Tension compound control system of high-speed carbon fiber winding device

Abstract

The invention provides a tension compound control system of a high-speed carbon fiber winding device, and the system comprises a tension measurement unit which is used for measuring the real-time tension of a carbon fiber connected between a pay-off roller and a winding roller of the high-speed carbon fiber winding device; the deflection angle measuring unit is used for measuring the real-time deflection angle and position of the carbon fiber when the carbon fiber is wound on the winding roller; and the control unit is used for adjusting the rotating speed of the winding roller and / or the pay-off roller through nonlinear feedback control based on the deviation between the real-time tension and the target tension when the carbon fiber is wound around the edge area of the winding roller, and adjusting the rotating speed of the pay-off roller through nonlinear feedback control when the carbon fiber is wound around the edge area of the winding roller. The length change condition of the carbon fibers connected between the pay-off roller and the winding roller is predicted through the real-time deflection angle, and the rotating speed of the winding roller and / or the pay-off roller is adjusted based on the prediction result. According to the tension compound control system provided by the invention, a targeted rotating speed control strategy can be provided according to different tension fluctuation conditions in a carbon fiber high-speed winding process.

Description

Technical Field

[0001] The present application belongs to the field of intelligent control technology for carbon fiber manufacturing, and specifically provides a tension composite control system for a high-speed carbon fiber winding device. Background Art

[0002] In the carbon fiber production and manufacturing process, it is usually necessary to perform pay-off and winding operations on different rollers. In order to improve production efficiency, the carbon fiber tow may have to run at a line speed of 100 to 150 m / min. If the tension in the winding process cannot be well controlled, it will have an adverse effect on the quality of the final product. Therefore, in order to ensure the uniformity of tension in the winding, laying and other processes (generally, the fluctuation is required to be controlled within ±2%), a fast-response, highly robust tension control system is required to control the high-speed winding process.

[0003] However, under high-speed operating conditions, the tension control system faces a complex disturbance environment, including nonlinear friction, variable load impact, structural return error, and dynamic changes in the winding diameter. When these factors combine, the tension fluctuation amplitude can reach 15% to 20% of the rated value, seriously affecting the consistency and reliability of the finished product.

[0004] The currently widely used proportional-integral-derivative (PID) controller has a simple structure and is easy to implement, offering good performance in static or medium- and low-speed scenarios. However, its linear nature limits its adaptability to nonlinear, strong coupling, and dynamic disturbances. When yarn speed fluctuates dramatically or the winding diameter changes significantly, PID control often suffers from large overshoot, slow response, and adjustment lag, failing to meet the dual requirements of precision and stability for high-speed intelligent manufacturing. Alternatively, there are solutions that utilize deep learning network optimization control strategies. For example, Chinese invention patent CN117775886A provides a high-performance tension control system using fuzzy PID control using a BP neural network based on a dung beetle optimization algorithm. However, a single control strategy struggles to effectively address tension instability caused by multiple factors. Summary of the Invention

[0005] In order to solve the problems existing in the above-mentioned prior art, the present application provides a tension composite control system for a high-speed carbon fiber winding device through an embodiment, wherein the high-speed carbon fiber winding device includes a pay-off roller and its driving motor, a winding roller and its driving motor, and a wire arrangement unit. The pay-off roller and the winding roller rotate around the axis at high speed under the drive of their respective driving motors, so that the carbon fiber is released from the pay-off roller and wound around the winding roller, and the wire arrangement unit is used to adjust the deflection angle of the carbon fiber when it is wound around the winding roller.

[0006] The tension compound control system includes: A tension measuring unit, used to measure the real-time tension of the carbon fiber connected between the pay-off roller and the winding roller; A deflection angle measuring unit, used to measure the real-time deflection angle and position of the carbon fiber when it is wound on the winding roller; A control unit adjusts the rotational speed of the winding roller and / or the pay-off roller through nonlinear feedback control based on the deviation between the real-time tension and the target tension when the carbon fiber is wound around an area other than the edge area of the winding roller; and, when the carbon fiber is wound around the edge area of the winding roller, predicts the change in the length of the carbon fiber connected between the pay-off roller and the winding roller through the real-time deflection angle, and adjusts the rotational speed of the winding roller and / or the pay-off roller based on the prediction result.

