A tension control system
By using a touch screen display, FPGA chip, and multiple filtering algorithms in the tension control system, combined with components such as an electrical regulator, the problems of incomplete data display and limited MCU chip resources are solved, achieving precision and stability in tension control, and ensuring constant coil tension and product quality.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- TIMACO (BEIJING) IND TECH CO LTD
- Filing Date
- 2023-12-19
- Publication Date
- 2026-06-05
Smart Images

Figure CN117886149B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of tension control technology, specifically a tension control system. Background Technology
[0002] In common automated equipment fields (coating machines, die-cutting machines, slitting machines, roll-to-roll coating), take-up and unwinding control is one of the most important technologies. As the take-up shaft radius gradually increases and the unwinding shaft radius gradually decreases, tension changes occur. Increased tension leads to stretching and deformation of the roll material, even breakage; insufficient tension causes wrinkling. In vacuum roll-to-roll coating applications, tension fluctuations severely affect the uniformity of film thickness during the coating process. (Explosion-proof removal...)
[0003] Existing tension control systems have the following problems:
[0004] 1. The use of digital tube displays to show tension values results in incomplete data display;
[0005] 2. It uses an MCU chip for control, which has limited resources and cannot be modified later;
[0006] 3. It is impossible to automatically adjust the working parameters of the tension control system based on the characteristics and properties of the roll material. Summary of the Invention
[0007] The present invention provides a tension control system to solve any of the technical problems mentioned above.
[0008] To address the aforementioned technical problems, this invention discloses a tension control system, comprising a tension controller, a control device, and a winding device. The control device is electrically connected to the tension controller. The winding device includes a guide roller, a floating roller, a floating roller potentiometer, and a mounting roller. The mounting roller is used to mount the roll material and is driven by a motor through a reducer. The motor is connected to an encoder. The tension controller is electrically connected to the encoder, the floating roller potentiometer, the tension detector, and a display. The display includes a setting module and a display module. The tension detector is used to detect the tension of the roll material in the winding device.
[0009] Preferably, the setting module is used to set the tension and taper, and the display module is used to display the tension data, taper data, roll diameter data, and floating roller position data.
[0010] Preferably, the control chip is an FPGA chip.
[0011] Preferably, the control chip contains a control program, which includes multiple filtering algorithms, such as: amplitude limiting filtering, median filtering, arithmetic mean filtering, recursive mean filtering, median mean filtering, and amplitude limiting mean filtering.
[0012] Preferably, the control device includes an electrical regulator, a magnetic powder clutch, a magnetic powder brake, an AC servo amplifier, and a frequency converter. The electrical regulator includes a pneumatic clutch and a pneumatic brake, which are used to change the motor torque. The AC servo amplifier and the frequency converter are used to control the operating parameters of the motor.
[0013] Preferably, the winding device includes a traction roller, a guide roller, a floating roller, a cylinder, a floating roller potentiometer, a first gear, a second gear, and a mounting roller. The traction roller is used to drive the roll material to move, the guide roller is used to control the direction of movement of the roll material, the push rod of the cylinder is hinged to the middle of the swing arm, one end of the swing arm is connected to the floating roller, and the other end of the swing arm drives the first gear to rotate. The first gear meshes with the second gear, and the gear shaft of the second gear is connected to the floating roller potentiometer.
[0014] Preferred options also include:
[0015] The tension acquisition module is used to acquire the actual tension detection value of the tension detector;
[0016] The calculation module is used to calculate the target operating parameters of the motor required to meet the target tension value;
[0017] The output module is used to send control commands to the motor to adjust the actual operating parameters of the motor to the target operating parameters, including the motor speed.
[0018] The monitoring module is used to monitor the tension deviation, roll thickness deviation, and roll width deviation of the tension control system. When any of these deviations exceeds the allowable range, the winding device will be stopped and an alarm will be triggered.
[0019] Preferably, the module includes:
[0020] The data acquisition unit is used to acquire the characteristic properties of the roll material, including: standard thickness of the roll material, material of the roll material, and standard width of the roll material.
