Superconducting cable winding method and system based on tension control
By using a tension wavefront propagation model and a dynamic compensation mechanism, the problem of warping caused by uneven tension during the winding of superconducting cables was solved, achieving synchronous tension control of multiple strips and improving the winding uniformity and stability of the cables.
Patent Information
- Application Number
- CN202511029924.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-25
- Publication Date
- 2025-11-11
AI Technical Summary
In existing technologies, uneven tension of different strips during the winding process of superconducting cables can cause warping, which affects the performance of the cables.
By establishing a tension wavefront propagation model and a dynamic compensation mechanism, the tension wavefront value, wavefront difference value, and winding speed of the strip are calculated to achieve dynamic tension adjustment and ensure tension balance of multiple strips at the same winding speed.
This effectively avoids the warping of the strip caused by tension mismatch, improves the winding uniformity and stability of the superconducting cable, and enhances the cable performance.
Smart Images
Figure CN120932989A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of power systems, and more particularly to a method and system for winding superconducting cables based on tension control. Background Technology
[0002] In modern power systems, the fabrication of superconducting cables involves winding a specified number of high-temperature superconducting flat strips at a certain angle and tension onto a single cable core, and then winding multiple layers as required.
[0003] In existing superconducting cable winding methods, multiple strips are typically wound using cable stranding or parallel winding techniques. In the cable stranding technique, a reel with a single superconducting strip wound on it is first mounted on a winch. A guide wheel, corresponding to the number of superconducting strips to be wound, is installed in front of the reel with an angular spacing of 360 degrees divided by the number of strips. The cable core passes through the center of the winch, and the superconducting strip is led out from the reel, guided by the guide wheel and a separator, and fixed onto the cable core. Tension control is applied to each guide wheel. The cable core moves linearly under the action of front and rear traction machines, while the winch rotates along with the reel, and the superconducting strip is wound onto the cable core. In the parallel winding technique, multiple superconducting strips are arranged in parallel according to the requirements for the number and spacing of superconducting strips in the superconducting cable. They are wound onto the cable core in a spiral manner without overlapping, with a winding angle relative to the cable core. However, in the aforementioned prior art, when multiple reels are wound at the same winding speed for the strip during the unwinding process, the different strips have different tensions. This causes the different superconducting strips on the cable core to warp when wound at the same winding speed, which in turn affects the performance of the superconducting cable. Summary of the Invention
[0004] This invention discloses a method and system for winding superconducting cables based on tension control, which can solve the technical problem in the prior art where the performance of superconducting cables is affected by the warping of the strips when winding cables with strips of different tensions.
[0005] In a first aspect, the present invention provides a method for winding a superconducting cable based on tension control, comprising:
[0006] Based on the distance between the tension wheel and the cable core of each strip and the real-time tension value of each strip, the tension wavefront value corresponding to each strip is obtained.
[0007] The wavefront difference value between two adjacent strips is calculated based on the wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value.
[0008] The winding speed of each strip is obtained, and the tension adjustment value is dynamically compensated according to the winding speed to obtain the dynamic tension adjustment value corresponding to each strip.
[0009] Based on the dynamic tension adjustment value and the real-time tension value, the tension value corresponding to each strip is obtained, and multiple strips are controlled to be wound on the cable core according to the winding speed based on the tension value to obtain a superconducting cable.
[0010] This invention discloses a tension-controlled superconducting cable winding method that achieves synchronous tension control of multiple strips by establishing a strip tension wavefront propagation model and a dynamic compensation mechanism. First, the tension wavefront value is calculated using the distance between the tension wheel and the cable core and the real-time tension value. This step considers the delay effect of the tension wave during strip transmission, transforming physical distance into tension fluctuation characteristics in the time dimension. Calculating the wavefront difference between adjacent strips captures the tension phase difference between different strips, generating a tension adjustment value to synchronize the tension fluctuations of each strip. Introducing a winding speed parameter dynamically compensates for the adjustment value, solving the problem of tension accumulation error caused by speed differences. Finally, by superimposing the real-time tension value and the dynamic adjustment value to form a closed-loop control, tension balance is ensured across multiple strips at the same winding speed, avoiding strip warping caused by local tension mismatch, thereby improving the performance of the superconducting cable.
[0011] As a preferred example, the step of obtaining the tension wavefront value corresponding to each strip based on the distance between the tension wheel of each strip and the cable core and the real-time tension value of each strip includes:
[0012] For any tension wheel:
[0013] The real-time tension value of the strip on the tension wheel is obtained in real time by a tension sensor preset on the tension wheel;
[0014] The distance between the tension wheel and the cable core is obtained, and the wavefront propagation coefficient corresponding to the tension wheel is determined based on the distance and the preset tension value corresponding to the tension wheel.
[0015] Based on the wavefront propagation coefficient, the real-time tension value, the preset tension value, and the distance, the tension wavefront value of the strip on the tension wheel is obtained through a preset tension wavefront value calculation function.
