CN116313499A - Winding equipment control method and system - Google Patents
Winding equipment control method and system Download PDFInfo
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- CN116313499A CN116313499A CN202310030285.2A CN202310030285A CN116313499A CN 116313499 A CN116313499 A CN 116313499A CN 202310030285 A CN202310030285 A CN 202310030285A CN 116313499 A CN116313499 A CN 116313499A
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- 238000004804 winding Methods 0.000 title claims abstract description 330
- 238000000034 method Methods 0.000 title claims abstract description 43
- 238000010079 rubber tapping Methods 0.000 claims abstract description 16
- 239000003550 marker Substances 0.000 claims description 43
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 34
- 229910052802 copper Inorganic materials 0.000 claims description 34
- 239000010949 copper Substances 0.000 claims description 34
- 238000007781 pre-processing Methods 0.000 claims description 21
- 238000004458 analytical method Methods 0.000 claims description 20
- 238000010586 diagram Methods 0.000 description 6
- 238000010191 image analysis Methods 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000033228 biological regulation Effects 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
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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
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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
- H01F41/076—Forming taps or terminals while winding, e.g. by wrapping or soldering the wire onto pins, or by directly forming terminals from the wire
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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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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The application discloses a winding equipment control method and system, which relate to the technical field of transformer winding, and the method comprises the following steps: acquiring winding information; collecting video images of a winding area where a coil framework is located; analyzing whether the coil skeleton is positioned at a preset position of the winding area or not based on the video image; if the coil framework is positioned at the preset position, a winding module is controlled to wind the coil framework, and the number of turns of real-time winding of the coil framework is obtained; tapping by combining the number of turns of the real-time winding and the number of turns of the planned tap, and counting the number of the real-time taps; when the number of the real-time taps is equal to the number of the planned taps, judging whether the number of turns of the real-time winding is equal to the number of turns of the planned winding or not; and if the number of turns of the real-time winding is equal to the number of turns of the planned winding, stopping winding and reminding the completion of winding. The utility model has the advantages of automatic wire winding and be difficult to appear wrong turn phenomenon.
Description
Technical Field
The application relates to the technical field of transformer winding, in particular to a winding equipment control method and system.
Background
A Transformer (Transformer) is a device that changes an ac voltage using the principle of electromagnetic induction. In electrical equipment and wireless circuits, it is often used as a step-up voltage, a matching impedance, a safety isolation, etc. In the manufacturing process of a dry-type rectifier transformer for variable frequency speed regulation, a copper strip is generally required to be wound on a hollow coil skeleton by manual operation of winding equipment, a tap is also required to be formed by pre-forming the copper strip at a preset position in the winding process, and the manufacturing of the rectifier transformer is completed by inserting an iron core into the hollow part of the coil skeleton after winding is finished.
With respect to the related art in the above, the inventors consider that there are the following drawbacks: the number of secondary groups of the dry-type rectifier transformer for variable frequency speed regulation is large, and the number of turns of each group is different, so that the phenomenon of turn staggering easily occurs in the process of winding by manual operation.
Disclosure of Invention
In order to overcome the defect that the phenomenon of misplacement is easy to occur in the winding process of manual operation, the application provides a winding equipment control method and system.
In a first aspect, the present application provides a winding apparatus control method, including the steps of:
acquiring winding information, wherein the winding information comprises planned winding turns, planned tap turns and planned tap quantity;
collecting video images of a winding area where a coil framework is located;
analyzing whether the coil skeleton is positioned at a preset position of the winding area or not based on the video image;
if the coil framework is positioned at the preset position, a winding module is controlled to wind the coil framework, and the number of turns of real-time winding of the coil framework is obtained;
tapping by combining the number of turns of the real-time winding and the number of turns of the planned tap, and counting the number of the real-time taps;
when the number of the real-time taps is equal to the number of the planned taps, judging whether the number of turns of the real-time winding is equal to the number of turns of the planned winding or not;
and if the number of turns of the real-time winding is equal to the number of turns of the planned winding, stopping winding and reminding the completion of winding.
