CN-122000195-A - Real-time intelligent regulation system for winding of miniature cable transformer

CN122000195ACN 122000195 ACN122000195 ACN 122000195ACN-122000195-A

Abstract

The invention relates to the technical field of winding of miniature transformer coils, in particular to a real-time intelligent regulating system for winding of a miniature transformer of a cable, which comprises an acquisition module for acquiring winding tension, main shaft driving current, an end face of a miniature transformer precursor and radial images in real time, a preprocessing module for preprocessing the images and then extracting end face contours and radial contours of coils of each layer, a calculation module for calculating tension standard deviation and radial offset and generating a winding comprehensive quality index WQI, and a judgment and optimization module for judging whether the quality of each layer of coil is qualified or not according to WQI, diagnosing abnormal reasons by analyzing the driving current standard deviation of the corresponding layer when the quality of the coil is unqualified, and generating instructions for correcting control parameters or quality evaluation parameters of a winding machine in a targeted manner. The real-time intelligent regulation system provided by the invention adopts real-time closed-loop quality control to replace the traditional post detection, so that the problem of quality degradation of the coil due to external disturbance is effectively solved, and an intelligent solution for quality guidance is provided for the preparation of the miniature transformer.

Inventors

PAN XUEQUAN
WANG DERONG
CUI JIAN
SUN WEIYU
Pan Youhai
YAN XIAOXIAO
WANG YUHUI

Assignees

江苏洪能电缆有限公司

Dates

Publication Date: 20260508
Application Date: 20260209

Claims (10)

1. A real-time intelligent regulation system for winding a miniature cable transformer is characterized by comprising, The winding machine control module is used for winding based on preset winding parameters; The acquisition module is used for acquiring winding tension data and driving current values of the spindle driving motor in real time and periodically acquiring end face image and radial image data of the miniature transformer precursor; The preprocessing module is connected with the acquisition module and is used for preprocessing the end face image and the radial image data of the miniature transformer precursor, and respectively extracting end face contour images and radial contour images of coils of the miniature transformer precursor formed by each layer from the end face image and the radial image data of the miniature transformer precursor; The calculation module is connected with the acquisition module and the preprocessing module and is used for calculating the tension standard deviation of each layer of coil based on the winding tension data, calculating the radial offset of each layer of coil based on the end face profile image and determining the winding comprehensive quality index WQI based on the tension standard deviation and the radial offset of each layer of coil; The judging and optimizing module is connected with the calculating module and is used for judging whether the quality of the coil of the corresponding layer is qualified or not based on the comprehensive quality index WQI of the coil corresponding to the winding, judging an abnormal reason based on the standard deviation of the driving current value when the corresponding layer is constructed when the coil is judged to be unqualified, and sending an instruction for correcting the control parameter and the quality evaluation parameter of the winding machine based on the abnormal reason; and the regulation and control module is connected with the judging and optimizing module and the winding machine control module and is used for dispatching the corresponding module based on the instruction of the judging and optimizing module.
2. The real-time intelligent regulation system according to claim 1, wherein the judging and optimizing module is configured to judge whether the quality of the coil of the present layer is acceptable based on the winding integrated quality index WQI of each layer of the coil, and to maintain system parameters and continue winding when the coil is judged to be acceptable, or to judge an abnormality cause based on a standard deviation of the spindle drive motor drive current when the coil is judged to be unacceptable; Wherein, the comprehensive quality index of the winding , Wherein TVc represents the standard deviation of the tension of the coil of the layer, TV max represents the maximum value of the standard deviation of the tension of the micro-transformer precursor in the winding process, RO c represents the radial offset , RO max of the coil of the layer, α represents the tension weight, and β represents the radial offset weight.
3. The real-time intelligent regulation system of claim 2 wherein the determination and optimization module is further configured to determine a standard deviation of the drive current based on the standard deviation of the drive current of the spindle drive motor, determine a cause of the anomaly based on the standard deviation of the drive current, and correct the spindle speed of the winding machine in the winding machine parameters based on a ratio of the winding integrated quality index WQI to a set preset winding integrated quality index when the tension anomaly is determined, or determine a correction direction based on the radial image data of the micro-transformer precursor when the micro-transformer precursor geometry defect is determined, and correct the bobbin offset in the winding machine parameters based on a ratio of the standard deviation of the drive current to the set preset drive current standard deviation.
4. The real-time intelligent regulation system of claim 3 wherein the judgment and optimization module is further configured to determine a composite mass ratio based on a ratio of the composite mass index WQI of the winding to the preset composite mass index of the winding, and to reduce the rotational speed of the spindle of the winding machine in the parameters of the winding machine based on the composite mass ratio, wherein the reduction of the rotational speed of the spindle is proportional to the composite mass ratio.
5. The system of claim 4, wherein the determining and optimizing module is further configured to determine a spindle speed difference based on a difference between the spindle speeds before and after the correction, and reduce a traverse shaft movement speed of the winder parameters based on the spindle speed difference, and wherein the traverse shaft movement speed is reduced by an amount proportional to the spindle speed difference.
6. The real time intelligent regulation system of claim 5, wherein the decision and optimization module is further configured to determine a displacement spool speed difference based on the difference in displacement speed of the displacement spool before and after correction, and to increase the tensioner torque in the winder parameter based on the displacement spool speed difference, and wherein the magnitude of the tensioner torque increase is proportional to the displacement spool speed difference.
7. The system of claim 6, wherein the determining and optimizing module is further configured to determine whether the coil quality is acceptable based on the modified composite quality index WQI, and maintain the system parameters and continue winding if the coil quality is acceptable, or modify the bobbin displacement in the parameters of the winding machine based on a ratio of the standard deviation of the driving current to the standard deviation of the preset driving current if the coil quality is unacceptable.
8. The real-time intelligent regulation system of claim 3 wherein the judgment and optimization module is further configured to determine a correction direction based on the radial image data of the miniature transformer precursor, and to determine a current fluctuation ratio based on a ratio of the standard deviation of the drive current to the standard deviation of the preset drive current, and to increase the displacement axis offset based on the current fluctuation ratio, and an increase in the displacement axis offset is proportional to the current fluctuation ratio.
9. The real-time intelligent regulation system of claim 8, wherein the determination and optimization module is further configured to determine whether the miniature transformer coil quality is acceptable based on the modified winding composite quality index WQI, and to maintain system parameters and continue winding if it is acceptable, or to determine that the system is sensitive if it is unacceptable, and to modify the preset winding composite quality index based on the duty cycle of the cumulative number of modifications of the system in the current number of winding layers of the miniature transformer precursor.
10. The real-time intelligent regulation system of claim 9 wherein the judgment and optimization module is further configured to determine a correction duty cycle based on a duty cycle of the system accumulated correction times in a current number of winding layers of the miniature transformer precursor, and to increase the preset winding composite quality index based on the correction duty cycle, and an increase in the preset winding composite quality index is proportional to the correction duty cycle.