[0016] The above scheme achieves precise control of the tension wavefront value of each strip through real-time monitoring and dynamic calculation. First, the real-time tension value of the strip is directly acquired using a tension sensor, ensuring the real-time nature and accuracy of the data source and providing a foundation for subsequent calculations. Second, by introducing the distance parameter between the tension wheel and the cable core, combined with a preset tension value, the wavefront propagation coefficient is calculated. This coefficient reflects the influence of the path length of the strip from the unwinding reel to the cable core on the tension wavefront propagation, thereby quantifying the dynamic differences between different strips during the winding process. Finally, through a preset tension wavefront value calculation function, the real-time tension value, preset tension value, wavefront propagation coefficient, and distance are comprehensively calculated to obtain the tension wavefront value that characterizes the current tension fluctuation state of the strip. This method not only considers the physical distance differences in the actual winding process but also correlates the strip path length with the maximum synchronization delay time through the wavefront propagation coefficient, effectively solving the warping problem caused by tension asynchrony during multi-strip winding and ensuring the uniformity and stability of the winding process.
[0017] As a preferred example, the calculation expression of the tension wavefront value calculation function is as follows:
[0018] φ i (t)=T i (t)-T i,ref +k i ·d i (t)
[0019] Wherein, the φ i (t) represents the tension wavefront value of the strip on the i-th tension wheel at the current time t; the T i (t) represents the real-time tension value of the strip on the i-th tension wheel at the current time t; the T i,ref The k represents the preset tension value corresponding to the i-th tension wheel; i The d represents the wavefront propagation coefficient corresponding to the i-th tension wheel; i (t) represents the distance between the i-th tension wheel and the cable core; wherein, the expression for calculating the wavefront propagation coefficient is:
[0020]
[0021] Wherein, the L i The length of the strip on the i-th tension pulley from the unwinding reel used for strip feeding to the cable core is represented by τ; the preset maximum tension synchronization delay time is represented by τ.
[0022] The above scheme establishes a mathematical model for tension wavefront values, comprehensively calculating the real-time tension of the strip, the preset tension, the wavefront propagation coefficient, and the distance between the tension wheel and the cable core to dynamically quantify the tension fluctuation state of each strip. Specifically, the tension wavefront value calculation function reflects the tension attenuation characteristics of the strip along the transmission path by combining the difference between the real-time tension and the preset tension with the product of the wavefront propagation coefficient and the distance. The wavefront propagation coefficient further correlates the physical transmission path of the strip with the maximum allowable delay time of the system by using the ratio of the strip length to the maximum tension synchronization delay time, ensuring that the tension adjustment of strips of different lengths can respond synchronously. This technique solves the problem of tension asynchrony caused by path differences and delays by accurately modeling the dynamic propagation process of strip tension, thereby avoiding warping during the winding process.
[0023] As a preferred example, the step of calculating the wavefront difference value between two adjacent strips based on the tension wavefront value, and determining the tension adjustment value corresponding to each strip based on the wavefront difference value, includes:
[0024] For any one of the strips:
[0025] According to the arrangement order of the tension wheels, the strip following the current strip is obtained as the adjacent strip of the current strip;
[0026] Calculate the wavefront difference between the adjacent strip and the strip based on the tension wavefront value;
[0027] The tension adjustment value corresponding to the strip is determined based on the wavefront difference value and the preset tension adjustment value calculation function.
[0028] The above scheme solves the tension synchronization problem during multi-strip winding by dynamically adjusting the tension adjustment value based on the wavefront difference between adjacent strips. Specifically, firstly, the adjacent strips are determined based on the arrangement order of the tension rollers, ensuring that the adjustment process conforms to the spatial distribution of the strips during actual winding and avoiding adjustment failure due to interference from non-adjacent strips. Secondly, by calculating the wavefront difference value between adjacent strips, the dynamic deviation between them during tension propagation is directly quantified, providing precise input parameters for subsequent adjustment. Finally, combined with a preset tension adjustment value calculation function, the wavefront difference value is converted into a specific tension adjustment amount, achieving adaptive adjustment based on the real-time state of adjacent strips, rather than relying on a fixed threshold or global average value, thereby effectively suppressing strip warping caused by local tension fluctuations.
[0029] As a preferred example, the calculation expression of the tension adjustment value calculation function is:
[0030]
[0031] ΔΦ i,i+1(t)=Φ i (t)-Φ i+1 (t)
[0032] Wherein, the ΔT i (t) represents the tension adjustment value corresponding to the strip on the i-th tension wheel; the K p This represents a preset proportional control gain; the Δφ i,i+1 (t) represents the wavefront difference value between the strip on the i-th tension pulley at the current time t and the adjacent strip corresponding to the strip; the K d Represents the preset differential control gain; the φ i+1 (t) represents the tension wavefront value of the adjacent strip on the (i+1)th tension wheel at the current time t; dt represents the differential at the current time t; dΔφ i,i+1 (t) represents the derivative of the wavefront difference value.
[0033] In the above scheme, dynamic compensation for tension wavefront differences between adjacent strips is achieved by constructing a composite adjustment function that includes proportional control gain and derivative control gain. Specifically, the proportional control gain acts on the wavefront difference value of adjacent strips at the current moment, directly correcting the real-time deviation between strips proportionally; the derivative control gain acts on the trend of tension wavefront value changes of adjacent strips, predicting the tension fluctuation trend in advance and making advance adjustments by introducing the wavefront value of adjacent strips at the next moment. The synergistic effect of the two can eliminate the wavefront difference at the current moment and suppress subsequent fluctuations caused by the tension propagation delay during the dynamic winding of the strips, thereby ensuring the tension synchronization of multiple strips during high-speed winding.
