitance value, measured height value, judgment result, and feedback output of each capacitor core to form a quality traceability file.

[0057] Different specifications of capacitor cores correspond to different combinations of design parameters. The preset parameters of commonly used design schemes are stored through the data storage module. When in use, the corresponding parameter formula can be called to achieve quick switching between different specifications.

[0058] The data storage module is also used to store the adjustment instructions for each batch of cores and the actual test results after adjustment, forming a data comparison record before and after adjustment, which is used to evaluate the effectiveness of the adjustment strategy and continuously optimize the feedback output logic.

[0059] In some embodiments, a human-machine interface is also included, which is used to display the measured capacitance value, the measured height value, the judgment result, and the adjustment parameters of the winding parameters.

[0060] The human-machine interface is also used to display the real-time pressure value, pressure fluctuation range, and preset target value range of each drive channel, so that operators can keep track of the pressing status in real time.

[0061] The human-machine interface is also used to display the current measured value, target value, and candidate calculation data of each level of strategy when the feedback output module outputs an abnormal alarm signal, to assist operators or manufacturing execution systems in troubleshooting.

[0062] Secondly, see Figure 2 This embodiment provides a method for packaging and synchronous measurement feedback control of coupled capacitor cores, including the following steps: Step 1: Place the stacked capacitor cores on the station of the automatic clamping device and apply a constant clamping force to the capacitor cores according to the preset pressure value.

[0063] In some embodiments, the constant clamping force is applied as follows: S1.1 The clamping drive mechanism drives the pressure head to move downwards, applying a clamping force to the stacked capacitor cores; S1.2 The pressure sensor detects the pressure applied to the capacitor core in real time and feeds the detection result back to the pressure closed-loop controller; S1.3 The pressure closed-loop controller dynamically adjusts the output of the clamping drive mechanism according to the feedback signal of the pressure sensor, so that the actual pressure value is maintained within the allowable fluctuation range of the preset pressure value, and maintains the constant clamping force after the clamping state is stable.

[0064] Constant pressure clamping is achieved through closed-loop pressure control, replacing the traditional clamping method that uses a fixed height as the control target. Pressure sensors provide real-time feedback of the actual pressure value, and the closed-loop pressure controller dynamically compensates for the output of the clamping drive mechanism, ensuring that each capacitor core receives consistent clamping force during packaging. This eliminates the impact of raw material thickness variations on the consistency of clamping. The constant clamping force ensures sufficient air expulsion between the dielectric layers, resulting in a stable clamping state and providing conditions consistent with the final usage state for accurate subsequent capacitance measurement.

[0065] The preset pressure value and allowable fluctuation range are calibrated based on the compression coefficient given in the design process and combined with process data; the compression coefficient is the ratio of the arithmetic sum of the thicknesses of all dielectric material layers inside the capacitor core to the measured height of the core as a whole under pressure. Different preset pressure values ​​are set according to the differences in the geometric dimensions of capacitor elements of different specifications.

[0066] Step 2: While maintaining the constant clamping force, simultaneously measure the capacitance and height of the capacitor core, and obtain the number of capacitor elements to get the measured capacitance value, measured height value, and number of elements.

[0067] In some embodiments, the method for synchronous measurement is as follows: S2.1 When the two measuring electrodes of the capacitance measuring unit are pressed together, they form electrical contact with the lead-out end or plate of the capacitor core. The capacitance measuring circuit obtains the capacitance value through the measuring electrodes and obtains the measured capacitance value. S2.2 The height measurement unit synchronously detects the actual height of the capacitor core under the compressed state to obtain the measured height value; S2.3 The component quantity measurement unit acquires image information of capacitor components or capacitor cores through an industrial camera, and combines image processing and target detection algorithms to count the number of components.

[0068] The capacitance measurement unit, height measurement unit and component count measurement unit are integrated on the station of the automatic pressing device, so that all measurements can be completed synchronously without displacing the core in the pressed state. The capacitance measurement is performed before the pressed state is released, and the measurement state is consistent with the final working state of the core, which avoids the capacitance value deviation caused by the rebound of the dielectric layer after the pressing force is released. Synchronous measurement eliminates the need for independent test stations and transfer links, effectively shortening the detection cycle and improving production efficiency.

[0069] Step 3: Compare the measured capacitance value with the preset target capacitance value, and compare the measured height value with the preset target height value, judge whether both meet the preset error requirements, and obtain a judgment result.

