Winding machine information

　　　          REPOSAL®  Winding Machine successfully overcomes the difficulty in the winding process of closed coils of fixed-length titanium plates with loops.

      These tiny looped titanium plates are shown here, small metal structures approximately 12mm long, 4mm wide and 1.5mm thick, and have a row of four circular holes through them, two of which are for The main body pulls the suture through, and the other two upper holes are used for the passage of another group of seam lines. The structure is small in size, and it is necessary to form a closed connecting loop through the structural member, and the closed connecting loop is formed by twisting the yarn fibers of the loose structure. A closed high-strength braided coil is passed through the middle, which seems simple, but its core technology is reflected in the Loop, that is, a high-strength coil, which is woven evenly, tightly, non-woven, and without joints.

        This kind of titanium plate with loops is divided into two types, fixed-length type and adjustable type, especially the fixed-length type, whose length ranges from 15mm to 60mm. It is necessary to wind this closed loop in the middle of a titanium plate with such a small volume. Coils, and because the number of colonies cannot exceed the standard, cannot be wound by hand, but must be wound by 

equipment, which is extremely difficult to process. Its structural parts are small in size, and the diameter of the holes is only 1-1.5mm. It needs to form twisted yarns under such conditions, so this product has always been processed manually by hand, and its efficiency is low and consistent. Sex is hard to guarantee.

Because of the small size of the structure, the diameter of the hole is only 1-1.5mm, and it needs to form twisted yarn under this condition, so this product has been processed manually, and its efficiency is low. Consistency is difficult to guarantee.

　　　REPOSAL® Winding Machine successfully developed this equipment according to the customer's request, completed the simultaneous formation of a closed loop (including fiber bundles with a loose structure) and passed it to the porous structural parts, and maintained the twisted structure, which greatly improved the closed loop. The winding efficiency, in addition to obtaining the incomparable consistency of pure hand-made, makes the product have the conditions for large-scale production.

REPOSAL has invested a lot of R&D efforts in the field of crossover coil winding machines and has achieved a series of remarkable results.

In terms of winding accuracy, through in-depth research and optimization of the wiring mechanism and control system, REPOSAL's divider coil winding machine can control the winding accuracy within a very small error range. For example, for the wire with a thin wire diameter, the winding machine can accurately wind according to the set number of turns and arrangement, to ensure that the position accuracy of each turn of wire reaches ±0.05 mm, which greatly improves the quality and performance stability of the coil, and makes the crossover more accurate in the audio signal processing.

In terms of improving winding efficiency, REPOSAL has developed a unique high-speed winding technology. Thanks to the use of an advanced motor drive system and an efficient drive, the winding speed of the winding machine is increased by 30% compared to conventional models. At the same time, combined with the intelligent control system, continuous and uninterrupted winding can be realized, which greatly shortens the winding time of a single coil. For example, a common divider coil that used to take about 10 minutes to be wound by hand, but only 3 to 4 minutes with REPOSAL's winding machine significantly improved production efficiency and provided strong support for large-scale production.

In terms of versatility, REPOSAL's crossover coil winders are highly adaptable. By designing replaceable winding dies and flexible parameter adjustment functions, it is possible to wind a wide range of divider coils with different specifications, shapes and parameter requirements. Whether it's a crossover coil for a miniaturized audio device or a crossover coil for a large professional audio system, high-quality winding can be achieved on the same winding machine. For example, for coil skeletons with different inner diameters, outer diameters and height requirements, the winding machine can quickly switch production modes through simple mold change and parameter setting to meet diverse market needs.

In addition, REPOSAL also pays attention to the research on the convenience and intelligence of the winding machine. A concise and easy-to-understand human-computer interface has been developed, so that operators can master the operation method with only simple training. At the same time, the winding machine also has intelligent fault diagnosis and early warning function, which can monitor the parameters in the winding process in real time, and once there is an abnormal situation, such as wire breakage, abnormal winding tension, etc., it will immediately send out an alarm and prompt the cause of the failure, which is convenient for the operator to deal with in time and reduce the risk of production interruption and equipment damage.

Enameled wire technological process: pay-off→anneal→paint→baking→cooling→take-up

1. Pay-off On a normally operating enameled machine, most of the operator's energy and physical strength are consumed in the pay-off part. The replacement of the pay-off reel makes the operator pay a lot of labor, and the joints are prone to quality problems when changing the line. An operating failure has occurred. An effective method is to pay off with large capacity.