[0007] The tension composite control system of the high-speed carbon fiber winding device provided in the present application adjusts the speed control strategy in a targeted manner according to the different tension fluctuation patterns and intensities in the middle area and the edge area during the high-speed winding of carbon fiber. Specifically, in the middle area, various randomly generated tension fluctuations are accurately and timely suppressed through nonlinear feedback control. In the edge area, based on the obtained carbon fiber winding position deviation angle, the appropriate speed adjustment amount is selected through the prediction results of the tension fluctuation situation, thereby effectively suppressing the regular tension fluctuations of the carbon fiber when it is wound in the edge area. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 A schematic diagram of the structure of a high-speed carbon fiber winding device from one perspective; Figure 2 This is a schematic diagram of the structure of the high-speed carbon fiber winding device from another perspective; Figure 3 Schematic diagram of the structure of a tension composite control system for a high-speed carbon fiber winding device provided according to an embodiment of the present application; Figure 4 This is a schematic diagram of the layout of the tension compound control system; Figure 5 is a flow chart of controlling the rotation speeds of the pay-off roller and the winding roller by the control unit in some embodiments; Figure 6 is a schematic diagram of the position change of carbon fibers wound in the edge region in some embodiments; Figure 7 is a schematic diagram of tension fluctuations of carbon fibers wound in edge regions in some embodiments; Figure 8 Schematic diagram of the position change of carbon fibers wound in the edge area in other embodiments; Figure 9 Schematic diagram of tension fluctuations of carbon fibers wound in edge regions in other embodiments; Figure 10 is a schematic structural diagram of a first control module in some embodiments; Figure 11 Schematic diagram of real-time changes in the tension of a carbon fiber bundle in a specific embodiment of the present application.

[0009] Numbers in the figure Pay-off roller 1, first motor 11, winding roller 2, second motor 21, winding roller axis 22, polished rod 31, bidirectional screw 32, guide hole module 33, third motor 34, tension measuring unit 4, deflection measuring unit 5, control unit 6. DETAILED DESCRIPTION

[0010] Hereinafter, the present application will be further described based on preferred embodiments with reference to the accompanying drawings.

[0011] In the description of the embodiments of the present application, it should be noted that if the terms "upper", "lower", "inside", "outside" and the like indicate an orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or are the orientation or positional relationship in which the products of the embodiments of the present application are usually placed when in use, they are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present application. In addition, in the description of the present application, in order to distinguish different units, words such as first and second are used in this specification, but these are not limited by the order of manufacture, nor can they be understood as indicating or implying relative importance. Their names may be different in the detailed description and claims of the present application. In addition, for ease of understanding, various components on the drawings are enlarged or reduced, but this practice is not intended to limit the scope of protection of the present application.

[0012] The vocabulary in this specification is used to illustrate the embodiments of the present application, but is not intended to limit the present application. It should also be noted that, unless otherwise clearly specified and limited, the terms "disposed", "connected", and "connected" should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection, a direct connection, an indirect connection through an intermediate medium, or a communication between the two components. For those skilled in the art, the specific meanings of the above terms in this application can be specifically understood.

[0013] <Structure of high-speed carbon fiber winding device> Figure 1 and Figure 2The side view and top view of a high-speed carbon fiber winding device are shown. As shown in the figure, the device includes a pay-off roller 1, a winding roller 2, a first motor 11, a second motor 21 and a wire arrangement unit. Among them, the first motor 11 is used to drive the pay-off roller 1 to rotate around its rotation axis to The second motor 21 is used to drive the winding roller 2 to rotate around its rotation axis (i.e. Figure 2 The winding roller axis 22) The angular velocity (or rotational speed) of the pay-off roller 1 is high-speed, so that the carbon fiber released from the pay-off roller 1 is wound on it; the wire arrangement unit arranged between the pay-off roller 1 and the winding roller 2 is used to guide the transmission direction of the carbon fiber, so that the carbon fiber is wound on the winding roller 2 according to the desired wire arrangement method.

[0014] The implementation methods of the above-mentioned parts are already known to those skilled in the art. For example, according to the winding speed index, suitable servo motors can be selected as the first motor 11 and the second motor 21. By applying PWM control signals to the control ends of the first motor 11 and the second motor 21 respectively, they can be driven to drive the pay-off roller 1 and the winding roller 2 to rotate at high speed according to the set speed.

[0015] For another example, a structure known to those skilled in the art, namely, a polished rod 31 + a bidirectional screw 32 + a guide hole module 33, can be used to form a wire arrangement unit. The bidirectional screw 32 and the polished rod 31 are arranged parallel to the rotation axis of the winding roller 2. One end of the guide hole module 33 has a bidirectional threaded hole for the bidirectional screw 32 to pass through, and the other end has a hole for the polished rod 31 to pass through. The center of the guide hole module 33 has a through hole for the carbon fiber to pass through. The two ends of the bidirectional screw 32 are aligned with the two ends of the winding position of the carbon fiber on the winding roller 2. During the high-speed winding process, the bidirectional screw 32 can be driven to rotate at a constant speed by a drive motor (such as a third servo motor 34). The guide hole module 33 will move back and forth along the axial direction of the bidirectional screw and the polished rod, thereby allowing the carbon fiber to be wound back and forth along the axial direction at a uniform arrangement speed on the winding roller 2.

