Study on the control of the speed curve of the coiling machine for precision coiling machine

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             Your factory is using a traditional winding machine, your wire machine structure is reasonable, high mechanical accuracy, the motor is also used a big brand of motor, but in the winding of precision coils, there will be a high defect rate, you carefully analyze before improving various factors - equipment structure, processing accuracy, tooling accuracy, skeleton accuracy, enamel wire quality, tension control, etc. But it still doesn't solve the problem. But to tell you that it's not just a hardware problem, but an algorithm problem, may surprise you. Because in your opinion, every time the spool is transferred, the spool has a corresponding response, but in fact, you may not have considered that in the winding process of the precision coil, the wire guide pin is connected at both ends of the coil, and the sudden change in speed may cause the coil to cross the line and be raised. These defects can degrade the performance of the coil.

            To solve this problem, we propose an acceleration and deceleration method based on 5-segment S-curve. The algorithm uses linear acceleration or deceleration at the end and end of the line motion control to help reduce coil defects. We first verify the feasibility of the algorithm by using ADAMS software. The software simulates the motion of the precision winding coil and obtains the velocity curve and displacement curve during the motion. Later, the experimental results show that the method of adopting S-curve in the alignment speed control can reduce the coil defect by up to 50%. This shows that the 5-section S-curve motion control algorithm is a promising method to improve the precision and efficiency of the winding process of electric precision coils. By using this algorithm, coil manufacturers can reduce the risk of coil defects and improve coil performance.

              

            Winding machine is a special production equipment for precision winding coils. They can be divided into stator winding machine, flying fork winding machine, ring winding machine and flat winding machine according to the working mode and object. Different types of equipment are suitable for the production of different objects. For example, the stator winding machine is mainly used to produce motor stator coils, while the parallel winding machine is used to produce electromagnetic switching coils.

            Ordinary algorithm of parallel winding machine in the production of precision winding coil products, although our mechanical structure, parts processing accuracy has been done very well, but often there is a problem of low wiring accuracy. In the process of winding a line coil, there are two main movements, one is the rotating movement of the skeleton, which is called winding movement, and the other is the translation movement of the guide needle, which is called wiring movement, and wiring transport is matched with winding movement. After years of technical accumulation, we analyze that the leading role in the alignment accuracy is the alignment movement of the guide needle. Therefore, if you want to improve the alignment accuracy of the coil, you need to optimize the alignment movement of the guide pin.

            In fact, we have always believed that the winding machine is equivalent to the lathe in the electrical industry, its importance is self-evident, so for its accuracy, there have been many experts and scholars to study this.

            Some people studied the mathematical model of precise alignment based on axial pressure compensation around the axis in the process of alignment. The axial pressure was used to improve the alignment regularity of the coil, and the mathematical model was established according to the analysis of the end point of the coil alignment, which improved the alignment accuracy of the coil.

            Some people use the 5-section S-curve control algorithm and the 7-section S-curve control algorithm respectively in the research. In motion control, the 7-section S-curve is more complicated than the 5-section S-curve control. This method has achieved more results in the field of CNC machining, but it is not mature in the field of winding machine.

            The tension instability caused by the friction between the enamelled wire and the conductor nozzle during coil winding has been studied, which leads to the uneven wiring of the coil and the breakage of the enamelled wire.

            Some people have studied the low efficiency of the winding machine in the traditional winding control because of the inertia error in the process of the winding machine. Instead, the servo motion wiring and the inertia error supplement are used to improve the control efficiency of the winding machine.

            PLC control is commonly used in the winding machine wiring control system, through PLC control servo motor can realize the winding machine wiring control, both PLC control stability and high precision servo motor advantages. However, there is a sudden impact of guide pin speed in the coil alignment of parallel winding machine, so it is necessary to further optimize the change of guide pin running speed to improve product quality and the smoothness of wire alignment speed. The S-curve algorithm is a kind of smooth transition of speed in the process of motion, which is often used in machining to solve the problem of breaking the tool caused by speed impact and improve the precision of machining products. In the winding machine, the speed of the guide needle can be changed into an arc smooth transition by controlling the movement track of the guide needle, improving the alignment accuracy and product quality.

