CN115410817A - Foil winding device and working method thereof - Google Patents
Foil winding device and working method thereof Download PDFInfo
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- CN115410817A CN115410817A CN202211044359.XA CN202211044359A CN115410817A CN 115410817 A CN115410817 A CN 115410817A CN 202211044359 A CN202211044359 A CN 202211044359A CN 115410817 A CN115410817 A CN 115410817A
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- 239000011888 foil Substances 0.000 title claims abstract description 253
- 238000004804 winding Methods 0.000 title claims abstract description 117
- 238000000034 method Methods 0.000 title claims abstract description 28
- 239000000463 material Substances 0.000 claims description 118
- 230000007246 mechanism Effects 0.000 claims description 82
- 230000005540 biological transmission Effects 0.000 claims description 33
- 238000006073 displacement reaction Methods 0.000 claims description 10
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- 238000001514 detection method Methods 0.000 claims description 5
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 3
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 3
- 229910052782 aluminium Inorganic materials 0.000 description 3
- 239000011889 copper foil Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 2
- 239000011229 interlayer Substances 0.000 description 2
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/094—Tensioning or braking devices
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01L—MEASURING FORCE, STRESS, TORQUE, WORK, MECHANICAL POWER, MECHANICAL EFFICIENCY, OR FLUID PRESSURE
- G01L3/00—Measuring torque, work, mechanical power, or mechanical efficiency, in general
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
- G06F17/00—Digital computing or data processing equipment or methods, specially adapted for specific functions
- G06F17/10—Complex mathematical operations
Abstract
The invention discloses a foil winding device and a working method thereof, which can automatically adjust the tension according to different foils and the geometric dimensions of the foils, ensure the optimal tension of a transformer winding, avoid the problems of insulation damage, heat dissipation, over-standard noise and the like of the winding caused by small tension, ensure the consistent stress value of the transformer winding and ensure the consistency of the product quality.
Description
Technical Field
The invention belongs to the technical field of foil winding, and particularly relates to a foil winding device and a working method thereof.
Background
The transformer low-voltage winding is wound by copper foil or aluminum foil, a coil wire is subjected to the action of electric power to vibrate in the operation process of the transformer, when the winding tension of the transformer winding is insufficient, on one hand, the tightness between coil layers is uneven, so that the insulation life of the transformer winding is seriously influenced, on the other hand, the noise exceeds the standard due to insufficient tension of the winding, and meanwhile, the temperature rise of the transformer winding exceeds the standard; therefore, the tension of foil winding is related to whether the transformer can operate stably, reliably, safely and up to the standard, which causes high attention of transformer manufacturers, thereby putting higher requirements on the winding quality of the foil in the production process of the transformer.
At present, foil has the following defects in the winding process: the tension force is improperly controlled due to improper operation of equipment or workers, so that gaps exist among interlayer foils of copper foils or aluminum foil windings, the problems of noise generation, excessive temperature rise and the like in the operation process of the transformer are finally caused, and even the safety accident that the transformer is damaged or the temperature rise is too high to cause fire is caused in serious cases; therefore, how to realize the accurate control of the tension in the foil winding process becomes a key problem to be solved urgently in the foil winding industry.
Disclosure of Invention
The invention aims to provide a foil winding device and a working method thereof, which are used for solving the quality problems of insulation damage, excessive temperature rise, excessive noise and the like of a low-voltage winding of a transformer caused by the fact that gaps exist among interlayer foils of a copper foil or an aluminum foil winding due to improper tension control caused by equipment or worker operation problems in the prior art.
In order to achieve the purpose, the invention adopts the following technical scheme:
in a first aspect, a foil winding device is provided, including: the device comprises a control host, a feeding mechanism, a tensioning mechanism and an auxiliary mechanism, wherein the control host is used for obtaining the optimal tensioning force of each layer of foil in a foil roll according to the material mechanical property parameters of the foil roll and the geometric dimension of each layer of foil in the foil roll, and obtaining the optimal torque value of the tensioning mechanism according to the optimal tensioning force, and the material mechanical property parameters comprise tensile strength, specified plastic elongation strength, yield strength and optimal stress value;
the feeding mechanism is used for conveying the foil material to the tensioning mechanism;
the tensioning mechanism comprises a tensioning assembly, a rotating assembly and a detecting assembly, wherein the tensioning assembly is fixed on the rotating assembly, the detecting assembly is mounted on the tensioning assembly, and the foil material is sleeved on the tensioning assembly;
the control host is used for outputting an optimal torque value obtained based on an optimal tension to the rotating assembly when a foil material is wound, so that the rotating torque of the rotating assembly is the optimal torque value;
the rotating assembly is used for driving the tensioning assembly to move according to an optimal torque value obtained by the control host machine based on an optimal tensioning force when a foil material is wound, so that the tensioning assembly applies pressure to the foil material to fasten the foil material;
the detection assembly comprises a torque detector, wherein the torque detector is used for detecting an actual torque value on the tensioning assembly and transmitting the actual torque value to the control host machine, so that the control host machine adjusts the rotating torque of the rotating assembly according to the received actual torque value, and the actual torque value on the tensioning assembly is kept to be the optimal torque value by adjusting the rotating torque of the rotating assembly;
and the auxiliary mechanism is used for pressing the tensioned foil material so as to prevent the release of the winding force on the tensioned foil material after the winding is intermittent or finished.