     The key to pay off is to control the tension. When the tension is large, it will not only draw the conductor thin, make the surface of the wire lose its brightness, but also affect many properties of the enameled wire. From the appearance point of view, the enameled wire that is drawn thinner has poor gloss; from the performance point of view, the elongation, resilience, flexibility, and thermal shock of the enameled wire are all affected. If the pay-off tension is too small, the line will easily jump and cause the line to be merged and the line to touch the furnace mouth. When paying off, the most fear is that the half-turn tension is high and the half-turn tension is small. This will not only cause the wires to loosen, break, and be thinned section by section, but also cause large jumps of the wires in the oven, resulting in failures of merging and touching the wires. Pay-off tension should be even and appropriate.

     Installing a booster wheel in front of the annealing furnace is very helpful for tension control. The maximum non-extension tension of soft copper wire at room temperature is about 15kg/mm2, the maximum non-extension tension at 400℃ is about 7kg/mm2; the maximum non-extension tension at 460℃ is 4kg/mm2; the maximum non-extension tension at 500℃ The extension tension is 2kg/mm2. In the normal enameled wire coating process, the tension of the enameled wire is significantly less than the non-extension tension, which is required to be controlled at about 50%, and the pay-off tension should be controlled at about 20% of the non-extension tension.

            In particular, the non-magnetic material in the magnetic liquid will be subjected to a magnetic field force in the non-uniform magnetic field, which makes many magnetic liquid acceleration sensors can be designed based on this characteristic.

            These characteristics make the magnetic liquid acceleration sensor has many advantages compared with the traditional acceleration sensor, such as no wear, high sensitivity and simple structure.

            However, most of the existing magnetic liquid acceleration sensors use solid mass blocks as non-magnetic substances, and use coils to detect changes in inductance under different accelerations to obtain output signals. However, its disadvantage is that it leads to complex magnetic circuit and poor sensor stability.

            A new solution emerged -- the capillary magnetic liquid acceleration sensor, good stability, simple magnetic circuit, accurate and reliable measurement results and long service life.

 The precise winding process ensures the efficient transfer of energy, thereby improving the efficiency and consistency of ablation. The uniformity of the precision wound coil affects the temperature distribution of the ablation area, avoiding local overheating or heat deficiency, which is essential to ensure the ablation effect and reduce complications. The stability of the winding process ensures the reliability of the operation. The high-quality winding process withstands stretching and bending during surgical operations, reducing the risk of breakage or functional failure. High-quality winding processes have a longer service life and are able to maintain stable performance through multiple operations, thereby reducing medical costs and improving resource efficiency. The quality of the winding process also affects the precise control of the ablation process. The high-precision winding process helps physicians to more precisely control the size and shape of the ablation area to achieve optimal treatment results.

Moreover, the RFA catheter winder is designed with operational safety in mind, reducing potential risks during operation and protecting operators and products from damage. It can adapt to different types of radiofrequency ablation catheter production requirements, and has good flexibility and scalability. The structure and design of special winding machines are often more simplified and easier to maintain and maintain, thus reducing long-term operating costs.

The advantages of radiofrequency ablation catheter winding machine are mainly reflected in professional design, high efficiency production, precise control, quality stability, easy operation, material saving, safety, strong adaptability, low maintenance cost and technological innovation. These advantages make the radiofrequency ablation catheter winding machine an indispensable key equipment in the production process of radiofrequency ablation catheter.

In the manufacture of power transformers, winding the transformer coil is a super important step, you think, the transformer coil is wound more firmly and neatly, the strength of the transformer and the ability to protect against short circuits can be greatly improved. However, most of the current transformer winding machines have to rely on manual extra sorting of the coil, the entire equipment is low in automation, and the production efficiency is not high, so the development of an excellent large transformer winding machine is a crucial thing for our company.

We have studied the main shaft technology of transformer winding machine, the relationship between compaction force and winding quality, and the control of compaction force. According to the principle and process flow of transformer winding, we put forward a whole design scheme of large transformer winding machine, including mechanical structure and electrical control. Mechanically, we simplify the complex structure of traditional transformer winders. In terms of electrical control, we ensure the stability of the motor when it starts and stops, and ensure that the winding coil is evenly tightened during the winding process. For the core parts of the transformer winding machine, spindle system and pressing device, we have calculated and selected the types and parameters. With the compaction device, we are able to provide real-time axial and radial compaction forces during the winding process of the transformer winding, which is very effective for improving the tightness of the winding.

