The core working principle of the transformer winding machine is to precisely wind the enameled wire on the transformer core skeleton according to the preset number of turns, tension, and arrangement spacing through collaborative control of the three core units of wire laying, wire arrangement, and spindle rotation, achieving standardized mass production of transformer windings.
1, Pre parameter configuration and wiring preparation
1. The operator enters the winding process parameters of the batch of transformers, including the total number of winding turns, the number of turns per layer of winding, the axial spacing of the wire arrangement, the tension threshold for wire release, and the rated winding speed;
2. Install the wire reel containing enameled wire onto the wire support bracket, pass through the tension regulator, guide wheel assembly, and wire breakage detector in sequence, and fix the enameled wire head at the starting position of the wire connection of the iron core skeleton.
2, Collaborative winding core process
1. The spindle drive unit drives the clamped iron core skeleton to rotate at a constant speed, and the wire release unit synchronously releases the corresponding length of enameled wire. The tension regulator detects and adjusts the wire release tension in real time to prevent the enameled wire from breaking due to excessive tension or relaxing and stacking due to insufficient tension;
2. The wiring unit performs axial reciprocating linear motion with the rotation speed of the spindle, ensuring that the enameled wire is neatly embedded into the wire slot of the skeleton strictly according to the preset spacing, avoiding problems such as overlapping, missing, and disorderly wiring;
3. When the number of winding turns reaches the preset parameter, the spindle stops rotating, the wiring unit resets to its initial position, the wire breaking device cuts off the enameled wire and fixes the wire end on the wiring terminal of the skeleton, completing the winding of a single set of transformer windings.
3, Precision and safety control mechanism
1. The equipment is equipped with a dedicated controller or PLC as the control core, which collects real-time spindle speed and cable displacement data through an encoder, adjusts the matching degree of each unit action in a closed loop, and ensures winding accuracy;
2. Equipped with safety functions such as tension over limit alarm, wire breakage detection shutdown, overload protection, etc., it automatically shuts down and triggers sound and light alarms in case of abnormalities, reducing the generation of waste parts.
