Development of PLC-based Tension Control System

Fiber winding tension is an important factor in the molding techniques of composite material which influences the quality of winding product directly, and the tension control is a key technique in fiber winding techniques. This paper introduces a closed-loop tension control system with the programmable logic controller （PLC） with function modules as its control kernel, the alternating current （AC） servo motor as execute element and the radius-following device to accomplish the real-time radius compensation. The mechanism of the tension control system is analyzed and the numerical model is set up. The compensation technique of the radius of the scroll is analyzed. Experimental results show that the system is well qualified with high control precision and high reaction speed.

Design and Analysis of a Novel Tension Control Method for Winding Machine

Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of prod?uct quality and e ciency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three di erent driven rollers(the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time?varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels accord?ing to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and sta?bility of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under di erent reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.

Variable Tension Control for Discontinuous Tape Winding of Composites Based on Constant Extension Ratio

Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.

Precision Tension Control System Using Magnetic Particle Clutch

The control of the stability of the filament tension is one of the crucial techniques ensuring the component quality of the composite materials. The open-loop tension control system, with industrial control computer as the core, magnetic particle clutch as the actuator, equipped with compensation technique is researched and manufactured. It can assure the tension control stability of the yarn in filament winding process and increase the control precision of the whole system.

A compensating technique for precise tension control

The Paper presents the mathematical model which has been Proved to be right and tha compensating tech-nique for the Precise tension control system on a nuznerical controlled winding machine. Which has been proved to bereasonable and feasible to Pereisely coned the tension of fihannt.

A LOCAL CONTROLLER BASED CONSTANT TENSION CONTROL SYSTEM

This paper is mainly about a local controller whose main function is to achieve the constant tension of the thin denier filament in the high speed winding process. A mathematic model of the induction motor while controlling its stator frequency and voltage is given. A new kind of variable parameter, real time constant tension control system is presented. The paper uses the microprocessor -INTEL 8097 as the CPU of the local controller. A standard serial communication interface-RS232 is used to communicate with the main computer. Computer simulation and experiment test show that this system has good control characteristics.

Research on Anti-Fluctuation Control of Winding Tension System Based on Feedforward Compensation

In the fiber winding process,strong disturbance,uncertainty,strong coupling,and fiber friction complicate the winding constant tension control.In order to effectively reduce the influence of these problems on the tension output,this paper proposed a tension fluctuation rejection strategy based on feedforward compensation.In addition to the bias harmonic curve of the unknown state,the tension fluctuation also contains the influence of bounded noise.A tension fluctuation observer(TFO)is designed to cancel the uncertain periodic signal,in which the frequency generator is used to estimate the critical parameter information.Then,the fluctuation signal is reconstructed by a third-order auxiliary filter.The estimated signal feedforward compensates for the actual tension fluctuation.Furthermore,a time-varying parameters fractional-order PID controller(TPFOPID)is realized to attenuate the bounded noise in the fluctuation.Finally,TPFOPID is enhanced by TFO and applied to control a tension control system considering multi-source disturbances.The stability of the method is analyzed by using the Lyapunov theorem.Finally,numerical simulations verify that the proposed scheme improves the tracking ability and robustness of the system in response to tension fluctuations.

Modeling and Analysis of Interstand Tension Control in 6-high Tandem Cold Rolling Mill

The interstand tension control is one of the most important ways to meet tight tolerances for strip product quality during tandem cold rolling process. Using coordinate analysis and parabolic approximation for the mass flow balance principle, the strip velocities eliminating the use of forward slips and backward slips were calculated. In order to reduce the effect of roll eccentricity on the tension measurement, a filter based on bilinear transformation was de- signed. Applying a first-order Taylor series approximation, the transfer function matrix model of interstand tension stress was derived. The actual measurements on-site and the final calculation results showed that the established model had high calculation accuracy and was beneficial for interstand tension control of random cold rolling process.

