Tension Control System Research Articles

Study of wire tension control system based on closed loop PID control in HS-WEDM

Wire electrical discharge machining (WEDM) is widely used in mould and die manufacturing, but the low machining accuracy limits its further developments, especially for high-speed wire electrical discharge machining (HS-WEDM) because of its non-even wire tension. A constant tension can restrain the high-frequency vibration of wire electrode effectively, which can improve the accuracy of workpiece surface. In this paper, a wire tension control system is designed to reduce the wire tension fluctuation, according to the process characteristic of HS-WEDM. Wire tension control system adopts a closed-loop control strategy. A mathematical model of control system is built based on DC servo motor, linear motion platform, and tension sensor. Meanwhile, a simulation model of transfer function is built to calculate proportion integration differentiation (PID) control parameters. Simulation results show that the calculated PID control parameters can satisfy the requirements of the control system. A series of experiments are designed to test the stability and reliability of wire tension control system and its workability. The value of wire tension fluctuation has been down by almost half with wire tension control system. The surface roughness of workpiece with wire tension control system is almost 0.6 μm lower than that without wire tension control system, which implies that this control system can improve the quality of parts manufacturing for HS-WEDM.

The Study of Continuous Rolling Mill Inter-stand Tension Inferential Control Systems

The inter-stand tension inferential control systems are used to stabilize the rolling motor torque. To stabilize the motor torque the electric drive system with the properties of the rolling motor torque supply may also be used. An alternate option may include torque stabilization by to the effect on speed of the previous, further or controlled mill stand. The tension control accuracy depends on how exact the unhindered rolling torque is determined. Nevertheless, a change in tension due to this factor may result in improving gauge accuracy in some systems. Using the model of the continuous rolling mill, the paper considers the force interaction between the stand electric drives for different technological conditions of rolling. It analyses the operation of the rolling mill using different system for tension inferential control. The finished studies prove that size alignment is provided with the tension control system affecting speed of the further stands. The paper verifies that the characteristics of the rolling mill including aligning ability depend on the rolling speed. It is a good practice to apply those results during the selection and calculation of the inferential tension controllers.

Design and implementation of adaptive PI control schemes for web tension control in roll-to-roll (R2R) manufacturing

In this paper, two adaptive Proportional-Integral (PI) control schemes are designed and discussed for control of web tension in Roll-to-Roll (R2R) manufacturing systems. R2R systems are used to transport continuous materials (called webs) on rollers from the unwind roll to the rewind roll. Maintaining web tension at the desired value is critical to many R2R processes such as printing, coating, lamination, etc. Existing fixed gain PI tension control schemes currently used in industrial practice require extensive tuning and do not provide the desired performance for changing operating conditions and material properties. The first adaptive PI scheme utilizes the model reference approach where the controller gains are estimated based on matching of the actual closed-loop tension control systems with an appropriately chosen reference model. The second adaptive PI scheme utilizes the indirect adaptive control approach together with relay feedback technique to automatically initialize the adaptive PI gains. These adaptive tension control schemes can be implemented on any R2R manufacturing system. The key features of the two adaptive schemes is that their designs are simple for practicing engineers, easy to implement in real-time, and automate the tuning process. Extensive experiments are conducted on a large experimental R2R machine which mimics many features of an industrial R2R machine. These experiments include trials with two different polymer webs and a variety of operating conditions. Implementation guidelines are provided for both adaptive schemes. Experimental results comparing the two adaptive schemes and a fixed gain PI tension control scheme used in industrial practice are provided and discussed.

Research on the Application of Proportional Controller Based on Phase Plane Division in the Tension Control System of Coating Device

The objective of this paper is to research on the application of proportional controller based on phase plane division in the tension control system of coating device to improve the quality of tension control. Firstly, the control strategy of proportional controller based on phase plane division and the parameter tuning methods are analyzed. Then the simulation model of tension control system is built with the help of MATLAB SIMULINK. Finally, the simulation results are given. Simulation results indicate that the tension control system is effectively controlled by the proportional controller based on phase plane division.

Optimization of Tension Control System for Cold Rolling Exit Section

Through theoretical analysis of the working condition of the tension roller and stress, user can discuss the main reasons of tension roller slip, and put forward the preventive measures to eliminate tension roller slip by using Euler formula and the research on the tension roller slip phenomenon of cold rolling. This technology has significant practical meaning for improving both the quality and efficiency of product.