[0034] As a preferred example, the step of obtaining the winding speed of each strip, and dynamically compensating the tension adjustment value based on the winding speed to obtain the dynamic tension adjustment value corresponding to each strip, includes:
[0035] The winding speed of each of the strips is obtained, and the average winding speed is calculated based on the winding speed and the total number of strips.
[0036] For any one of the strips:
[0037] The dynamic compensation factor corresponding to the strip is calculated based on the winding speed and the average winding speed of the strip.
[0038] Based on the dynamic compensation factor and the tension adjustment value corresponding to the strip, the dynamic tension adjustment value corresponding to the strip is obtained.
[0039] The above solution addresses tension control deviations caused by speed differences during simultaneous winding of multiple strips by introducing a dynamic compensation mechanism for winding speed. First, a benchmark reference value is established by calculating the average winding speed of all strips, providing a quantitative basis for subsequent compensation. For a single strip, a dynamic compensation factor is calculated by comparing its actual winding speed with the average speed. This factor reflects the degree of deviation of a specific strip from the overall speed. The dynamic compensation factor is combined with the initially calculated tension adjustment value to form the final dynamic tension adjustment value, enabling the tension control parameters to respond in real-time to fluctuations in winding speed. This dual adjustment mechanism retains the initial adjustment effect based on tension wavefront differences while incorporating dynamic compensation due to speed differences, effectively suppressing uneven strip stress caused by speed asynchrony and thus avoiding warping defects.
[0040] As a preferred example, the calculation expression for the dynamic compensation factor is:
[0041]
[0042] Wherein, the v avg (t) represents the average winding speed of the strip at the current time t; the v i (t) represents the winding speed of the strip on the i-th tension wheel at the current time t; n represents the total number of strips; a i (t) represents the dynamic compensation factor corresponding to the strip on the i-th tension wheel at the current time t; β represents the preset attenuation coefficient.
[0043] The above scheme introduces a dynamic compensation factor to dynamically compensate for the tension adjustment value by combining the difference between the average winding speed and the actual winding speed of a single strip. First, the average winding speed of all strips is calculated to reflect the baseline level of the overall winding speed. Second, for the deviation of the winding speed of a single strip from the average value, an attenuation coefficient is used to proportionally adjust the speed difference, generating a dynamic compensation factor. This factor converts the speed difference into a compensation weight in the form of an exponential function, so that strips with speeds higher than the average receive positive compensation, and strips with speeds lower than the average receive negative compensation, thereby balancing the impact of speed differences between different strips on tension. The introduction of the attenuation coefficient further optimizes the sensitivity of the compensation, avoiding over- or under-compensation due to instantaneous speed fluctuations, ultimately ensuring that the tension adjustment value can dynamically adapt to actual winding conditions and reduce the risk of strip warping.
[0044] As a preferred example, obtaining the tension value corresponding to each strip based on the dynamic tension adjustment value and the real-time tension value includes:
[0045] For any one of the strips:
[0046] The sum of the dynamic tension adjustment value and the real-time tension value corresponding to the strip is obtained, and the sum is used as the tension value corresponding to the strip.
[0047] The above scheme achieves precise control of the tension of each strip by superimposing dynamic tension adjustment values and real-time tension values. Specifically, firstly, the tension of the strip is dynamically compensated by a dynamic tension adjustment value, which has been optimized according to the differences in winding speed to adapt to tension deviations caused by speed fluctuations during the winding process of different strips. Secondly, the real-time tension value directly reflects the current actual tension state of the strip. The final tension value obtained by adding the two values includes both the anticipation and compensation for dynamic changes and the accuracy of real-time monitoring, thereby ensuring that multiple strips maintain tension synchronization during the winding process and avoiding strip warping or uneven alignment due to tension differences.
[0048] As a preferred example, the expression for calculating the tension value is:
[0049] T cmd,i (t)=T i (t)+a i (t)·ΔT i (t)
[0050] Wherein, the T cmd,i This represents the tension value of the strip on the i-th tension wheel.
[0051] The above scheme dynamically corrects the final tension value by directly adding the real-time tension value to the dynamic tension adjustment value. Specifically, the real-time tension value reflects the current actual tension state of the strip, while the dynamic tension adjustment value is based on the wavefront difference between adjacent strips and the adjustment amount after winding speed compensation. The superposition of the two can integrate the tension fluctuations of the strip itself and the external dynamic compensation requirements in real time, ensuring the real-time nature and coordination of tension control. Through this calculation expression, the basic information of real-time tension is retained, while the adjustment amount after dynamic compensation is introduced, avoiding the error accumulation caused by relying on a single parameter, thereby accurately controlling the final tension value of each strip and preventing strip warping caused by uneven tension.
[0052] On the other hand, the present invention discloses a superconducting cable winding system based on tension control, including a tension wave module, a tension adjustment module, a dynamic compensation module and a cable winding module;
[0053] The tension wave module is used to obtain the tension wave front value corresponding to each strip based on the distance between the tension wheel of each strip and the cable core and the real-time tension value of each strip.
[0054] The tension adjustment module is used to calculate the wavefront difference value between two adjacent strips based on the tension wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value.
[0055] The dynamic compensation module is used to obtain the winding speed of each strip, so as to dynamically compensate the tension adjustment value according to the winding speed, and obtain the dynamic tension adjustment value corresponding to each strip.