ELECTRO-HYDRAULIC COMPOUND CONTROL METHOD AND CHARACTERISTIC OF CONTROL FOR TENSION SYSTEM WITH HIGH INERTIA LOADS

Based on the pressure regulation circuit adopting electro-hydraulic proportional relief valve to control tension, a new type of electro-hydraulic compound control circuit with throttle control unit is presented, which can obtain optimal dynamic damping ratio through real-time altering pressure-flow gain of the throttle control unit, improve the dynamic characteristic of tension follow-up control for the tension system with high inertia loads. Moreover, the characteristic when the cable linear velocity variation causes change of tension is investigated, and a compound control strategy is proposed. The theoretical analysis and experimental results show that the electro-hydraulic compound control circuit is effective and the characteristic of the compound control strategy is satisfactory.

H_∞ Control of Looper-Tension Control Systems Based on a Discrete-Time Model

High control performances cannot be obtained by most of the existing looper-tension control approaches through only considering controller designs based on continuous time models, which cannot meet the requirements of modern computer control systems with high control accuracy. In order to solve the above problems, a state feedback H∞ control method based on a discrete-time model for looper-tension control systems in hot rolling mills is presen- ted. The considered system is approximated by a discrete-time loope∞tension control system model. Based on a Lya- punov functional method, a state feedback H∞ control law is developed which makes the closed-loop system asymp totically stable with guaranteed H∞ performance. The controller gains are obtained by solving a set of linear matrix inequalities （LMIs）. In contrast to the existing results, the proposed approach can obtain good H∞ performance and effectively reduce external disturbances. The strip tension is also less affected by the change of looper angel, so good control performances can be obtained. Moreover, this control scheme is easy to implement, and can be applied to other linear systems. A simulation example with practical parameters is provided to illustrate the effectiveness of the developed method.

Evenness Control of Rapier Loom Tension by Using Neural Network

The neural network model (NNM) is used to control the evenness of rapier loom tension and to model the uncertain parameters of drafting process. This model can estimate recursively the tension and incorporate predictive control strategies. After controlling the effect testing,it can be seen that the behavior is excellent following different set point and variations, such as the diameter of the beam of weaver, air stream, density of warp and weft, type of textile, etc. An optimum steady state scheme has been fixed in keeping evenness of tension of loom. This method improves obviously the efficiency and quality of production.

A Study on a Wire Tension Adaptive Control System of a Multi-wire Saw in Computer Simulation

Based on the analysis of the mechanism of wire tension control by using torque motors in the multi-wire saw machining process, some mathematical models of a tension control system are studied, and an adaptive algo- rithm is designed for controlling the wire tension. In this algorithm of tension control, the rotation speeds and waving angle of motors are measured and fed back to the controller, and the NLMS（ normalized least mean squares） algorithm is used to calculate the adaptive correction value and control the wire tension accurately. The computer simulation results in Matlab software validate the high accuracy for controlling the system of the wire tension with the NLMS algorithm in the multi-wire saw machining process.

Compound control for speed and tension multivariable coupling system of reversible cold strip mill

To weaken the nonlinear coupling influence among the variables in the speed and tension system of reversible cold strip mill, a compound control(CC) strategy based on invariance principle was proposed. Firstly, invariance principle was used to realize static decoupling between the speed and tension of reversible cold strip mill. Then, considering the influence caused by the time variation of steel coil radius and rotational inertia of the left and right coilers, as well as the uncertainties, a CC strategy that is composed of extended state observer(ESO) and global sliding mode control(GSMC) with backstepping adaptive was proposed,which further realized dynamic decoupling and coordination control for the speed and tension system. Theoretical analysis shows that the resulting closed-loop system is global bounded stable. Finally, the simulation was carried out on the speed and tension system of a 1422 mm reversible cold strip mill by using the actual data, and through the comparison of the other control strategies, validity of the proposed CC strategy was shown by the results.

On the Mechanical Analysis and Control for the Tension System of the Cylindrical Filament Winding

The constant winding tension can make the filament arranged in order. The stress distribution between the filament balance fully gives play to the enhancement of filament, and increases the intensive workload of the composite winding material. This paper conducts the mechanical analysis for the unwinding roller and tension measuring roller of the cylindrical winding machine so that gets the mechanical model, gives error compensation formula caused by the radius change of the yarn group in the unwinding side, designs the closed-loop control system and utilizes the dynamical- integral PID control strategy to achieve the tension control during the process of the cylindrical winding.