Research on the Simulation of Tension Control System of the Traction Wire Rope Cleaning and Detection Line of Pay-Off Unit

Take the traction wire rope cleaning and detection line of pay-off unit as an example, investigate the general law of the change during paying off of traction wire rope cleaning and detection line and build the mathematical model in each step of the paying off tension control system. Build the simulation model using MATLAB on the foundation of the mathematical model and research on the model. Afterwards, it is proved that the demand of keeping the tension of pay-off unit constant can be meet through regulating magnetic braking torque of pay-off unit.

Warp Tension Control System Based on IMC

To ensure stability of warp tension during weaving process, the paper presented a warp tension control system which uses two permanent magnet synchronous motor (PMSM) drive let-off and take-up mechanism respectively. Based on analyzing factors influencing warp tension, a warp tension mathematical model was established. The paper proposed a tension adjustment arithmetic based on internal model control (IMC) method. The method has only one adjustable parameter which decides performance of the system. The simulation results show that the warp tension control system based on IMC has a fine effect on tension stability of warp and it is significantly superior to conventional PID control in terms of robustness and immunity.

Research on Tension Control System of Wire Saw Slicing Machine

Nowadays, wire sawing becomes the most advanced brittle crystals slicing technology because of its advantages of slicing larger crystals ingots into very small thickness, high surface quality, high yield wafers. In the process, the thin wire, which is the processing tools, travels at high speed, and subjects to external excitation from many aspects. Wire saw tension control is the core and difficulty of the control system. Mathematical models of tension subsystems were studied. The control strategy of swing arm motor tension direct closed-loop combination of speed difference indirect closed-loop was proposed. The developed tension control hardware and software system reached the functional requirements and technical indicators, and constant tension precision control was solved effectively.

Coiling Tension Control System of PID Simulation

Coiling tension control system is the main control means to ensure the quality of the rolling process. According to the characteristics of coiling tension control characteristics and the requirements of actual engineering, establish the mathematical model of the double closed loop control system and use the traditional PID to tuning the model parameters. It is proved by Matlab simulation experiments that traditional PID can effectively improve the response process of coiling tension control system and greatly enhance the dynamic and steady-state performance.

Design of the Hydraulic System of Lead Plate Coiling Machine

This paper mainly introduces the process of lead electrolysis, the structure and working principle of lead plate coiling machine and Its’ parts, coiling machine components. First of all, rewind section hydraulic system adopts a return to the oil throttle speed control, it is stable and can bear a certain change load, can overcome the stage before the tension fluctuation of the impaction to the rotation speed of hydraulic motor. Secondly, speed and tension control system adopt electro-hydraulic servo valve and proportional relief valve are respectively to the drum speed and output torque control,it has high precision and accurate in speed and tension control. contact coiling section use electro hydraulic servo position control system with close loop control to improve the accuracy of position control. Finally, calculate parameters of each working section of hydraulic control system , verify the hydraulic component model and the rationality of the hydraulic circuit.

Genetic Algorithm Based Fuzzy Logic Controller for Wire-EDM Machine

Wire tension as well as wire feed should be controlled tightly for the geometry and corner accuracy of wire-EDM. A closed-loop wire tension control system for Micro-Wire-EDM is presented to guarantee a smooth wire transport and a constant tension value. To keep smooth wire transportation and avoid wire breakage during wire feeding, the reel roller is modified and the clip reel is removed from the wire transport mechanism. A genetic algorithm-based fuzzy logic controller (FLC) is proposed to investigate the dynamic performance of the closed-loop wire tension control system. Theoretical analysis and experimental research demonstrate that the developed wire transport system can result in satisfactory transient response, steady-state response and robustness. The proposed FLC can obtain faster transient response and smaller steady-state error than PI controller.

Fuzzy Control with Adjustable Factors in Tension Control System

The variable tension control system of strip winding is a nonlinear, strong coupling and time-varying system. Traditional fuzzy controller with fixed control rules cannot obtain the desired control performance of the strip winding system. So the fuzzy control algorithm with adjustable factorαis proposed, and the introduction of adjustable factors can change the fuzzy control rules. The tension fuzzy controller with adjustable factorαis designed, and simulation model of the system is established using Matlab software. The result of simulation shows that tension fluctuation of the tension fuzzy control system with adjustable factor get small, comparing the tension fuzzy control system with adjustable factors with the ordinary tension fuzzy control system. The tension fuzzy control system with adjustable factors has fast system response and strong anti-interference ability.