The static analysis of the radial compaction device of the winding machine is also carried out by using finite element method, and the structure optimization is carried out according to the analysis results. We find that as the number of layers and turns of the winding increases, the required axial and radial compression forces change accordingly. By analyzing the experimental data, we find that there is a maximum value and a minimum value in the range of quality requirements, and it is the most reasonable choice to make the compression force approximately proportional to the number of layers and the number of turns.

The large transformer winding machine developed by our company has been preliminatively debugged and put into the market. After testing, the performance parameters of this transformer winding machine are in line with the design requirements, and the operation is stable and efficient. It can be wound to make a tight and regular transformer winding coil, and has been fully recognized by the market.

As a power grid equipment, power transformer converts voltage through the electromagnetic induction between the winding coils of the transformer. With the continuous development of the market, higher requirements are put forward for the manufacturing level of transformers, and the market needs more energy-saving and efficient transformers. Therefore, the optimization of the transformer manufacturing process is particularly critical. Quality and performance depend on the process equipment. The technical level of the transformer winding machine directly reflects the manufacturing level of the transformer. Therefore, accelerating the development of transformer winding machine is an important guarantee to improve the performance of transformer.

The winding coil of the transformer is the core component of the transformer and constitutes the electromagnetic induction part of the transformer. It generally includes high voltage winding and low voltage winding, respectively connected to the high voltage grid and low voltage grid. The winding of large power transformers usually adopts concentric winding, that is, the high and low voltage transformer winding coils are centrally set on the core column. The manufacture of transformer winding is the core process of transformer, and its quality plays a crucial role in the performance of transformer, affecting the appearance of transformer size, weight, mechanical properties, insulation and heat resistance and other important indicators.

In the past, the production of transformer winding coils relied on manual, and workers had to wind insulated wires manually to the winding die frame in accordance with the process requirements. Turns calculation also have to rely on manual, this old-fashioned method is inefficient, and because the worker's skills are not strong enough, the quality of the winding coil is poor, the number of turns may be miscalculated or missed, and ultimately lead to the finished winding coil performance can not be guaranteed. Later appeared semi-automatic transformer winding machine, which is driven by the motor to rotate the spindle to wind the transformer winding coil, although it improves the production efficiency, but the wiring work still has to rely on manual, only suitable for flat winding transformer winding coil winding, and winding head winding, welding and other operations must still be completed manually, so the product quality is not stable.

Later, with the emergence of TTL logic gate circuits, in the mid-1970s, with the development of CMOS technology, various types of equipment program control a large number of applications of digital integrated circuits, Western countries and Japan and other industrial powers have emerged CNC winding mechanism manufacturing industry. These CNC transformer winding machines represent the advanced level of winding mechanism manufacturing technology, especially the winding equipment produced in Japan, Italy, the United States and Germany is the leading technology.

Now the transformer winding machine as the core parts of the transformer production equipment, the market demand is very large, and the transformer manufacturing enterprises at home and abroad attach great importance to the development and application of advanced technology of transformer winding machine. Domestic transformer winding machine production enterprises are small, insufficient technical reserves, limited research and development funds, so there is still a big gap compared with foreign advanced products, the market share is low, unable to compete with foreign countries. To solve the key technical problems of transformer winding machine is the key to improve the quality of domestic winding equipment and enhance the market competitiveness. In order to meet the demand of transformer manufacturers for high quality and low price winding equipment, especially large transformer winding machine, on the basis of learning from foreign advanced experience, combined with domestic research results, the development of large transformer winding machine has important significance and practical value.

               Research and development background and characteristics of precision current transformer winding machine

              The precision of coil in current transformer is very important, because it directly affects the accuracy of current measurement and the reliable operation of power system. The specific importance of coil accuracy is reflected in the following aspects.

              Electrical energy metering: In a power system, accurate measurement of current is the key to calculating energy consumption. If the coil in the current transformer is not accurate, it will lead to an error in the measurement of electrical energy, which can lead to a miscalculation of energy costs, with possible financial implications for both the utility and the consumer.

              Fault detection: The current transformer is used to monitor the current level to detect abnormal conditions in the power system, such as short circuit and overload. If the accuracy of the coil is not high, it may lead to false positives or neglect of potential faults, which affects the reliability of the power system.

              Overcurrent protection: Current transformers play a key role in overcurrent protection devices, detecting overcurrent events and triggering circuit breakers or other protective devices. The accuracy of the coil directly affects whether the overcurrent can be accurately detected to ensure the safety of the power system.

