REPOSAL®winding machine's advantages in crossover winding machines

REPOSAL® numerical control honeycomb winding machine, specially designed for honeycomb inductor coil, honeycomb coil with its small size, small distribution capacitance, and large inductance in some special occasions has irreplaceable. All of these excellent properties are due to the unique structure of the honeycomb coil,

Traditional honeycomb winding machine is to rely on a set of complex gear system to achieve the function, if you need to wind different honeycomb coils, need to manufacture and replace different gears, quite cumbersome and very low efficiency, REPOSAL® CNC honeycomb winding machine uses high-precision control system, with specific algorithms, high precision, fast speed, through different Settings can be wound different widths, different fold points, Different number of turns of honeycomb coil, let you wind honeycomb coil handy.

The inductance of the honeycomb coil is large, mainly because of its special structure. After it is wound, from the appearance, it is like a honeycomb, formed by the regular winding of coils to form a honeycomb, in this one honeycomb, the magnetic flux of each honeycomb is interconnected, and the magnetic flux density of these small magnets changes with the change of time and position, just like the food in a honeycomb. This distribution of magnetic flux pores makes the inductance of the honeycomb coil larger, because it has more magnet interaction, thus forming more magnetic flux, improving the permeability of the current, making the inductance increase.

At the same time, since the magnetic flux of each small magnet in the honeycomb coil is interconnected, the inductance can be increased by increasing the size of the honeycomb. The larger inductance of the honeycomb coil is due to its shape and the distribution of magnetic flux pores, rather than due to the increase in resistance.

The insulated wire wrapped around the honeycomb coil can be a single strand of enameled wire, or can be multiple strands of enameled wire or silk-covered wire.

People are usually curious about how this kind of coil is wound out, and the following is a demonstration of the CNC honeycomb coil winding machine developed by our company.

               REPOSAL®successfully releases hot micro flowmeter winding machine 

                                           ----------solve the problem of heat pipe coil winding process

       Flowmeter is one of the commonly used instruments in industrial production, the most common such as all kinds of water meters in life, gear water meters, electromagnetic water meters, ultrasonic water meters, etc., according to the different industry applications, chemical, petroleum, pharmaceutical, food and other industries are also widely used, can measure the volume or quality of various fluids through the pipeline in a given time. Easy to measure in each fluid automation control.

          However, in medical, aerospace, military and other fields, we may need to measure tiny fluid flows, and in microfluidic processes, micro-thermal flow meters are also necessary, which can measure very small fluid flows, thereby helping researchers control the flow of fluid in microfluidic devices and optimize device performance.

         Another example is the flow control of pure oxygen fluid in the ventilator, the flow control of the medical dosage ratio, the flow equivalent is very small, and at the same time, it requires extremely high measurement accuracy, so the thermal micro-flow meter should appear according to demand.

          The thermal micro flowmeter is mainly made of the principle of capillary heat compensation. In the thermal micrometer, the fluid passes through a small pipe, and on the outer wall of the pipe, the thermal micrometer winding machine is used to wind a very small electric heating coil, which usually uses a fine platinum resistance wire, with a diameter between 0.02 and 0.05mm. When the fluid flows through the platinum resistance heating coil, the temperature of the fluid increases slightly. At this time, another set of platinum resistance coils wound by the thermal micro-flowmeter winding machine can sense a higher resistance, and the controller converts this resistance value into a flow value.

          The diameter of the platinum resistance coil in the micrometer is very small, and the texture is fragile, and it will heat up after being energized. When the fluid passes through the capillary of the flowmeter, the flow will take away the heat of the platinum resistance coil wound by the hot micro-flowmeter winding machine, resulting in a decrease in the temperature of the platinum resistance coil. In order to keep the temperature of the platinum resistance coil stable, the micro flowmeter will provide a certain current according to the measurement needs to maintain the temperature of the hot wire at a constant operating temperature. By measuring the change in current provided to the hot wire, the mass flow rate of the fluid can be obtained.

             Thermal micro flowmeter has many advantages, the main advantage is high accuracy, can measure the flow range of small small fluid, the accuracy can usually be within 1%. Moreover, it is small in size and can be easily designed into module units for convenient arrangement. It can also directly output electrical signals, and the communication with the data collector is convenient.

However, its manufacturing difficulty is high, especially the platinum resistance heating coil, the need for hot micro-flowmeter winding machine, in a very small diameter capillary wound diameter 0.02-0.05 platinum wire, the small diameter of the platinum wire itself is more fragile, the capillary also needs to overcome the radial displacement caused by the tension of the platinum wire during the winding process, and requires orderly arrangement. The tension is stable and the resistance is consistent, so the process is extremely difficult, and the current micro-precision winding technology of this hot micro flowmeter winding machine has been supported by sensor companies in Japan, the Netherlands and Germany for a long time.

