Armature winding machine equipment In the enameled wire winding process, the tension is a very important parameter. The enameled wire manufacturer provides the reference value of the winding tension when the enameled wire leaves the factory, and must ensure that the process value meets the wire requirements during use, and the wire is excessively stretched. Will have an impact on product quality. For some long cable packages, especially those used for precision sensors, if the tension is not controlled, the electrical parameter distribution of the product will be discrete. Therefore, tensiometer is indispensable for automatic armature winding machine, and it has become an important indicator of armature winding machine performance.
With the continuous introduction of new products and technologies, the tension meter has also developed rapidly in recent years, from the previous development of the tension preset by spring machinery to the current electronic measurement real-time adjustment to ensure the stability of the tension. The electronic feedback control tension meter is an accessory used on the latest high-end armature winding machines. It can adjust the tension in real time according to the tension fluctuation. The electronic tension meter uses electromagnetic tension control. This kind of tension meter is mostly equipped with imported armature winding machine, and the accessories are expensive. In addition, it needs to be used with a new host and software, and its use cost is too high.
1. Tension control principle
At present, part of the tension meter equipped with the armature winding machine is mechanical. The tension adjustment is achieved by adjusting the tension of the spring and the friction plate. Due to the discreteness of the relevant mechanical parameters, the value on the tension meter can only be used as a rough reference during actual use. In order to avoid the inaccuracy of the tensioner, it is necessary to hook one end of the enameled wire with a tension meter to test the tension (P1), adjust the elastic force and pressing force according to the situation, because it is manually measured and adjusted, plus the The movement of the machine head during the circumnavigation process, the spring bounce, the change of friction lining friction, and the cumulative change of the outer dimensions of the wire package will cause the fluctuation and deviation of the tension, which will eventually cause the relative electrical parameters of the product to appear larger.
When the armature winding machine is circling at a higher speed, the wire tension control is not only related to the set relative pre-tightening force, but also related to the influence of the damper and pulley inertia force. Within the allowable range, the higher the speed, the greater the tension . Using this principle, a set of tension realization fine-tuning system can be designed, and an electronic tension meter (non-locking type) with data output interface can be selected to install on the machine to achieve real-time tension measurement. According to the tension feedback, the armature winding machine speed can be real-time adjust.
2. Tension measurement
The installation diagram of the tension meter is shown in Figure I. The tension meter is mounted on a pulley and pulled on the enameled wire. The tension meter is installed on it without affecting the winding process. At the same time, the tension value during the winding can be read in real time, and the tension can be carried out according to the obtained tension. Corresponding adjustment, if the value deviation is large, generally adjust the tension on the spring tension meter, and if the deviation value is small, generally adjust the orbiting speed appropriately.
The relationship between the winding tension F1 and the reading F2 of the tension gauge can be obtained by P2 analysis:
In order to facilitate side measurement, the pulley position of the tension gauge is generally pulled to the right angle position (P3). At this time, F2=F1, and the value of the tension gauge is the tension value.
As a universal tool, the tension meter is more convenient to calibrate. Regular calibration can ensure the accuracy of the tension value reading. This method of installing a tension gauge can accurately reflect the winding tension value, avoiding the inaccurate reference reading of the tensioner itself, the inconsistent manual side measurement and the inestimable speed factor. The side measurement method is simple, reliable and intuitive.
3. Control of tension
There is a corresponding relationship between the winding speed (line speed) and the tension in a certain range. The speed is fast, the tension is large, and the speed is small. The tension is small. For the wire drawing machine, it can only control the speed of the shaft, but there are more layers in the winding. In the case of coils, the diameter of the skeleton becomes larger due to the accumulation of winding, which will cause the line speed to become faster. At this time, the spindle speed should be reduced in time to maintain the line speed and the tension. For long skeletons, the large-scale movement of the machine head causes the force of the line to fluctuate. The more you move to the side, the greater the tension. At this time, the speed should be adjusted appropriately, and the tension value of the electronic tension meter can be linked to the speed control. Make a tensiometer with real-time adjustment.
The use of this method can improve the efficiency of winding, the control of the tension index is more accurate, and the consistency of the wire group is also guaranteed. The control effect has a lot to do with the equipment of the motor and the whole system, so PID parameters need to be adjusted on each machine.
4. Use effect
NIDE's side test and control method for tension have been used in practice. The induction coil for a certain type of sensor needs to be paired in the realization. To meet the requirements, a set of (4) resistance and inductance deviations must not exceed 0.5%. Combinations, originally only about 50 groups per 1,000 can be selected, but after improvement, it is increased to about 200 groups, which greatly improves production efficiency. The PID control of tension and speed is realized on a simple armature winding machine. The control method is relatively simple. The author did not purchase new tools and equipment during the implementation process, which greatly improved the winding effect. The low-cost improvement scheme can be applied to other armature winding machines. The user provides reference.
NIDE provides a cost-effective transformation solution to the problem of instability in tension control of ordinary automatic armature winding machine. By reading the tension value during the winding process, it can fine-tune the winding speed to achieve stable tension control. The improved scheme has low implementation cost, is simple and reliable, and has good practical value.