[0070] In some embodiments, the comparison and judgment method is as follows: S3.1: The data comparison and analysis module compares the measured capacitance value with the preset target capacitance value interval, and judges whether the measured capacitance value falls within the target capacitance value interval; S3.2: The data comparison and analysis module compares the measured height value with the preset target height value interval, and judges whether the measured height value falls within the target height value interval; S3.3: When both the measured capacitance value and the measured height value fall within their respective target intervals, it is judged as qualified; when any parameter exceeds the corresponding interval, it is judged that the error requirement is not met.

[0071] For example, the preset allowable capacitance deviation is ±3%, and the preset allowable height deviation is 0 to -5 mm, and the specific values are set according to product specifications and process requirements.

[0072] The interval judgment method is adopted, in which the target capacitance value and the target height value are expressed in the form of intervals. If the measured value falls within the interval, it is judged as qualified, and if it exceeds the interval, feedback is triggered. Different from the traditional control method that takes a fixed point value as the target, the interval judgment is more suitable for the characteristic of raw material thickness dispersion in actual production, and avoids misjudgment and unnecessary adjustment caused by normal dispersion.

[0073] Step 4: According to the judgment result, if the error requirement is met, the packaging is completed according to the current pressing state; if the error requirement is not met, the adjustment parameters of the winding parameters are calculated and output according to the capacitance deviation, the height deviation and the number of components, following a three-level hierarchical adjustment strategy.

[0074] In some embodiments, the calculation method of the adjustment parameters is as follows: First level: It is judged to meet the requirements, and no adjustment is made.

[0075] When the measured capacitance value falls within the target capacitance value range and the measured height value falls within the target height value range, it is judged as qualified and no adjustment is required. The output is "Meets requirements, no parameter adjustment is required". The core is then packaged using the packing strap according to the current compression state.

[0076] The measured core capacitance falls within the target range. ,Right now Furthermore, the measured height of the core element falls within the target range. ,Right now

[0077] Second stage: Adjust the electrode length or the number of element turns.

[0078] When the measured capacitance or height value exceeds the allowable deviation range, the packing parameter adjustment range is determined based on the capacitance deviation range of the individual component and the component capacitance change corresponding to the unit packing parameter. Within the packing parameter adjustment range, values ​​are taken according to a preset adjustment step size, and the adjusted capacitor core capacitance value and adjusted capacitor core height value corresponding to each value are predicted to generate multiple candidate arrays. From the multiple candidate arrays, candidate arrays in which both the adjusted capacitance value and adjusted height value fall into the corresponding target range are selected, and the group in which the adjusted capacitance value is closest to the center value of the target range is selected to obtain the corresponding packing parameter adjustment amount.

[0079] S4.1 Calculate the capacitance deviation range of a single capacitor element. Based on the difference between the lower and upper boundaries of the range between the measured capacitance value and the target capacitance value, a capacitance deviation range is formed. Combining this with the number of elements connected in series in the capacitor core, the total capacitance deviation range is converted into the capacitance deviation range of a single element. The capacitance deviation range of a single element is equal to the total capacitance deviation range multiplied by the number of elements connected in series.

[0080] When the capacitance deviation is positive, it indicates that the capacitance is too small, and the plate length or the number of component turns needs to be increased; when the capacitance deviation is negative, it indicates that the capacitance is too large, and the plate length or the number of component turns needs to be reduced.

[0081] 1) Calculate the capacitance deviation range of a single capacitor element: ; .

[0082] The deviation between the measured capacitance value and the lower and upper boundaries of the target capacitance forms a capacitance deviation range. In this case, the capacitor core consists of multiple capacitor elements connected in series. The number of series-connected elements obtained by measurement.

[0083] This indicates that the capacity is too small and the electrode length (or number of turns) needs to be increased. This indicates that the capacity is too large and the length of the plates (or the number of turns) needs to be reduced.

[0084] S4.2 Calculate the change in element capacitance per unit adjustment. Based on the functional relationship between the capacitance of a single element and the length of the plate, calculate the change in element capacitance corresponding to a unit change in plate length; Alternatively, based on the functional relationship between the capacitance of a single component and the number of turns of the component, calculate the change in component capacitance corresponding to a change in the number of turns of the component.

[0085] The unit adjustment amount is the change in element capacitance per unit plate length or per unit number of element turns; Single component capacitor

[0086] Change in capacitance per unit plate length ,in, The length of the electrode plate; Change in element capacitance per unit number of turns ,in, The number of turns of the component; S4.3 Calculate the adjustable range of plate length or component turns. Based on the capacitance deviation and the capacitance change per unit adjustment, determine the range that the plate length or component turns need to be adjusted; a positive adjustment value indicates an increase, and a negative adjustment value indicates a decrease.

