多股簧绕制成型过程中时变非线性张力控制建模及仿真

Research on Time-varying and Nonlinear Tension Control Model in the Winding Process of SWHS and Simulation

针对当前多股簧数控加工机床存在的钢丝张力一致性不佳、张力控制系统调试效率低的问题,研究了张力产生机理,建立了时变非线性动力学模型。以3股钢丝的多股簧为例研究了钢丝间张力互相作用机制,并基于Matlab/Simulink搭建张力控制系统仿真平台,探索了某一通道阻尼突增对所有钢丝张力一致性的影响。仿真结果表明,钢丝张力突增使得钢索成型点后移,各钢丝捻角变大,进而导致放卷速度、牵引速度及张力产生波动。通过不同预设张力值下控制系统的仿真偏差与试验偏差曲线的对比,验证了仿真模型的有效性。仿真系统具有与实际张力控制系统相匹配的响应特性,仿真结果重现了多股簧实际加工过程中存在的一些现象及问题,对实际加工过程中张力控制系统参数的调整具有指导意义。

Aiming on improving the tension consistency of wires and the debugging efficiency of tension control system, a dynamic model that describe the mechanism of tension generation is established to research the characteristics of time-varying and nonlinear system. Taking 3 wires stranded-wire helical spring (SWHS) as an example, the mechanism of tension interaction between wires is deduced. And a simulation model based on Matlab/Simulink platform is constructed to study the effect of sudden increase in resistance of a channel on tension consistency, accordingly. Sudden increase in tension causes the forming point of rope to move backward, which results in the increase of twist angle and the fluctuation of rolling speed and pulling speed. The effectiveness of the simulation model is verified by comparing the simulation deviation of the control system with the experimental deviation curve under different preset tension values. The response characteristics of simulation system is adapting to the actual system, and the result is a good way to reproduce some phenomena existing in the actual machining process, which is instructive to adjust the parameters of the tension control system.