Through adopting above-mentioned technical scheme, judge whether the coil skeleton is in preset position department through the video image analysis of gathering the winding region at coil skeleton place, confirm the position of good coil skeleton earlier before the wire winding can reduce the probability that the follow-up wire winding in-process appears wrong turn phenomenon, obtain the wire winding information that current coil skeleton needs to carry out the wire winding, take a percentage the opportunity according to wire winding information control, and stop the wire winding when real-time tap quantity equals with the plan tap quantity and real-time wire winding turns equals with the plan wire winding turns, the wire winding process has met the plan wire winding standard this moment, can carry out the wire winding and accomplish the warning. Compared with manual operation winding, the phenomenon of error turn is less likely to occur by reading winding information and automatically completing winding.
Optionally, the analyzing whether the coil former is at the preset position of the winding area based on the video image includes the following steps:
preprocessing the video image to obtain a preprocessed image;
identifying a first marker bit and a second marker bit which are preset in the winding area in the preprocessing image, wherein one end of the coil skeleton is positioned between the first marker bit and the second marker bit when the coil skeleton is positioned at the preset position of the winding area;
judging whether the first flag bit is recognized or not;
if the first zone bit is not recognized, judging whether the second zone bit is recognized or not;
and if the second marker bit is identified, judging that the coil skeleton is positioned at the preset position.
By adopting the technical scheme, the video image is preprocessed after being obtained, so that the identification of the subsequent zone bit is facilitated, the coil skeleton is judged to be at the preset position only when one end of the coil skeleton is positioned between the first zone bit and the second zone bit, and the coil skeleton can shield the first zone bit and can not shield the second zone bit when the coil skeleton is positioned between the first zone bit and the second zone bit, and therefore, the identification of the zone bit can be carried out on the video image, and the coil skeleton is judged to be at the preset position when the second zone bit is identified but the first zone bit is not identified.
Optionally, after the control winding module winds the coil bobbin and acquires the number of real-time winding turns of the coil bobbin, the method further includes the following steps:
the laser module is controlled to emit tap calibration laser, and the tap calibration laser is positioned on the outer side of the coil framework and is parallel to the central axis of the coil framework.
By adopting the technical scheme, the emitted tap calibration laser can be used for alignment of subsequent tap positions.
Optionally, the step of tapping by combining the number of real-time winding turns and the planned tap number of turns, and counting the number of real-time taps includes the steps of:
judging whether the number of turns of the planned tap is reached or not based on the number of turns of the real-time winding;
if the number of turns of the planned tap is reached, the winding is suspended, and the tap position is adjusted based on the tap calibration laser;
tapping after adjusting the tap position;
and continuing winding after the tap is finished, and counting the number of the taps in real time.
Through adopting above-mentioned technical scheme, when real-time wire winding turns reaches the plan tap turns, need carry out the operation of taking a percentage, need pause the wire winding at this moment earlier to mark laser according to the tap and finely tune the position of taking a percentage, can take a percentage after adjusting the position of taking a percentage to the laser department of marking a percentage, and statistics real-time tap quantity, continue to carry out the wire winding operation after the tap finishes until reaching the next plan tap turns.
Optionally, before the control winding module winds the coil bobbin and obtains the number of real-time winding turns of the coil bobbin, the method includes the following steps:
the copper strip to be wound is pulled to be connected with the coil framework;
and controlling the constant tension of the copper strip to be wound within a preset tension range.
By adopting the technical scheme, the copper strip to be wound is connected with the coil framework, the tension of the copper strip to be wound is kept stable, the coil can be wound on the coil framework in order in the winding process, and the winding is prevented from being loose or broken.
In a second aspect, the present application further provides a winding apparatus control system, wherein the system includes:
the information acquisition module is used for acquiring winding information, wherein the winding information comprises planned winding turns, planned tap turns and planned tap quantity;
the image acquisition module is used for acquiring video images of a winding area where the coil framework is positioned;
the position analysis module is connected with the image acquisition module and used for judging whether the coil framework is positioned at a preset position in the winding area according to the video image;
the winding module is used for winding the copper strips to be wound to the coil framework and calculating and obtaining the number of turns of real-time winding of the coil framework;
the tapping module is connected with the winding module and the information acquisition module and is used for tapping in the winding process and counting the number of taps in real time;
the control module is connected with the information acquisition module, the position analysis module, the winding module and the tap module;
when the position analysis module judges that the coil framework is positioned at the preset position, the control module controls the winding module to perform winding;
when the control module judges that the number of the real-time taps is equal to the number of the taps, the control module further judges whether the number of the real-time winding turns is equal to the planned winding turns or not;
and if the number of turns of the real-time winding is equal to the number of turns of the planned winding, the control module controls the winding module to stop winding and to remind of winding completion.
