Research on Tension Control System of Reciprocating Winding

When the enameled wire is winded onto the poles of the motor stator or rotor, the winding quality hugely relies on the control precision of the tension. Therefore, it is necessary to control the tension of the enameled wire in winding process. A tension control system is built with single chip microcomputer, the encoder and the servo motor. The PID feedback controller and feedforward controller are combined to form feedforward feedback controller, which using feedback information of swing angle deviation and feedforward information of wire frame position to adjust the pay off speed dynamically and control tension of enameled wire further. A procedural experimental modelling method is discussed in order to identify the feedforward model. The experiment is performed, it is found that in the typical situation of setting tension 1500 g, the tension fluctuation rate of the PID controller with feedforward model is only 2%, which is far better than that of pure PID controller with a fluctuation rate of 14%. The result shows that the proposed experimental modelling method hosts the characteristics of good accuracy, universality and applicability.

Conceptual solutions for control systems of differential tensioners for belt conveyors

Differential tensioning devices for belt conveyors in general and intermediate drives of extended conveyors in the form of closed traction loops are a new type of automatic tensioning devices that differ from other known designs by the presence of a stepwise discrete belt tension control system with separation of compensation functions for belt stretching under load and control of its tension during the operation of the conveyor in order to create optimal modes of belt loading. The article analyzes the well-known and practical concepts of belt conveyor control systems in general. The possibility of controlling the traction force realized by the intermediate belt drive by controlling the tension of the traction and load-carrying belts is shown. On the basis of the analysis, conceptual solutions for control systems for differential tensioning devices of belt conveyors are proposed with the possibility of both autonomous use and application in the structure of an integrated conveyor control system. Possible structures of linear parts of differential tensioning devices are presented, as well as options for the implementation of executive parts that directly move tensioning elements.

DDPG-Based Continuous Thickness and Tension Coupling Control for the Unsteady Cold Rolling Process

Cold rolling is an important part of the iron and steel industry, and the unsteady rolling process of cold rolling usually brings significant influences on the stability of product quality. In the unsteady rolling process, various disturbances and uncertainties such as variable lubrication state, variable equipment working conditions lead to difficulties in the establishment of state space model of thickness and tension, which has become a thorny problem in thickness and tension control. In this paper, we present a model-free controller based on Deep Deterministic Policy Gradient(DDPG), which can continuously control the thickness tension of the unsteady rolling process without the mathematical model. We first formulate the thickness and tension control problem to Markov Decision Process(MDP). We apply strategies such as dividing state space variables with mechanism model, defining reward function and state normalization, the random disturbance and complex uncertainties of unsteady cold rolling process are coped with by utilizing the DDPG controller. In addition, these strategies also ensure the learning performance and stability of the DDPG controller under random disturbance. Simulations and experiments show that the proposed the DDPG controller does not require any prior knowledge of uncertain parameters and can operate without knowing unsteady rolling mathematical models, which has better accuracy, stability and rapidity for thickness and tension in the unsteady rolling process than proportional integral(PI) controller. The artificial intelligence-based controller brings both product quality improvement and intelligence to cold rolling.

Optimal analysis and application of the warp tension control system for a rapier loom

Traditional proportional–integral–derivative (PID) control performance optimization is an essential method to improve a loom’s warp tension control performance. This work proposes an improved genetic algorithm optimized PID control scheme to overcome the decline in control performance of the traditional PID control algorithm in a loom’s warp tension control system. Through the decoupling analysis of loom motion mechanism, the establishment of warp tension model and the optimization of fitness evaluation mechanism of genetic algorithm can effectively overcome the problems of local optimal solution and algorithm degradation of genetic algorithm. Simulation experiments were carried out with the traditional PID, the integral separation PID, and the genetic PID in warp tension control. The results show the advantage of the genetic-PID algorithm to control warp tension stability. Ultimately, according to the functional characteristics of the loom mechanism, a tension control platform for experimental studies was established. The test results show that the maximum fluctuation range of warp tension is within [−2, +6] at the test speed of 850 rpm, which meets the requirements of long-term stable and reliable control of warp tension under different weaving conditions.