[0056] The cable winding module is used to obtain the tension value corresponding to each strip according to the dynamic tension adjustment value and the real-time tension value, so as to control multiple strips to be wound on the cable core according to the winding speed according to the tension value, thereby obtaining a superconducting cable.
[0057] This invention discloses a tension-controlled superconducting cable winding system that achieves synchronous tension control of multiple strips by establishing a strip tension wavefront propagation model and a dynamic compensation mechanism. First, the tension wavefront value is calculated using the distance between the tension wheel and the cable core and the real-time tension value. This step considers the delay effect of the tension wave during strip transmission, transforming physical distance into tension fluctuation characteristics in the time dimension. Calculating the wavefront difference between adjacent strips captures the tension phase difference between different strips, generating a tension adjustment value to synchronize the tension fluctuations of each strip. Introducing a winding speed parameter dynamically compensates for the adjustment value, solving the problem of tension accumulation error caused by speed differences. Finally, by superimposing the real-time tension value and the dynamic adjustment value to form a closed-loop control, tension balance is ensured across multiple strips at the same winding speed, avoiding strip warping caused by local tension mismatch, thereby improving the performance of the superconducting cable. Attached Figure Description
[0058] To more clearly illustrate the technical solution of this application, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0059] Figure 1 This is a schematic flowchart of a superconducting cable winding method based on tension control provided in an embodiment of the present invention;
[0060] Figure 2 This is a schematic flowchart of a superconducting cable winding method based on tension control provided in an embodiment of the present invention;
[0061] Figure 3 This is a schematic diagram of the structure of a strip feeding device provided in an embodiment of the present invention;
[0062] Figure 4 This is a schematic diagram of the winding process of a superconducting cable provided in an embodiment of the present invention. Detailed Implementation
[0063] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.
[0064] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains; the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the application; the terms “comprising” and “having”, and any variations thereof, in the specification, claims, and foregoing description of the drawings are intended to cover non-exclusive inclusion.
[0065] In the description of the embodiments of this application, technical terms such as "first" and "second" are used only to distinguish different objects and should not be construed as indicating or implying relative importance or implicitly specifying the number, specific order, or primary and secondary relationship of the indicated technical features. In the description of the embodiments of this application, "multiple" means two or more, unless otherwise explicitly defined.
[0066] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of this application. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a mutually exclusive, independent, or alternative embodiment. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.
[0067] In the description of the embodiments in this application, the term "and / or" is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can represent: A existing alone, A and B existing simultaneously, and B existing alone. Additionally, the character " / " in this document generally indicates that the preceding and following related objects have an "or" relationship.
[0068] In the description of the embodiments of this application, the term "multiple" refers to two or more (including two), similarly, "multiple sets" refers to two or more (including two sets), and "multiple pieces" refers to two or more (including two pieces).
[0069] In the description of the embodiments of this application, unless otherwise expressly specified and limited, technical terms such as "installation," "connection," "joining," and "fixing" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this application can be understood according to the specific circumstances.
[0070] See Figure 1 To address the technical problem in existing technologies where the performance of superconducting cables is affected by the warping of the strips when winding cables with different tensions, an embodiment of the present invention provides a superconducting cable winding method based on tension control, comprising:
[0071] Step 101: Based on the distance between the tension wheel and the cable core of each strip and the real-time tension value of each strip, obtain the tension wavefront value corresponding to each strip.
[0072] Step 102: Calculate the wavefront difference value between two adjacent strips based on the tension wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value.
[0073] Step 103: Obtain the winding speed of each strip, and dynamically compensate the tension adjustment value according to the winding speed to obtain the dynamic tension adjustment value corresponding to each strip.
[0074] Step 104: Based on the dynamic tension adjustment value and the real-time tension value, obtain the tension value corresponding to each strip, and control multiple strips to be wound on the cable core according to the winding speed according to the tension value to obtain a superconducting cable.
[0075] In this first embodiment, when calculating the tension wavefront value corresponding to each strip in step 101, in order to improve the accuracy of the calculation of the tension wavefront value, step 101 can obtain the tension wavefront value through the following steps. Specifically, step 101 includes:
[0076] Step 1011: For any tension wheel: The real-time tension value of the strip on the tension wheel is obtained in real time by a tension sensor preset on the tension wheel.
[0077] Step 1012: Obtain the distance between the tension wheel and the cable core, and determine the wavefront propagation coefficient corresponding to the tension wheel based on the distance and the preset tension value corresponding to the tension wheel.
[0078] Step 1013: Based on the wavefront propagation coefficient, the real-time tension value, the preset tension value, and the distance, obtain the tension wavefront value of the strip on the tension wheel through a preset tension wavefront value calculation function.
[0079] In this embodiment, the calculation expression of the tension wavefront value calculation function is as follows:
[0080] φ i (t)=T i (t)-T i,ref +k i ·d i (t)
[0081] Wherein, the φ i (t) represents the tension wavefront value of the strip on the i-th tension wheel at the current time t; the T i (t) represents the real-time tension value of the strip on the i-th tension wheel at the current time t; the T i,ref The k represents the preset tension value corresponding to the i-th tension wheel; i The d represents the wavefront propagation coefficient corresponding to the i-th tension wheel; i (t) represents the distance between the i-th tension wheel and the cable core; wherein, the expression for calculating the wavefront propagation coefficient is:
[0082]
[0083] Wherein, the L i The length of the strip on the i-th tension pulley from the unwinding reel used for strip feeding to the cable core is represented by τ; the preset maximum tension synchronization delay time is represented by τ.