            To sum up, an algorithm based on 5-segment S-curve motion control is proposed to solve the problem of velocity shock in the process of coil alignment by analyzing the law of coil alignment. ADAMS software is used to simulate the trajectory of the guide pin to verify the feasibility of the algorithm. And the application of the example proves that the 5-section S-shaped curve can effectively solve the phenomenon of crossing and protruding in the process of winding, and improve the precision of winding.

            Coil wiring principle

            The winding method is flat winding, that is, the enameled wire moves synchronously with the guide pin and always keeps perpendicular to the skeleton during winding. The frame is driven by the winding motor with the guide needle movement, the enameled wire is wound on the skeleton, in which the guide needle is located in the wiring arrangement mechanism and the winding mechanism are two independent mechanisms. The winding mechanism is divided into three stages according to the motion process of the guide pin, namely acceleration and deceleration stage, uniform speed stage and end point return stage. The acceleration and deceleration stage can be divided into two parts: acceleration stage and deceleration stage. In the early stage of the alignment movement, the guide pin speed from zero to uniform speed belongs to the acceleration stage. At the end of the alignment movement, the process of decelerating until the speed reaches zero is a deceleration stage. The middle constant velocity stage is the constant velocity motion stage of the guiding needle. The terminal reentry stage is a process in which the guide needle accelerates backward again after slowing down and stopping. Here we explain:


            Acceleration and deceleration stage

            In order to arrange the lines evenly, the two movements of guide pin movement and skeleton rotation should meet certain coordination relations during acceleration and deceleration stage. The time for the guide needle to move one diametral width distance must be equal to the time for the skeleton to rotate once, that is, the guide needle to move just one diametral distance when the skeleton rotates once.

            Uniform phase

            After the guide needle completes the acceleration process, it enters the uniform speed stage, that is, the speed is unchanged in this stage, and the speed of the skeleton and the translation speed of the guide needle both reach the maximum set quota. In this stage, the time for each line diameter of the guide needle to move is equal to the time for the bone frame to rotate one week.

            End reentry cline

            When the guide needle moves to the end of the skeleton, if the remaining distance is not enough to arrange the enameled wire of the next wire diameter, this time it is necessary to jump out of the current layer of coil for the crossover line, which is called the end return jump. When the end point returns to the jump layer, the current layer can no longer be routed, so it is necessary to jump out of the current layer to the next layer for winding. At this time, the guide needle will continue to move down the wire diameter distance of a enamelled wire after decelerating to the return point, and the guide needle will stop moving to 8 o 'clock, so as to achieve the jump layer. The reentry movement of the guide needle after the jump floor drives the enameled wire to arrange the wire in reverse, and continues the next acceleration and deceleration, uniform speed, and end point rewinding cycle.

            The end-point reentry process has an important effect on the alignment accuracy of the coil. Since the guide needle and the coil skeleton are always vertical in the process of wire alignment, and the speed before reentry is reduced from the speed of uniform movement to zero, it just stops at the reentry point, and then the reverse acceleration is carried out again. Therefore, the process before and after the end point reentry can be understood as the reverse movement of the guide needle. The motion characteristics of the end points after reentry into the cline are consistent with those before reentry. This end reentry design does not cause wear and extrusion between the enamelled wire and the skeleton, thus avoiding deformation of the enamelled wire.


            In engineering practice, the commonly used motion control algorithms include trapezoidal curve algorithm and S-shaped curve algorithm.

The trapezoidal curve algorithm is relatively easy to realize the motion control, but there is speed change in the process of wiring, which is easy to cause the problem that the wound coil will bulge or cross the line. In the process of motion control, the speed of S-curve algorithm is an arc transition, which can avoid the impact caused by speed sudden change.

            Compared with 7-segment S-curve, 5-segment S-curve is more efficient in motion control because the number of control segments is less and the program running time is shorter. At the same time, the smooth transition of speed change is satisfied. Therefore, 5-segment S-curve is used as the guide pin control mode. The 5-section S-shaped curve divides the winding process into five stages: acceleration stage, acceleration and deceleration stage, uniform speed stage, acceleration and deceleration stage.

                 

            The winding process should be divided into 5 stages during the winding control. These 5 stages correspond to the acceleration stage, acceleration stage, uniform stage, acceleration stage and deceleration stage of the S-shaped curve respectively. Each stage needs to complete the winding control according to the groove width of the coil skeleton and the acceleration of the coil. If the control process is forced to stop due to external interference factors, the winding will be automatically stopped.