Through adopting above-mentioned technical scheme, gather the video image in the winding region of coil skeleton place through image acquisition module to whether judge through the analysis of position analysis module that the coil skeleton is in preset position department, confirm the position of coil skeleton earlier before the wire winding can reduce the probability that the phenomenon appears wrong turn in the follow-up wire winding process, the information acquisition module can acquire the current coil skeleton and need carry out the wire winding information of wire winding, the control module control of taking a percentage the opportunity according to wire winding information takes a percentage, and when real-time tap quantity and plan tap quantity equal and real-time wire winding number of turns and plan wire winding number of turns equal control module control wire winding module stop wire winding, the wire winding process has met the plan wire winding standard this moment, can carry out wire winding completion and remind. Compared with manual operation winding, the phenomenon of error turn is less likely to occur by reading winding information and automatically completing winding.
Optionally, the location analysis module includes:
the preprocessing unit is connected with the image acquisition module and used for acquiring the video image acquired by the image acquisition module and preprocessing the video image to obtain a preprocessed image;
the marker bit identification unit is used for identifying a first marker bit and a second marker bit preset in the winding area in the preprocessing image;
and the judging unit is connected with the marker bit identifying unit and is used for judging that the coil skeleton is positioned at the preset position when the marker bit identifying unit identifies the second marker bit and does not identify the first marker bit.
By adopting the technical scheme, the preprocessing unit is beneficial to the identification of the subsequent zone bit by preprocessing the video image after acquiring the video image, the coil skeleton is judged to be at the preset position only when one end of the coil skeleton is positioned between the first zone bit and the second zone bit, and the coil skeleton can shield the first zone bit and can not shield the second zone bit when the coil skeleton is positioned between the first zone bit and the second zone bit, so that the zone bit identification can be carried out on the video image through the zone bit identification unit, and the judgment unit outputs the judgment result to judge that the coil skeleton is at the preset position when the zone bit identification unit identifies the second zone bit but does not identify the first zone bit.
Optionally, the system further comprises:
the laser module is used for emitting tap calibration laser, and the tap calibration laser is positioned on the outer side of the coil framework and is parallel to the central axis of the coil framework.
By adopting the technical scheme, the tap calibration laser emitted by the laser module can be used for aligning the subsequent tap positions.
Optionally, the tap module includes:
the tap unit is connected with the winding module, and is used for adjusting the tap position according to the tap calibration laser when the number of turns of the real-time winding reaches the number of turns of the planned tap, and performing tapping;
and the counting unit is connected with the tap unit and is used for counting the number of the taps in real time.
Through adopting above-mentioned technical scheme, when real-time wire winding turns reaches the plan tap turns, take a percentage the operation through the tap unit, need pause the wire winding earlier this moment to mark laser according to the tap and finely tune the position of taking a percentage, can take a percentage after adjusting the position of taking a percentage to the laser department of marking a percentage, and count real-time tap quantity through the statistics unit, continue to carry out the wire winding operation after the tap finishes until reaching the next plan tap turns.
Optionally, the system further comprises:
and the tension maintaining module is used for pulling the copper strip to be wound to be connected with the coil framework and controlling the constant tension of the copper strip to be wound within a preset tension range.
By adopting the technical scheme, the copper strip to be wound is connected with the coil framework through the tension maintaining module, the tension of the copper strip to be wound is maintained stable, the coil can be wound on the coil framework in order in the winding process, and the winding is prevented from being loose or broken.
In summary, the present application includes at least one of the following beneficial technical effects:
1. the method comprises the steps of acquiring video image analysis of a winding area where a coil framework is located, judging whether the coil framework is located at a preset position or not, determining the position of the coil framework before winding, reducing the possibility of occurrence of a phenomenon of wrong turns in the subsequent winding process, acquiring winding information of the current coil framework needing to be wound, controlling tap time according to the winding information, stopping winding when the number of taps in real time is equal to the number of taps in a planning mode and the number of turns of the winding in real time is equal to the number of turns of the winding in the planning mode, enabling the winding process to meet the planning winding standard at the moment, and reminding completion of winding. Compared with manual operation winding, the phenomenon of error turn is less likely to occur by reading winding information and automatically completing winding.
