The technical application of winding machines in the manufacturing of power equipment

The technical application of winding machines in the manufacturing of power equipment

The manufacturing of power equipment is an important basic industry of the national economy, and the production quality of its core components directly affects the safe and stable operation of the power system. As one of the key equipment in power equipment production, winding machines have significantly improved the manufacturing efficiency and product quality of transformers, motors, reactors, and other equipment through automated and intelligent coil winding processes. With the development of the power industry towards high voltage and large capacity, winding machine technology is undergoing a profound transformation from mechanization to digitization and intelligence.

1、 Basic working principle and classification of winding machines

A winding machine is a specialized equipment that wraps conductive materials around a skeleton or iron core according to specific rules by rotating the main shaft in conjunction with the movement of the wire arrangement mechanism. According to different application scenarios, it can be divided into three categories: parallel winding machines, circular winding machines, and special winding machines. The parallel winding machine is mainly used for layer or cake winding of transformer coils, controlling the tension and arrangement of the wires through a precision servo system; The circular winding machine is suitable for distributed winding of motor stator windings and uses multi station synchronization technology to improve production efficiency; Special winding machines serve the manufacturing of special structures such as superconducting coils and hollow reactors.

In the manufacturing of power transformers, winding machines need to handle huge spans from 0.1mm thin wires to 10mm or more flat copper wires. Modern equipment, through modular design, can quickly replace components such as winding heads and tensioners, achieving multiple uses for one machine. The high-voltage winding machine is also equipped with an automatic insulation material wrapping system, which synchronously completes interlayer insulation treatment during the winding process.

2、 Key technological breakthroughs and innovative applications

1. Intelligent tension control system

The closed-loop tension control based on fuzzy PID algorithm is the core technology to ensure the tightness of the coil. By monitoring the speed of the pay off wheel, wire tension, and changes in winding radius in real-time, the system can dynamically adjust the torque output and control tension fluctuations within ± 2%. In the manufacturing of ultra-high voltage transformers, this technology effectively avoids the problem of insulation paper wrinkles caused by uneven tension.

2. Three dimensional adaptive wiring technology

In response to the demand for winding irregular iron cores, a machine vision guided robotic arm collaborative control system is adopted to achieve precise winding of spatial curve paths. In a certain ± 800kV converter transformer project, this technology successfully solved the problem of winding uniformity of trapezoidal cross-section iron core, reducing the DC resistance imbalance of the winding to below 0.5%.

3. Digital twin and process simulation

By establishing a digital twin model of the winding process, winding parameters can be optimized in a virtual environment. After applying this technology in a large motor factory, the development cycle of new products has been shortened by 40%, and material waste has been reduced by 15%. The process simulation system can also predict the stress distribution during the winding process, avoiding coil deformation.

4. Online quality inspection system

Integrated infrared thermal imager and partial discharge detection device can detect insulation defects in real-time during the winding process. The data of a certain intelligent winding machine project shows that online detection has reduced the product repair rate by 70%, and a complete process quality traceability database has been established.

3、 Industry Technology Development Trends

1. Adaptive processing of composite materials

With the application of new materials such as carbon fiber composite wires and nano insulation materials, winding machines are developing multi material collaborative processing capabilities. The emergence of new static elimination devices and low-temperature winding technology has provided possibilities for the manufacturing of superconducting power equipment.

2. Deep integration of digital factories

Under the industrial Internet architecture, as an intelligent production unit, the winding machine realizes data exchange with the MES system. A digital workshop case shows that the overall equipment efficiency (OEE) has increased to 85% and energy consumption has decreased by 22%.

3. Green manufacturing technology

Environmentally friendly processes such as solvent-free insulation treatment and copper wire laser cleaning are gradually becoming popular. The new winding machine adopts regenerative braking technology, which reduces energy consumption by 30% compared to traditional equipment and meets the requirements of the dual carbon target.

4. Artificial intelligence optimization

Deep learning algorithms are applied to the autonomous optimization of process parameters. A research project has shown that AI models can improve winding efficiency by 18% and extend the service life of molds.

4、 Application effectiveness and industry impact

In ultra-high voltage transmission projects, the windings of converter transformers produced by intelligent winding machines have local discharge controlled below 5pC, which is better than the requirements of IEC standards. In the field of new energy, the automated production of stator windings for wind turbines has reduced the manufacturing time from 72 hours to 18 hours per unit. The distribution transformer industry has reduced the average no-load loss of products by 15% through the popularization of CNC winding technology.

The current winding machine technology still faces technical bottlenecks such as superconducting coil winding accuracy and composite material interface control. In the future, with the emergence of new demands such as 5G communication and quantum computing, wire winding technology will develop towards sub micron precision. Industry experts predict that the next generation of winding machines will integrate flexible electronic manufacturing technology, achieve heterogeneous integration of power electronic equipment, and provide more advanced equipment support for the construction of smart grids.

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