Based on the disclosure, when the foil is wound, the optimal tension force of the foil during winding is calculated according to the material mechanical property parameters and the geometric dimension of the foil coil, so that the optimal torque value is calculated according to the optimal tension force; then, the control host machine can control the rotation torque of the rotating assembly on the one hand based on the optimal torque value, and can drive the tensioning assembly to move by controlling the rotating assembly on the other hand, so that the tensioning assembly generates pressure on the foil material, the optimal torque value of the rotating assembly is transmitted to the tensioning assembly, the foil material is ensured to bear the optimal torque value during winding, and the winding tension is the optimal tension; meanwhile, the actual torque value on the tensioning component can be detected in real time by arranging the torque detector and fed back to the control host, so that the rotating torque of the rotating component can be adjusted in real time according to the detected torque in the winding process, the actual torque value of the tensioning component is kept to be the optimal torque value, and the tensioning force is further adjusted through the torque value; through the design, the tension can be automatically adjusted according to different foils and the geometrical sizes of the foils, so that the optimal tension of the transformer winding can be ensured, the problems of insulation damage, heat dissipation, excessive noise and the like of the winding during the operation of the transformer due to small tension can be avoided, the consistent stress value of the transformer winding can be ensured, and the consistency of the product quality can be ensured.
In one possible design, the feed mechanism includes: the device comprises a mobile station, a lifting assembly, a tray and two guide rails which are arranged in parallel, wherein the two guide rails are arranged right below a tensioning mechanism;
the mobile station is slidably mounted on the two guide rails, the lifting assembly is mounted on the top surface of the mobile station, and the tray is fixed on the lifting end of the lifting assembly.
Based on the disclosure, the invention discloses a specific structure of a feeding mechanism, namely, the foil material can horizontally move along a tensioning assembly by the back and forth movement of a mobile platform on a guide rail, and the foil material can vertically move up and down by a lifting assembly on the mobile platform; from this, can realize that the foil coil stock of different specification models installs on tensioning assembly through the ascending removal in horizontal direction and vertical direction.
In one possible design, a weighing sensor is arranged on the contact surface of the tray and the foil material, a displacement sensor is arranged at the bottom of the tray, and the weighing sensor and the displacement sensor are respectively and electrically connected with the control host.
Based on the above disclosure, the weighing sensor is arranged, so that the measurement of the quality of the foil material can be realized, and the displacement sensor can ensure the moving accuracy of the mobile station, so that the foil material can be accurately installed on the tensioning assembly.
In one possible design, the rotating assembly comprises a motor, a rotating shaft, a first transmission gear, a second transmission gear and an electromagnetic torquer, wherein the rotating assembly is mounted on the fixed frame, and the control host is electrically connected with the electromagnetic torquer and the motor;
the fixing frame comprises a first fixing plate, a second fixing plate, a rotating column and a supporting plate, wherein the end part of the second fixing plate is hinged with one end of the supporting plate through the rotating column, and a clamping groove for mounting the rotating shaft is formed in the other end of the supporting plate;
one end of the rotating shaft is fixedly connected with the electromagnetic torquer, the other end of the rotating shaft is rotatably connected in the clamping groove, and the tensioning assembly is installed on the rotating shaft;
the motor is installed on the first fixing plate, wherein the first transmission gear is fixed on an output shaft of the motor, the first transmission gear is in transmission connection with the second transmission gear, the second transmission gear is in transmission connection with the tensioning assembly, and the tensioning assembly is driven by the motor to be driven to move so as to apply pressure to the foil material.
In one possible design, the tension assembly includes: the device comprises a telescopic piece, a fixing ring, a rotating ring and a plurality of supporting plates, wherein the supporting plates are uniformly arranged along the circumferential direction of a rotating shaft, each supporting plate is an arc-shaped plate, and the torque detector is arranged on the contact surface of any supporting plate and a foil material;
the fixed ring is fixed at one end of the rotating shaft close to the clamping groove, the rotating ring is slidably mounted at one end of the rotating shaft close to the first fixed plate, and the second transmission gear is in threaded connection with the rotating ring;
every fagging corresponds one the extensible member, wherein, the extensible member adopts many connecting rod structures, the head end of extensible member articulates on the rotating ring, the tail end of extensible member articulates on solid fixed ring, just the link of each connecting rod articulates in the extensible member corresponds the side on the fagging.
Based on the disclosure, the invention discloses a specific structure of the tensioning mechanism, when the feeding mechanism translates the foil material to the front of the tensioning mechanism, the supporting plate is separated from the rotating shaft by rotating the supporting plate, so that one end of the tensioning assembly is exposed, and at the moment, the feeding mechanism can be operated by the control host to move back and forth and up and down, so that the foil material is sleeved on the tensioning assembly (namely sleeved on the supporting plate); after the suit finishes, the operation of steerable motor then of main control system, in order to drive the rotation of second drive gear through first drive gear, and then the drive swivel becket removes along the axial direction of pivot, in order to drive the axial direction removal of extensible member along the pivot, finally drive the radial direction removal of each fagging along the pivot, in order to exert pressure to the foil coil stock, and simultaneously, torque sensor on the fagging can real-time detection fagging blowing moment of torsion when rotating, and feed back to main control system, therefore, closed-loop control can be formed, thereby realize the real-time regulation of fagging moment of torsion.
In one possible design, the detection assembly further includes: and the pressure sensor is also arranged on the contact surface of any supporting plate and the foil material, and the pressure sensor is electrically connected with the control host.
Based on the above disclosure, the pressure sensor can detect the pressure of the supporting plate on the foil material in real time and feed the pressure back to the control host, and the control host can control the motor to rotate according to the pressure data detected by the pressure sensor, and meanwhile, the problem that the foil material is deformed due to no slip between the foil material and the supporting plate or the excessive pressure can be avoided according to the monitored pressure data.
In one possible design, the assist mechanism includes: the device comprises a first roller, a second roller, a torque sensor and a hydraulic mechanism, wherein the first roller and the second roller are sequentially fixed on a fixed frame along the vertical direction, and are parallel to each other;
the torque sensor is installed on the first roller, the output end of the hydraulic mechanism is fixedly connected with the first roller and used for driving the first roller to move along the vertical direction, the torque sensor is electrically connected with the control host, and the control host is electrically connected with the controlled end of the hydraulic mechanism.