           The domestic precision winding mechanism manufacturing system from low-end to high-end, there are huge challenges, because there are shortcomings in the manufacturing equipment link, not only the problem of individual equipment such as hot micro flow meter winding machine, but the entire precision winding machine industry is lack of independent development conditions, the industry is keen to imitate foreign industry technology for a long time, and the user long-term superstition imported equipment, It is also one of the conditions for domestic winding machine enterprises to lack independent development, so the cost of domestic thermal micro-flow meters has been high.

           The main components of scanning electron microscope are electron optics system, signal collection and processing system, vacuum system, image processing display and recording system, power system and computer control system. The core part is the electron optical system, which is mainly composed of electron gun, electromagnetic condenser, diaphragm, scanning system, astigator, objective lens and various centering coils.

           Reposal® winding machine As a professional supplier of precision winding solutions, we focus on the electromagnetic condenser, objective and astigmatic, because the main components are enamoured wire windings, and the precision and consistency of the windings are highly related to the image quality of the scanning electron microscope.

          Electromagnetic lens coil.

           The electromagnetic lens is mainly used to restrain the electron beam and it can be regarded as a convex lens in optics. Because the electron beam in a rotating symmetric magnetic field will be subjected to the Lorentz force, resulting in a focusing effect. Therefore, the quality of the enamelled wire winding coil that can generate this rotationally symmetric rather than uniform magnetic field and make the electron beam focus imaging is very important.

           The enamelled wire winding coil in the magnetic lens, when the current passes through the coil, the pole shoe is magnetized, and a magnetic field is established in the heart cavity, producing a focusing effect on the electron beam. There are two kinds of enamelled wire winding in the magnetic lens, namely, the enamelled wire winding of the condenser and the enamelled wire winding of the objective lens. The lens near the electron gun is the enamelled wire winding of the condenser, while the one near the sample is the enamelled wire winding of the objective lens. General condenser is the high excitation lens enamelled wire winding, high excitation lens enamelled wire winding has many turns, a cylindrical multi-layer arrangement, requires good rotation symmetry

             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.

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.

         Since these polarized wire grids, which are wound by precision winding machines, have no underlying substrate, they have the advantage that they are not affected by substrate related dispersion and absorption, and there is no beam deviation during transmission. This provides a thin, compact and versatile polarization element with a high degree of polarization over a wide transmission range.

         At present, because there is no professional winding machine, most of the polarization grid used in our country is imported polarization grid, and the price is expensive; However, the domestic processing method of wire grid mainly uses manual winding, which has low precision and long production cycle. At the same time, the winding machine at home and abroad is mainly used in electronic components, sensors, etc., the control variable is relatively single, and the main control mode is tight layout, even the high precision winding machine, there are few equal spacing layout for the polarization line grid, so the accuracy can not meet its needs. Therefore, it is very important for the coiler to overcome the polarization grid precision winding technology.

                 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.

 REPOSAL® precision winding machine

              REPOSAL® winding machine releases special winding machine for frequency divider inductors

            In daily life, have you ever noticed more than one horn on your car? And more expensive cars have more horns. According to normal people's thinking, the car as long as there is a horn can emit sound signals on the line, more horn is why? The reason is very simple, for example, the turn signal and the warning horn are completely different, the sound frequency is different, and the sound range of the speakers used for high and low is naturally different. A single speaker cannot play a full frequency sound, and a sound may require a combination of multiple channels of sound to achieve a clear cue.

            Therefore, in order to make each speaker emit audio suitable for it, it is necessary to use a tool such as a frequency divider. In simple words, the frequency divider is a filter circuit composed of a capacitor and a frequency divider inductor coil wound by the frequency divider winding machine. The capacitor filters the low frequency to the tweeter, and the frequency divider inductor is wound by the frequency divider winding machine to filter the high bottom to the low frequency to the woofer, so as to distinguish the sound signals in different frequency bands in a sound. It has different sound frequency channels, high frequency sound channels can only pass high frequency sound, middle and low frequency sound the same. After the sound is distinguished, the sound is amplified and played in the corresponding sound amplifier, and finally we can get the most accurate audio we want.

            Frequency dividers are divided into two categories, one is a power divider, and the other is an electronic divider.

            The power divider is set in the speaker, the power amplifier in the speaker first amplifies the sound power, and then the power divider divides it into three audio signals, high, middle and low, and finally sends it to different speakers for playback. The advantage of this power divider is that it is simple and convenient to connect and use, but its disadvantages are also obvious, that is, its power consumption is large and the parameter deviation value is large, the error of the sound frequency is large, and its error is related to the impedance of the speaker, so it is not convenient to adjust.

            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.

Insulation tape winding machine

      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.

             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.