Design of Insulation Tape Tension Control System of Transformer Winding Machine Based on Fuzzy PID

With the rapid development of science and technology as well as the comprehensive societal progress, the demand for electricity in all walks of life is also increasing. As is known to all, the mechanical structure and tension control of a transformer winding machine is the key to improving the quality of coil winding, due to coil winding being generally considered the core technology of transformer manufacturing. Aiming at the synchronous winding control problem of the conductor and insulating layer of the transformer winding machine, this paper presents a mechanical structure and tension control scheme of a new type of transformer winding machine. Based on the dynamic analysis and modeling of the mechanical structure of the winding machine, the speed control of the main speed roller by the fuzzy PID control rate is implemented initially. Combined with the actual demand of the project, the feasibility and effectiveness of the control target with different tension are verified by the simulation experiment and further compared with the traditional PID control method. The simulation results show that the proposed fuzzy PID control rate can realize the automatic and efficient winding of the transformer winding machine, showing that it is superior to the traditional PID control rate in overcoming the disturbance and controlling effect.

Application of embedded soft PLC in the control system of rapier loom

At present, the rapier loom has gradually become the mainstream equipment in the manufacturing industry. In order to make the rapier loom realize automated production and further improve the production efficiency of the rapier loom, improve the programmability of the system, and reduce the cost of system maintenance. The thesis developed a rapier loom control system based on embedded soft PLC, and carried out experiments and applications in the field. The contribution and innovation of this paper is to develop a complete low-cost control system, and through a genetic algorithm optimized PID algorithm to complete the more effective control of the loom tension system. The embedded soft PLC system proposed in this paper reduces the overall maintenance cost of the system and improves the programmability of the system. This text carries on the systematic scheme design to the embedded soft PLC from the hardware system and the software system respectively. First, according to the actual requirements, this article designs the overall scheme of the embedded software PLC hardware system with STM32F407ZGT6 as the core. Then this article is based on the embedded soft PLC hardware platform, according to the international standard of industrial control programming, writes the embedded soft PLC low-level driver software. Secondly, this article analyzes the factors that affect the warp tension during the operation of the rapier loom, and proposes the use of genetic algorithm to optimize the warp tension control method of the traditional PID algorithm. Finally, we conducted verification tests and on-site application debugging for the entire set of rapier loom embedded soft PLC control system. We controlled the warp tension as the main experimental object. The results show that this control system effectively improves the control accuracy of the warp tension of the rapier loom and meets the actual needs of industrial applications. The whole system has a good application prospect in the warp tension control of rapier looms.

A practical compensation algorithm of stress relaxation due to single tension

PurposeDue to the deformation between the pylon and the girder caused by single tension of cables, the previously tensioned steel strands have stress relaxation, resulting in the actual cable forces being less than the design cable forces. To compensate the stress loss caused by the single tension of cables, this paper aims to present a practical compensation algorithm of stress relaxation during the construction period.Design/methodology/approachFrom the perspective of the essential cause of the stress relaxation, finite element analysis is used to solve the tension control force of each steel strand after a rigorous theoretical formula derivation.FindingsThe deformation and tension control force of each steel strand decrease with the advance of the tension sequence, and the decline rate drops gradually. However, the calculated force values of the steel strand are in good agreement with the measured value as the cable length decreases.Originality/valueThe previous rough calculation methods for the tension force of steel strands cannot meet the accuracy, and the accurate calculation methods often include the solution of nonlinear equations, which complicate the calculating process. Otherwise, there are few studies on the compensation of stress loss by calculating the deformation of the steel strand during the tension process. So, it developed an accurate and efficient algorithm to determine the tension control forces.

Research on integral separation control of warp tension based on fuzzy parameter optimization

In textile machines, the stability of warp tension is one of the decisive factors for the reliability, stability and product quality of weaving process. In order to meet the improving requirement for weaving efficiency and fabric quality, it is proposed that a fuzzy optimization integral separation PID warp tension control scheme based on process sampling to improve the warp tension control level of loom. Aiming at the problems of time-varying, nonlinear and variable coupling in the warp tension control system of loom, the forming mechanism of warp tension is modeled and analyzed, and the sampling scheme of warp tension based on process is proposed. Based on the periodic change of warp tension at macro level and continuous fluctuation at micro level, the integral separation control and fuzzy optimization theory are introduced to optimize the control effect of the control system on the basis of classical PID control algorithm. Finally, the simulation and experiment show that the scheme can improve the tension controls performance and effectively reduce the tension error fluctuation.