Design Of A Tension Control System For Rectangular Coil Winding

With the rapid advancement of industrial technology,various electrical products,such as motors and transformers,have become indispensable in the industrial sector.The quality of the windings,which are the core component of these electrical products,directly impacts their performance.To improve the quality of the coil forming,a constant winding tension is required during the coil winding process.However,different shapes of coils have varying requirements for tension control.The equal radius characteristic of round coils enables them to be wound without experiencing significant fluctuations in tension.In contrast,the non-equal radius geometry of rectangular coils leads to non-linear changes in the wire speed of the wound wire,causing large tension fluctuations that can impact the efficiency and quality of the coil winding process.Therefore,to address the tension control requirements during the winding of rectangular coils,this paper presents a tension control system specifically designed for rectangular coil winding.This study aims to address the issue of tension fluctuation during the winding process of rectangular coils by analyzing the methods of tension generation and control in the winding system.To buffer the tension disturbance caused by the switch of the long and short sides of the rectangular coil in the winding process,a floating roller mechanism is used.The position of the floating roller reflects the fluctuation of tension.Hence,the study presents a tension control scheme based on the feedback of the floating roller displacement detection,enabling closed-loop position control.To address the challenges of time-varying tension control and multiple disturbances during the winding process,the study develops a dynamic model of the winding and unwinding parts and a dynamic model of the angular displacement of the floating roller to analyze the dynamic characteristics of the rectangular coil winding process.In order to meet the demand for constant tension during the winding of rectangular coils and to minimize the impact of edge switching and winding speed on tension,a rectangular coil model is established to reflect the change in coil radius with rotation angle.To design the tension control system,the study combines the fuzzy control theory with the fractional-order PID algorithm.A fuzzy fractional-order PID tension controller is designed,which effectively improves the accuracy and stability of the rectangular coil winding tension by selecting appropriate affiliation functions and establishing a sound fuzzy rule base.To satisfy the requirements for controlling the winding of rectangular coils,an appropriate hardware configuration for the control system is selected based on the coordinated movement of the winding and payoff wheels and the tension control process of the system.The upper computer’s human-machine interface and the lower computer’s motion control program are designed to facilitate the control of the rectangular coil winding process.Beckhoff PLC is selected as the controller for the tension control platform,which comprises a displacement sensor for feedback and a cylinder and a servo motor for actuation.Based on this platform,an experiment for rectangular coil winding was conducted,and the results demonstrated that the tension control system designed by the study ensures a tension fluctuation of not more than±4% of the reference tension during the rectangular coil winding process.Additionally,the wire spacing during the winding process was uniform,and the winding quality was excellent.