[0016] It should be noted that what is described above is only an optional implementation of the high-speed carbon fiber winding device. Without departing from the above concept, those skilled in the art can reasonably select the type and model of the drive motor and adapt the structure or form of the wiring unit according to the specifications of the pay-off roller and the winding roller, as well as the carbon fiber tow size, winding speed and other indicators.

[0017] <Overall Architecture of Tension Composite Control System> for Figure 1 、 Figure 2The device shown needs to control the speed difference between the pay-off roller and the winding roller through a tension control system so that the carbon fiber between the winding roller and the pay-off roller is maintained at the desired tension when running at high speed and is evenly wound on the winding roller according to the preset arrangement.

[0018] To achieve the above objectives, the present application provides a tension composite control system for a high-speed carbon fiber winding device, which includes a tension measuring unit 4, a deflection measuring unit 5, and a control unit 6. The tension measuring unit 4 is used to measure the real-time tension of the carbon fiber connected between the pay-off roller 1 and the winding roller 2; the deflection measuring unit 5 is used to measure the real-time deflection of the carbon fiber when it is wound on the winding roller 2; and the control unit 6 is used to adjust the rotation speed of the winding roller 2 and / or the pay-off roller 1 in real time.

[0019] In an embodiment of the present application, when the carbon fiber is wound around an area other than the edge area of the winding roller 2, the control unit 6 adjusts the rotational speed of the winding roller 2 and / or the pay-off roller 1 by nonlinear feedback control based on the deviation between the real-time tension obtained by the tension measuring unit 4 and the preset target tension; when the carbon fiber is wound around the edge area of the winding roller 2, the real-time deflection angle measured by the deflection measuring unit is used to predict the length change of the carbon fiber connected between the pay-off roller 1 and the winding roller 2, and the rotational speed of the winding roller 2 and / or the pay-off roller 1 is adjusted based on the prediction result.

[0020] Figure 3 FIG. 1 shows an architecture diagram of the tension compound control system in some embodiments. Figure 4 For the tension composite control system Figure 1 The following is a detailed description of the specific implementation of each part of the tension composite control system in conjunction with the accompanying drawings.

[0021] refer to Figure 3 and Figure 4 The tension measuring unit 4 is arranged between the pay-off roller 1 and the winding roller 2, and is used to measure the real-time tension of the carbon fiber between the pay-off roller 1 and the winding roller 2. In some optional embodiments, a tension sensor such as WFGL-3 can be selected, and the measured real-time tension data can be transmitted to the control unit 6 via wired or wireless communication.

[0022] The deflection angle measuring unit 5 is also arranged between the pay-off roller 1 and the winding roller 2. Preferably, it is arranged close to the winding roller 2 to obtain the real-time deflection angle of the carbon fiber when it is wound on the winding roller 2. Figure 2As shown, the purpose of providing the wire arrangement unit is to guide the carbon fiber to be wound onto the winding roller 2 in a direction perpendicular to the winding roller axis 22 through its guiding function. However, in the actual winding process, due to various factors, the carbon fiber often deviates from the ideal direction during the winding process (in the embodiment of the present application, the angular deviation between the direction of the wire bundle when the carbon fiber is wound onto the winding roller 2 and the perpendicular direction of the winding roller axis 22 is called the deflection angle).

[0023] In some optional embodiments, the deflection angle measurement unit 5 can be constructed by a high-definition imaging device and an image recognition module. For example, an industrial-grade high-definition CCD, CIS or other imaging device is used and placed above the winding roller 2 to obtain a dynamic image of the winding in real time. The image recognition module is pre-installed with a dynamic target recognition algorithm to perform image segmentation and dynamic target extraction from the dynamic image obtained by the high-definition imaging device, thereby obtaining the real-time deflection angle of the carbon fiber bundle. The above-mentioned real-time deflection angle information is also transmitted to the control unit in a wired or wireless manner. In addition, in addition to obtaining the real-time deflection angle information of the carbon fiber bundle through the target recognition algorithm, the deflection angle measurement unit 5 can also determine the specific position information of the carbon fiber wound on the winding roller 2 and also transmit it to the control unit 6.

