The advantages of Type R transformer and the status quo of type R transformer winding machine
R-Core
transformers, when they first appeared, really made people bright. Its iron
core is made of high-quality cold-rolled silicon steel strip, which has been
delicately manufactured to form a unique waist circle, and the cross-section
shows a full circle, which can be made in one go without cutting. Of course,
this of course is not only a unique process, but the design will give the type
2 transformer a series of interesting advantages. Below we explore these
advantages in detail and make a comparison with other types of transformers.
Let's first talk about a feature of type r transformers. The core of the R-type transformer is a rectangle, and because the whole silicon steel sheet is converted into an iron core, its cross-section is actually circular. Compact shape design: The appearance design of the R-type transformer is quite simple, and the typical standard core has the characteristics of thin, small and light. This compact design means that the R-type transformer performs well in terms of space occupancy, making it particularly suitable for applications with space constraints.
The
R-type transformer has a very small magnetic leakage: due to the uniform
arrangement of its coils, the magnetic leakage is very small, and the magnetic
gap has little effect on it. The total flux of magnetic flux leakage is reduced
to a very low degree, which allows the two-star transformer to work even in
close proximity to other sensitive equipment without interfering with other
sensitive equipment.
Type
R transformer, its two winding arrangement is very uniform. The coil winding of
the Type R transformer is carefully designed to ensure a balanced distribution
of current inside the coil. This helps to reduce resistance losses and improve
efficiency.
In
addition, there is a particularly different advantage relative to the ring
transformer is the R-type transformer, its two windings, it is wound on the
skeleton, and it is a double-layer skeleton cladding structure, so its
insulation performance is particularly good, and the ring transformer, its coil
is actually wound on the iron core above, in the actual process, the iron core
above it, it will wrap insulation film, However, the thickness of the
insulation film is relatively small, so its insulation strength cannot be
compared with this R-type transformer. So this means that R-Core transformers
can operate safely in high-voltage environments and are more reliable.
In
addition, it has another feature, that is, its size structure will be
relatively compact, and its dimensions in the xyz three directions are
different, so it can be installed in a small space according to the needs of
many different ways ah, can be installed horizontally, sideways and
longitudinal installation, which provides a lot of options for the installation
personnel. Make Type R transformers suitable for various spatial layouts.
Another
point is that its special design of an iron core, the iron core of the R-type
transformer, it is wound into a rectangle from inside to outside, but it is a
high-quality cold rolled silicon steel strip from inside to outside that is the
whole width and narrowness, from fine to thick and then to fine, its
cross-section is actually round, it optimizes the magnetic flux path, greatly
reducing the iron loss. Improve the overall efficiency.
Low
temperature rise: Due to its compact design, the temperature rise of the R-type
transformer is relatively low. This helps extend the life of the equipment and
reduces the need for cooling systems. High efficiency: Low loss and optimized
design guarantee high efficiency of type R transformers. This is essential to
save energy and reduce operating costs.
Then
let's take a look at a feature of toroidal transformers.
The
core of a toroidal transformer consists of a cold-rolled silicon steel strip of
the same width wound in an involute pattern from the inside out into a ring.
Different windings are then wound in a radial fashion around this core ring. So
its structure is very simple. However, this structure will bring a relatively
large loss, so this feature will make the toroidal transformer power density
performance is relatively general.
Another
is when the ring transformer is wound, it is the enamelled wire is wrapped
around the core ring in a radiating way, but its inner and outer circle, that
is, the circumference of the inner circle and the outer circle of the ring, it
is actually different, so in the actual process, there is no way to wind the
enamelled wire evenly. Specifically, when the enameled wire is wound on the
inside, it will accumulate more, and when it is wound on the outside, because
the circumference of the outer circle will be larger than the circumference of
the inner circle, so the winding of the enameled wire will be sparse, which
will directly lead to the local current density imbalance, increasing the
resistance loss of the coil.
Large
magnetic leakage: due to the toroidal transformer, its coil wiring supplier can
not be uniform, so its magnetic leakage is also more, and sometimes the
transformer needs to be placed in the metal mold to reduce the influence of
magnetic leakage, which will increase the complexity of manufacturing and
installation.