2. The tension of the copper strip to be wound is kept stable, so that the coil can be wound on the coil framework in order in the winding process, and the situation that the winding is loose or broken is avoided.
Drawings
Fig. 1 is a system configuration diagram of one implementation of a winding apparatus control system according to an embodiment of the present application.
Fig. 2 is a system configuration diagram of one implementation of a location analysis module according to an embodiment of the present application.
Fig. 3 is a schematic step diagram of one implementation of the winding device control method according to the embodiment of the present application.
Fig. 4 is a schematic step diagram of one implementation of the winding device control method according to the embodiment of the present application.
Fig. 5 is a schematic step diagram of one implementation of the winding device control method according to the embodiment of the present application.
Fig. 6 is a schematic step diagram of one implementation of the winding device control method according to the embodiment of the present application.
Detailed Description
The present application is described in further detail below in conjunction with figures 1 to 6.
The embodiment of the application discloses a winding equipment control system.
Referring to fig. 1, the winding device control system includes an information acquisition module, an image acquisition module, a position analysis module, a winding module, a tap module, and a control module. The information acquisition module is connected with the control module, is further connected with a preset background server, and can prestore winding information of coil framework adaptation in the background server, and the information acquisition module can call the winding information from the background server before winding and transmits the winding information to the control module. The winding information includes a planned winding number, a planned tap number, and a planned tap number, the planned tap number typically being plural, the planned tap number representing a tap operation required when the actual winding number reaches the planned tap number.
The coil skeleton is placed on the winding roller in the winding region through manual work or manipulator for the winding roller is located the cavity of coil skeleton, and the position that is most suitable for the wire winding on the winding roller is marked with first zone bit and second zone bit as the position of predetermineeing. The first zone bit and the second zone bit can be marked in a spraying or sticking paper mode, and the colors of the first zone bit and the second zone bit are different, so that the first zone bit and the second zone bit can be distinguished when being identified. The first marker bit and the second marker bit are spaced, and after the coil framework is placed on the winding roller, when the coil framework shields the first marker bit and does not shield the second marker bit, the coil framework is indicated to be at a preset position most suitable for winding.
The image acquisition module can be a high-definition camera, the image acquisition module is arranged right above the winding roller in the winding area, the image acquisition module can acquire video images containing the winding roller in real time, the image acquisition module is connected with the position analysis module, and the image acquisition module transmits the video images to the position analysis module after acquiring the video images. The position analysis module is connected with the control module, an image recognition model based on OpenCV is preset in the position analysis module, the position analysis module can recognize the first marker bit and the second marker bit through the image recognition model, judge whether the coil skeleton is at a preset position according to the recognition result, and finally send the judgment result to the control module so that the control module can perform subsequent operation.
The winding equipment control system further comprises a laser module and a tension maintaining module, wherein the laser module is arranged beside the winding roller, the laser module can emit tap calibration laser parallel to the central axes of the winding roller and the coil skeleton, and the laser can be used for maintaining alignment of tap positions when the subsequent tap module taps according to the tap calibration laser. The tension control module is arranged at the winding module, the tension control module can extend the support from the winding module to the direction of the coil framework, the coil framework can be pulled to be wound with the coil framework through the extending support to be connected with the copper strip to be wound, the copper strip to be wound is tensioned through the tension controller in the tension control module to promote the tension of the copper strip to be wound, the tension of the copper strip to be wound is maintained in a tension range preset in the tension controller, and accordingly the tension of the copper strip to be wound is kept stable, the coil can be wound on the coil framework neatly in the winding process, and the situation that winding is loose or broken is avoided.
The control module can be industrial PLC, and the control module is further connected with a winding module and a tapping module, wherein the winding module comprises a winding machine and a turns measuring instrument. Specifically, after the control module receives the judgment result sent by the position analysis module, the winding machine is controlled to start winding the coil skeleton by using the copper strip to be wound based on the planned winding number in the winding information, the number of turns is counted by the winding number measuring instrument, the number of turns is transmitted to the control module in real time, and the real-time winding number of turns is compared with the planned tap number of turns each time the control module receives a new real-time winding number of turns. And when the number of turns of the real-time winding is the same as the number of turns of any scheduled tap, the winding is stopped by the control winding module, and the tap module is controlled to enable the copper strip to be wound to be preformed to finish the tap operation.