              Load management: The load management of a power system requires accurate measurement of current in order to make reasonable load distribution and adjustment. If the precision of the coil is not high, it may lead to unbalanced load distribution, affecting the efficiency and stability of the power system.

              Automated control: In modern power systems, automated control systems rely on accurate current measurement data for real-time adjustment and control. The precision of the coil is critical to the response speed and performance of the system.

              Waveform analysis: Current transformers are also used for power quality analysis, including harmonic analysis. The precision of the coil determines the accurate analysis of the current waveform, which helps to solve the power quality problem.

Although R type transformer is widely used, but in fact the production of manufacturers are not many, the reason is limited by the R-Core transformer winding machine, so far, there are many R-Core transformer winding machine is the principle of manual wiring, so its winding production efficiency is relatively low, Up to now, many factories are using manual winding in the winding of R-shaped transformers.

In response to this situation, we have launched an automatic R-Core transformer winding machine with high precision, complete functions, easy to use, stable and cost advantages, which has been widely recognized by customers since its launch. Our R type transformer winders have the following features:

1. R-Core transformer winding machine special controller, high precision, stable and reliable, easy to operate, computer (single chip microcomputer) control, full key operation, working state digital display.

2. 1000 sets of process data can be stored and called, and it has the function of button and foot start and stop, and the speed can be increased and decreased during the winding process.

3. Handle built-in start-stop switch, which can improve efficiency, especially convenient for debugging.

4. The configuration of a first-line brand laser amplifier, long life, high precision, low failure rate, stable and reliable counting, laser amplifier installation structure optimization, can be far away from the coil skeleton end face accurate and reliable detection of the number of turns, fundamentally solve the probe collision roller and skeleton movement brought about by the count unreliable problem.

5. R-Core transformer winding machine press wheel adopts step bearing design, which can effectively control the axial movement of the skeleton in the rotation process.

6, the controller has complete functions: abnormal alarm function, such as overload, reverse wiring direction, speeding and so on.

7. Linear acceleration and deceleration function can be set at the beginning and end of winding, which can eliminate the sudden acceleration and deceleration effect and avoid disorderly or broken lines.

REPOSAL® releases layer-wound high-voltage package full-automatic interlayer insulation winding machine

　 Suzhou Xiepu Electronic Machinery Equipment Co., Ltd. successfully released the SP-D102M7 model of layer-wound high-voltage package automatic interlayer insulation winding machine-this model greatly improves the winding efficiency of layer-wound high-voltage package coils, and the coil is consistent Sex. The REPOSAL® winding machine reduces the winding cost of the layer-wound high-voltage package. In the new model, it has added a compact insulation belt automatic cutting mechanism, and high-quality solutions such as dynamic balance performance after multiple skeletons are wound.

Analysis of winding tension of loop winding machine

                  Toroidal winding machine-Toroidal coil winding machine-Enameled wire is wound radially on the closed toroidal structure (for details, please refer to the toroidal winding machine tutorial): With the rapid development of the domestic power industry, the demand for current transformer coils Increasingly, the development of current transformer coil winding equipment is imminent. In order to meet the needs of the market, we have developed a current transformer toroidal coil winding machine based on imported equipment. During the design and testing process, we found that, The key to the design of toroidal winding machine is the control of winding tension.

　　　　　 This automatic winding machine is composed of a frame, a pay-off mechanism, a winding head, a tape head, a clamping device, and a control system.

　　　　 loop winding machine, automatic winding machine,

　　　　1, the working principle of toroidal winding machine

Firstly, the wires are evenly wound on the wire storage ring, and then the wires wound on the wire storage ring are wound on the skeleton by a shuttle. The skeleton is driven by the servo motor to rotate, so that the wires are evenly arranged on the skeleton when the wire is wound to a certain amount , And then wind the tape on the frame through the wire storage ring, and then wind it.

　　　　2, analysis of winding tension

　　　　 Through our continuous practice, we have discovered that during the entire winding process, using appropriate force to wind the wire tightly on the skeleton is the key to the quality of the winding. Therefore, we will focus on the factors that affect the winding tension.

　　　　 1. The grinding moment of the rotating part of the thread bobbin

　　　　 2. The moment of inertia caused by the acceleration of the thread bobbin part (including the wire wrapped in the bobbin).

　　　　The main part of the frictional torque is generated by the tension mechanism, which prevents the wire shuttle from moving and tightens the wire to generate winding tension.