[0087] Calculate the adjustable range of electrode length (or number of element turns); ,

[0088] Adjustable range of electrode length . This indicates increasing the length of the electrode plate. This indicates a reduction in the length of the electrode plate.

[0089] ,

[0090] Adjustable range of component turns Similarly, This indicates increasing the number of component turns. This indicates a reduction in the number of component turns.

[0091] S4.4 Calculate the adjusted core capacitance and core height. Set the minimum adjustment amount for the electrode length or the minimum adjustment amount for the number of element turns, and take values ​​that are integer multiples of the minimum adjustment amount within the adjustable range. Predict the adjusted core capacitance and core height based on the dielectric thickness, compression coefficient, and electrode thickness.

[0092] 1) The value of the electrode length adjustment is: , It must be an integer multiple of 0.05m; Predicted core capacitance after adjustment:

[0093] The electrode length adjustment is equivalent to the element turn adjustment. ,in (total thickness of the component); Predicted change in heart height after adjustment:

[0094] in, For the thickness of the medium, To set the core compression coefficient under preset pressure, The thickness of the electrode plate; Predicted post-adjustment heart height

[0095] 2) Set the minimum adjustment amount for the number of component turns; Within the adjustable range of component turns, the component turns adjustment amount is taken as: , It must be an integer multiple of 0.25 revolutions; Predicted adjustment of core capacitance

[0096] Predicted change in heart height after adjustment

[0097] in, For the thickness of the medium, To set the core compression coefficient under preset pressure, (Electrode thickness) Predicted post-adjustment heart height ; S4.5 Substitute different electrode length adjustment amounts or element turn number adjustment amounts into the calculation formula to obtain multiple candidate arrays. Each candidate array contains the adjustment amount, the predicted adjusted core capacitance value, and the predicted adjusted core height value.

[0098] Specifically, different values ​​for adjusting the electrode length are taken. Or different values ​​for the number of turns of the component. Substituting each value into the accounting formula and performing calculations yielded multiple sets of results. )or( The candidate array of ).

[0099] S4.6 From all candidate arrays that satisfy the condition that the predicted capacitance value falls within the target capacitance value range and the predicted height value falls within the target height value range, select the scheme whose adjusted capacitance value is closest to the center value of the target range, determine the corresponding plate length adjustment amount or component turn number adjustment amount, and output the adjustment parameters.

[0100] If no candidate data set can simultaneously satisfy both capacitance and height deviation requirements, then proceed to the third-level strategy.

[0101] Specifically, from all arrays that satisfy the following conditions: Predicting core capacitance In the target capacitance range Inside; Predict heart height Within the target altitude range Inside; Select the adjusted capacitance value The scheme that is closest to the center value of the target interval is determined. (or ) Recommended plate length is from Adjusted to

[0102] Alternatively, it is suggested that the number of component turns be determined by... Adjusted to

[0103] If no data set can simultaneously meet the capacitance and height deviation requirements, then switch to the third-level strategy.

[0104] Level 3: Adjust the number of components, then adjust the plate length or the number of component turns.

[0105] S4.7 If the core height is too high or the capacitance value is too low, reduce one component; if the core height is too low or the capacitance value is too high, add one component. Determine whether the adjusted number of components meets the allowable deviation requirements. If it does, continue to the next step. If it does not, jump to S4.10 and output an abnormal alarm signal.

[0106]

[0107] judge Does it meet the allowable deviation requirement (±1) for the component?

[0108] If so, proceed to the next step; If not, jump to S4.10 and output an abnormal alarm signal.

[0109] S4.8 Calculate the base capacitance and base height after adjusting the number of components.

[0110]

[0111]

[0112] S4.9 Determine whether the capacitance value and height value after adjusting the number of components fall within the target capacitance value range and the target height value range simultaneously.

[0113] If both conditions are met, an adjustment suggestion is output, recommending that the number of components be adjusted to the corresponding value while the winding parameters remain unchanged; if any parameter does not meet the requirements, proceed to the next step.

[0114] Specifically, determine whether the conditions are met: Core capacitance value Fall into the target range ,Right now

[0115] Heart height Fall into the target range ,Right now

[0116] If both conditions are met, then an adjustment suggestion is output: the suggested component quantity is adjusted from... Adjusted to The winding parameters remain unchanged; If any parameter does not meet the requirements, the adjustable range of capacitor deviation, plate length, or number of component turns will be recalculated. S4.10. Referring to the methods of S4.2 to S4.6 of the second level, calculate the adjusted core capacitance value and core height value, generate a candidate array, and output the optimal adjustment parameters, including the adjustment amount of the number of components and the adjustment amount of the electrode length or the adjustment amount of the number of component turns.