Based on the above disclosure, by arranging the torque sensor, on one hand, the tension force during winding of the winding can be detected in real time, and on the other hand, when the torque value is reduced due to the winding completion, the hydraulic mechanism can be controlled by the control host to apply pressure on the foil material, so that the original winding force of the foil material is prevented from being released; from this, auxiliary system can prevent effectively that foil coil material use in original rolling tensile release, ensures the in close contact between each layer of foil coil material, avoids in the foil coil material transportation because of the rolling power release contact friction in order to lead to the problem that the foil surface produced the burr.
In one possible design, the control host is arranged in an operation box, wherein the operation box is arranged on a fixed frame, and an operation interface is arranged on the operation box;
the operation interface comprises a foil parameter input area, a feeding mechanism operation area and a foil parameter display area, wherein the foil parameter display area is used for displaying the weight of the foil coil before material number, specification model, product name, specification model and winding and the weight after winding, and the foil parameter display area is also provided with a bar code outlet for printing material management and control information bar codes.
Based on the above disclosure, an operation interface is provided, so that a worker can conveniently process and operate a winding during manufacturing, parameters such as material information of a foil material, weight before and after winding and the like are displayed on the operation interface, and meanwhile, after the foil material is used up, a control host can be operated to print a material management and control information bar code of the foil material from a bar code outlet of the operation interface so as to record parameters (such as material number, specification model, product name, specification model, weight before winding, weight after winding and the like) of the foil material through the bar code.
In a second aspect, there is provided a working method of the foil winding apparatus according to the first aspect or any one of the possible designs of the first aspect, including:
acquiring material mechanical property parameters of a foil material and the geometric dimension of each layer of foil in the foil material, wherein the material mechanical property parameters comprise tensile strength, specified plastic elongation strength, yield strength and an optimal stress value;
judging whether the optimal stress value is smaller than any one of tensile strength, specified plastic elongation strength and yield strength;
if not, calculating to obtain the optimal tension of each layer of foil in the foil roll based on the geometric dimension and the optimal stress value;
calculating to obtain an optimal torque value of a tensioning mechanism in the foil winding device based on the optimal tensioning force of each layer of foil in the foil coil;
according to the optimal torque value, adjusting the rotation torque of a rotating assembly in a foil winding device to enable the rotation torque of the rotating assembly to be the optimal torque value, and according to the optimal torque value, driving a tensioning assembly in the foil winding device to move by using the rotating assembly to enable the tensioning assembly to apply pressure to a foil to fasten the foil;
and acquiring an actual torque value of the tensioning assembly transmitted by a torque detector in the tensioning mechanism, and adjusting the rotating torque of a rotating assembly in the tensioning mechanism according to the optimal torque value so as to keep the actual torque value on the tensioning assembly to be the optimal torque value by adjusting the rotating torque of the rotating assembly until the foil material is completely wound.
In one possible design, the thickness, width and radius of each layer of foil in the foil material, the tensioning assembly comprises a plurality of supporting plates, and the supporting plates are arc-shaped plates;
calculating the optimal tension of each layer of foil in the foil roll based on the geometric dimension and the optimal stress value, wherein the optimal tension comprises the following steps:
calculating to obtain the optimal tension according to the following formula (1);
F＝σA 0 (1)
in the above formula (1), F is the optimum tension, σ is the optimum stress value, and A 0 Is the sectional area of any layer of foil in the foil coil, wherein:
when any layer of foil is round angle, A 0 ＝a×b-0.858r 2 In the formula, a is the thickness of any layer of foil, b is the width of any layer of foil, and r is a fillet radius;
when any foil is round, A 0 ＝a×b-0.858r 2 R is the radius of the round edge;
correspondingly, based on the optimal tension of each layer of foil in the foil coil, the optimal torque value of a tensioning mechanism in the foil winding device is calculated and obtained, and the method comprises the following steps:
calculating to obtain an optimal torque value of a tensioning mechanism in the foil winding device according to the following formula (2);
in the formula (2), T is the optimal torque value, and R is the outer circle radius of the supporting plate.
Has the advantages that:
(1) The invention can automatically adjust the tension according to different materials and different geometric dimensions of the foil, thereby effectively ensuring that the low-voltage winding of the transformer bears the consistent tension, and avoiding serious quality problems of heat dissipation, noise exceeding, insulation damage and the like of the winding when the transformer runs due to the over-small tension of the winding.
(2) The invention fundamentally solves the problem of unbalanced three-phase resistance caused by inconsistent tension of the low-voltage winding of the transformer due to uncontrollable factors such as specification and model of the transformer, operators, material batches and the like in the production process of transformer enterprises.
(3) The invention can effectively prevent the problem of releasing the original winding tension in the production process of the foil material, ensure that proper tension is kept between layers of the foil material, and avoid the problems that the foil material is contacted due to the release of the winding tension, possibly generates friction in the transfer process, generates burrs on the surface of the foil material and the like and is scrapped.
(4) The intelligent online monitoring system adopts an intelligent real-time closed-loop online monitoring technology and a refined management concept, monitors a torque value in real time through the sensor, monitors a tension force through the pressure sensor, and monitors the weight before and after winding through the weighing sensor, provides an intelligent decision basis and a material visual management means for operators, improves decision scientificity, and reduces the operation intensity of work.
Drawings
Fig. 1 is a schematic perspective view of a foil winding apparatus according to an embodiment of the present invention;
fig. 2 is a top view of a foil winding apparatus according to an embodiment of the present invention;
fig. 3 is a schematic perspective view of a feeding mechanism according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a feeding mechanism according to an embodiment of the present invention;
FIG. 5 is a schematic structural diagram of a tensioning mechanism according to an embodiment of the present invention;
fig. 6 is a schematic step diagram of an operating method of a foil winding apparatus according to an embodiment of the present invention.