[0084] In this embodiment one implementation, refer to Figure 3 The superconducting coil feeding device shown includes multiple parallel feeding devices for conveying the strip, multiple parallel guide rollers for winding the strip onto the cable core, multiple parallel tension guide rollers for tension control of the strip, and a cable core rotation drive device for driving the cable core to slide forward and rotate spirally. Figure 3 As can be seen, in the superconducting coil unwinding device, multiple unwinding devices placed coaxially side by side simultaneously unwind the strip. The strip is wound obliquely downwards onto the cable core via guide rollers. Tension rollers are installed between the unwinding devices and the guide rollers. Each strip corresponds to one guide roller and one tension roller, and their tension is controlled independently. The cable core rotation drive device includes a linear drive assembly and a rotation drive assembly to achieve axial movement while rotating the cable core. It is important to note that the number of tension rollers and guide rollers is the same as the number of superconducting strips. By controlling the tension of multiple tension rollers, multiple superconducting strips are smoothly wound onto the cable core.
[0085] Reference Figure 3 The superconducting coil feeding device shown can feed the strip at a preset speed. At this time, the tension sensor on the tension guide wheel can obtain the real-time tension value of each strip. The tension wavefront value of each strip can be determined according to the real-time tension value and the distance between the tension guide wheel and the cable core.
[0086] Specifically, the tension wavefront value corresponding to each of the strips is calculated using a pre-constructed wavefront propagation model; wherein the calculation expression of the wavefront propagation model is:
[0087] φ i (t)=T i (t)-T i,ref +k i ·d i (t)
[0088] Where k is a preset wavefront propagation coefficient; the φ i (t) represents the tension wavefront value of the strip on the i-th tension wheel at the current time t; the T i (t) represents the real-time tension value of the strip on the i-th tension wheel at the current time t; the T i,ref The k represents the preset tension value corresponding to the i-th tension wheel; i The d represents the wavefront propagation coefficient corresponding to the i-th tension wheel; i (t) represents the distance between the i-th tension wheel and the cable core; where φ i (t) This comprehensively reflects tension deviation and spatial position information, used to measure the "leading" or "lagging" state of strip tension. According to the formula, the tension wavefront value equals the current tension value minus the target tension value, plus the product of the wavefront propagation coefficient and distance. This is because, although multiple unwinding devices simultaneously unwind the strip, the strip on the unwinding reels inherently has different winding tightness. However, to ensure that the tension of each strip is the same, each tension wheel needs to be adjusted separately. This results in the tension wheels being in different positions (the distance from the tension wheel to the cable core is different) even when the tension is adjusted to be the same, i.e., d. i (t) are different; the greater the distance, the greater the delay in tension adjustment. Therefore, through k i ·d i (t) Perform tension compensation adjustment.
[0089] The expression for calculating the wavefront propagation coefficient is as follows:
[0090]
[0091] Wherein, the L i The length of the strip on the i-th tension pulley from the unwinding reel used for strip feeding to the cable core is represented by τ; τ represents the preset maximum tension synchronization delay time. τ is the maximum allowable tension synchronization delay time. Then, the wavefront propagation coefficient k corresponding to the i-th tension pulley is fine-tuned according to actual testing. i The warping of the strip indicates insufficient compensation, requiring an increase in k. i If the strip becomes taut, deformed, or broken, it is necessary to reduce k. i .
[0092] In this embodiment one, the T ref A preset tension value is assigned to each tension guide roller. This preset tension value can be determined using the following calculation expression:
[0093] T ref =σ yield ·A·S
[0094] Where, σ yield Here, A is the yield strength of the tape material, such as the yield strength of high-temperature superconducting tape, which is 300-700 MPa; A is the cross-sectional area of the tape, i.e., A = width w × thickness h; S is the safety factor, which can be 0.1-0.3. For example, when the yield strength of the high-temperature superconducting tape is 500 MPa, the thickness is 0.1 mm, and the width is 10 mm, A = 10. -6 m 2 When the safety factor is 0.15, then T ref =500×106Pa×10-6m2×0.15=75N.
[0095] In this embodiment, the above steps achieve precise control of the tension wavefront value of each strip through real-time monitoring and dynamic calculation. First, the real-time tension value of the strip is directly obtained using a tension sensor, ensuring the real-time nature and accuracy of the data source and providing a foundation for subsequent calculations. Second, by introducing the distance parameter between the tension wheel and the cable core, combined with a preset tension value, the wavefront propagation coefficient is calculated. This coefficient reflects the influence of the path length of the strip from the unwinding reel to the cable core on the tension wavefront propagation, thereby quantifying the dynamic differences of different strips during the winding process. Finally, through a preset tension wavefront value calculation function, the real-time tension value, preset tension value, wavefront propagation coefficient, and distance are comprehensively calculated to obtain the tension wavefront value that can characterize the current tension fluctuation state of the strip. This method not only considers the physical distance differences in the actual winding process but also correlates the strip path length with the maximum synchronization delay time through the wavefront propagation coefficient, effectively solving the warping problem caused by tension asynchrony when winding multiple strips, and ensuring the uniformity and stability of the winding process.
