Video instructions for use of toroidal transformer winding machine

    Precision winding machine

      Precision winding machine For general winding machines, including CNC and automatic winding machines, only the set number of turns of enameled wire is required to be wound, and the appearance is roughly flat, but there are some special high-demand occasions , It is required that the arrangement of enameled wires must be neat without a random winding.

       This kind of coil has several advantages. First, the consistency of inductance is very high. Second, the enameled wire occupies less space, and the enameled wire can reach the ideal neat arrangement. Third, the energy density is high. Fourth, the high temperature resistance performance is better. , The enameled wires are in line contact, and in the case of random winding, the superimposition between the wires will have a little contact, and it is easy to break down under high temperature and high pressure.

       In order to achieve a stable and neat arrangement, in addition to the requirements for enameled wires, compared with general coil winding machines, high requirements are put forward for the electronic control, mechanism design and manufacturing accuracy of structural parts of the fine winding machine.

           Choice of winding number counting unit:

           The winding count unit can be selected. The number of turns on the display is composed of 5-digit digital tubes. When the default turn count unit is 0.1 turns, the maximum number of turns that can be set by this controller is 9999.9 turns. When the counting unit is changed to 1 circle, the maximum number of circles can reach 99999 circles

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.

 Toroidal transformer Taping Machine Instructions

Double wire parallel winding ring coil winding machine

Micro toroidal                   coil     winding

          Before winding:

         Outer diameter 7.5mm        

         Inner diameter 4mm

         Height 2.3mm

         Enameled wire diameter: 0.17mm

         80 laps.

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

      Motor winding machine, the early control mode is high and low speed mode, the No. 3 terminal of the controller is connected to the com terminal of the frequency conversion, and the No. 6 line is connected to the segment speed input terminal of the inverter. When the No. 3 terminal is disconnected from the No. 6, the frequency conversion The inverter outputs a set high-frequency power supply. When terminal 3 and terminal 6 are disconnected, the inverter outputs a set low-frequency power supply. After the improvement, the terminal 3 and 6 of the REPOSAL' s winding machine controller The No. terminal will output a 0-10V analog voltage to the inverter according to the value set on a controller, and the No. 3 terminal and No. 6 terminal are connected to the com and Ain terminals of the inverter (Taiwan Dongyuan inverter), the inverter According to the different voltage signals received, output power at different frequencies.

　　 REPOSAL's  winding machine controller is compatible with two control methods, and can be switched between the two methods according to customer requirements. See the video description for the specific switching direction.

General debugging method of winding machine

      Some people look at the winding machine and feel a bit like a lathe, but in fact the winding machine has to wind a neat coil. Compared with the smoothness of the lathe, it is much more complicated, so we will find that the lathe has a long time ago The national standard has quantitative standards for its various indicators, but the winding quality of the winding machine has many condensing factors and it is difficult to quantify.

     It is precisely because of the above reasons that at first I feel that the winding machine should be very easy to debug, but after the facts, I will be a little frustrated. Although the winding machine debugging is indeed more complicated than imagined, but if we master the basic laws After that, it's not difficult to practice more.

    First of all, we must have a preliminary understanding of the structure of the winding machine, otherwise, we are not familiar with the structure of the winding machine, and there is no professional technical personnel training. Automatic debugging of the winding machine will be incompetent.