Design Of Automatic Transformer Winding Machine Control System Based On DANCER Tension Detection

Transformer is the core device of the power industry.The rapid development of the power industry has driven the rapid increase in the demand for transformers.A core process in the transformer production process is the winding of the transformer coil,and the wire needs to maintain a stable tension during the winding process.The tension of the circular coil is better controlled.For the rectangular coil,in addition to the change of the winding radius in the winding process,but it also necessary to consider the tension fluctuation during the winding process due to the irregular shape of the coil itself.So it is more difficult to maintain constant tension when winding rectangular coil.In actual production,such tension fluctuation will affect product quality and the service life of the product will be reduced.Therefore,the development and design can keep the transformer with constant tension winding machine control system is of great significance to the development of the winding machine industry.In this paper,the control system of transformer winding machine based on the dancer tension detection is designed to realize the constant tension winding of transformer coil.Firstly,the winding process of rectangular coil is analyzed in this paper,and the change rules of wire speed,acceleration and winding length in the winding process are obtained,and the tension control with or without compensation system is compared and analyzed.A master-slave synchronous tension control system based on Dancer mechanism is designed according to the changing law during the winding process.The control strategy of the uncoiler,the unwinder and the whole tension control system is obtained by analyzing the uncoiler and the unwinder,and the system model is established.Based on Simulink,the simulation of the system is completed,and the motion relationship between the masterslave axis and the law of tension change during the system operation has been analyzed.The adjustment ability of the tension control system based on Dancer tension detection and the restraining effect on the tension fluctuation are verified,which can realize the constant tension winding of the coil.Then,the overall scheme of the winding machine is designed according to the design requirements.Beckhoff industrial computer is used for winding process design,machine tool movement and logic control,and wire tension control.Using Ether CAT as the communication method,the servo mechanism as driving device is connected in series to realize multi axis linkage motion control;using I/O terminal module to connect the corresponding devices,and the signal is fed back to the industrial computer.All devices are connected and communicated with industrial computer through the coupler,and the control of each part is realized through the operation of human-machine interface.Finally,design the control system of the winding machine,determining the software and hardware scheme of the control system and the selection analysis of some components;and analyze the software flow of the control system and complete the configuration of the manmachine interface.By analyzing the simulation curve of the tension control system,it is verified that the tension control system based on the Dancer mechanism can quickly adjust the tension change during the winding process of the rectangular coil and has a good restraining effect on the tension fluctuation.The movement of the oscillating rod during the winding process buffers the change of the wire tension and compensates the tension fluctuation of the coil.By adjusting the speed change of the unwinding slave shaft,the stable speed difference between the winding main shaft and the unwinding slave shaft is maintained to ensure a rectangular coil constant tension winding.