Reference numerals: 10-a fixing frame; 20-a mobile station; 30-a lifting assembly; 40-a tray; 50-a guide rail; 60-a displacement sensor; 70-a motor; 80-a rotating shaft; 90-a first drive gear; 100-a second transmission gear; 11-a first fixing plate; 12-a second fixing plate; 110-a telescoping member; 120-a pressure sensor; 130-bracing plate; 140-a first drum; 150-a second drum; 160-operation box; 170-torque detector; 13-spin columns; 14-a support plate; 180-electromagnetic torquer; 190 fixing the ring; 200-rotating ring.
Detailed Description
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the present invention will be briefly described below with reference to the accompanying drawings and the embodiments or the description of the prior art, it is obvious that the following description of the structure of the drawings is only some embodiments of the present invention, and it is also possible for those skilled in the art to obtain other drawings based on the drawings without creative efforts. It should be noted that the description of the embodiments is provided to help understanding of the present invention, and the present invention is not limited thereto.
It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments of the present invention.
It should be understood that, for the term "and/or" as may appear herein, it is merely an associative relationship that describes an associated object, meaning that three relationships may exist, e.g., a and/or B may mean: a exists independently, B exists independently, and A and B exist simultaneously; for the term "/and" as may appear herein, which describes another associative object relationship, it means that there may be two relationships, e.g., a/and B, which may mean: a exists independently, and A and B exist independently; in addition, for the character "/" that may appear herein, it generally means that the former and latter associated objects are in an "or" relationship.
The embodiment is as follows:
referring to fig. 1 to 5, the foil winding apparatus provided in this embodiment may include, but is not limited to: the control system comprises a control host, a feeding mechanism, a tensioning mechanism and an auxiliary mechanism, wherein the control host is used as a control center of the whole device and is used for performing data processing and cooperative control of all parts in the device.
In this embodiment, the mechanical property parameters and the geometric dimensions of the material are input into the control host by an operator in advance, wherein the mechanical property parameters may include, but are not limited to: tensile strength, specified plastic elongation strength, yield strength, and optimal stress values, while geometric dimensions may include, but are not limited to: the thickness, width and radius of each layer of foil in the foil roll; in the actual winding process, the control host machine firstly judges whether the input optimal stress value is smaller than any one of tensile strength, specified plastic elongation strength and yield strength, if so, the control host machine prompts a worker to input again, and if the optimal stress value is not smaller than any one of the three, the control host machine calculates the optimal tension of each layer of foil in the foil roll based on the optimal stress value and the geometric dimensions, and calculates the optimal torque value when each layer of foil is wound based on the optimal tension so as to adjust the tension when the foil roll is wound based on the calculated optimal torque value.
In a specific application, the feeding mechanism is used for conveying the foil material to the tensioning mechanism so that a worker can sleeve the foil material on the tensioning mechanism, and the foil material is wound by the tensioning mechanism; alternatively, the tensioning mechanism may include, but is not limited to: the device comprises a tensioning assembly, a rotating assembly and a detecting assembly, wherein the tensioning assembly is fixed on the rotating assembly, the detecting assembly is installed on the tensioning assembly, and the foil material is sleeved on the tensioning assembly; therefore, in the actual winding process, the control host is configured to output an optimal torque value obtained based on the optimal tension to the rotating assembly, so that the rotating torque of the rotating assembly is the optimal torque value; the rotating assembly is used for driving the tensioning assembly to move according to an optimal torque value obtained by the control host machine based on an optimal tensioning force when the foil material is wound, so that the tensioning assembly applies pressure to the foil material to fasten the foil material; therefore, the device provided by the embodiment can control the rotation torque of the rotating assembly based on the optimal torque value on one hand, and can drive the tensioning assembly to move by controlling the rotating assembly on the other hand, so that the tensioning assembly generates pressure on the foil material, the optimal torque value of the rotating assembly is further transmitted to the tensioning assembly, the foil material is ensured to bear the optimal torque value during winding, and the winding tensioning force is the optimal tensioning force; of course, in this embodiment, each layer of foil in the foil roll is wound, so that it is equivalent to ensure that each layer of foil in the foil roll bears an optimal torque value during winding, and the winding tension is the optimal tension.
Optionally, in this embodiment, for example, the detection component may include, but is not limited to: a torque detector 170, wherein the torque detector 170 is configured to detect an actual torque value on the tensioning assembly and transmit the actual torque value to the control host, so that the control host adjusts the rotation torque of the rotating assembly according to the received actual torque value, so as to maintain the actual torque value on the tensioning assembly at the optimal torque value by adjusting the rotation torque of the rotating assembly; therefore, closed-loop control can be formed, and real-time adjustment of the torque of the tensioning assembly is achieved.
In addition, this embodiment still is provided with complementary unit, and it is used for compressing tightly the foil coil stock after the tensioning to after coiling interval or coiling completion, prevent the rolling force release on the foil coil stock after the tensioning.
Therefore, by the explanation, the tension force can be automatically adjusted according to different materials and different geometric dimensions of the foil, so that the low-voltage winding of the transformer can be effectively ensured to bear the consistent tension force, and serious quality problems of heat dissipation, excessive noise, insulation damage and the like of the winding when the transformer runs due to the fact that the tension force of the winding is too small are avoided.
Referring to fig. 1 to 5, a specific structure of each mechanism in the foil winding apparatus is provided as follows:
first, the feeding mechanism may include, but is not limited to: the mobile station 20, the lifting assembly 30, the tray 40 and two guide rails 50 arranged in parallel to each other, as shown in fig. 1, 3 and 4, the two guide rails 50 may be, but are not limited to, installed directly below the tensioning mechanism, such as on the fixed frame 10 or on the ground, and the installation direction is the width direction of the fixed frame 10; it will be appreciated that the length of the guide 50 may be specifically set according to the space where the foil winding device is located.
Meanwhile, the mobile station 20 is slidably mounted on two guide rails 50, the lifting assembly 30 is mounted on the top surface of the mobile station 20, and the tray 40 is fixed on the lifting end of the lifting assembly 30; therefore, in practical use, foil materials can be placed on the tray 40 and driven by the moving table 20 to move on the two guide rails 50, and the tray 40 is lifted in the vertical direction through the lifting assembly 30, so that the foil materials of different specifications and models can be installed on the tensioning assembly through movement in the horizontal direction and the vertical direction.