[0117] If, under the condition of adding or removing a component, it is still impossible to find a set of adjustment values ​​that can simultaneously meet the allowable deviation requirements of capacitance and height, an abnormal alarm signal will be output, indicating that there may be problems such as the dielectric thickness deviating from the design value, abnormal winding tension, or incorrect component stacking quantity and order. The current measured value, target value, and candidate calculation data of each level of strategy will be output for operators or manufacturing execution systems to troubleshoot.

[0118] The quality control has been transformed from "post-event sampling" to "in-process intervention." The feedback output module attempts adjustments step by step according to the principle of prioritizing the smallest adjustment. The second stage only adjusts the winding parameters, with a small adjustment range and simple operation; the third stage introduces the adjustment of the number of components to expand the adjustment capability. The adjustment effect of each stage is verified through predictive calculations to ensure that the output scheme simultaneously meets the requirements of capacitance and height deviation, avoiding the drawbacks of blind adjustment based on traditional manual experience.

[0119] Step 5: Fix the packaged capacitor cores according to the designed quantity using support strips and pressure plates to assemble them into complete capacitor cores. Adjust the overall height of the cores using several adjusting cardboard pieces to match the designed height.

[0120] After packaging, multiple packaged cores are secured into a complete capacitor core using support strips and pressure plates. Adjustable cardboard is used to compensate for minor differences between the overall height of the assembled core and the designed height, ensuring the final product meets assembly dimensional requirements. This step is the final stage of packaging and synchronous measurement feedback control, ensuring that cores that have passed constant pressure packaging and online inspection are correctly assembled into their final form.

[0121] Thirdly, this application also provides a product for packaging and synchronous measurement feedback control of coupled capacitor cores, comprising: A clamping module is used to provide clamping conditions while maintaining a constant clamping force on the capacitor core; The measurement module is used to obtain the actual capacitance and actual height of the capacitor core under compressed conditions; The analysis module is used to calculate the capacitance deviation range of a single element based on the capacitance deviation and the number of elements in the capacitor core when the actual capacitance or the actual height exceeds the corresponding target range, and to determine the packing parameter adjustment range based on the capacitance deviation range. The prediction module is used to take values ​​within the packaging parameter adjustment range according to a preset adjustment step size, predict the adjusted capacitor core capacitance value and adjusted capacitor core height value corresponding to each value, and generate multiple candidate arrays. The optimization module is used to filter out candidate arrays from the multiple candidate arrays in which both the adjusted capacitance value and the adjusted height value fall into the corresponding target interval, and select the group from the candidate arrays whose adjusted capacitance value is closest to the center value of the target interval to obtain the corresponding packing parameters.

[0122] It should be noted that, in the several embodiments provided in this application, it should be understood that the disclosed apparatus and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of modules is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple modules may be combined or integrated into another device, or some features may be ignored or not executed. The modules described as separate components may or may not be physically separated. The components shown as modules may be one or more physical units, that is, they may be located in one place or distributed in multiple different places. Some or all of the modules can be selected to achieve the purpose of the solution in this embodiment according to actual needs.

[0123] Furthermore, in the various embodiments of the present invention, the modules can be integrated into one processing unit, or each module can exist physically separately, or two or more modules can be integrated into one unit. The integrated unit described above can be implemented in hardware or as a software functional unit.

[0124] An electronic device provided in this application includes a memory and a processor. The memory stores a computer program, and when the processor executes the computer program, it implements the steps of the coupling capacitor core packing and synchronous measurement feedback control method described in any of the above embodiments.

[0125] Another electronic device provided in this application embodiment may further include: an input port connected to a processor for transmitting multimodal data collected by an external acquisition device to the processor; a display unit connected to the processor for displaying the processor's processing results to the outside world; and a communication module connected to the processor for enabling communication between the electronic device and the outside world. The display unit may be a display panel, a laser scanning display, etc.; the communication method adopted by the communication module includes, but is not limited to, Mobile High Definition Link (HML), Universal Serial Bus (USB), High Definition Multimedia Interface (HDMI), and wireless connection (including Wi-Fi, Bluetooth, Bluetooth Low Energy, and IEEE 802.11s-based communication technology).

[0126] This application provides a computer-readable storage medium storing a computer program. When the computer program is executed by a processor, it implements the steps of the coupling capacitor core packing and synchronous measurement feedback control method described in any of the above embodiments.