[0021] The parameter acquisition unit is used to acquire the actual operating parameters of the winding device, including the actual angular velocity of the traction roller and the actual angular velocity of the mounting roller.
[0022] The analysis unit is used to calculate the target operating parameters of the motor based on the characteristic properties of the roll material and the actual operating parameters of the winding device.
[0023] Preferably, the monitoring module includes:
[0024] The setting unit sets the target tension value based on the characteristics of the roll material;
[0025] The specification setting unit sets the allowable range of tension deviation, thickness deviation, and width deviation based on the characteristics of the roll material.
[0026] Image acquisition unit, used to acquire real-time images of the roll material;
[0027] A measuring unit is used to obtain the actual width and actual thickness of the roll material;
[0028] The comparison unit is used to calculate the difference between the actual tension detection value and the target tension value to obtain the tension deviation value, and to determine whether the tension deviation value is within the preset allowable range of the tension deviation value; to calculate the difference between the actual width of the roll and the standard width of the roll to obtain the roll width deviation value, and to determine whether the roll width deviation value is within the preset allowable range of the roll width deviation value; and to calculate the difference between the actual thickness of the roll and the standard thickness of the roll to obtain the roll thickness deviation value, and to determine whether the roll thickness deviation value is within the preset allowable range of the roll thickness deviation value.
[0029] If any of the tension deviation, roll thickness deviation, or roll width deviation exceeds the allowable range for the corresponding deviation, the alarm unit will stop the winding device and display the alarm information for the corresponding item.
[0030] Preferably, the analysis unit calculates the target motor speed based on Formula 1, which is:
[0031] ;
[0032] Where n is the target motor speed and k is the yield coefficient of the roll material; B represents the yield strength of the roll material; H represents the actual thickness of the roll material; and H represents the actual width of the roll material. The diameter of the traction roller; The angular velocity of the traction roller; To install the roller angular velocity; This refers to the maximum outer diameter of the roll material; Where is the drum diameter; g is the acceleration due to gravity, g = 9.8 N / kg; i is the reduction ratio of the reducer; P is the rated power of the motor. This refers to the output efficiency of the motor.
[0033] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments.
[0034] Compared with the prior art, the present invention has the following beneficial effects:
[0035] By adopting a full touchscreen, not only can numbers and letters be displayed, but also icons and Chinese characters, making information display more comprehensive. The use of virtual buttons on the full touchscreen to implement control functions solves the problem of limited button or knob control functions. The use of FAGA chips can add corresponding resources as needed, supporting rich peripheral interfaces and solving the problem of limited pin resources of MCU chips. By adding multiple filtering algorithms to the program, the application requirements of different data are solved. When connecting multiple different types of devices, the corresponding filtering algorithm can be switched for each different data. Attached Figure Description
[0036] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used in conjunction with embodiments of the invention to explain the invention and do not constitute a limitation thereof. In the drawings:
[0037] Figure 1 This is a connection block diagram of the tension control system of the present invention;
[0038] Figure 2 This is a schematic diagram of the winding device structure of the present invention;
[0039] In the diagram: 1. Traction roller; 2. Guide roller; 3. Floating roller; 4. Cylinder; 5. Potentiometer; 6. Mounting roller; 71. First gear; 72. Second gear. Detailed Implementation
[0040] The preferred embodiments of the present invention will be described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.
[0041] Furthermore, in this invention, the use of terms such as "first" and "second" is for descriptive purposes only and does not specifically refer to any order or sequence, nor is it intended to limit the invention. They are merely used to distinguish components or operations described using the same technical terms and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the technical solutions and features of the various embodiments can be combined with each other, but this must be based on the ability of those skilled in the art to implement them. If a combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.
[0042] The present invention provides the following embodiments.
[0043] Example 1
[0044] This invention provides a tension control system, characterized in that it includes a tension controller, a control device, and a winding device. The control device is electrically connected to the tension controller. The winding device includes a guide roller 2, a floating roller 3, a floating roller potentiometer 5, and a mounting roller 6. The mounting roller 6 is used to mount the roll material and is driven by a motor through a reducer. The motor is connected to an encoder. The tension controller is electrically connected to the encoder, the floating roller potentiometer 5, the tension detector, and a display. The display includes a setting module and a display module. The tension detector is used to detect the tension of the roll material in the winding device.