Optionally, referring to fig. 3 and 4, for example, rollers are disposed at four corners of the bottom of the mobile station 20, and the rollers are slidably embedded into the two guide rails, so as to realize the movement of the mobile station 20; in this embodiment, the driving manner of the roller may be driven by a stepping motor; meanwhile, the top surface of the tray 40 may be, but is not limited to, a structure with two high ends and a low middle part, so as to ensure the stability of the foil material placement; the lifting unit may be a hydraulic telescopic rod, an electric telescopic rod, or a hydraulic telescopic table, and the lifting unit is not limited to the above example as long as the lifting function can be achieved.
Furthermore, in this embodiment, for example, a weighing sensor is disposed on a contact surface of the tray 40 and the foil material, and a displacement sensor 60 is disposed at the bottom of the tray 40, of course, the weighing sensor and the displacement sensor 60 are respectively electrically connected to the control host, so as to upload weighing data and displacement data; through the above design, the measurement of the quality of the foil coil on the tray 40 can be realized, thereby facilitating the display of the parameters of the foil coil, and the displacement sensor can ensure the moving accuracy of the mobile station 20, thereby ensuring that the foil coil can be accurately installed on the tensioning assembly of the tensioning mechanism.
Therefore, through the above detailed explanation of the feeding mechanism, the present invention can realize the movement of the foil material in the vertical direction and the horizontal direction (in the direction of the guide rail) by means of the moving table 20, the guide rail 50 and the lifting assembly 30, so as to mount the foil material on the tensioning assembly for the subsequent winding operation.
Next, the embodiment discloses one of the specific structures of the rotating assembly:
in the present embodiment, the rotating assembly is mounted on the fixing frame 10, wherein the rotating assembly may include, but is not limited to: the control system comprises a motor 70, a rotating shaft 80, a first transmission gear 90, a second transmission gear 100 and an electromagnetic torquer 180, wherein the control host is electrically connected with the electromagnetic torquer 200 and the motor 70; referring to fig. 1, 2 and 5, the fixing frame 10 includes a first fixing plate 11, a second fixing plate 12, a rotating column 13 and a supporting plate 14, wherein an end of the second fixing plate 12 is hinged to one end of the supporting plate 14 through the rotating column 13, and the other end of the supporting plate 14 is provided with a slot for mounting the rotating shaft 80, meanwhile, one end of the rotating shaft 80 is fixedly connected to the electromagnetic torquer 180, the other end of the rotating shaft 80 is rotatably connected to the slot, and the tensioning assembly is mounted on the rotating shaft 80; from this, when feed mechanism translated the foil coil stock to the tensioning mechanism before, through rotatory backup pad 14, with its separation pivot 80, made the one end of tensioning assembly expose, at this moment, rethread control host computer operation feed mechanism front and back, reciprocated to locate the foil coil stock cover on the tensioning assembly.
Referring to fig. 1, 2 and 5, the motor 70 is mounted on the first fixing plate 11, wherein the first transmission gear 90 is fixed on an output shaft of the motor 70, the first transmission gear 90 is in transmission connection with the second transmission gear 100, and the second transmission gear 100 is in transmission connection with the tensioning assembly, and is used for driving the tensioning assembly to move under the driving of the motor 70 so as to apply pressure to the foil material; therefore, the working process of the rotating assembly is as follows: the motor 70 drives the first transmission gear 90 to rotate, so that the first transmission gear 100 rotates, and the tensioning assembly is driven by the second transmission gear 100 to do telescopic motion, so that pressure is applied to the foil material; meanwhile, the control host can output the optimal torque value to the electromagnetic torquer 180, so that the torque of the rotating shaft 80 is controlled through the electromagnetic torquer 180, the optimal torque value is transmitted to the tensioning assembly, the foil material is guaranteed to bear the optimal torque value during winding, and the winding tensioning force is the optimal tensioning force.
Furthermore, the following further explains the working process of the tensioning mechanism in combination with the tensioning assembly:
in this embodiment, the tension assembly may include, but is not limited to: the telescopic member 110, the fixing ring 210, the rotating ring 220 and the plurality of supporting plates 130, as shown in fig. 1, 2 and 5, the plurality of supporting plates 130 are uniformly arranged along the circumferential direction of the rotating shaft 80, and each supporting plate 130 is an arc-shaped plate; meanwhile, the fixing ring 210 is fixed at one end of the rotating shaft 80 close to the clamping groove, the rotating ring 220 is slidably mounted at one end of the rotating shaft 80 close to the first fixing plate 11, and the second transmission gear 100 is in threaded connection with the rotating ring 220; in addition, each supporting plate 130 corresponds to one extensible member 110, wherein the extensible member 11 adopts a multi-link structure, the head end of the extensible member 11 is hinged to the rotating ring 220, the tail end of the extensible member 11 is hinged to the fixing ring 210, and the connecting end of each link in the extensible member 11 is hinged to the corresponding supporting plate 130.