Due to the influence of the winding ring surface and its deviation from the center position in the winding gear, even if the winding is at a constant speed, the movement speed of the thread shuttle is small and uniform, which generates the moment of inertia caused by acceleration, which affects the winding tension.

The movement speed of the thread shuttle can be regarded as composed of two speeds: one is the speed Vo equal to the speed of the pulley on the winding gear, and the other is the speed at which the thread shuttle releases the amount of wire. The former is a constant, and the latter is calculated as follows ( see picture 1)

　　　　 loop winding machine winding tension analysis 1

　　　　 So in order to reduce the acceleration of the thread bobbin, it is required:

　　　　 1. The frame profile H should be small, and the profile should be as close as possible to the center of the winding gear, that is, the value of 1 should be small.

　　　　 2. The thread hook flat diameter R should be as small as possible.

　　　　 3. The winding speed ω cannot be too high (this is in conflict with improving production efficiency).

　　　　The approximate curve of the speed Vx and acceleration а of the mountain thread shuttle is obtained by the graphical method, and the description is as follows (see Figure 2 and Figure 3):

　　　　 loop winding machine winding tension analysis 2

　　　　 1. When the small pulley on the winding gear is at the 0° position, the speed of the thread shuttle is equal to the speed of the small pulley V0, when the speed of the thread shuttle gradually increases from 0-60°, there is a positive acceleration at this time. =600-180`) when the thread shuttle moves at a constant speed, the speed is Vm>Vo. When а=180°～263°, the speed of the thread shuttle gradually decreases. At this time, there is a negative acceleration a = 263°. The speed of the thread shuttle is equal to the pulley speed V. When а=263°～345°, the speed of the thread shuttle continues to decrease. Small, that is, it is lower than V and has a negative acceleration. When а=345°, the speed of the thread shuttle is the minimum Vo, when а=345°～360°, the speed of the thread shuttle increases gradually and there is a positive acceleration.

　　　　 2. When the winding gear rotates at a constant speed, the speed of the thread shuttle will be zero if it is small, so the friction tension mechanism always acts as a brake to keep the wire tensioned.

　　　　 3. If Vp is the average linear velocity of the thread bobbin; Vo is the linear velocity of the pulley on the winding gear; L is the perimeter of the wire of the potentiometer, then

4. When the winding speed ω is not large: the wire bobbin diameter R is small, and the potentiometer profile size H is also small. When the profile is as close as possible to the center of the winding gear, the acceleration change is small and large, and the inertia caused by the acceleration The torque is much smaller

Common accessories of transformer winding machine　

          The winding process of the transformer winding machine directly affects the formation of the coil, and the experience is constantly summarized in the actual use of the winding machine and applied to the winding operation. Felt is a friction material used to fix the enameled wire, keep the enameled wire stable during operation, and remove dirt and burrs on the surface of the enameled wire. The clamping force of felt is also one of the sources of enameled wire tension. The tensioner is one of the most important components in the online tension device, and it is also the main component of tension control during the operation of the winding machine. Common tensioners are friction, magnetic damping, and magnetic powder braking.

　　　The winding machine needs many accessories to assist the normal operation of the equipment. Common accessories include spools, molds, clamps, tensioners, thread passing devices (mainly explaining the function and composition of the threading device, the threading device plays a role in conveying, protecting, and reversing during the winding operation, so that the enameled wire can be smoothly removed from (The pay-off bucket is transported to the take-up reel)

　　　Ceramic wheel is the most common component in stringing equipment. It has two types: full ceramic wheels and semi-ceramic wheels. All ceramic wheels are generally used for multi-wire winding occasions. Its structure is relatively simple, consisting of a bearing and a wheel body. The structure of the semi-ceramic wheel is similar to that of the full ceramic wheel, consisting of a bearing, an inner core, and a plastic retaining ring, and is generally used to wind a single enameled wire.

       In power transmission and power supply systems such as power plants and substations, voltage transformers are an indispensable electrical appliance. The voltage transformer for measurement specifies the accuracy level of the voltage transformer according to the error generated when the voltage is changed. Voltage transformers of level 0. 2 and above are generally called precision voltage transformers, which are mainly used in the laboratory to expand the measurement limit with the standard meter for precise measurement of voltage, power and electrical energy; or as a standard to check low standards, Low-accuracy voltage transformer; it can also be used with standard meters to test the corresponding meters.