[0024] The control unit 6 includes a target tension determination module, a first control module, a second control module and a switching module. Figure 5 FIG. 4 shows a flow chart of how the control unit 6 controls the rotation speeds of the pay-off roller 1 and the winding roller 2 in some optional embodiments. Figures 3 to 5 As shown, the control unit 6 receives the real-time tension of the carbon fiber obtained by the tension measuring unit 4, and the deflection angle and position information of the carbon fiber when it is wound onto the winding roller 2 obtained by the deflection measuring unit 5, wherein the position information is transmitted to the switching module, and the switching module determines whether the carbon fiber has been wound onto the edge area of the winding roller 2. If the judgment result is no, the first control module is used to adjust the rotation speed of the winding roller 2 and / or the pay-off roller 1 in real time in combination with the target tension generated by the target tension determination module. If the judgment result is no, the second control module is used to adjust the rotation speed of the winding roller 2 and / or the pay-off roller 1 in real time.

[0025] Specifically, when the position of the carbon fiber on the winding roller 2 is in the non-edge area, the first control module simultaneously obtains the real-time tension of the carbon fiber obtained by the tension measuring unit 4 and the target tension generated by the target tension determination module, and outputs the real-time adjustment amount of the rotation speed of the winding roller 2 and / or the pay-off roller 1 through nonlinear feedback control; when the position of the carbon fiber on the winding roller 2 is in the edge area, the second control module predicts the length change of the carbon fiber connected between the pay-off roller 1 and the winding roller 2 after obtaining the real-time deflection angle, and outputs the real-time adjustment amount of the rotation speed of the winding roller 2 and / or the pay-off roller 1 according to the prediction result.

[0026] It can be seen that in the embodiment of the present application, different control strategies are adopted for different winding positions of the carbon fiber on the winding roller 2. The specific reasons are analyzed as follows: During the carbon fiber winding process, there are many factors that cause tension fluctuations, and the degree and mode of influence of different factors show different characteristics. For example, when the carbon fiber bundle is wound to the middle area of the winding roller 2, the sudden change in tension is generally due to the instantaneous speed change of the motor, uneven control pulses, differences in the assembly of mechanical structures such as bearings, and friction. The appearance of the above factors is often random, causing the tension curve to show random jitter. For this random jitter phenomenon, the more suitable control method is the closed-loop feedback control method to suppress the tension changes caused by various random factors.

[0027] In contrast, when the carbon fiber bundle is wound to the edge of the winding roller 2, the main factor affecting the carbon fiber tension becomes the expansion and contraction of the carbon fiber length caused by the mismatch between the rotation speed of the cable arrangement unit and the winding roller 2. Figure 6 The carbon fiber is shown wrapped around the edge area. Because the guide hole module (not shown) of the left wiring unit enters the edge area before the carbon fiber bundle, the carbon fiber bundle has a deflection angle. Furthermore, the guide hole module will reach the end of the bidirectional screw before the carbon fiber bundle and thus move in the opposite direction (at time t1). For a period of time after time t1, the movement direction of the guide hole module is opposite to the arrangement direction of the carbon fiber, and the distance between the guide hole module and the winding position of the carbon fiber continues to shorten. The carbon fiber wound between the pay-off roller 1 and the winding roller 2 will experience obvious relaxation, resulting in a significant decrease in real-time tension. Until time t2, the line connecting the guide hole module and the winding position of the carbon fiber is perpendicular to the axial direction of the winding roller 2, and the tension drop reaches the maximum. After time t2, the distance between the two increases again, reducing the relaxation phenomenon, and the tension continues to increase until time t3 when the carbon fiber is wound to the end of the winding roller 2, and the tension returns to a level similar to that at time t1. Thereafter, the movement direction of the guide hole module and the arrangement direction of the carbon fiber become the same again, and the tension will be maintained at the same level when the speeds of the two remain unchanged. Figure 7 Shown in Figure 6 At different moments in the process, the real-time tension changes are Figure 6 、 Figure 7 It can be found that the tension drop-rise phenomenon occurs before the carbon fiber arrangement direction turns back.

[0028] Figure 8 The figure shows another change in the motion state of the carbon fiber when it is wound to the edge area of the winding roller 2, wherein the winding position of the carbon fiber enters the edge area before the guide hole module and turns back in the wiring direction before the guide hole module. Figure 9 Shown in Figure 8 The real-time tension changes at different moments in the process. Obviously, in this case, the tension maintain-drop-rise-maintain phenomenon will also occur, and the tension drop-rise process occurs after the carbon fiber wiring direction turns back.