[0045] Preferably, the setting module is used to set the tension and taper, and the display module is used to display the tension data, taper data, roll diameter data, and floating roller position data.
[0046] In this embodiment, the control of gradually decreasing roll tension as the roll diameter increases in the winding system is called taper tension control. The taper data is the value at which the tension decreases for every certain increase in roll diameter.
[0047] The beneficial effects of the above technical solution are as follows:
[0048] By replacing the digital tube display with a touch screen, the problem of incomplete data display on the digital tube was solved. The touch screen can display not only numbers and letters, but also icons and Chinese characters, making the information display more comprehensive.
[0049] Example 2
[0050] Based on Example 1, the control chip adopts an FPGA chip.
[0051] The beneficial effects of the above technical solution are as follows:
[0052] By replacing MCU chips with FPGA chips, the problem of limited pin resources of MCU chips is solved. FPGA chips can add corresponding resources as needed and support rich peripheral interfaces. Resources can be configured later as needed, which improves the flexibility of tension controller configuration. Compared with MCU chips, FPGA chips have faster speed and higher bandwidth, which can meet the requirements of real-time processing and ensure the parallelism of tension controller processing requirements. Due to the support of more interfaces and protocols, the matching components that were originally terminated can be integrated into the device, reducing BOM costs.
[0053] Example 3
[0054] Based on Example 1 or 2, a control program is written into the control chip, and multiple filtering algorithms are added to the control program. The filtering algorithms include: amplitude limiting filtering method, median value filtering method, arithmetic mean filtering method, recursive average filtering method, median value average filtering method, and amplitude limiting average filtering method.
[0055] The beneficial effects of the above technical solution are as follows:
[0056] By setting up multiple filtering algorithms, the problem of some data failing to meet the processing requirements after the tension controller receives many different types of input signals is solved. Through multiple filtering algorithms, the system adapts to the changing rates and fluctuation ranges of various data. The corresponding filtering algorithm can be switched for different data types, enabling the tension controller to process multiple types of data simultaneously. This improves the control accuracy of the tension controller on input data and enhances the degree of tension control.
[0057] Example 4
[0058] Based on any one of Embodiments 1-3, the control device includes an electrical regulator, a magnetic powder clutch, a magnetic powder brake, an AC servo amplifier, and a frequency converter. The electrical regulator includes a pneumatic clutch and a pneumatic brake. The pneumatic clutch, pneumatic brake, magnetic powder clutch, and magnetic powder brake are used to change the motor torque. The AC servo amplifier and the frequency converter are used to control the operating parameters of the motor.
[0059] Preferably, the winding device includes a traction roller 1, a guide roller 2, a floating roller 3, a cylinder 4, a floating roller potentiometer 5, a first gear 71, a second gear 72, and a mounting roller 6. The traction roller 1 is used to drive the roll material to move, the guide roller 2 is used to control the direction of movement of the roll material, the push rod of the cylinder 4 is hinged to the middle of the swing arm 8, one end of the swing arm 8 is connected to the floating roller 3, and the other end of the swing arm drives the first gear 71 to rotate. The first gear 71 meshes with the second gear 72, and the gear shaft of the second gear 72 is connected to the floating roller potentiometer 5.
[0060] The beneficial effects of the above technical solution are as follows:
[0061] During the center winding process, as the roll diameter increases, the angular velocity gradually decreases while the linear velocity of the roll remains constant. Initially, the tension of the roll acting on the floating roller 3 is balanced by the weight of the floating roller 3 and the thrust of the cylinder 4. At this time, the floating roller 3 is in the middle equilibrium position. As the diameter of the roll increases, the floating roller 3 swings upward, driving the potentiometer to rotate, causing the feedback signal to deviate from the original equilibrium voltage value. By comparing this signal with the voltage signal at the given point, the deviation value is obtained. After calculation, the motor speed is adjusted to reduce the motor speed, so that the tension value of the roll returns to the given value. At this time, the floating roller 3 will return to the original equilibrium position. Throughout the winding process, as the diameter of the roll changes, the motor speed is continuously adjusted to keep the tension of the roll constant.