The tap module comprises a tap unit and a statistics unit, wherein the tap unit is connected with the winding module, when the number of turns of the real-time winding reaches the number of turns of the planned tap, the winding module stops winding, the tap position is adjusted according to the tap calibration laser, when the tap position is adjusted to the tap calibration laser, the tap unit enables a copper strip to be wound to be preformed so as to finish the tap operation, when the tap unit finishes the tap operation, the count of a tap counter preset in the statistics unit is increased by one, the statistics unit is connected with the control module, and the statistics unit can transmit the real-time tap number counted by the tap counter to the control module in real time. Finally, when the control module judges that the number of the real-time winding turns reaches the planned winding turns and the number of the real-time taps reaches the planned tap number, the control module stops winding the wire by controlling the winding module and plays the sound broadcasting of the winding completion through a preset loudspeaker.
Referring to fig. 2, the position analysis module includes a preprocessing unit, a flag bit recognition unit, and a judgment unit, where the preprocessing unit is connected with the image acquisition module, and the preprocessing unit may acquire the video image acquired by the image acquisition module, and perform image preprocessing operations such as noise reduction, sharpening, and the like on the video image to obtain a preprocessed image. The marker bit identification unit is connected with the preprocessing unit, acquires a preprocessed image obtained after preprocessing by the preprocessing unit, and identifies a first marker bit and a second marker bit in the preprocessed image through an image identification model based on OpenCV to obtain an identification result. The judging unit is connected with the marker bit identifying unit, acquires and analyzes the identifying result of the marker bit identifying unit, judges that the coil skeleton is at a preset position when the identifying result is that the second marker bit is identified and the first marker bit is not identified, and judges that the coil skeleton is not at the preset position when the identifying result is other results.
The implementation principle of the embodiment is as follows:
the video image of the winding area where the coil framework is located is acquired through the image acquisition module, whether the coil framework is located at a preset position or not is judged through the position analysis module, the position of the coil framework is determined before winding, the possibility that a phenomenon of wrong turns occurs in the subsequent winding process can be reduced, the information acquisition module can acquire the winding information of the current coil framework, the tap module controls the tap time according to the winding information, and when the real-time tap number is equal to the planned tap number and the real-time winding turns are equal to the planned winding turns, the control module controls the winding module to stop winding, the winding process accords with the planned winding standard at the moment, and the winding completion reminding can be carried out. Compared with manual operation winding, the phenomenon of error turn is less likely to occur by reading winding information and automatically completing winding.
In a second aspect, the embodiment of the application also discloses a winding device control method.
Referring to fig. 3, the winding apparatus control method specifically includes the steps of:
s101, acquiring winding information.
The manager can store the winding information of the coil framework in the background server in advance, and can call the winding information from the background server before winding. The winding information includes a planned winding number, a planned tap number, and a planned tap number.
S102, collecting video images of a winding area where the coil framework is located.
The high-definition camera is used for acquiring video images, the winding area comprises a winding roller, and the coil skeleton is placed on the winding roller.
S103, analyzing whether the coil framework is positioned at a preset position of a winding area or not based on the video image, and if the coil framework is positioned at the preset position, executing the step S104.
The position, which is most suitable for winding, on the winding roller is marked with a first zone bit and a second zone bit as preset positions. The first zone bit and the second zone bit can be marked in a spraying or sticking paper mode, and the colors of the first zone bit and the second zone bit are different, so that the first zone bit and the second zone bit can be distinguished when being identified. The first marker bit and the second marker bit are spaced, and after the coil framework is placed on the winding roller, when the coil framework shields the first marker bit and does not shield the second marker bit, the coil framework is indicated to be at a preset position most suitable for winding. If the coil framework is not at the preset position, a position deviation alarm is sent out through a loudspeaker so as to remind a manager on the scene of adjusting the position of the coil framework.
S104, controlling the winding module to wind the coil framework, and obtaining the number of turns of the coil framework in real time.
