The future research directions for winding machines should be expanded from the following aspects:
(1) Analyze the production process flow of the fully automatic transformer winding machine, design the overall scheme of the winding machine, analyze the mechanical structure design of the winding host, tension adjustable pay-off stand, automatic wire arrangement device, main and auxiliary insulation layer supply and drive device, establish the control system of the fully automatic transformer winding machine, including Beckhoff control system, servo system for the three axes of the winding machine, and servo system for tension control, and carry out hardware selection and design as well as software design.
(2) Design an automatic wire arrangement control system that allows for the selection of winding geometry based on the coil structure. The system operates with a high-precision wire arrangement drive mechanism centered around an AC servo system, where the winding spindle and wire arrangement mechanism are driven separately. For winding errors caused by changes in spindle speed and wire arrangement direction, an inertial error compensation method is employed to ensure tight arrangement between coil turns. A simulation curve analysis is conducted to study the particularities of rectangular coil winding, and a wire tension control scheme with a buffer compensation mechanism is designed in comparison to the traditional wire tension control scheme. Winding experiments are conducted under both schemes, and the experimental results are analyzed to verify whether the automatic wire arrangement control system designed in this paper exhibits good performance.
(3) Model and analyze the winding structure of rectangular transformers, establish a tension control system scheme for insulating tapes, perform force analysis on each component of the system and establish mathematical models, design a multi-input single-output (MISO) insulating tape tension controller, achieve stability in insulating tape winding tension control, and perform simulation analysis on winding radius, winding angle, and winding tension values in the Simulink system. Verify the reasonableness of the controller based on the simulation results. In the actual transformer winding process, verify whether the tape tension controller designed in this paper has good performance when adjusting the winding tension setpoint at different winding speeds.