[0062] Example 5
[0063] In addition to any one of Examples 1-4, it also includes:
[0064] The tension acquisition module is used to acquire the actual tension detection value of the tension detector;
[0065] The calculation module is used to calculate the target operating parameters of the motor required to meet the target tension value;
[0066] The output module is used to send control commands to the motor to adjust the actual operating parameters of the motor to the target operating parameters, including the motor speed.
[0067] The monitoring module is used to monitor the tension deviation, roll thickness deviation, and roll width deviation of the tension control system. When any of these deviations exceeds the allowable range, the winding device will be stopped and an alarm will be triggered.
[0068] Preferably, the calculation module includes:
[0069] The data acquisition unit is used to acquire the characteristic properties of the roll material, including: standard thickness of the roll material, material of the roll material, and standard width of the roll material.
[0070] The parameter acquisition unit is used to acquire the actual operating parameters of the winding device, including the actual angular velocity of the traction roller and the actual angular velocity of the mounting roller.
[0071] The analysis unit is used to calculate the target operating parameters of the motor based on the characteristic properties of the roll material and the actual operating parameters of the winding device.
[0072] Preferably, the monitoring module includes:
[0073] The setting unit sets the target tension value based on the characteristics of the roll material;
[0074] The specification setting unit sets the allowable range of tension deviation, thickness deviation, and width deviation based on the characteristics of the roll material.
[0075] Image acquisition unit, used to acquire real-time images of the roll material;
[0076] A measuring unit is used to obtain the actual width and actual thickness of the roll material;
[0077] The comparison unit is used to calculate the difference between the actual tension detection value and the target tension value to obtain the tension deviation value, and to determine whether the tension deviation value is within the preset allowable range of the tension deviation value; to calculate the difference between the actual width of the roll and the standard width of the roll to obtain the roll width deviation value, and to determine whether the roll width deviation value is within the preset allowable range of the roll width deviation value; and to calculate the difference between the actual thickness of the roll and the standard thickness of the roll to obtain the roll thickness deviation value, and to determine whether the roll thickness deviation value is within the preset allowable range of the roll thickness deviation value.
[0078] If any of the tension deviation, roll thickness deviation, or roll width deviation exceeds the allowable range for the corresponding deviation, the alarm unit will stop the winding device and display the alarm information for the corresponding item.
[0079] Preferably, the analysis unit calculates the target motor speed based on Formula 1, which is:
[0080] ;
[0081] Where n is the target motor speed, and k is the yield coefficient of the roll material (with a value greater than 0 and less than 1); B represents the yield strength of the roll material; H represents the actual thickness of the roll material; and H represents the actual width of the roll material. The diameter of the traction roller; The angular velocity of the traction roller; To install the roller angular velocity; This refers to the maximum outer diameter of the roll material; Where is the drum diameter; g is the acceleration due to gravity, g = 9.8 N / kg; i is the reduction ratio of the reducer; P is the rated power of the motor. This refers to the output efficiency of the motor.
[0082] In this embodiment, the yield coefficient of the roll material is determined based on the actual thickness of the roll material.
[0083] In this embodiment, the maximum outer diameter of the roll material is the preset diameter value after the roll material is wound.
[0084] In this embodiment, the diameter of the roll is the diameter of the roll inside the roll when the roll is not wound with the roll material.
[0085] The beneficial effects of the above technical solution are as follows:
[0086] By periodically acquiring the characteristic properties of the roll material and the actual operating parameters of the winding device, the motor speed required to maintain constant roll tension is quickly calculated. Control commands are then transmitted to the motor via the output module, allowing the motor to adjust its speed promptly, thus ensuring constant roll tension and preventing quality issues caused by tension fluctuations. The monitoring module monitors deviations in the tension control system and issues alarm commands for items exceeding the deviation range, shortening incident handling time and ensuring the efficiency of the tension control system. Monitoring the tension value separately ensures stable operation of the tension control system. Monitoring the thickness and width of the roll material ensures stable product quality. This guarantees product specification stability and allows for timely readjustment of the target tension value when changes in roll thickness and width occur. If deviations exceed the predetermined range, the machine is stopped immediately to avoid further economic losses and prevent dangerous equipment damage and personnel injury from continued operation.