Specifically, the real-time winding turns of the coil skeleton are obtained through a turns measuring instrument, namely the turns measuring instrument counts the real-time winding turns in real time, and sends the real-time winding turns to the current execution main body. The current execution main body can be intelligent control equipment such as a computer, a tablet and the like.
It should be noted that, in specific implementation, the coil that the winding module winds to the coil skeleton includes high voltage coil and low voltage coil, to two kinds of coils, obtain the step of the real-time wire winding turns of coil skeleton as follows:
the real-time winding turns comprise high-voltage coil winding turns and low-voltage coil winding turns;
if the coil is a high-voltage coil, acquiring winding stop points of a winding module, acquiring the number of turns of the coil at each winding stop point in real time, acquiring a cut-off time point, and accumulating the number of turns of the coil at a plurality of stop points to obtain the number of turns of the high-voltage coil winding at the cut-off time point;
if the coil is a low-voltage coil, acquiring zero clearing points of the winding module, acquiring the number of turns of the coil at each zero clearing point in real time, and winding the low-voltage coil of the seat with the number of turns of the coil at each zero clearing point.
If the coil is a low-voltage coil, only the number of turns of the coil at each zero clearing point is required to be obtained, and after the number of turns of the coil at each zero clearing point is obtained, zero clearing treatment is performed; if the coil is a high-voltage coil, the number of turns of the coil at each stop point is accumulated.
S105, combining the number of turns of the real-time winding and the number of turns of the planned tap to carry out tap, and counting the number of the real-time taps.
Wherein the number of planned tap turns is typically plural, and the planned tap turns represent the tap operation required when the actual winding turns reach the planned tap turns. And comparing the number of the real-time winding turns with the number of the planned tap turns, and when the number of the real-time winding turns is the same as any planned tap number of turns, suspending winding by the control winding module, starting tap operation and simultaneously counting the number of the real-time taps.
S106, when the number of the real-time taps is equal to the number of the planned taps, judging whether the number of the real-time winding turns is equal to the number of the planned winding turns, and if the number of the real-time winding turns is equal to the number of the planned winding turns, executing the step S107.
And if the number of the real-time winding turns is not equal to the planned winding turns, continuing winding.
S107, stopping winding and reminding of winding completion.
Wherein, broadcast the voice broadcast that wire winding was accomplished through the speaker of predetermineeing to remind the manager to change the coil skeleton.
The implementation principle of one implementation mode of the embodiment of the application is as follows:
the method comprises the steps of acquiring video image analysis of a winding area where a coil framework is located, judging whether the coil framework is located at a preset position or not, determining the position of the coil framework before winding, reducing the possibility of occurrence of a phenomenon of wrong turns in the subsequent winding process, acquiring winding information of the current coil framework needing to be wound, controlling tap time according to the winding information, stopping winding when the number of taps in real time is equal to the number of taps in a planning mode and the number of turns of the winding in real time is equal to the number of turns of the winding in the planning mode, enabling the winding process to meet the planning winding standard at the moment, and reminding completion of winding. Compared with manual operation winding, the phenomenon of error turn is less likely to occur by reading winding information and automatically completing winding.
In one implementation manner of the embodiment of the present application, referring to fig. 4, step S103 specifically includes the following steps:
s201, preprocessing a video image to obtain a preprocessed image.
The preprocessing of the video image comprises the operations of noise reduction processing, sharpening processing and the like on the video image, so as to obtain a preprocessed image.
S202, identifying a first zone bit and a second zone bit which are preset in a winding area in the preprocessed image.
The method comprises the steps of identifying a first zone bit and a second zone bit in a preprocessed image through an image identification model based on OpenCV. When the coil skeleton is positioned at a preset position of the winding area, one end of the coil skeleton is positioned between the first zone bit and the second zone bit.
S203, judging whether the first flag bit is recognized, and if the first flag bit is not recognized, executing step S204.
If the first marker bit is identified, the coil skeleton is judged not to be at the preset position.
S204, judging whether the second flag bit is recognized, and if the second flag bit is recognized, executing step S205.
And if the second marker bit is not recognized, judging that the coil skeleton is not at the preset position.
S205, judging that the coil framework is at a preset position.