Data-Driven Cooperative Intelligent Controller Based on the Endocrine Regulation Mechanism

A data-driven mechanism can achieve effective control by utilizing the online/offline data of the target system, although its performance has not been tuned to a better level. The endocrine regulating mechanism in the human body establishes a rapid responding system to maintain the balance of the body, which can be mathematically derived and therefore provide an inspiration for optimizing the industrial controller. In this paper, a novel data-driven cooperative intelligent controller inspired by the regulating principle of the endocrine system in the human body is proposed. The data-driven component of the proposed controller optimizes the controller parameters by collecting and processing runtime data of the target system. The endocrine regulation-inspired enhancing component tunes the intensity of control signals adaptively. Both the components are further organized by an adaptive distributor so that their behaviors can be regulated dynamically. A dynamic tension control system for acrylic fiber production is taken to verify the performance of the proposed controller. Simulation results show that the proposed controller can realize effective control on systems with unknown or varying models, meanwhile featuring rapid response and effective regulation against external disturbance.

Compound Tension Control of an Optical-Fiber Coil System: A Cyber-Physical System View

The full-automatic optical-fiber coil winding equipment is a complex electromechanical system which contains signal acquisition, data processing, communications, and motor control. In the complex electromechanical system, the subsystems rely on wired or wireless network technology to complete the real-time perception, coordinate, accurate, and dynamitic control, and information exchange services. The paper points to the full-automatic optical-fiber coil winding equipment with the characteristics of cyber-physical system to research its numerical design. We present a novel compound tension control system based on the experimental platform dSPACE to achieve semiphysical simulation of compound tension control system and examine the functions of control system.

Design and Analysis of the Fuzzy PID Controller of the Carbon Fiber Multilayer Loom

According to the characteristics of carbon fiber and tension requirement of multilayer angle interlocking loom, tension in the weaving process of carbon fiber needs to be consistent.Based on this requirement, a kind of fuzzy PID controller is designed.Through the real-time detection and feedback of tension sensor, the fuzzy PID controller for the tension control system compensates tension timely, so as to realize the constant tension.In this article, the design ideas of analog PID controller, parameter adjustment rules are introduced.The simulation of tension control system has been done through MATLAB software.The results show that the controller can meet the control requirements.

Based on Model Reference Design of Lead Sheets Servo Winder Tension Control System of Electro-Hydraulic Design Simulation and Analysis

In this paper,for the precision of tension control affects the products quality and performance of the device. In the coiling process while the tension control of the lead plate coiling machine is not stable, it will cause uneven thickness of lead sheet, affect the winding quality of lead sheets, and impact electrolysis efficiency. In this paper, according to the requirements of electrolytic process and the lead sheet winder actual working process, designing a tension control system in order to improve the precision of tension control.

Simulation of PFC Algorithm in the System of Tension Control of Shaftless Driven

Through the in-depth study of working principle and application of PFC algorithm, the paper introduces PFC algorithm to the constant tension control of the system of shaftless driven in printer. In order to better implement constant tension control of shaftless driven control system, the paper choose a first order system as the transfer function of the system of tension model. The paper carries on the silulation of the system’s output of constant tension ,aiming at the situation of the changing of the internal parameters of prediction model for PFC algorithm, such as the attenuation coefficient of reference trajectory , the change of fitting points , prediction horizon and so on, matching of prediction model and tension model of PFC algorithm. The simulation system provides a theoretical basis to build the actual tension control system.

Study on Constant Tension Winch with PDF Controller Applications in Ocean Engineering

To ensure safe and stable dragging operations of engineering equipments under the complex sea conditions as well as realizing the quick response and precise control of constant tension winch, the design of the hydraulic control system for constant tension winch regards constant tension winch as research objects coupled with a combination of PDF control (pseudo differential control) algorithm. By establishing the PDF mathematical model of hydraulic control scheme, calculateing the appropriate PDF controller parameters and using sumlink simulation analysis. It is safe to draw a conclusion that the PDF based control algorithm of constant tension control system bears a good dynamic response characteristics and robustness to meet control requirements of constant tension winch in operation under complex sea conditions, in order to provide a reference for further research and development of the constant tension control technology.

Based on Model Reference Design of Lead Sheets Servo Winder Tension Control System of Electro-Hydraulic Design Simulation and Analysis

Based on Model Reference Design of Lead Sheets Servo Winder Tension Control System of Electro-Hydraulic Design Simulation and Analysis

Control System of Tension Test for Spring Fan Wheel Assembly

This design is a basic method for testing spring fan wheel assembly and steel cable tension control system. PLC is used as logic control core. Stepping motor and magnetic powder braker is used as an executive element. The constant tension control of the running process of the system is completed. The fuzzy control process of PID system includes two parts of tension loading and damping loading. The method of modular software is used to make the program structure clear.