[0087] By considering the material of the roll, its inner diameter, maximum outer diameter, and real-time roll diameter, the tension value for each time period is corrected to ensure that the tension received during the roll winding process remains constant. Taking into account energy transfer losses and transmission ratio, the required speed of the motor for each time period is obtained. The real-time roll diameter is confirmed by using the known angular velocity and diameter of the direct traction roller, ensuring the accuracy of the real-time roll diameter. This improves the accuracy of the calculated speed, reduces the fluctuation of tension on the roll, and ensures the stable quality of the finished roll.
[0088] Example 6
[0089] Based on Embodiment 5, the floating roller is provided with several force measuring areas on its outer side, each force measuring area is provided with a force measuring layer, and each force measuring layer is provided with several force sensors; it also includes:
[0090] The first calculation unit is used to calculate the first tension;
[0091] ;
[0092] The first tension is E, the elastic modulus of the roll material is E, and the actual thickness of the roll material is B. This represents the maximum allowable deformation of the roll material. The speed non-uniformity coefficient of the motor (with a value greater than 0 and less than 1); This refers to the rated speed of the motor; The coefficient of friction between the roll material and the guide roller; This is the adjustment coefficient (with a value greater than 0 and less than 1); Where is the output efficiency of the motor; S is the contact area between the floating roller and the roll material; n is the target motor speed; The preset speed tension adjustment coefficient (with a value greater than 0 and less than 1);
[0093] The second calculation unit controls the winding device to operate for a certain period of time based on the first tension and the target motor speed, wherein the force sensor detects Z times; and the second calculation unit obtains the force state value of the floating roller based on the force sensor detection value.
[0094] ;
[0095] ;
[0096] R represents the force state value of the floating roller detected by the force sensor in the vth time, and R represents the comprehensive force state value of the floating roller. The vth test detects the actual value of the bth force sensor; G is the total number of force sensors. This represents the actual detection value of the b-th force sensor in the (v-1)th detection. , , These are the first evaluation coefficient (set based on the influence of uniform force during the same test) and the second evaluation coefficient (based on...). The ratio setting), and the third evaluation coefficient (set according to the influence of the change in the force sensor between the two detections);
[0097] when If the value is greater than the corresponding first preset value and / or R is greater than the corresponding second preset value, an early warning will be issued to remind maintenance.
[0098] when If R is less than or equal to the corresponding first preset value and R is less than or equal to the corresponding second preset value, the winding device is operated with the first tension as the target tension.
[0099] The beneficial effects of the above technical solution are as follows:
[0100] 1. Based on the characteristic properties of the roll material and the actual working parameters of the winding device, determine the motor speed (target motor speed) required to maintain constant roll material tension. At the same time, based on the target motor speed and the parameters of the roll material, obtain the first tension that matches the properties of the roll material itself.
[0101] The tension controller controls the winding device to operate for a certain period of time based on the first tension and the target motor speed, during which the force sensor detects Z times; and the second calculation unit obtains the force state value of the floating roller based on the force sensor detection value, thereby determining whether the set first tension and target motor speed are appropriate according to the actual force state of the floating roller, ensuring reliable tension control of the roll material.
[0102] Obviously, those skilled in the art can make various modifications and variations to this invention without departing from its spirit and scope. Therefore, if these modifications and variations fall within the scope of the claims of this invention and their equivalents, this invention also intends to include these modifications and variations.