[0029] In the embodiments of the present application, Figure 6 、 Figure 7 The tension fluctuation mode shown is called the first fluctuation mode. Figure 8 、 Figure 9 The tension fluctuation pattern shown is called the second fluctuation pattern. From the above analysis, it can be seen that the tension fluctuations that occur when the two types of carbon fibers are wound to the edge area of the winding roller 2 are different from the randomly generated tension fluctuations, and have obvious regularity: the greater the real-time deflection angle when the carbon fiber is wound to enter the edge area, the more drastic the change in tension decrease-increase, and vice versa.

[0030] For such intense and regular tension fluctuations, adopting various closed-loop feedback adjustment methods may result in continuous overshoot of the feedback adjustment amount, causing the tension to oscillate back and forth, thereby affecting the winding effect of the carbon fiber at the edge of the winding roller.

[0031] Based on the above analysis, in the embodiment of the present application, different control strategies are adopted in different areas of the carbon fiber winding to the winding roller 2 to reasonably suppress the tension fluctuations at different positions, so that the carbon fiber winding effect reaches the global optimum.

[0032] The preferred implementations of the first control module and the second control module are described below respectively.

[0033] <First Control Module> In the present application, the first control module adopts a nonlinear feedback control method to control the rotation speed of the winding roller and / or the pay-off roller based on the deviation between the real-time tension obtained by the tension measurement unit and the target tension output by the target tension determination module. Preferably, the target tension can change with the change of the winding diameter of the carbon fiber wound on the winding roller, and its expression is shown in the following formula: (1), in, is the real-time winding diameter of the winding roller when winding carbon fiber. This value can be estimated by the number of reciprocating lines of carbon fiber wound on the winding roller and the parameters such as the diameter of the carbon fiber bundle (obviously, is a time-varying variable amount of change), is the target tension, is the initial value of the target tension, is the core diameter of the winding roller, is the maximum winding diameter of the winding roller when winding carbon fiber. This formula includes three target tension adjustment items, among which, is the main variable diameter term in the form of an exponential function, reflecting the degree of tension reduction as the roll diameter increases, where 、 are the adjustment coefficient and index adjustment factor of the item respectively, is a nonlinear buffer term in the form of a tanh function, which is used to make the target tension curve smoother. 、 are the adjustment coefficient and rate adjustment factor of this item respectively, is a periodic disturbance term in the form of a sinusoidal function, 、 are the adjustment coefficient and frequency adjustment factor respectively.

[0034] The tension function shown in formula (1) can provide a high initial tension in the early stage of winding, quickly transition control in the middle stage, and slowly decay in the later stage. At the same time, it introduces periodic disturbance compensation to deal with system jitter or fiber micro-elastic fluctuations, and has strong engineering fitting capabilities.

[0035] Figure 10 In some preferred embodiments, the architecture of the first control module is shown. Figure 10 , the first control module includes a tracking differentiator, an extended state observer and a nonlinear state error feedback controller.

[0036] The tracking differentiator is used to smooth the target tension. Preferably, a third-order tracking differentiator can be used to smooth the reference tension signal. The tracking differentiator uses a nonlinear function with saturation characteristics to generate the first-order, second-order, and third-order derivatives of the reference signal and limits the rate of change at signal abrupt changes to prevent the system from oscillating due to a sharp response. In some optional embodiments, the third-order tracking differentiator is shown in the following formula: (2), (2) In the formula, 、 、 Target tension and the smooth tracking values of its first-order derivative and second-order derivative, 、 is the weight parameter, is a nonlinear function and can be expressed as follows: (3), in, is the preset segment boundary, is a symbolic function.

[0037] The extended state observer (ESO) estimates the tension, its rate of change, and the total system disturbance based on the real-time tension measurements. Specifically, it introduces a disturbance state variable based on the original tension observation results, so that the external disturbance and unmodeled dynamics can be uniformly expressed as a total disturbance and incorporated into the tension estimation process.

[0038] In some optional embodiments, the ESO state update formula is: (4), in, For real-time tension, 、 are the estimated values of real-time tension and its first-order derivative, is the estimated value of the total disturbance of the system, , , is the gain coefficient of the extended state observer.

[0039] The smoothed results of the target tension and its first-order derivative and second-order derivative by the tracking differentiator, the real-time tension and its first-order derivative estimated by the extended state observer, and the total disturbance of the system are input into the nonlinear state error feedback controller (NLSEF). The nonlinear state error feedback controller adjusts the speed of the winding roller and / or the pay-off roller in real time based on the smoothed target tension and the estimated results of the extended state observer.

[0040] In some optional embodiments, the control rate of the nonlinear state error feedback controller is It can take the form shown below: (5), in, is the preset segment boundary, 、 is the feedback gain.