Optionally, in this embodiment, for example, the torque detector 170 is disposed on a contact surface of any supporting plate 130 and the foil material, wherein a pressure sensor 120 is further disposed on any supporting plate 130, and the pressure sensor 120 is electrically connected to the control host; therefore, through the foregoing explanation, the working process of the whole tensioning mechanism is as follows:
when the mobile station 20 transports the foil roll to the lower part of the rotating shaft 80, the supporting plate 14 is rotated to separate the rotating shaft 80, so that one end of the tensioning assembly is exposed, at the moment, the control host operates the feeding mechanism to move back and forth and up and down through the control host, so that the foil roll is sleeved on the supporting plates 130, at the moment, the control host controls the motor 70 to operate to drive the second transmission gear 100 to rotate through the first transmission gear 90, so as to drive the rotating ring 200 to move along the axial direction of the rotating shaft 80, further drive the telescopic member 100 to move along the axial direction of the rotating shaft 80, and finally drive each supporting plate 130 to move along the radial direction of the rotating shaft 80, so as to apply pressure on the foil roll; meanwhile, in the winding process, the control host can control the electromagnetic torquer 180 to work based on the optimal torque value and apply the optimal torque to the supporting plate 130 through the rotating shaft 80, and can drive the telescopic piece 11 to move through the control motor 70, so that the supporting plate 130 generates pressure on the foil material, the optimal torque value of the rotating shaft 80 is further transmitted to the supporting plate 130, the foil material is ensured to bear the optimal torque value in the winding process, and the winding tension is the optimal tension; meanwhile, the torque sensor 170 on the supporting plate can detect the torque of the supporting plate 130 during discharging rotation in real time and feed the torque back to the control host, so that closed-loop control can be formed, and the real-time adjustment of the torque of the supporting plate is realized; in addition, the pressure sensor 120 can detect the pressure of the supporting plate 130 on the foil material in real time and feed the pressure back to the control host, and the control host can control the motor 70 to rotate according to the pressure data detected by the pressure sensor 120, and meanwhile, the problem that the foil material is not slipped from the supporting plate 130 or deformed due to overlarge pressure can be avoided according to the monitored pressure data.
In this embodiment, for example, the supporting plate 130 may be, but is not limited to, provided with 3 supporting plates, and the torque detector may be, but is not limited to, a torque sensor; for example, a sleeve may be disposed between the rotating ring 200 and the rotating shaft 80, wherein the sleeve is fixedly sleeved on the rotating shaft 80, and the rotating ring 200 is screwed on the sleeve.
Through the detailed explanation of the tensioning mechanism, the tensioning mechanism can automatically adjust the tensioning force according to the geometric dimension of the foil, so that the low-voltage winding of the transformer is effectively ensured to bear the consistent tensioning force, and the serious quality problems of heat dissipation, noise exceeding and insulation damage of the winding when the transformer runs due to the fact that the tensioning force of the winding is too small are avoided.
Finally, one of the structures of the auxiliary mechanism is disclosed as follows:
referring to fig. 1, a first roller 140, a second roller 150, a torque sensor and a hydraulic mechanism, wherein the first roller 140 and the second roller 150 are sequentially fixed on a fixed frame 10 along a vertical direction, and the first roller 140 and the second roller 150 are parallel to each other; meanwhile, the torque sensor is mounted on the first roller 140, the output end of the hydraulic mechanism is fixedly connected to the first roller 140 and used for driving the first roller 140 to move in the vertical direction, the torque sensor is electrically connected to the control host, and the control host is electrically connected to the controlled end of the hydraulic mechanism; through the design, on one hand, the tension force of the winding can be detected in real time, and on the other hand, when the torque value is reduced due to the winding completion, the hydraulic mechanism can be controlled by the control host machine to apply pressure on the foil material, so that the original winding force of the foil material is prevented from being released; from this, auxiliary system can prevent effectively that original rolling tension from releasing in the foil use, ensures the in close contact between each layer of foil, avoids the problem that the contact friction produced the burr in order to lead to the foil surface because of the rolling power release in the foil transportation.
Furthermore, in a specific application, the example fixing frame 10 is further provided with an operation box 160, wherein the control host is disposed in the operation box 160, and an operation interface is disposed on the operation box 160; optionally, for example, the operation interface may include, but is not limited to, a foil parameter input area, a feeding mechanism operation area, and a foil parameter display area, where the foil parameter input area is used to input a material name, a material mechanical property parameter of a foil material, and a geometric size, and certainly, the input area also provides functions of screening, deleting, modifying, and the like; similarly, the foil parameter display area is used for displaying the material number, the specification model, the product name, the specification model, the weight before winding and the weight after winding of the foil material, and is also provided with a bar code outlet for printing the material management and control information bar code; in addition, the operation area of the feeding mechanism is provided with a front moving button, a rear moving button, an upper moving button and a lower moving button, wherein the front moving button and the rear moving button control the moving platform 20 to move back and forth, and the upper moving button and the lower moving button control the lifting component 30 to move up and down; through the design, the winding material parameter input, the winding foil material parameter display after winding and the operation of each part during winding can be conveniently carried out by the working personnel, so that the use convenience can be improved, and the management workload can be reduced.
In this embodiment, the control host further has a data storage function, and can store corresponding data during each winding process, so that the historical data can be selected through an operation interface when the same material is subsequently used for winding.
Therefore, through the detailed explanation of the foil winding device, the optimal tension is set through the geometrical parameters and the material mechanical property parameters of the foil by the aid of a calculation model and a sensing technology of a control host, and the winding tension is effectively controlled through an intelligent mechanism, so that the tension of each layer of foil in the foil is accurately controlled in the winding process.
In a possible design, referring to fig. 6, in a second aspect of the present embodiment, on the basis of the first aspect of the embodiment, the working method of the foil winding apparatus in the first aspect of the embodiment is provided, which may include, but is not limited to, the following steps S1 to S6.
S1, obtaining material mechanical property parameters of a foil material and the geometric dimension of each layer of foil in the foil material, wherein the material mechanical property parameters comprise tensile strength, specified plastic elongation strength, yield strength and an optimal stress value.
And S2, judging whether the optimal stress value is smaller than any one of tensile strength, specified plastic elongation strength and yield strength.
S3, if not, calculating to obtain the optimal tension of each layer of foil in the foil roll based on the geometric dimension and the optimal stress value; in a specific application, the geometric dimensions may include, but are not limited to, the thickness and width of each foil in the foil roll, and the radius of the foil roll, wherein the optimal tension may be calculated by using the following formula (1):
F＝σA 0 (1)
in the above formula (1), F is the optimum tension, σ is the optimum stress value, and A 0 Is the cross-sectional area of any layer of foil, wherein:
when any layer of foil is round, A 0 ＝a×b-0.858r 2 Wherein a is any one layer of foilThe thickness b is the width of any layer of foil, and r is the radius of a fillet;
when any foil is round, A 0 ＝a×b-0.858r 2 And r is the radius of the round edge.