       With the rapid development of science and technology and electronic application technology, the requirements for technical indicators such as the rated primary voltage and accuracy of voltage transformers are getting higher and higher, and the demand for various types of voltage transformers is increasing. In the past, voltage transformers were mostly manually wound with annular iron cores and thick enameled wires. The products were large and heavy. In the daily winding, processing and production process, the degree of mechanization was not high, the labor intensity of workers was high, and the production efficiency was low. It is necessary to improve the voltage transformer design process and develop a new type of mechanical equipment for winding the voltage transformer.

 People's Republic of China Electronics Industry Standard

General technical conditions for parallel winding machine sj/t 10313—92

General specification of parallel winding machine

1 Subject content and scope of application

This standard specifies the technical requirements, test methods, inspection rules and markings, packaging, transportation and storage requirements for parallel winding machines.

This standard is applicable to parallel winding machines whose skeleton cross-sectional shape is round or rectangular coils.

This standard does not apply to winding machines that wind toroidal, honeycomb, and saddle coils.

2 reference standards

　　 GB191 packaging, storage and transportation pictorial mark

　　 GB4006.1 winding coil cylindrical bobbin type size

　　 GB4006.2 winding coil tapered coil type size

　　 GB4215 Measurement of noise power level of metal cutting machine tools

　　 GB5080.7 Equipment Reliability Test The verification test plan for failure rate and mean time between failures under the assumption of constant failure rate

　　GB6109.1 enameled round winding wire part one general regulations

        This type of winding machine of Xiepu has a stroke of 1.5 meters, adopts pneumatic quick assembly and quick disassembly, convenient operation, mature and stable structure, easy maintenance, easy operation of the system, complete functions, and strong expandability.

        At present, according to customer requirements, a heating coil with a stroke of up to 1.5 meters is wound on this machine. Because the equipment is structured in place, the winding has a satisfactory effect. The customer currently plans to add mica tape winding function on this basis. 

             In modern society, electricity is like a surging torrent, injecting strong impetus into our life and production. With the rapid development of China's science and technology and economy, the demand for electricity is increasing day by day, and the demand for transmission and distribution transformers, as an important cornerstone of the power system, is also rising.

            The transformer is the "heart" of the power system, and the winding coil inside it is a key component of this "heart". The winding quality of the enameled wire and insulating tape in the winding coil directly determines the reliability of the transformer. The quality of this winding depends to a large extent on the performance of the transformer winding machine.

            With the sharp rise in demand for transformers, the performance requirements for transformer winding machines are becoming more and more demanding. A high-performance transformer winding machine must not only meet the requirements of safety, intelligence and high efficiency, but also have high-stability hardware, easy-to-use software and excellent tension control.

            However, at present, the development of China's transformer winding machine industry is still facing many challenges. The level of intelligence is relatively low, the stability needs to be improved, and most of the high-end equipment relies on imports, and the price is high.

            REPOSAL® machine is well aware of these challenges and has been working hard to improve the performance and quality of its products. It continues to increase R&D investment, is committed to improving the intelligent level and stability of the winding machine, and strives to contribute to the development of the industry.

            When the transformer winding machine is working, its coil is usually metal wire and insulating paper, because they have a certain elasticity, the change of coil conveying speed or roll radius will lead to the change of winding tension. For example, in the winding and unwinding process, if the angular velocity of the roll is constant, the change in the radius of the coil will cause tension fluctuations. If the tension is too large, the coil may become thinner or even break; If the tension is too small, the material will be unevenly arranged or wrinkled, which will affect the quality of the transformer winding coil.

            Compared with foreign countries, China's existing domestic transformer winding machine has deficiencies in tension control. Its tension is usually generated by mechanical friction, which is not stable enough, which can easily lead to problems such as sparse arrangement of wires and insulating tapes, and out-of-tolerance of the outer diameter of the coil. In addition, compared with developed countries in Europe and the United States, there is a gap in the overall development level of China's transformer winding machine in terms of processing quality and production efficiency.

            The specific performance is as follows: First, the processes such as wiring and wiring, adding insulation layers rely on manual operation, which is inefficient and unstable in quality. Second, the motor frequently starts, stops and reverses during the winding process, the tension fluctuates greatly, the coil winding is irregular, and the quality is difficult to guarantee. Third, the mechanical structure of the domestic winding machine is relatively simple, and it is not competent for the winding task of complex coils.

            The development of foreign transformer winding machines is relatively mature. The T-600AH automatic transformer winding machine from Trishul.Engineers in India can wind wires and insulating tapes synchronously, with high precision, stable tension and high efficiency. The EFECO 800 automatic winding machine from Tuboly.Astronic AG in Switzerland is even more excellent, with high-speed, high-precision winding and an intelligent cable routing system. The products of companies such as MTM in Canada, LAE in Italy and UPI in Korea also have high intelligence and stability.