Usually
when we manufacture a ring transformer, its insulation layer is wrapped in a
layer of insulation film on the ring core, it is no skeleton, so its insulation
performance will be much worse than the double-skeleton R-type transformer,
which makes it difficult to meet the safety standards in high voltage
environments.
And
another point is that when it is installed, because its shape is circular, that
is to say, when it is installed, the length and width must be equal, and then
there is only one thickness difference, which is relatively speaking, the
choice in space use will be less, so generally speaking, it is relative to
R-type transformer, it needs more installation space.
With
a more detailed understanding, we can better understand the advantages of Type
R transformers over ring transformers, especially in terms of efficiency, space
utilization, insulation performance and flexibility. These factors will have a
significant impact on different applications, and choosing the right type of
transformer is crucial to the performance of the power system.
R-Core
transformers are widely used in a variety of electronic equipment, including
monitors, printers, computer terminals, photocopiers, fax machines, satellite
broadcast receivers, hi-Fi loudspeakers, measuring and testing equipment, power
equipment, flow metering equipment, medical electronic equipment, financial
equipment, industrial equipment, elevator lifts, signal equipment and so on.
The use of R-type transformer can greatly improve the quality and efficiency of
the product.
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.
Related Post
REPOSAL® winding machine has successfully provided competitive solutions to the electron microscopy winding process
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
Study on the control of the speed curve of the coiling machine for precision coiling machine
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.
REPOSAL® winding Machine successfully overcomes the polarization grid precision winding technology
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.
REPOSAL® has successfully released a radiofrequency ablation catheter 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.
Precision Winding Machine | Hollow Coil Winding Machine | Whole Column Coil 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.
U-shaped core winding machine
Transformer coil winding machine
Stable, high-speed and safe U-shaped core coil winding machine
The U-shaped coil winding machine is suitable for the winding of the bottom edge of the U-shaped core.Usually, the center of the U-shaped core is difficult to coincide with the rotation axis of the winding machine, resulting in a large vibration of the winding machine. , Affecting efficiency.
This type of winding machine developed by our company does not rotate the U-shaped iron core, only reciprocates, and rotates around the product to reduce vibration and improve efficiency.
With the optimized clamping method, it only takes 2 seconds to complete the clamping.
Therefore, the rotating parts of this type of machine have a large diameter and a high speed.There are similar machines on the market, and the larger ones do not have a protective cover. Safety accidents often occur.This machine of the company has a protective cover design.
Transformer winding crepe paper | Transformer winding crepe paper | Transformer winding crepe paper
Transformer insulating crepe paper has good mechanical strength, high withstand voltage strength, wrinkles on the surface, and a certain degree of toughness. Moreover, it is easy to cut. After the transformer is wound and formed, it still maintains a certain strength in the oil immersion of the rear tooling. This feature can very well protect the enameled wire of the transformer from being squeezed and broken, that is, it meets the insulation requirements. It also meets the mechanical performance requirements.
Therefore, it is widely used for transformer insulation. Generally used in transformers, but less used in transformers, because the core structure of transformers is annular, because the surface of the insulating crepe paper has wrinkles and friction is large, so the annular wrapping machine is used. Winding is more difficult, so in general, if crepe paper is required for the transformer coil, manual winding is used. We have successfully overcome this problem by improving the details.
Video instructions for use of toroidal transformer winding machine
Suzhou REPOSAL Electronic Mechanical Equipment Co., Ltd. specializes in providing: toroidal transformer winding machine, current transformer winding machine, voltage transformer winding machine, ring voltage regulator winding machine, inductance coil winding machine, iron core chamfering machine , Parallel winding machine and other coil processing equipment and winding machine accessories.
The company has the advantages of R&D and production of the entire plant of electronic transformers and transformers. It is different from many assembly manufacturers in the industry. We have gathered many engineering and technical personnel in the winding machine industry. After many years of research and development and production experience, we have developed a new generation of series winding. Equipment, especially toroidal winding equipment, is widely used in manufacturing industries such as toroidal transformers, transformers, voltage regulators, inductive coils, etc., and has received many praises from the industry; Customers provide more professional and quality products and services.