Claims
1. A tension control system, characterized in that: The device includes a tension controller, a control device, and a winding device. The control device is electrically connected to the tension controller. The winding device includes a guide roller (2), a floating roller (3), a floating roller potentiometer (5), and a mounting roller (6). The mounting roller (6) is used to mount the roll material. The mounting roller (6) is driven by a motor through a reducer. The motor is connected to an encoder. The tension controller is electrically connected to the encoder, the floating roller potentiometer (5), the tension detector, and the display. The display includes a setting module and a display module. The tension detector is used to detect the tension of the roll material in the winding device. The winding device includes a traction roller (1), a guide roller (2), a floating roller (3), a cylinder (4), a floating roller potentiometer (5), a first gear (71), a second gear (72), and a mounting roller (6). The traction roller (1) is used to drive the roll material to move, the guide roller (2) is used to control the direction of movement of the roll material, the push rod of the cylinder (4) is hinged to the middle of the swing arm (8), one end of the swing arm (8) is connected to the floating roller (3), and the other end of the swing arm drives the first gear (71) to rotate. The first gear (71) meshes with the second gear (72), and the gear shaft of the second gear (72) is connected to the floating roller potentiometer (5). Also includes: The tension acquisition module is used to acquire the actual tension detection value of the tension detector; The calculation module is used to calculate the target operating parameters of the motor required to meet the target tension value; The output module is used to send control commands to the motor to adjust the actual operating parameters of the motor to the target operating parameters, including the motor speed. The monitoring module is used to monitor the tension deviation, roll thickness deviation, and roll width deviation of the tension control system. When any of these deviations exceeds the allowable range, the winding device will be stopped and an alarm will be triggered. The calculation module includes: The data acquisition unit is used to acquire the characteristic properties of the roll material, including: standard thickness of the roll material, material of the roll material, and standard width of the roll material. The parameter acquisition unit is used to acquire the actual working parameters of the winding device, including the actual angular velocity of the traction roller (1) and the actual angular velocity of the mounting roller (6). The analysis unit is used to calculate the target operating parameters of the motor based on the characteristic properties of the roll material and the actual operating parameters of the winding device; The monitoring module includes: The setting unit sets the target tension value based on the characteristics of the roll material; The specification setting unit sets the allowable range of tension deviation, thickness deviation, and width deviation based on the characteristics of the roll material. Image acquisition unit, used to acquire real-time images of the roll material; A measuring unit is used to obtain the actual width and actual thickness of the roll material; The comparison unit is used to calculate the difference between the actual tension detection value and the target tension value to obtain the tension deviation value, and to determine whether the tension deviation value is within the preset allowable range of the tension deviation value; to calculate the difference between the actual width of the roll and the standard width of the roll to obtain the roll width deviation value, and to determine whether the roll width deviation value is within the preset allowable range of the roll width deviation value; and to calculate the difference between the actual thickness of the roll and the standard thickness of the roll to obtain the roll thickness deviation value, and to determine whether the roll thickness deviation value is within the preset allowable range of the roll thickness deviation value. If any of the tension deviation, roll thickness deviation, or roll width deviation exceeds the allowable range for the corresponding deviation, the alarm unit will stop the winding device and display the alarm information for the corresponding item. The analysis unit calculates the target motor speed based on Formula 1, which is: ; Where n is the target motor speed and k is the yield coefficient of the roll material; B represents the yield strength of the roll material; H represents the actual thickness of the roll material; and H represents the actual width of the roll material. The diameter of the traction roller; The angular velocity of the traction roller; To install the roller angular velocity; This refers to the maximum outer diameter of the roll material; Where is the drum diameter; g is the acceleration due to gravity, g = 9.8 N / kg; i is the reduction ratio of the reducer; P is the rated power of the motor. This refers to the output efficiency of the motor.
2. The tension control system according to claim 1, characterized in that: The setting module is used to set tension and taper, while the display module is used to display tension data, taper data, roll diameter data, and floating roller position data.
3. A tension control system according to claim 1, characterized in that: The control chip uses an FPGA chip.
4. A tension control system according to claim 3, characterized in that: The control chip contains a control program with multiple filtering algorithms, including: amplitude limiting filtering, median filtering, arithmetic mean filtering, recursive mean filtering, median mean filtering, and amplitude limiting mean filtering.
5. A tension control system according to claim 1, characterized in that: The control device includes an electrical regulator, a magnetic powder clutch, a magnetic powder brake, an AC servo amplifier, and a frequency converter. The electrical regulator includes a pneumatic clutch and a pneumatic brake, which are used to change the motor torque. The AC servo amplifier and the frequency converter are used to control the operating parameters of the motor.