In this embodiment, since the geometric dimensions of each layer of foil in the foil roll are the same, the tension and the optimal torque value of each layer of foil are also the same, so that the optimal tension of each layer of foil can be calculated by using the geometric dimensions of any layer of foil, and then the optimal torque value can be calculated based on the calculated optimal tension, as shown in step S4 below.
S4, calculating to obtain an optimal torque value of a tensioning mechanism in the foil winding device based on the optimal tensioning force of each layer of foil in the foil coil; in the specific application, the optimal torque value of a tensioning mechanism in the foil winding device is calculated according to the following formula (2):
in the formula (2), T is the optimal torque value, R is the excircle radius of the supporting plate, and the excircle radius is the radius of the circle where the arc of the supporting plate is positioned.
S5, adjusting the rotation torque of a rotating assembly in the foil winding device according to the optimal torque value to enable the rotation torque of the rotating assembly to be the optimal torque value, and driving a tensioning assembly in the foil winding device to move by the rotating assembly according to the optimal torque value to enable the tensioning assembly to apply pressure to the foil to fasten the foil.
S6, obtaining an actual torque value of a tensioning assembly transmitted by a torque detector in the tensioning mechanism, and adjusting the rotation torque of a rotating assembly in the tensioning mechanism according to the optimal torque value so as to keep the actual torque value on the tensioning assembly to be the optimal torque value by adjusting the rotation torque of the rotating assembly until the foil material is wound.
In this embodiment, reference may be made to the first aspect of the embodiment for technical effects achieved by the method, which are not described herein again.
Finally, it should be noted that: the above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A foil winding apparatus, comprising: the device comprises a control host, a feeding mechanism, a tensioning mechanism and an auxiliary mechanism, wherein the control host is used for obtaining the optimal tensioning force of each layer of foil in a foil material according to the material mechanical property parameters of the foil material and the geometric dimension of each layer of foil in the foil material, and obtaining the optimal torque value of the tensioning mechanism according to the optimal tensioning force, and the material mechanical property parameters comprise tensile strength, specified plastic elongation strength, yield strength and optimal stress value;
the feeding mechanism is used for conveying the foil material to the tensioning mechanism;
the tensioning mechanism comprises a tensioning assembly, a rotating assembly and a detecting assembly, wherein the tensioning assembly is fixed on the rotating assembly, the detecting assembly is mounted on the tensioning assembly, and the foil material is sleeved on the tensioning assembly;
the control host is used for outputting an optimal torque value obtained based on the optimal tension to the rotating assembly when a foil material is wound, so that the rotating torque of the rotating assembly is the optimal torque value;
the rotating assembly is used for driving the tensioning assembly to move according to an optimal torque value obtained by the control host machine based on an optimal tensioning force when a foil material is wound, so that the tensioning assembly applies pressure to the foil material to fasten the foil material;
the detection assembly comprises a torque detector, wherein the torque detector is used for detecting an actual torque value on the tensioning assembly and transmitting the actual torque value to the control host machine, so that the control host machine adjusts the rotating torque of the rotating assembly according to the received actual torque value, and the actual torque value on the tensioning assembly is kept to be the optimal torque value by adjusting the rotating torque of the rotating assembly;
and the auxiliary mechanism is used for pressing the tensioned foil material so as to prevent the release of the winding force on the tensioned foil material after the winding is intermittent or finished.
2. A foil winding apparatus according to claim 1, wherein the feeding mechanism comprises: the device comprises a mobile station (20), a lifting assembly (30), a tray (40) and two guide rails (50) which are arranged in parallel, wherein the two guide rails (50) are arranged right below a tensioning mechanism;
the mobile station (20) is slidably mounted on the two guide rails (50), wherein the lifting component (30) is mounted on the top surface of the mobile station (20), and the tray (40) is fixed on the lifting end of the lifting component (30).
3. The foil winding device according to claim 2, wherein a weighing sensor is arranged on the contact surface of the tray (40) and the foil roll, a displacement sensor (60) is arranged at the bottom of the tray (40), and the weighing sensor and the displacement sensor (60) are respectively and electrically connected with the control host.
4. The foil winding device according to claim 1, wherein the rotating assembly comprises a motor (70), a rotating shaft (80), a first transmission gear (90), a second transmission gear (100) and an electromagnetic torquer (200), wherein the rotating assembly is mounted on a fixed frame (10), and the control host is electrically connected with the electromagnetic torquer (200) and the motor (70);
the fixing frame (10) comprises a first fixing plate (11), a second fixing plate (12), a rotating column (13) and a supporting plate (14), wherein the end part of the second fixing plate (12) is hinged with one end of the supporting plate (14) through the rotating column (13), and the other end of the supporting plate (14) is provided with a clamping groove for mounting the rotating shaft (80);
one end of the rotating shaft (80) is fixedly connected with the electromagnetic torquer (200), the other end of the rotating shaft (80) is rotatably connected in the clamping groove, and the tensioning assembly is installed on the rotating shaft (80);
the motor (70) is installed on the first fixing plate (11), wherein the first transmission gear (90) is fixed on an output shaft of the motor (70), the first transmission gear (90) is in transmission connection with the second transmission gear (100), and the second transmission gear (100) is in transmission connection with the tensioning assembly and used for driving the tensioning assembly to move under the driving of the motor (70) so as to apply pressure to the foil material coil.