The implementation principle of one implementation mode of the embodiment of the application is as follows:
the video image is preprocessed after being obtained, so that the identification of the subsequent zone bit is facilitated, the coil skeleton is judged to be at the preset position only when one end of the coil skeleton is located between the first zone bit and the second zone bit, and the coil skeleton can shield the first zone bit and cannot shield the second zone bit when the coil skeleton is located between the first zone bit and the second zone bit, and therefore the identification of the zone bit can be carried out on the video image, and the coil skeleton is judged to be at the preset position when the second zone bit is identified but the first zone bit is not identified.
In one implementation manner of the embodiment of the present application, the following step is further included after step S104:
and controlling the laser module to emit tap calibration laser.
The tap calibration laser is positioned outside the coil framework and is parallel to the central axis of the coil framework, and the emitted tap calibration laser can be used for alignment of subsequent tap positions.
In one implementation manner of the embodiment of the present application, referring to fig. 5, step S105 specifically includes the following steps:
s301, judging whether the number of turns of the planned tap is reached or not based on the number of turns of the real-time winding, and if the number of turns of the planned tap is reached, executing step S302.
If the number of the tap turns is not planned, continuing winding.
S302, suspending winding and adjusting the tap position based on the tap calibration laser.
And adjusting the tap position according to the tap calibration laser, and performing tapping when the tap position is adjusted to the tap calibration laser.
S303, adjusting the tap position and then carrying out tapping.
And pre-forming the copper strip to be wound at the tap position to finish the tap operation.
S304, winding is continued after the tap is finished, and the number of the taps in real time is counted.
The implementation principle of one implementation mode of the embodiment of the application is as follows:
when the number of turns of the real-time winding reaches the number of turns of the planned tap, the tap operation is needed, the winding is needed to be stopped at the moment, the tap position is finely adjusted according to the tap calibration laser, the tap can be carried out after the tap position is adjusted to the tap calibration laser, the number of the real-time taps is counted, and the winding operation is continued until the number of turns of the next planned tap is reached after the tap is ended.
In one implementation of the embodiment of the present application, referring to fig. 6, before step S104, the following steps are further included:
s401, the copper strip to be wound is pulled to be connected with the coil framework.
The support can be extended from the winding module to the coil framework, and the copper strip to be wound can be pulled to be connected with the coil framework quickly through the extending support.
S402, controlling the constant tension of the copper strip to be wound within a preset tension range.
The copper strip to be wound is tensioned through the tension controller to improve the tension of the copper strip to be wound, and the tension of the copper strip to be wound is maintained within a tension range preset in the tension controller.
The implementation principle of one implementation mode of the embodiment of the application is as follows:
the copper strip to be wound is connected with the coil framework, tension of the copper strip to be wound is kept stable, the coil can be wound on the coil framework in order in the winding process, and the situation that the winding is loose or broken is avoided.
The foregoing are all preferred embodiments of the present application, and are not intended to limit the scope of the present application in any way, therefore: all equivalent changes in structure, shape and principle of this application should be covered in the protection scope of this application.
Claims (10)
1. A winding apparatus control method, characterized by comprising the steps of:
acquiring winding information, wherein the winding information comprises planned winding turns, planned tap turns and planned tap quantity;
collecting video images of a winding area where a coil framework is located;
analyzing whether the coil skeleton is positioned at a preset position of the winding area or not based on the video image;
if the coil framework is positioned at the preset position, a winding module is controlled to wind the coil framework, and the number of turns of real-time winding of the coil framework is obtained;
tapping by combining the number of turns of the real-time winding and the number of turns of the planned tap, and counting the number of the real-time taps;
when the number of the real-time taps is equal to the number of the planned taps, judging whether the number of turns of the real-time winding is equal to the number of turns of the planned winding or not;
and if the number of turns of the real-time winding is equal to the number of turns of the planned winding, stopping winding and reminding the completion of winding.
2. The method of claim 1, wherein analyzing whether the bobbin is at a preset position of the winding area based on the video image comprises the steps of:
preprocessing the video image to obtain a preprocessed image;
identifying a first marker bit and a second marker bit which are preset in the winding area in the preprocessing image, wherein one end of the coil skeleton is positioned between the first marker bit and the second marker bit when the coil skeleton is positioned at the preset position of the winding area;
judging whether the first flag bit is recognized or not;
if the first zone bit is not recognized, judging whether the second zone bit is recognized or not;
and if the second marker bit is identified, judging that the coil skeleton is positioned at the preset position.