[0096] In this embodiment, step 102 can improve the accuracy of tension adjustment value calculation by calculating the tension adjustment value for each strip through the following steps. Specifically, the steps include:
[0097] Step 1021: For any one of the strips: according to the arrangement order of the tension wheels, obtain the next strip after the strip as the adjacent strip of the strip.
[0098] Step 1022: Calculate the wavefront difference between the adjacent strip and the strip based on the tension wavefront value.
[0099] Step 1023: Determine the tension adjustment value corresponding to the strip based on the wavefront difference value and the preset tension adjustment value calculation function.
[0100] In this embodiment, the calculation expression of the tension adjustment value calculation function is:
[0101]
[0102] ΔΦ i,i+1 (t)=Φ i (t)-Φ i+1 (t)
[0103] Wherein, the ΔT i (t) represents the tension adjustment value corresponding to the strip on the i-th tension wheel; the K p This represents a preset proportional control gain; the Δφ i,i+1 (t) represents the wavefront difference value between the strip on the i-th tension pulley at the current time t and the adjacent strip corresponding to the strip; the K d Represents the preset differential control gain; the φ i+1 (t) represents the tension wavefront value of the adjacent strip on the (i+1)th tension wheel at the current time t; dt represents the differential at the current time t; dΔφ i,i+1 (t) represents the derivative of the wavefront difference value.
[0104] Wherein, K p The proportional control gain determines the system's response strength to wavefront differences, i.e., the response speed of tension control. Its value can range from 1.0 to 3.0. The method for determining this value is to start with a small value greater than 0 and gradually increase it, for example, 0.1, observing the tension change curve of the superconducting tape. When K... p When the value exceeds a certain threshold, the tension change curve will oscillate; this is the critical proportional control gain. To ensure stable operation, K must be guaranteed. p The value should be less than the critical proportional control gain, and should be between 0.4 and 0.6 times the critical proportional control gain. And K...d The differential control gain is used to suppress system oscillations (strip jitter), and its value can be between 0.05 and 0.2. The method for determining this value is K. d =K p ×T s T s This is the tension control cycle.
[0105] In this embodiment, the above steps dynamically adjust the tension adjustment value based on the wavefront difference between adjacent strips, thereby solving the tension synchronization problem during multi-strip winding. Specifically, firstly, adjacent strips are determined based on the arrangement order of the tension wheels, ensuring that the adjustment process conforms to the spatial distribution relationship of the strips during actual winding, avoiding adjustment failure due to interference from non-adjacent strips. Secondly, by calculating the wavefront difference value between adjacent strips, the dynamic deviation between them during tension propagation is directly quantified, providing accurate input parameters for subsequent adjustment. Finally, combined with a preset tension adjustment value calculation function, the wavefront difference value is converted into a specific tension adjustment amount, achieving adaptive adjustment based on the real-time state of adjacent strips, rather than relying on a fixed threshold or global average value, thereby effectively suppressing strip warping caused by local tension fluctuations.
[0106] In this embodiment, step 103 can be performed by calculating the dynamic tension adjustment value through the following steps to improve the accuracy of the dynamic tension adjustment value calculation. Specifically, the steps include:
[0107] Step 1031: Obtain the winding speed of each of the strips, and calculate the average winding speed based on the winding speed and the total number of strips.
[0108] Step 1032: For any one of the strips: Calculate the dynamic compensation factor corresponding to the strip based on the winding speed of the strip and the average winding speed.
[0109] Step 1033: Based on the dynamic compensation factor and the tension adjustment value corresponding to the strip, obtain the dynamic tension adjustment value corresponding to the strip.
[0110] In this embodiment, the calculation expression for the dynamic compensation factor is:
[0111]
[0112] Wherein, the v avg (t) represents the average winding speed of the strip at the current time t; the v i (t) represents the winding speed of the strip on the i-th tension wheel at the current time t; n represents the total number of strips; a i(t) represents the dynamic compensation factor corresponding to the strip on the i-th tension wheel at the current time t; β represents the preset attenuation coefficient.
[0113] In this embodiment, the above steps address the tension control deviation caused by speed differences during synchronous winding of multiple strips by introducing a dynamic compensation mechanism for winding speed. First, a benchmark reference value is established by calculating the average winding speed of all strips, providing a quantitative basis for subsequent compensation. For a single strip, a dynamic compensation factor is calculated by comparing its actual winding speed with the average speed. This factor reflects the degree of deviation of a specific strip from the overall speed. The dynamic compensation factor is combined with the initially calculated tension adjustment value to form the final dynamic tension adjustment value, enabling the tension control parameters to respond in real-time to fluctuations in winding speed. This dual adjustment mechanism retains the initial adjustment effect based on tension wavefront differences while incorporating dynamic compensation due to speed differences, effectively suppressing uneven strip stress caused by speed asynchrony and thus avoiding warping defects.
[0114] In this embodiment, step 104 can be performed by calculating the tension value through the following steps to improve the accuracy of the tension value calculation. Specifically, the steps include: for any one of the strips: obtaining the sum of the dynamic tension adjustment value and the real-time tension value corresponding to the strip, and using the sum as the tension value corresponding to the strip.
