Research On Full Digital Tension Control System Of Winding Machine

Applications of enameled wires can be easily found in daily life.Winding machines are essential regarding to the production and fabrication of enameled wires,while sophisticated and highly-performed tension control system can guarantee the winding quality.Nowadays,tension control systems employed in majority of domestic winding machines have low precision and lacks intelligence,automation as well as informatization.Unfortunately,most papers just present simulation results without experimental demonstration.In the line with"Made in China 2025" outline,to overcome deficiencies currently existed in tension control systems and improve their performances in all aspects,both simulations and experiments are specifically presented in this paper as solutions.All work and results are demonstrated as follows.(1)The control method of measuring angular displacement and active payout is selected.A closed-loop feedback control system is formed with rod-spring mechanical structure,encoder,AC servo motor and microcontroller,to control the swing angle of the rod and indirectly control the tension of the enameled wire.The communication program is stated and the remote settings of operating parameters and the remote transmission of the operating data can be realized.(2)Controlled object is the combination of AC servo motor and rod-spring mechanical structure in this paper.Experiments are performed to obtain the transient response plot of controlled object with typical signal as the input.The precise transfer function of controlled object is derived by analyzing on the aforementioned response plot.(3)PID algorithm with incomplete derivation is chosen and the tuned PID parameters are obtained according to Ziegler-Nichols closed-loop tuning method.The transient performances and steady errors of the system are studied using the simulation model of wire winding.Value ranges of PID parameters are discussed and determined.The method of parameter optimization is summarized and the optimized PID parameters are obtained.(4)An experimental system is built,and it works normally using the optimized and tuned PID parameters respectively.The experimentally optimized PID parameters with better performance are obtained by multiple experiments.The maximum tension turbulence of enameled wire with diameter 0.08mm at constant and disturbed winding speed are±0.8%and±1.0%,respectively.The maximum tension turbulence of enameled wire with diameter 0.15mm at constant winding speed is×1.0%.