            In terms of tension control research, many scholars have been exploring it in depth since the 90s of the last century. Bastogne T, Koc H and other scholars have pioneered theoretical research and modeling simulation. Entering the 21st century, more scholars are getting involved.

            REPOSAL® machine actively pays attention to the relevant research results at home and abroad, and applies beneficial theories and technologies to the improvement of its own products.

            The winding electronically controlled tracking system proposed by Mahawan B et al. in 2001 can still realize the trajectory tracking control of equipment under large interference. In 2008, Wen P et al. designed a tension control scheme that allowed the winding speed to be changed under a certain tension fluctuation while maintaining quality. In 2010, Ponsart J C et al. applied the observer theory to a transformer winding machine to improve the accuracy of tension control. In 2017, Mahesh Ghate et al. optimized the tension system for a specific winding machine and showed good robustness. In 2020, Ma Quanjin et al. designed a dual-PID tension control system to address the tension fluctuation problem in a 3-axis fiber winding machine applied with filament winding technology.

            Since the 70s of the last century, China has begun to develop transformer winding machines, and has achieved certain results through imitation and the efforts of scholars. However, due to the monopoly of foreign core technologies, there is still a gap with foreign countries, especially in terms of manufacturing processes and control schemes.

            At present, the domestic transformer winding machine is mainly in the semi-automatic stage. For example, F. of Dongguan Zongheng Electromechanical Technology Co., Ltd. TWloo CXL transformer winding machine for small and medium-sized transformer coil winding. The ZBR.800/1000/1200 multi-head automatic wiring winding machine of Jiangxi             Yibo Automation Equipment Co., Ltd. can realize automatic wire arrangement.

REPOSAL® machine has been committed to promoting the development of domestic transformer winding machine in the direction of full automation and intelligence, and constantly optimizing its own manufacturing process and control scheme.

            However, there is still a breakthrough in the layout of insulating tape and tension control in China, which greatly affects the quality and production efficiency of the winding coil. Therefore, it is of great significance to develop a control system that can automatically arrange wires and insulating tapes with constant tension.

            Tension control is a key technology for transformer winding machine equipment. If the tension is too small, the wire or insulating tape will slacken, accumulate and wrinkle; Excessive tension can cause it to deform, stretch excessively, or even break. For transformer winding machines, the tension control condition directly affects the compactness between the layers of the winding wires.

            At present, there are three main schemes of tension control: manual, semi-automatic and fully automatic. The manual control needs to be adjusted manually in stages, the semi-automatic control adjusts the tension by detecting the change of the roll diameter, and the fully automatic control is adjusted by directly measuring and feeding back the tension data by the tension detector.

            In the 80s of the last century, manual tension control was mostly used in China, which was gradually replaced due to the increase in demand. Since the beginning of this century, domestic scholars have conducted in-depth research on the automatic tension control system for rewinding and unwinding.

            In 2005, Yang Tao and others from Tianjin Polytechnic University used a PLC design scheme to accurately control the winding speed of fine enameled wire. In 2010, Shi Yaoyao et al. studied the discontinuous coil process and realized winding through the PID algorithm. In 2018, Zhiyong w et al. established a constant tension control system for the problem of triaxial fiber winding machine. In 2020, Song Chenliang et al. optimized the tension adjustment effect of the winding machine through the pendulum tension adjustment mechanism and the deformed PID control algorithm.

            REPOSAL® machine has never stopped exploring tension control solutions, and constantly tries to innovate to enhance the competitiveness of products.

            However, due to the complex structure of transformer winding equipment and many influencing factors, the tension control system has nonlinearity and coupling in different situations, which is still a difficult point in equipment control. Constant tension control is very important to ensure the quality of winding, so it is of practical significance to study the constant tension control system suitable for industrial production.

            In the winding coil structure of distribution transformer, insulating paper tapes need to be arranged between the wire layers, so the transformer winding coils are usually wound in layers. The winding process is more complicated, the pilot wire is unwound and sent to the spindle mold base, during which the oscillating roller adjusts the tension and speed, and the spindle motor drives the spindle winding. Then the insulating tape is unwound and sent to the spindle mold base, and multiple coil rolls cooperate to adjust the tension. Finally, a plurality of motors work together to drive the spools and other spools for the first layer of winding and arrangement, after the completion of the wire motor reversal, the pressure roller shears the insulating paper, the glue sprayer glues, and then the next layer of winding.

