Design And Research Of The Crude Foil Engine Control System

Tension control is very important part of process control in the process of copper foil production. Good Crude Foil Engine transmission control system improves production quality and productivity. Owing to the low control accuracy and the inferior tension control performance of the copper foil production device, a suit of control system to fit copper foil production was researched.Firstly, the copper foil production process flow, the Crude Foil Engine principle, production technique performance and technics parameter were detailedly analysed for revealing the relation of copper foil ply, cathode roller velocity and winding roller velocity. The copper foil tension arising and the impact of tension on the system were strongly discussed for setting up tension mechanics model and mathematical model of constant tension control.Those provided theoretical foundation and system control basis for further designing the Crude Foil Engine control system.Secondly, the tension control of Crude Foil Engine was focused to research. The dynamic analysis of copper foil winding tension was done, for which has a non-linear, strong-coupling, time-varying, strong disturbances, such as characteristics.meanwhile, the math relationship between all kinds of disturbance and tension was set up and all kinds of disturbance compensation strategy was put forward. Targeted at winding copper foil layers loose inside and tight outside in the actual copper foil production, winding characteristics and dynamic tension model of Crude Foil Engine were focused on and taper tension control technology was introduced in practical engineering for presenting indirect tension control strategy of System. Based on general taper tension control model taper control model was simplified, which combined with the principle of constant tension control.The taper sub-model of constant tension control was founded.In order to achieve indirect tension control strategy, a number of control algorithms was used. To prevent the integral accumulation of PID computing result, the integral separated PID control technology was used, which was validated in MATLAB simulation environment. In the course of the experiment show that the mathematical model of indirect tension control system can basically reflect the dynamic process of tension control, the integral separation PID control algorithm can meet the tension control performance requirements. Then, a set of Crude Foil Engine control system with better openness, autonomy and flexibility was designed, in which PLC as the control core, intervers and servo drivers as bottom controller, frequency conversion motor and servo motor for the implementation of components, touch panel as HMI. RS-485 communication was used to achieve remote control to drive units, which improved the system integration and reliability. Meanwhile, the software design of Crude Foil Engine control system was introduced, in order to achieve control functions.Finally, a number of dynamic parameters debugging and functions debugging were described in the production debugging, espacially the PID parameters tuning method and results.In the paper, the expand critical proportion method was used to setting tension-tuning PID parameters,which shortened the debug time and improved the system accuracy. After the completion of tension control system, static error ratio and wave property were analysed. The results show that the control system is more adaptive to the change of copper foil roll diameter.