Study On Tension Control System For Filament-winding

Filament winding is a common processing to manufacture fiber composite material. Filament winding tension, as an important control parameter, effects the quality of winding products directly, therefore, tension control is one of the key technology for filament winding process. However, whether the reasonable tension could be brought into effect exactly and stably depends on the tension control system. The main works in this paper are as follows:(1) A closed loop tension control system is designed, with IPC & PMAC as the main controller, a direct current torque motor as the tension actuator, a tension sensor for feeding back the change of fiber tension in real-time.(2) According to actual working status of tension control system, the integral shifted PID controller is chosen, and the simulation based on Matlab for this tension control system is also studied.(3) Based on analyzing for control soft, the software configuration for the tension control system is set up. In order to enhance the real-time capability and the stability of this tension control system, following techniques, including multi-thread technique, multimedia timer technique and dual buffer technique etc, are used in the part of data acquisition and processing. Moreover, the capability of real-time disposal is studied for Windows Operating System.(4) The background management program with friendly interfaces is designed in the Window's platform, including initialization of system, order sending, fiber break checking and alarm, display of history data, system help and so on. And the communication between the upper and lower computer is completed through the functions of PMAC DLL-PComm32.(5) After completing the effective calibration on the torque motor and tension sensor, the overshoot and fluctuation of tension are analyzed through the dynamic test in order to validate the status of hardware and the performance of system. Furthermore, combined with the character of PMAC software, a novel control algorithm is brought forward and achieved. According to the experiment results and analysis, the system meets the requirement well.