5. A foil winding arrangement according to claim 4, wherein the tensioning assembly comprises: the telescopic part (110), the fixing ring (190), the rotating ring (200) and the plurality of supporting plates (130), wherein the plurality of supporting plates (130) are uniformly arranged along the circumferential direction of the rotating shaft (80), and each supporting plate (130) is an arc-shaped plate;
the fixing ring (190) is fixed at one end, close to the clamping groove, of the rotating shaft (80), the rotating ring (200) is slidably mounted at one end, close to the first fixing plate (11), of the rotating shaft (80), and the second transmission gear (100) is in threaded connection with the rotating ring (200);
every fagging (130) corresponds one extensible member (110), wherein, extensible member (11) adopt many connecting rod structure, the head end of extensible member (11) articulates on swivel becket (200), the tail end of extensible member (11) articulates on solid fixed ring (190), just the link of each connecting rod articulates in extensible member (11) corresponds the side on fagging (130).
6. A foil winding apparatus according to claim 1, wherein the detection assembly further comprises: and the pressure sensor (120) is arranged on the contact surface of any supporting plate (130) and the foil material, and the pressure sensor (120) is electrically connected with the control host.
7. A foil winding arrangement according to claim 6, wherein the auxiliary mechanism comprises: the device comprises a first roller (140), a second roller (150), a torque sensor and a hydraulic mechanism, wherein the first roller (140) and the second roller (150) are sequentially fixed on a fixed frame (10) along the vertical direction, and the first roller (140) and the second roller (150) are parallel to each other;
the torque sensor is mounted on the first roller (140), the output end of the hydraulic mechanism is fixedly connected with the first roller (140) and used for driving the first roller (140) to move along the vertical direction, the torque sensor is electrically connected with the control host, and the control host is electrically connected with the controlled end of the hydraulic mechanism.
8. The foil winding device according to claim 1, wherein the control host is disposed in an operation box (160), wherein the operation box (160) is mounted on the fixing frame (10), and an operation interface is disposed on the operation box (160);
the operation interface comprises a foil parameter input area, a feeding mechanism operation area and a foil parameter display area, wherein the foil parameter display area is used for displaying the material number, the specification model, the product name, the specification model, the weight before winding and the weight after winding of a foil coil, and the foil parameter display area is further provided with a bar code outlet for printing a material management and control information bar code.
9. A method of operating a foil winding device according to any one of claims 1-8, comprising:
acquiring material mechanical property parameters of a foil material and the geometric dimension of each layer of foil in the foil material, wherein the material mechanical property parameters comprise tensile strength, specified plastic elongation strength, yield strength and an optimal stress value;
judging whether the optimal stress value is smaller than any one of tensile strength, specified plastic elongation strength and yield strength;
if not, calculating to obtain the optimal tension of each layer of foil in the foil roll material based on the geometric dimension and the optimal stress value;
calculating to obtain an optimal torque value of a tensioning mechanism in the foil winding device based on the optimal tensioning force of each layer of foil in the foil coil;
according to the optimal torque value, adjusting the rotation torque of a rotating assembly in a foil winding device to enable the rotation torque of the rotating assembly to be the optimal torque value, and according to the optimal torque value, driving a tensioning assembly in the foil winding device to move by using the rotating assembly to enable the tensioning assembly to apply pressure to a foil to fasten the foil;
and acquiring an actual torque value of the tensioning assembly transmitted by a torque detector in the tensioning mechanism, and adjusting the rotating torque of a rotating assembly in the tensioning mechanism according to the optimal torque value so as to keep the actual torque value on the tensioning assembly to be the optimal torque value by adjusting the rotating torque of the rotating assembly until the foil material is completely wound.
10. The method of claim 9, wherein the geometric dimensions comprise: the thickness, the width and the radius of each layer of foil in the foil coil stock, the tensioning assembly comprises a plurality of supporting plates (130), and the supporting plates (130) are arc-shaped plates;
calculating the optimal tension of each layer of foil in the foil roll based on the geometric dimension and the optimal stress value, wherein the optimal tension comprises the following steps:
calculating to obtain the optimal tension according to the following formula (1);
F＝σA 0 (1)
in the above formula (1), F is the optimum tension, σ is the optimum stress value, A 0 Is the sectional area of any layer of foil in the foil coil, wherein:
when any layer of foil is round, A 0 ＝a×b-0.858r 2 Wherein a is the thickness of any layer of foil, and b is any layer of foilR is a fillet radius;
when any foil is round, A 0 ＝a×b-0.858r 2 R is the radius of the round edge;
correspondingly, based on the optimal tension of each layer of foil in the foil coil, the optimal torque value of a tensioning mechanism in the foil winding device is calculated and obtained, and the method comprises the following steps:
calculating to obtain an optimal torque value of a tensioning mechanism in the foil winding device according to the following formula (2);
in the formula (2), T is the optimal torque value, and R is the outer circle radius of the supporting plate (130).
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| CN202211044359.XA CN115410817A (en) | 2022-08-29 | 2022-08-29 | Foil winding device and working method thereof |
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| CN202211044359.XA CN115410817A (en) | 2022-08-29 | 2022-08-29 | Foil winding device and working method thereof |
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| CN114864269A (en) * | 2022-04-22 | 2022-08-05 | 广州中车骏发电气有限公司 | Intelligent control system and control method for tension of transformer winding |
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| US4381852A (en) * | 1980-10-20 | 1983-05-03 | Westinghouse Electric Corp. | Automatic tensioning control for winding stator coils |
| JPH1121015A (en) * | 1997-07-08 | 1999-01-26 | Matsushita Electric Ind Co Ltd | Tension device |
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Country or region after: China Address after: 510000 No.15 Huashan Road, Shilou Town, Panyu District, Guangzhou City, Guangdong Province (factory building C) Applicant after: Guangzhou Junfa Electrical Equipment Co.,Ltd. Address before: 510000 No.15 Huashan Road, Shilou Town, Panyu District, Guangzhou City, Guangdong Province (factory building C) Applicant before: GUANGZHOU CRRC JUNFA ELECTRIC CO.,LTD. Country or region before: China |