[0127] For descriptions of relevant parts of the capacitor core packaging and synchronous measurement feedback control system, electronic equipment, and computer-readable storage medium provided in the embodiments of this application, please refer to the detailed description of the corresponding parts in the capacitor core packaging and synchronous measurement feedback control method provided in the embodiments of this application, and they will not be repeated here. Furthermore, parts of the technical solutions provided in the embodiments of this application that are consistent with the implementation principles of corresponding technical solutions in the prior art have not been described in detail to avoid excessive elaboration.

[0128] The above content is only for illustrating the technical concept of the present invention and should not be construed as limiting the scope of protection of the present invention. Any modifications made to the technical solution based on the technical concept proposed in this invention shall fall within the scope of protection of the claims of this invention.

Claims

1. A method for packaging and synchronously measuring feedback control of coupled capacitor cores, characterized in that, Includes the following steps: Step 1: Under the condition that the capacitor core is kept under constant clamping force, obtain the actual capacitance and actual height of the capacitor core under the clamping state; Step 2: When the actual capacitance or the actual height exceeds the corresponding target range, calculate the capacitance deviation range of a single element based on the capacitance deviation and the number of elements in the capacitor core, and determine the packing parameter adjustment range based on the capacitance deviation range. Step 3: Within the packaging parameter adjustment range, take values ​​according to a preset adjustment step size, predict the adjusted capacitor core capacitance value and adjusted capacitor core height value corresponding to each value, and generate multiple candidate arrays; Step 4: Select candidate arrays from the multiple candidate arrays where both the adjusted capacitance value and the adjusted height value fall within the corresponding target interval. Select the candidate array whose adjusted capacitance value is closest to the center value of the target interval to obtain the corresponding packaging parameters.

2. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, The packaging parameters are either winding parameters or the number of components; the winding parameters are either the electrode length or the number of component turns.

3. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, In step 1, the constant clamping force is obtained as follows: Obtain the actual clamping force of the capacitor core, and adjust the actual clamping force according to the deviation between the actual clamping force and the preset pressure value, so that the actual clamping force is maintained within the allowable fluctuation range of the preset pressure value.

4. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, The allowable fluctuation range corresponding to the preset pressure value is calibrated based on the given clamping coefficient and process data. The compression coefficient is the ratio of the arithmetic sum of the thicknesses of all dielectric material layers inside the capacitor core to the measured height of the core as a whole under pressure.

5. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, In step 2, the method for calculating the capacitance deviation range of the individual component is as follows: Based on the difference between the lower and upper boundaries of the actual capacitance and the target capacitance value range, the total capacitance deviation range of the capacitor core is determined. Then, combined with the number of series connections of the components in the capacitor core, the total capacitance deviation range is converted into the capacitance deviation range of a single component.

6. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, The step of determining the packing parameter adjustment range based on the capacitance deviation range includes: The packing parameter adjustment range is determined based on the capacitance deviation range of the individual component and the capacitance change of the component corresponding to the unit packing parameter.

7. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, In step 3, the predicted values ​​for each value correspond to the adjusted capacitor core capacitance and the adjusted capacitor core height, including: Based on the adjustment amount of the packaging parameters corresponding to the values, combined with the dielectric thickness, compression coefficient, and electrode thickness, the adjusted capacitor core capacitance and capacitor core height are predicted.

8. The method for packaging and synchronous measurement feedback control of coupled capacitor cores according to claim 1, characterized in that, When the capacitor core cannot be made to meet the target range by adjusting the packing parameters based on the capacitance deviation and height deviation; First, adjust the number of components, then recalculate the capacitor deviation range and the packing parameter adjustment range, generate a candidate array, and output the best one that includes both the component quantity adjustment and the packing parameter adjustment.

9. A system for implementing the coupling capacitor core packing and synchronous measurement feedback control method according to any one of claims 1-8, characterized in that, Includes measuring devices and control units; The measuring device is integrated into the packaging device and is used to measure the actual capacitance, actual height and number of components of the capacitor core under compressed conditions. The control unit is signal-connected to the measuring device and is used to compare the actual capacitance and actual height with the preset target capacitance value and preset target height value, respectively. When the comparison result does not meet the error requirements, the control unit calculates the packing parameters based on the capacitance deviation, height deviation and number of components.

10. The system of the coupling capacitor core packaging and synchronous measurement feedback control method according to claim 9, characterized in that, The capacitance measurement unit includes at least two measuring electrodes and a capacitance measurement circuit; When the at least two measuring electrodes are pressed together, they respectively form electrical contact with the corresponding leads or plates of the capacitor core, and the capacitance measuring circuit obtains the capacitance value through the measuring electrodes. The height measuring unit is a displacement sensor, located at the follow-up position of the pressure head of the packaging device, and obtains the actual height value by detecting the amount of travel displacement of the pressure head relative to the reference surface.

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