[0115] In this embodiment, the expression for calculating the tension value is:
[0116] T cmd,i (t)=T i (t)+a i (t)·ΔT i (t)
[0117] Wherein, the T cmd,i This represents the tension value of the strip on the i-th tension wheel.
[0118] In this embodiment, after determining the tension value of each strip, the gap between each superconducting strip is determined by the interval between its corresponding guide rollers. When the tension guide rollers correspond one-to-one with the pay-off device and their positions can be adjusted on the frame, multiple strips are wound into a superconducting cable at the stated tension value. Figure 4 As shown. From Figure 4 It can be seen that multiple strips are wound in parallel on the cable core with their respective corresponding tension values.
[0119] In this embodiment, the above steps achieve precise control of the tension of each strip by superimposing the dynamic tension adjustment value and the real-time tension value. Specifically, firstly, the tension of the strip is dynamically compensated by the dynamic tension adjustment value, which has been optimized according to the difference in winding speed to adapt to the tension deviation caused by speed fluctuations during the winding process of different strips; secondly, the real-time tension value directly reflects the current actual tension state of the strip. The final tension value obtained by adding the two includes both the prediction and compensation for dynamic changes and the accuracy of real-time monitoring, thereby ensuring that multiple strips maintain tension synchronization during the winding process and avoiding strip warping or uneven arrangement due to tension differences.
[0120] like Figure 2 As shown, based on the above method embodiments, corresponding device embodiments are provided; one embodiment of the present invention provides a superconducting cable winding system based on tension control, including a tension wave module 201, a tension adjustment module 202, a dynamic compensation module 203 and a cable winding module 204.
[0121] The tension wave module 201 is used to obtain the tension wavefront value corresponding to each strip based on the distance between the tension wheel and the cable core of each strip and the real-time tension value of each strip.
[0122] The tension adjustment module 202 is used to calculate the wavefront difference value between two adjacent strips based on the tension wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value.
[0123] The dynamic compensation module 203 is used to obtain the winding speed of each strip, so as to dynamically compensate the tension adjustment value according to the winding speed, and obtain the dynamic tension adjustment value corresponding to each strip.
[0124] The cable winding module 204 is used to obtain the tension value corresponding to each strip according to the dynamic tension adjustment value and the real-time tension value, so as to control multiple strips to be wound on the cable core according to the winding speed according to the tension value, thereby obtaining a superconducting cable.
[0125] It is understood that the above-described device embodiments correspond to the method embodiments provided by the present invention, and can implement the tension-controlled superconducting cable winding method provided by any of the above-described method embodiments of the present invention.
[0126] It should be noted that the device embodiments described above are merely illustrative, and some or all of the modules can be selected to achieve the purpose of this embodiment according to actual needs. Furthermore, in the accompanying drawings of the device embodiments provided by this invention, the connection relationships between modules indicate that they have communication connections, which can specifically be implemented as one or more communication buses or signal lines. Those skilled in the art can understand and implement this without any creative effort.
[0127] This embodiment discloses a superconducting cable winding method based on tension control, which achieves synchronous tension control of multiple strips by establishing a strip tension wavefront propagation model and a dynamic compensation mechanism. First, the tension wavefront value is calculated using the distance between the tension wheel and the cable core and the real-time tension value. This step considers the delay effect of the tension wave during strip transmission, transforming physical distance into tension fluctuation characteristics in the time dimension. Calculating the wavefront difference between adjacent strips captures the tension phase difference between different strips, generating a tension adjustment value through the difference value to synchronize the tension fluctuations of each strip. Introducing a winding speed parameter for dynamic compensation of the adjustment value solves the problem of tension accumulation error caused by speed differences. Finally, by superimposing the real-time tension value and the dynamic adjustment value to form a closed-loop control, it ensures tension balance among multiple strips at the same winding speed, avoiding strip warping caused by local tension mismatch, thereby improving the performance of the superconducting cable. Furthermore, this embodiment is based on the intuitive wavefront synchronization principle, requiring no complex mathematical model; the control logic is simple and easy to understand, facilitating engineering implementation and maintenance. Real-time and precise control of the tension of each superconducting tape is achieved through a dynamic compensation factor, exhibiting good robustness under various operating conditions. Tension synchronization between tapes is achieved by utilizing wavefront differences, effectively suppressing tape warping and stress concentration.
[0128] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications are also considered to be within the scope of protection of the present invention.
Claims
1. A method for winding a superconducting cable based on tension control, characterized in that, include: Based on the distance between the tension wheel and the cable core of each strip and the real-time tension value of each strip, the tension wavefront value corresponding to each strip is obtained. The wavefront difference value between two adjacent strips is calculated based on the wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value. The winding speed of each strip is obtained, and the tension adjustment value is dynamically compensated according to the winding speed to obtain the dynamic tension adjustment value corresponding to each strip. Based on the dynamic tension adjustment value and the real-time tension value, the tension value corresponding to each strip is obtained, and multiple strips are controlled to be wound on the cable core according to the winding speed based on the tension value to obtain a superconducting cable.
