Design And Analysis Of Tension Control System For Transformer Insulation Layer Winding

Coil winding is the core process of transformer manufacturing.Transformer insulation performance is determined by the winding quality of the interlayer insulation layer.In order to ensure transformer insulation performance and improve production efficiency,it is necessary to ensure uniform winding tension of the insulation layer.Traditional transformer insulation layer winding requires manual operation,and the tension control during the winding process depends on the work experience and proficiency of the workers,resulting in low insulation layer winding efficiency during the transformer production process,and it is difficult to ensure product quality consistency.Aiming at the requirement of automatic winding tension control of the core-type transformer insulation layer,this paper uses the idea of continuous winding of thin strip-shaped insulation tape instead of wide strip-shaped insulation layer to design the tension control system.Firstly,this paper establishes the mechanical structure of tension control by analyzing the tension control method and the movement characteristics of the master and slave shafts.Studies the dynamic characteristics of the insulating layer winding process,and analyzes the time-varying characteristics of the roll diameter and inertia of the unwinding and winding parts,and the tension fluctuations.The reason is to establish a dynamic model.add a hybrid Dancer mechanism in the unwinding part to ease the sudden change in tension,and study the influence of Dancer inertia and upstream and downstream span length on its resonance frequency and response performance.Secondly,design a closed-loop tension control scheme with Beck Hoff industrial PC as the core controller,AC servo motor as the actuator,and displacement sensor as the feedback unit.In order to improve the problem of insufficient precision of the conventional PID algorithm for tension control,the variable universe fuzzy control theory and PID algorithm are combined to design the tension control system,based on the dynamic characteristics of the system,scientifically quantify the universe,select the membership function,and select the membership function according to the tension control.Based on theory and expert experience,reasonable establishment of fuzzy rule library,design expansion factor,and verify the stability and response performance of the control system through simulation.It can realize the goal of the control system to adjust the control parameters in real time according to the error and the change of the error,and at the same time meet the demand for precise control of the winding tension of the transformer insulation layer.Finally,according to the winding process,the lower computer motion program is designed to realize the coordinated movement of the master and slave axes,according to the transformer production requirements,the upper computer human-computer interaction interface is developed to realize the process parameter design,intelligent optimization,and system status monitoring.And through the experimental platform to test the ability of the control system on the tension control accuracy and the weakening of the tension fluctuation during the winding process of the elliptical transformer insulation layer.