Design And Development Of Automatic Control System For Combined Transformer Coil Winding Machine

Combined winding machine is the special equipment for production of transformer coil. It not only wind wire coil but also can wind foil coil. The project is entrusted from SENERGE Electrical Equipment Ltd., on the basis of mechanical structure of350combined transformer coil winding machine, combining advanced design concepts of wire winding machine and foil winding machine at home and abroad, in order to design efficient and stable automatic control system for the machine.In the control system, Mitsubishi FX3U-80MT/ES PLC used as the main controller, Siemens Smart Line700IE touch screen used as human-computer interface, they jointly complete the control tasks, such as production parameters setting, coil-winding, monitoring of operating status and alarm processing; Mitsubishi’s analog input and output module is used for exchanging data between analog and PLC; automatic wire-ranging and automatic foil-correction organizations is driven by Mitsubishi servo system, in order to achieve high precise of wire-ranging and foil-correction; winding spindle is driven by AC motor and Mitsubishi inverter, and fitted with a rotary encoder in order to automatically count the winding turns of wire and foil; foil tension control uses open-loop control mode, actuators are magnetic brake and gear; pneumatic system can complete a series of auxiliary actions.In the wire-winding part, the key is to achieve high-precision automatic wire-ranging. Using high-precision servo motor and winding motor to build a servo system, wire-ranging servo moves smooth and precisely along with winding motor revolves under PLC program controls. Finally, the wire is ranged close and uniformly and the accuracy achieves±0.01mm; meanwhile, the speed of winding spindle can reache200r/min when wire is winded, improving wire-winding efficiency greatly.In this subject, there are several production lines and they use two different sets of wire-ranging servo system. Aim at two different sets of servo systems, separately design automatic wire-ranging PLC program, and use a reasonable idea to solve the problem of cumulative error; precise control of the winding turns is realized by the idea of successive approaching, when the total turns is close to the given turns, by means of two or three times transient spindle start and stop to gradually reach the given turns, eventually improve accuracy of turns, without affecting the efficiency of wire-winding; taking different coils using different production parameters into account, write the PLC program about preserve and display the different coils, and configure the corresponding touch screen display, saving time of inputting coil parameters, reducing the labor intensity of workers’parameters-input.In the foil-winding part, automatic foil-correction system using closed-loop control mode, and adopting analog sensor to detect position of foil material on winding machine as feedback, and using PID controller with dead zone, and outputting position signal to the correction servo, finally correct the offset of foil material and the correction accuracy achieves±0.01mm. Foil tension system uses open-loop control mode, adopting the PLC program to calculate the current values of unwinding radius, by means of keeping the ratio of the radius and exciting current in the magnetic brake constant to achieve substantially constant tension.On account of some problems exist in tension open-loop control, comes up with two sets of detailed closed-loop tension solutions and then do some simulation using matlab.In addition, this chapter also comes up with a closed-loop tension solutions which adopts tension macro function of inverter. This paper also proposes the method of applying Siemens WinCC to debug tension closed-loop at the scene and then uses PLC program of tension simulation and WinCC configuration screens to debug the closed-loop tension system.In addition, this paper also introduces mechanical structure, production process, use and installation of hardware, interface configuration and so on. At last, this paper recommends the problem of site commissioning and then puts forward corresponding solutions.