2. The method for winding a superconducting cable based on tension control according to claim 1, characterized in that, The process of obtaining the tension wavefront value corresponding to each strip based on the distance between the tension wheel and the cable core of each strip and the real-time tension value of each strip includes: For any tension wheel: The real-time tension value of the strip on the tension wheel is obtained in real time by a tension sensor preset on the tension wheel; The distance between the tension wheel and the cable core is obtained, and the wavefront propagation coefficient corresponding to the tension wheel is determined based on the distance and the preset tension value corresponding to the tension wheel. Based on the wavefront propagation coefficient, the real-time tension value, the preset tension value, and the distance, the tension wavefront value of the strip on the tension wheel is obtained through a preset tension wavefront value calculation function.
3. The method for winding a superconducting cable based on tension control according to claim 2, characterized in that, The calculation expression for the tension wavefront value calculation function is as follows: φ i (t)=T i (t)-T i,ref +k i ·d i (t) Wherein, the φ i (t) represents the tension wavefront value of the strip on the i-th tension wheel at the current time t; the T i (t) represents the real-time tension value of the strip on the i-th tension wheel at the current time t; the T i,ref The k represents the preset tension value corresponding to the i-th tension wheel; i The d represents the wavefront propagation coefficient corresponding to the i-th tension wheel; i (t) represents the distance between the i-th tension wheel and the cable core; wherein, the expression for calculating the wavefront propagation coefficient is: Wherein, the L i The length of the strip on the i-th tension pulley from the unwinding reel used for strip feeding to the cable core is represented by τ; the preset maximum tension synchronization delay time is represented by τ.
4. The method for winding a superconducting cable based on tension control according to claim 1, characterized in that, The step of calculating the wavefront difference value between two adjacent strips based on the tension wavefront value, and determining the tension adjustment value corresponding to each strip based on the wavefront difference value, includes: For any one of the strips: According to the arrangement order of the tension wheels, the strip following the current strip is obtained as the adjacent strip of the current strip; Calculate the wavefront difference between the adjacent strip and the strip based on the tension wavefront value; The tension adjustment value corresponding to the strip is determined based on the wavefront difference value and the preset tension adjustment value calculation function.
5. A method for winding a superconducting cable based on tension control according to claim 4, characterized in that, The calculation expression for the tension adjustment value calculation function is as follows: DF i,i+1 (t)=Φ i (t)-Φ i+1 (t) Wherein, the ΔT i (t) represents the tension adjustment value corresponding to the strip on the i-th tension wheel; the K p This represents a preset proportional control gain; the Δφ i,i+1 (t) represents the wavefront difference value between the strip on the i-th tension pulley at the current time t and the adjacent strip corresponding to the strip; the K d Represents the preset differential control gain; the φ i+1 (t) represents the tension wavefront value of the adjacent strip on the (i+1)th tension wheel at the current time t; dt represents the differential at the current time t; dΔφ i,i+1 (t) represents the derivative of the wavefront difference value.
6. The method for winding a superconducting cable based on tension control according to claim 1, characterized in that, The step of obtaining the winding speed of each strip, and dynamically compensating the tension adjustment value based on the winding speed to obtain the dynamic tension adjustment value corresponding to each strip, includes: The winding speed of each of the strips is obtained, and the average winding speed is calculated based on the winding speed and the total number of strips. For any one of the strips: The dynamic compensation factor corresponding to the strip is calculated based on the winding speed and the average winding speed of the strip. Based on the dynamic compensation factor and the tension adjustment value corresponding to the strip, the dynamic tension adjustment value corresponding to the strip is obtained.
7. A method for winding a superconducting cable based on tension control according to claim 6, characterized in that, The calculation expression for the dynamic compensation factor is as follows: Wherein, the v avg (t) represents the average winding speed of the strip at the current time t; the v i (t) represents the winding speed of the strip on the i-th tension wheel at the current time t; n represents the total number of strips; a i (t) represents the dynamic compensation factor corresponding to the strip on the i-th tension wheel at the current time t; β represents the preset attenuation coefficient.
8. The method for winding a superconducting cable based on tension control according to claim 1, characterized in that, The step of obtaining the tension value corresponding to each strip based on the dynamic tension adjustment value and the real-time tension value includes: For any one of the strips: The sum of the dynamic tension adjustment value and the real-time tension value corresponding to the strip is obtained, and the sum is used as the tension value corresponding to the strip.
9. A method for winding a superconducting cable based on tension control according to claim 8, characterized in that, The expression for calculating the tension value is: T cmd,i (t)=T i (t)+a i (t)·ΔT i (t) Wherein, the T cmd,i This represents the tension value of the strip on the i-th tension wheel.
10. A superconducting cable winding system based on tension control, characterized in that, Includes a tension wave module, a tension adjustment module, a dynamic compensation module, and a cable winding module; The tension wave module is used to obtain the tension wave front value corresponding to each strip based on the distance between the tension wheel of each strip and the cable core and the real-time tension value of each strip. The tension adjustment module is used to calculate the wavefront difference value between two adjacent strips based on the tension wavefront value, so as to determine the tension adjustment value corresponding to each strip based on the wavefront difference value. The dynamic compensation module is used to obtain the winding speed of each strip, so as to dynamically compensate the tension adjustment value according to the winding speed, and obtain the dynamic tension adjustment value corresponding to each strip. The cable winding module is used to obtain the tension value corresponding to each strip according to the dynamic tension adjustment value and the real-time tension value, so as to control multiple strips to be wound on the cable core according to the winding speed according to the tension value, thereby obtaining a superconducting cable.