Description

Real-time intelligent regulation system for winding of miniature cable transformer Technical Field The invention relates to the technical field of miniature transformer coil winding, in particular to a real-time intelligent regulating system for cable miniature transformer winding. Background Micro transformers are key functional cores in modern cable systems. By providing electrical isolation and signal coupling, the device connection safety is fundamentally ensured, and efficient composite transmission and performance optimization of data and electric power are realized. However, as cable systems become increasingly more dependent on their functionality, conventional quality control modes, which are currently dominated by "pre-control" and "post-detection", have exhibited hysteresis. This mode allows control of the raw material prior to winding and evaluation of coil quality by sampling or final inspection at the finishing stage, but is still of a static, discrete passive nature. Even though there have been studies attempting to improve winding quality by optimizing the structure of winding machines, the industry generally lacks a clear, quantitative on-line process quality control and optimization system. In actual production, random disturbance such as wire quality fluctuation, mechanical abrasion and the like often causes the phenomenon that the process parameters are qualified, but the quality of a finished product is deteriorated. Because the abnormal state in the production process cannot be identified and intervened in situ in real time, the quality problem is often not exposed until the finished product stage, which not only causes reworking and waste, but also restricts the further improvement of the consistency and reliability of the product. Therefore, how to obtain key quality information such as the uniformity of the precursor flat cable of the miniature transformer in situ in the winding process, and adjust the process parameters in real time according to the key quality information, so as to form a self-adaptive closed loop facing the final quality, has become a bottleneck to be broken through in the industry. Chinese patent CN120376328a discloses a full-automatic winding equipment for miniature transformer, including the rotation axis, one side of rotation axis is provided with the pay-off roller, one side of pay-off roller is provided with first distance sensor, one side of rotation axis still is provided with the line ball drum, the both ends of line ball drum are provided with the bracing piece, the line ball drum with the bracing piece rotates to be connected, a plurality of movable holes have been seted up on the line ball drum, a plurality of the movable hole divide into two sets of, a set of activity Kong Chengzheng spiral arrangement sets up, another set of the movable hole is reverse spiral arrangement setting, activity in the movable hole is provided with the movable block, be provided with in the line ball drum and be used for controlling two sets of the control mechanism that the movable block stretches out in turn in the movable hole. The invention is switched by the spiral bulge structures in two different directions, is suitable for winding wires in different directions, and is more compact in winding the wires on the iron core. Although the method improves the compactness of wire winding to a certain extent, the method mainly focuses on the adaptability improvement of a mechanical structure, and basically still belongs to open-loop passive execution, so that the quality consistency problem caused by fluctuation in the production process cannot be fundamentally solved, and a real-time monitoring system is constructed in the process of winding the miniature transformer, and is endowed with the method for dynamically correcting the winding parameters of the miniature transformer based on the monitoring result, so that the external interference risk is overcome, the transition from pure open-loop optimization to intelligent closed-loop control of quality guidance is realized, and the core challenge of improving the manufacturing quality and reliability of the miniature transformer at present is already achieved. Disclosure of Invention The invention provides a real-time intelligent regulation system for winding a cable miniature transformer, which is used for solving the problems that the existing miniature transformer lacks real-time quality control and automatic correction means in the winding process, so that the winding process is difficult to resist external environment interference and the quality of a finished coil is deteriorated. The invention provides a real-time intelligent regulation system for winding a miniature cable transformer, which comprises, The winding machine control module is used for winding based on preset winding parameters; The acquisition module is used for acquiring winding tension data and driving current values of the spindle driving motor in real