[0041] In some preferred embodiments, a BP network or a similar deep learning network may be added to the first control module to achieve adaptive adjustment of control parameters of the nonlinear state error feedback controller.

[0042] Specifically, a BP network with a three-layer feedforward structure can be used, which includes an input layer, a hidden layer and an output layer. The hidden layer adopts a hyperbolic tangent activation function to improve the ability to extract nonlinear features. Its input is the tension tracking error and the tension state estimation value output by the expanded state observer, and the output is the adaptive correction value of the feedback gain in the control law.

[0043] The BP network can be trained online, allowing the controller to automatically adjust parameters in response to dynamic conditions such as changes in coil diameter and load disturbances, significantly improving system robustness, reducing tension fluctuations, and minimizing the oscillation amplitude of the control output. The structure and training methods of the aforementioned BP network are well known to those skilled in the art. Without departing from the technical principles of this application, those skilled in the art can adaptively adjust the specific structure and parameters of the BP neural network based on actual winding requirements.

[0044] <Second Control Module> The second control module is used to adjust the rotation speed of the winding roller 2 and / or the pay-off roller 1 in real time when the carbon fiber is wound in the edge area. According to the previous analysis, it can be known that in this application, the core goal of the edge area speed control is to solve the regular and violent fluctuations in tension caused by the rapid change in the distance between the wiring unit and the carbon fiber winding position in a short period of time.

[0045] In the case of uniform arrangement, the carbon fiber arrangement speed can be considered to be equal to the product of the rotation speed of the winding roller 2 and the wire diameter of the carbon fiber. Therefore, when the wire diameter remains unchanged, if the rotation speeds of the winding roller 2 and the pay-off roller 1 remain unchanged during the period from the carbon fiber winding position entering the edge interval to leaving the edge interval, the tension fluctuation during this period can be expressed as the following function: (6), in, 、 Respectively represent the moment when the carbon fiber winding position enters and leaves the edge area, for to The change in tension between is a tension fluctuation mode (such as the first fluctuation mode or the second fluctuation mode described above), The deflection angle at the moment (i.e. the moment when the carbon fiber is wound to the edge area), for The speed of the winding roller at the moment is fed back to the control system in real time because the speed difference between the winding roller and the pay-off roller is fed back to the control system in real time. Can also be The speed of the pay-off roller at all times, For tension fluctuation mode The corresponding tension variation function.

[0046] The following conclusion can be drawn from formula (6): When the motion state remains unchanged, the intensity of the tension fluctuation of the carbon fiber when it is wrapped in the edge area is related to the angle of the carbon fiber when it is arranged along the axial direction and enters the edge area. related, The larger the value, the greater the amplitude of tension fluctuation; and the speed of winding roller 2 (or pay-off roller 1) when entering the edge area. related, The larger the value, the shorter the period of tension fluctuation at the same deflection angle, that is, the closer it is to the shock pulse in a short time; in addition, the time of occurrence of this tension fluctuation is consistent with the tension fluctuation mode. Related.

[0047] visible, Therefore 、 ,and is a function of parameters. If the change of the function value can be accurately obtained, the speed of the pay-off roller 1 and / or the winding roller 2 can be adjusted in a targeted manner, so that The state when the carbon fiber winding position enters the edge area can be maintained until the carbon fiber winding position leaves the edge area, and then the first control module resumes taking over the speed control of the pay-off roller 1 and / or the winding roller 2.

[0048] To this end, in some preferred embodiments of the present application, the second control module adjusts the rotation speed of the winding roller 2 and / or the pay-off wheel 1 in real time when the carbon fiber is wound in the edge area through the following steps: The first step is to obtain the moment when the carbon fiber is wound to the edge area declination and the speed of the winding roller or pay-off roller ; The second step is based on declination of time , determine the tension fluctuation pattern of carbon fibers when they are wrapped around the edge area ; The third step is to predict the carbon fiber winding in the edge area. 、 、 The tension variation function of the parameter ; The fourth step is to use the predicted tension change function , determine the speed adjustment of the winding roller and / or pay-off roller when the carbon fiber is wound in the edge area ; The fifth step is based on The rotational speed of the winding roller and / or the pay-off roller when the carbon fibers are wound in the edge region is adjusted.

[0049] In some preferred embodiments, a deep learning network trained on time prediction function, such as LSTM, can be used to predict the tension change function. To make predictions, first obtain different 、 、 The corresponding tension change waveform is constructed to construct a training set, and then the training set is used to train the LSTM network. After the training is completed, the real-time measured 、 and tension fluctuation patterns As the input parameter, LSTM is used to predict the tension change waveform of the carbon fiber wrapped in the edge area.