安钢冷轧1550 mm连退炉内张力控制与分析

结合安钢冷轧连退机组实际工艺流程,以安钢冷轧1 550 mm连退机组退火炉为研究平台,分析与研究了其炉内带钢张力,这对于薄带钢高速运行低张控制优化具有一定指导意义,可实现冷轧连退薄带钢高效化生产。

往复式压缩机中间接筒与曲轴箱的连接螺栓断裂失效分析

针对某石化公司重整单元新氢往复压缩机2023年所发生的中间接筒与曲轴箱连接螺栓断裂问题,根据其外观形貌、螺栓材质、螺栓受力情况分析其可能的断裂原因,并从工艺操作、设备安装要求、螺栓紧固方式方面,提出解决方案,保障装置的安稳长满优运行。

基于PLCSIM Advanced和Simulink的自动化生产线仿真实训平台设计

为解决自动化生产线实训线下课程实验硬件套数不足、实验时长和场地受限等问题,提升教学质量,设计了一种基于PLCSIM Advanced和Simulink的自动化生产线仿真实训平台。该仿真平台以实训设备为依托,使用Simulink搭建被控对象仿真模型,在PLCSIM Advanced仿真控制器中编写控制算法,通过应用程序接口(application programming interface,API)通信实现对象模型与控制器间数据的实时交换和仿真。以纸张张力控制设备为例,介绍了仿真实训平台搭建和实施过程。实践教学表明,该仿真平台提高了自动化生产线实训课程的教学成效,激发了学生实践学习的兴趣,提升了学生发现、解决复杂工程问题的能力,让学生深刻体会到团队合作和有效沟通的重要性。

基于机器视觉的纱线非接触张力控制方法与试验验证

为避免传统接触式测量方法导致检测设备与纱线直接接触带来的摩擦损耗,提出了纱线张力非接触式测量方法,设计了基于机器视觉的纱线张力非接触测量系统。使用双目相机检测纱线末端的消耗速度,调控纱线另一端的主动式携纱器的收放速度,使纱线平稳运行,维持纱线张力稳定。研究表明,所设计基于机器视觉的纱线张力非接触式测量系统较常规接触式张力控制方法,控制纱线张力变化幅度降低到25%左右,具有较高的精度和可靠性,能实现三维编织纱线张力的主动控制,具有较强的应用潜力。

硅锭线切割张力控制方法对比研究

为满足低成本、低切损、高精度、高稳定性的硅片切割要求,在分析常用的两种线切割张力控制方法优缺点的基础上,采用ADAMS软件进行了弹簧式张力控制原理的建模与动力学仿真,并基于Simulink与MFAC控制算法对电控式张力控制进行了ADAMS与MATLAB动力学联合仿真。结果表明,两种张力控制方法所得到的电极丝加速度变化曲线走势一致,电控式张力控制在快速性及精确性方面优于弹簧式张力控制,但平稳性较差。进而,提出弹簧与电控相结合的张力控制方法,并在ADAMS中完成建模与动力学仿真。结果表明,该装置可在一定程度上取长补短。

钢混组合梁斜拉桥非对称张拉施工控制的拉索索力统计敏感性分析

针对非对称张拉施工斜拉桥存在的主梁和桥塔线形控制难题,以某大跨度钢混组合梁斜拉桥施工控制为例,开展了拉索索力统计敏感性分析研究。以斜拉索索力为设计参数,综合采用均匀试验和正交试验设计方法以及多元线性回归和极差分析显著性检验方法,对成桥和施工阶段主梁和桥塔截面的内力、位移进行统计敏感性分析。结果表明:提出的索力统计敏感性分析方法可准确获得成桥和施工阶段的敏感性索力参数;对于成桥阶段,S10、MS10、S9号斜拉索索力为结构线形的敏感性参数;非对称张拉施工时,S10、MS10、S9、MS9、S8、MS8、S5、MS5号斜拉索索力为影响主梁和塔顶截面位移的敏感性参数;若采用对称张拉施工,S10、MS10、S8、MS8、S9、MS9、S7、MS7号斜拉索索力则为影响主梁和塔顶截面位移的敏感性参数。