            The REPOSAL ® winding machine has been tested on the company's existing mature winder equipment. Among them, the slot width of the coil skeleton is L=30 mm, and the diameter of the enameled wire is 1 mm. The experiment is carried out. The coil products wound before and after the improvement of the control algorithm improve the defects of some protruding and cross-wire in the previous coil products, effectively solve the problems of coil protruding and sag caused by the process of coil wiring, and improve the quality of the coil products.

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    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.

       

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           In addition to other ways to solve the high speed release of optical fiber, an important way is to ensure the smooth release of optical fiber through optical fiber winding. Optical fiber winding technology is the requirement of the pointer to the optical fiber guided missile and the technology of winding the optical fiber on the spool. In view of the unique properties of optical fiber and the special use of optical fiber guided missile, optical fiber winding becomes a complicated technical problem. In the process of automatic winding, the technical difficulties related to the properties of optical fiber are as follows:


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          Strip coil: refers to a coil with a relatively large length and diameter, which is divided into a rigid frame and a flexible frame. In its winding process, the main characteristics are as follows, one is that its clamping needs to be clamped at both ends. The other is because of the comparison of its length and diameter. The corresponding torsional rigidity is relatively small, so it is necessary to synchronize the angular velocity at both ends of the clamping. In response to the process requirements of this type of coil, REPOSAL has successfully developed a high-speed precision synchronous winding machine. Fast, can significantly improve the winding efficiency of such strip coils.
Research and development background and characteristics of precision current transformer winding machine

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               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.

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              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.

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      Research and development of horseshoe hollow cup motor coil and winding machine

 In recent years, China has paid more and more attention to hollow cup motor and automatic winding technology, and has made good progress and breakthroughs in the research and development and manufacturing of winding machine equipment.

One of the key reasons for the impact on the performance of the motor is the rotor coil in the motor, the rotor in the hollow cup motor has no iron core, small inertia, excellent functionality and a wide range of applications. In addition, in the research and development of coil winding equipment, the saddle-shaped coil arrangement is regular, and the utilization efficiency of magnets is high.

                          

Compared with the old traditional motor with an iron core, the energy conversion efficiency is significantly higher than the latter, and the reaction speed will be much faster, and the hollow cup motor has high efficiency, fast response speed and stable performance. Because the hollow cup motor has no lag, additional electromagnetic interference is low, very high motor speed can be achieved, and the speed setting is sensitive at high speed, so it has relatively stable and stable performance. In addition, the energy density of the hollow cup motor is much greater than that of other motors, and the weight will be much less than that of an iron core motor with the same power.

Now according to the forming method of the coil, in the hollow cup motor coil, its production technology can be roughly divided into two process routes: winding production technology and one molding production technology.

Compared with the two methods, the first winding production technology is more complex, and the efficiency of winding the coil is relatively low. In order to improve the winding efficiency of coil production, the winding machine can be added to the production process of one molding. According to the hollow cup coil shape and winding method, the common hollow cup winding method can be divided into three kinds of parallel straight winding, saddle winding and oblique winding. The first parallel straight winding is generally used for hollow cup motor winding with relatively few turns. The last two are the two coil winding processes commonly used by the relatively advanced hollow cup motor manufacturers abroad.

Winding machine selection

Winding machine selection

       In the narrow sense, the winding machine mainly refers to the winding machine of various enamelled wire coils, these coils may be transformers, relays, inductors, current transformers, various sensors, these coils can be seen everywhere in our lives, the common feature is to use enamelled wire winding, the difference is according to the design requirements, and the cost and efficiency requirements of industrial products, Its winding process is not corresponding, so derived from a variety of different winding machine, we show on the official website is only a part of the conventional winding machine, and some are customized, or special industries are not displayed, if you need to know, you can contact us.

          Coils can be seen everywhere in our lives, such as the electric meter in the home, there are metering induction coils, trip coils in the circuit breaker, transformer coils in the community, various motor coils in industrial automation, various sensor coils, starting coils on the car, ignition coils, power motor coils on the bullet train, etc., it is no exaggeration to say that we live in a world of coils. There are so many coils, and the corresponding winding machines are different, so the winding machine is as important to the electrical world as the lathe is to the mechanical world.

          There are so many types of winding machines, if you are not familiar with them, those selections have become a big problem, we now make a simple introduction from several aspects.

          One is the winding method, which is generally divided into parallel winding machine, ring winding machine, and flying fork winding machine.