[0050] In some preferred embodiments, tension change functions of different shapes can be pre-established and the corresponding speed adjustment Then, in the fourth step, the tension change function waveform closest to the function waveform predicted in the third step is selected from the above mapping relationship library to determine the speed adjustment amount of the winding roller or the pay-off roller to be achieved. ; In other preferred embodiments, a trained deep learning network can also be used to implement the function of determining the speed adjustment amount through the tension change function.

[0051] According to the speed adjustment of the winding roller or the pay-off wheel, it can be expressed in different forms. For example, when the speed adjustment of the winding roller is performed, It can be positive first and then negative, that is, first accelerate the winding roller and then decelerate it; when adjusting the speed of the pay-off roller, It can be negative first and then positive, that is, the pay-off roller slows down first and then accelerates; if the speed of the winding roller and the pay-off roller are adjusted at the same time, The drive motors are assigned accordingly to the winding and pay-off rollers.

[0052] The above describes the specific implementation of the second control module. It should be noted that since the second control module does not adopt closed-loop feedback control, its adjustment is only used to suppress the deterministic tension fluctuations that occur in the reciprocating stage of the wire arrangement. Therefore, the edge area cannot be too small. If the edge area is too small, under the state of high-speed winding, it may cause the problem of not being able to adjust the rotation speed of the winding roller 2 or the pay-off roller 1 in time. Since the speed of the carbon fiber axially arranging the wire is related to the rotation speed of the winding roller 2 or the pay-off roller 1 and the wire diameter of the carbon fiber, therefore, in some preferred embodiments, the width of the edge area increases with the increase of the product of the minimum rotation speed of the winding roller 2 or the pay-off roller 1 and the wire diameter of the carbon fiber, and the minimum rotation angular velocity of the winding roller 2 is not less than 100 revolutions per minute.

[0053] In addition, it should be pointed out that when the carbon fiber is wound to an area outside the edge area, the carbon fiber winding may also have an angle deviation. However, in this case, the change in the angle is generally affected by random factors such as the mechanical matching error of the wiring unit and the friction during movement. It can be included in the overall random fluctuation of the tension and uniformly adjusted by the first control module through nonlinear feedback control.

[0054] In some specific embodiments, the tension compound control system of the present application can be implemented by reasonably selecting various types of equipment known to those skilled in the art. For example, for the target tension determination module, the switching module, the tracking differentiator, the expansion state tracker, the nonlinear state error feedback controller in the first control module, and the speed adjustment amount generation in the second control module, the parts mainly involve numerical calculation (differentiation, state estimation, feedback control, logical judgment, etc.) processing, which can be processed in real time and quickly by PLC; for BP neural networks and LSTM deep learning networks, which involve reasoning processes, high-performance servers and other devices can be used for implementation, and high-speed communication between the two is carried out through protocols such as OPC UA, Modbus or HTTP; in addition, data storage and retrieval can be realized through the database in the server, and interactive operations such as system status monitoring and parameter adjustment can be performed through its interactive UI interface.

[0055] <Specific Example 1> This embodiment is a simulation example used to verify the tension adjustment effect of the composite control system provided in this application, wherein the parameters of the carbon fiber winding device and the control system are set as follows: Pay-off roller core diameter: 0.15m, Winding roller core diameter: 0.15m, Initial tension: 50N, Maximum roll diameter: 0.2m, : 0.6, :2, : 0.15, :10m -1 , : 0.1, :10rad / m, Permissible speed range: 100 rpm to 120 rpm.

[0056] Figure 11The figure shows the real-time tension diagram when the speed of a high-speed carbon fiber winding device is controlled by the tension composite control system of the present application. For comparison, the figure also shows the real-time tension situation when a conventional PI control strategy is used. Figure 11 It can be seen that the use of the technical solution of the present application can not only effectively suppress the random fluctuations of the tension in the middle area, but also specifically predict the "trough" linearity formed by the periodic decrease and increase of the tension in the edge area, and reduce the impact of the above-mentioned problem on the winding effect as much as possible through speed adjustment.

[0057] The above is a detailed introduction to the specific implementation methods of the present application. For those skilled in the art, several improvements and modifications can be made to the present application without departing from the principles of the present application. These improvements and modifications also fall within the scope of protection of the claims of the present application.