            Taking Switzerland EFECO 800 transformer winding machine as an example, its mechanical structure mainly includes spindle mold base, winding spindle, glue spraying machine, etc. The winding spindle includes a spindle motor, a reducer, etc., which drives the spindle to rotate and the foot switch controls the start and stop. The wire winding mechanism has pay-off wheels, adjusting handwheels, etc., and the insulating tape winding mechanism has tension feedback devices. The wiring mechanism is composed of a wire spool, a wire trolley, etc., which can achieve accurate wire arrangement.

            For transformer winding machines, the tension control directly affects the compactness between the winding lines. In practice, the machining accuracy and the performance of the sensing device will have an impact on the tension control. For example, the change of reel diameter, the start-stop and acceleration and deceleration of the reel, the accuracy of equipment manufacturing and assembly, the forward and reverse rotation of the motor, and the hardware performance.

            There are three ways to test tension. Directly using the tension sensor to measure, the operation is simple but the limitation is large; Floating roller tension detection, the measuring device is flexible but the accuracy is low; Floating roller/feedback composite tension detection, high accuracy but complex method.

            In the process of arranging the transformer winding machine, the adjustment of the wiring mechanism and the winding position and the control of the wiring angle are the key to ensure the compactness of the winding wire.

            The cable arrangement mechanism measures the angle through the rotary encoder on the spindle and transmits the data to the controller, and the controller drives the wire motor after processing to realize the speed coupling of winding and wire arrangement.

            In the actual winding, the tension of the wire and the insulating tape should be kept constant and cooperate with the wire arrangement. In the automatic wiring control scheme, the main controller controls the motor unit to work together, the spindle and the wiring mechanism cooperate with the layered winding, the encoder feeds back the data in real time, and adjusts the speed of each axis according to the control algorithm to ensure the accuracy of the wiring.

            The angle of the cable is very important, too large or too small will affect the effect of the line. When winding, the line is adjusted according to the change in angle, the feed rate is brought in, and the overall trajectory is followed. Since winding is carried out in layers, divided into wire layers (odd layers) and insulating layers (even layers), the wire laying process can be divided into multiple stages and cycles.

            The automatic wiring of the transformer winding machine has high requirements for the motor control algorithm, which requires the coordinated operation of the motors of each shaft and the close cooperation of the drive actuator to jointly complete the automatic winding and arrangement of the transformer coil. The common multi-motor cooperative control structures include parallel synchronous control, master-slave motor control, cross-coupling collaborative control, adjacent cross-coupling control and deviation coupling step control, each with its own advantages and disadvantages.

            In conclusion, transformer winding machines are very important in the power field. Although China has made certain achievements in this field, it still needs to make continuous efforts to strengthen independent research and development, improve the technical level, narrow the gap with foreign countries, promote the development of the industry, and contribute more to the power industry. REPOSAL® machine will continue to uphold the spirit of innovation and enterprising, and make unremitting efforts to improve the overall level of China's transformer winding machine.

                 Radiofrequency ablation has ablation and cutting functions, and the main therapeutic mechanism is thermal effect. Radio frequency refers to radio frequency, frequency up to 150,000 times per second of high frequency vibration, but it does not belong to the division of bands in radio communication.

            The coiling process is completed by continuous test and optimization of the coiling machine.

            The working flow of this winding machine is as follows:

            1. The active wire feeding device of the radiofrequency ablation catheter winding machine ensures that the wires are constantly connected and not tied.

            2. Double fold section A measurement line.

            3. Manual folding head.

            4. Manually fix the thread head (Two schemes are tentatively proposed for fixing the thread head)

            4.1 Fix the starting position with glue. The fixture locks the PEEK tube.

            4.2 Kangtong wire is hung on the feature of steel pipe. Glue to fix the ends after wrapping.)

            5. Press the start button of the radiofrequency ablation catheter winding machine to wrap.

            6.(During the winding process of the radiofrequency ablation catheter winding machine, both AB and AB segments have adjustable tension)

            7. Wrap the jump grid to the specified position (the specific hop length can be set, and the rotation Angle can be set.

            8. After the radiofrequency ablation catheter winding machine is finished, the feeder stops at the end and maintains tension.

            9. Fix the end of the line by manual dispensing

            10. Both ends of the radiofrequency ablation catheter winding machine are coaxial, and the rotation direction is synchronized.

            11. Adjustable pre-drawing force is required at both ends of the locking shaft core.