The core working principle of the transformer winding machine is to synchronize and cooperate with the winding spindle, tension control mechanism, and wire arrangement actuator through the numerical control system, accurately match the three core process parameters of winding turns, wire tension, and wire arrangement position, and achieve automatic and precise winding of transformer coils
1, Core Execution Unit
(1) Winding spindle
1. Responsible for clamping and fixing the coil skeleton of the transformer, providing stable rotational power through servo motor drive, and the speed can be infinitely adjusted according to the wire diameter and winding turns requirements. Some models are equipped with positioning stop function to ensure the positional accuracy of the final wire head.
(2) Tension control mechanism
1. Magnetic powder brakes or pneumatic tensioners are commonly used to adjust the unwinding resistance in real-time through closed-loop feedback, stabilize the output tension of the wire, and avoid problems such as wire stretching deformation, coil interlayer misalignment, or wire breakage during the winding process.
(3) Cable laying mechanism
1. Generally, a ball screw transmission structure is used, which, in conjunction with a numerical control system, moves back and forth along the axis of the winding spindle to evenly arrange the wire in the winding groove of the skeleton, ensuring that the coil layers are neat and the thickness is consistent.
(4) Numerical Control System
1. As the core of the whole machine control, it stores preset winding process programs, synchronously collects real-time data such as spindle speed, wire position, tension feedback, and turn count, and realizes full process automation control. High end models also have wire breakage detection and abnormal alarm functions.
2, Complete winding process
1. Loading preparation: Install the transformer frame onto the winding spindle fixture, thread the lead material and fix it on the tension pay off reel to complete the initial wire head fixing operation.
2. Process parameter setting: Enter process parameters such as target turns, winding layers, wire diameter specifications, set tension values, and wire spacing through the touch interface.
3. Automatic winding: The CNC system starts up, and the winding spindle rotates at the set speed. The tension mechanism synchronously releases the stable tension of the wire, and the wire arranging mechanism moves back and forth along the axis to accurately wind the wire on the skeleton, while real-time counting of the number of winding turns.
4. Closing process: After reaching the preset number of turns, the spindle stops rotating, the wiring mechanism is reset to its initial position, the wire head is locked and cut off, and the semi-finished transformer that has been wound is removed.
During the operation, it is strictly prohibited to touch the rotating winding spindle and wiring mechanism. Equipment maintenance requires cutting off the main power supply and locking with tags. Professional trained operators are required to carry out debugging and operations.