Claims

1. A tension composite control system for a high-speed carbon fiber winding device, comprising a pay-off roller and its drive motor, a winding roller and its drive motor, and a wire arrangement unit. The pay-off roller and the winding roller rotate at high speed around their axes driven by their respective drive motors, releasing the carbon fiber from the pay-off roller and winding it around the winding roller. The wire arrangement unit is used to adjust the deflection angle of the carbon fiber when it is wound around the winding roller. include: A tension measuring unit, used to measure the real-time tension of the carbon fiber connected between the pay-off roller and the winding roller; A deflection angle measuring unit, used to measure the real-time deflection angle and position of the carbon fiber when it is wound on the winding roller; A control unit adjusts the rotational speed of the winding roller and / or the pay-off roller through nonlinear feedback control based on the deviation between the real-time tension and the target tension when the carbon fiber is wound around an area other than the edge area of the winding roller; and, when the carbon fiber is wound around the edge area of the winding roller, predicts the change in the length of the carbon fiber connected between the pay-off roller and the winding roller through the real-time deflection angle, and adjusts the rotational speed of the winding roller and / or the pay-off roller based on the prediction result.

2. The tension composite control system of the high-speed carbon fiber winding device according to claim 1, characterized in that: The control unit comprises: a target tension determination module, configured to determine the target tension; a first control module, which adjusts the rotation speed of the winding roller and / or the pay-off roller in real time through nonlinear feedback control based on the deviation between the real-time tension and the target tension; a second control module, which predicts a change in the length of the carbon fiber connected between the pay-off roller and the winding roller according to the real-time deflection angle, and adjusts the rotation speed of the winding roller and / or the pay-off roller in real time based on the prediction result; A switching module is used to select the first control module to adjust the rotational speed of the winding roller and / or the pay-off roller when the carbon fiber is wound to an area outside the edge area of the winding roller, and to select the second control module to adjust the rotational speed of the winding roller and / or the pay-off roller when the carbon fiber is wound to the edge area of the winding roller.

3. The tension composite control system of the high-speed carbon fiber winding device according to claim 2, characterized in that: The target tension is expressed as follows: ， in, is the real-time winding diameter of the winding roller when winding carbon fiber, is the target tension, is the initial value of the target tension, is the core diameter of the winding roller, is the maximum winding diameter of the winding roller when winding carbon fiber, 、 、 is the adjustment coefficient, is the index adjustment factor, is the rate adjustment factor, is the frequency adjustment factor.

4. The tension composite control system of the high-speed carbon fiber winding device according to claim 2, characterized in that: The first control module includes: a tracking differentiator for smoothing the target tension; An extended state observer estimates the tension and its rate of change as well as the total disturbance of the system based on the real-time tension measurement value; The nonlinear state error feedback controller adjusts the rotation speed of the winding roller and / or the pay-off roller in real time based on the smoothed target tension and the estimation result of the expansion state observer.

5. The tension composite control system of the high-speed carbon fiber winding device according to claim 4, characterized in that: The first control module optimizes the control parameters of the nonlinear state error feedback controller through a deep learning network.

6. The tension composite control system of the high-speed carbon fiber winding device according to claim 2, characterized in that: The width of the edge area increases with the increase of the product of the minimum rotation speed of the winding roller and the wire diameter of the carbon fiber, and the minimum rotation speed of the winding roller is not less than 100 revolutions per minute.

7. The tension composite control system of the high-speed carbon fiber winding device according to claim 6, characterized in that: The second control module adjusts the rotation speed of the winding roller and / or the pay-off roller in real time when the carbon fiber is wound in the edge area through the following steps: Get the moment when the carbon fiber is wound to the edge area declination and the speed of the winding roller or pay-off roller ; based on declination of time , determine the tension fluctuation pattern of carbon fibers when they are wrapped around the edge area ; It is predicted that the carbon fiber will be wrapped around the edge area. 、 、 The tension variation function of the parameter ; According to the predicted tension change function , determine the speed adjustment of the winding roller and / or pay-off roller when the carbon fiber is wound in the edge area ; based on The rotational speed of the winding roller and / or the pay-off roller when the carbon fibers are wound in the edge region is adjusted.

8. The tension composite control system of the high-speed carbon fiber winding device according to claim 7, characterized in that: The tension variation function is predicted using a trained deep learning network with a time prediction function.

9. The tension composite control system of the high-speed carbon fiber winding device according to claim 7, characterized in that: The tension fluctuation mode includes a first fluctuation mode and a second fluctuation mode, wherein: When the carbon fiber is wound into the edge area and is in the first wave mode, the real-time tension of the carbon fiber between the pay-off roller and the winding roller fluctuates, first decreasing and then increasing, before the arrangement direction of the carbon fiber turns back. When the carbon fiber is wound into the edge area and is in the second wave mode, the real-time tension of the carbon fiber between the pay-off roller and the winding roller fluctuates by first decreasing and then increasing after the arrangement direction of the carbon fiber is reversed.

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