3. The method of claim 1, further comprising the steps of, after the control winding module winds the coil bobbin and obtains the real-time winding turns of the coil bobbin:
the laser module is controlled to emit tap calibration laser, and the tap calibration laser is positioned on the outer side of the coil framework and is parallel to the central axis of the coil framework.
4. A method of controlling a winding apparatus according to claim 3, wherein said tapping in combination with said real-time winding turns and said planned tap turns, and counting the number of real-time taps, comprises the steps of:
judging whether the number of turns of the planned tap is reached or not based on the number of turns of the real-time winding;
if the number of turns of the planned tap is reached, the winding is suspended, and the tap position is adjusted based on the tap calibration laser;
tapping after adjusting the tap position;
and continuing winding after the tap is finished, and counting the number of the taps in real time.
5. The method of claim 1, wherein the step of, before the control winding module winds the coil bobbin and acquires the real-time winding turns of the coil bobbin, comprises the steps of:
the copper strip to be wound is pulled to be connected with the coil framework;
and controlling the constant tension of the copper strip to be wound within a preset tension range.
6. A winding apparatus control system, the system comprising:
the information acquisition module is used for acquiring winding information, wherein the winding information comprises planned winding turns, planned tap turns and planned tap quantity;
the image acquisition module is used for acquiring video images of a winding area where the coil framework is positioned;
the position analysis module is connected with the image acquisition module and used for judging whether the coil framework is positioned at a preset position in the winding area according to the video image;
the winding module is used for winding the copper strips to be wound to the coil framework and calculating and obtaining the number of turns of real-time winding of the coil framework;
the tapping module is connected with the winding module and the information acquisition module and is used for tapping in the winding process and counting the number of taps in real time;
the control module is connected with the information acquisition module, the position analysis module, the winding module and the tap module;
when the position analysis module judges that the coil framework is positioned at the preset position, the control module controls the winding module to perform winding;
when the control module judges that the number of the real-time taps is equal to the number of the taps, the control module further judges whether the number of the real-time winding turns is equal to the planned winding turns or not;
and if the number of turns of the real-time winding is equal to the number of turns of the planned winding, the control module controls the winding module to stop winding and to remind of winding completion.
7. The winding plant control system of claim 6, wherein the position analysis module comprises:
the preprocessing unit is connected with the image acquisition module and used for acquiring the video image acquired by the image acquisition module and preprocessing the video image to obtain a preprocessed image;
the marker bit identification unit is used for identifying a first marker bit and a second marker bit preset in the winding area in the preprocessing image;
and the judging unit is connected with the marker bit identifying unit and is used for judging that the coil skeleton is positioned at the preset position when the marker bit identifying unit identifies the second marker bit and does not identify the first marker bit.
8. The winding apparatus control system of claim 6, further comprising:
the laser module is used for emitting tap calibration laser, and the tap calibration laser is positioned on the outer side of the coil framework and is parallel to the central axis of the coil framework.
9. The winding plant control system of claim 8, wherein the tap module comprises:
the tap unit is connected with the winding module, and is used for adjusting the tap position according to the tap calibration laser when the number of turns of the real-time winding reaches the number of turns of the planned tap, and performing tapping;
and the counting unit is connected with the tap unit and is used for counting the number of the taps in real time.
10. The winding apparatus control system of claim 6, further comprising:
and the tension maintaining module is used for pulling the copper strip to be wound to be connected with the coil framework and controlling the constant tension of the copper strip to be wound within a preset tension range.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310030285.2A CN116313499A (en) | 2023-01-10 | 2023-01-10 | Winding equipment control method and system |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310030285.2A CN116313499A (en) | 2023-01-10 | 2023-01-10 | Winding equipment control method and system |
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| Publication Number | Publication Date |
|---|---|
| CN116313499A true CN116313499A (en) | 2023-06-23 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310030285.2A Pending CN116313499A (en) | 2023-01-10 | 2023-01-10 | Winding equipment control method and system |
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| Country | Link |
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| CN (1) | CN116313499A (en) |
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- 2023-01-10 CN CN202310030285.2A patent/CN116313499A/en active Pending
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