Variable tension control method for winding high-capacity capacitor core
By establishing a tension mathematical model and performing real-time correction calculations, the problems of poor capacitor forming and self-healing chain effect caused by traditional tension control methods were solved, achieving high-quality winding and consistency control of large-capacity capacitor cores.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- CHENGDU HONGMING ELECTRONICS CO LTD
- Filing Date
- 2026-03-24
- Publication Date
- 2026-05-15
AI Technical Summary
Traditional tension control methods are prone to poor forming during the winding of large-capacity capacitor cores, which can easily lead to voltage arcing and self-healing chain effects, causing capacitor failure, and failing to effectively correct winding quality problems.
By establishing a tension mathematical model and combining real-time sampled tension values, equipment and material deviations, correction calculations are performed to output precise tension roller control parameters in real time. Furthermore, by learning and updating the tension curve, closed-loop management is achieved, thereby improving the accuracy and consistency of tension control.
This technology enables high-quality winding of large-capacity capacitor cores, avoiding poor forming and capacity deviation, improving product consistency and quality, and ensuring the stability and reliability of capacitors.
Smart Images
Figure CN122051052A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of capacitor core winding technology, specifically relating to a variable tension control method for winding large-capacity capacitor cores. Background Technology
[0002] Pulsed power sources, as a key technology for the practical application of pulsed power technology, have applications spanning both military and civilian fields, such as electromagnetic launch, inertial confinement fusion, laser weapons, environmental treatment, radiation modification, nanotechnology, and biomedicine. Pulsed capacitors possess advantages such as high discharge power, high utilization efficiency, significant potential for increased energy density, and flexible and convenient combination, making them the preferred energy storage unit for pulsed power sources in defense and high-tech fields. High-energy-density pulsed capacitors (referred to as high-energy-density pulsed capacitors) are the most important components in high-power pulsed drive power supplies, primarily responsible for storing and releasing energy. As pulsed power supplies develop towards higher power, higher repetition frequency, and miniaturization, higher requirements are placed on pulsed capacitors. Pulsed capacitors typically consist of dozens or even hundreds of large-capacity cores connected in series and parallel through welding to form a core assembly. The winding process, as a key process in capacitor manufacturing, determines the capacitance, voltage withstand level, and current withstand level of the core; therefore, the quality of the winding process determines the performance of the core and even the entire capacitor. During core winding, tension control devices are used to shape the core. However, ineffective control may cause the shaped core to fail under extreme conditions. Therefore, precise tension control is crucial to the performance of high-end capacitors.
[0003] like Figure 1 As shown, the large-capacity capacitor core winding equipment mainly includes a metallized film reel 1, a tension roller 2, a capacitor core reel 4, and one or more ( Figure 1 The metallized film 3 on the metallized film roll 1 (two in total) is wound around multiple tension rollers 2 (generally, each type of metallized film 3 corresponds to at least two or more tension rollers 2 to meet the tension requirements during the winding process) before being wound onto the capacitor core roll 4. The basic working principle of the tension rollers 2 is that the rollers are covered with air bladders, and the outer diameter is changed by controlling the volume of gas inside the air bladders, thereby changing the tension of the metallized film 3. Figure 2 As shown, among the multiple tension rollers 2 corresponding to each metallized film 3, at least one tension roller 2 is mounted on the weighing sensor 5 and connected to the inflation component (not shown in the figure) to detect the real-time tension of the metallized film 3, so that the processor can control the tension roller 2 according to the detected real-time tension information.
[0004] Traditional tension control methods using the tension roller 2 in the aforementioned large-capacity capacitor core winding equipment mainly include the following two approaches: First, setting a constant tension parameter through a processor to achieve core winding; second, setting staged variable tension parameters through a processor to achieve core winding. The first method results in a tight inner coil and a loose outer coil in the large-capacity capacitor core, leading to poor core formation and excessive capacity deviation. Under extreme conditions, poor interlayer density of the core film can cause voltage arcing, triggering a self-healing chain effect that leads to capacitor core failure and high-energy-density pulse capacitor failure. The second method uses multiple stages of tension and pressure to generate output tension. The step-wound stage is a weak point in the core formation; under extreme conditions, poor interlayer density of the capacitor core film during the step-wound stage can cause voltage arcing, triggering a self-healing chain effect that leads to capacitor core failure and high-energy-density pulse capacitor failure. Furthermore, neither of these traditional control methods effectively corrects deviations, and tension execution deviations caused by differences in the winding equipment and the metallized film itself reduce winding quality. Summary of the Invention
[0005] The purpose of this invention is to provide a variable tension control method for winding large-capacity capacitor cores that has better tension control effect and has a correction function in order to solve the above problems.
[0006] The present invention achieves the above objectives through the following technical solutions:
[0007] A variable tension control method for winding large-capacity capacitor cores is implemented using a large-capacity capacitor core winding device. The device includes a metallized film roll, tension rollers, and a capacitor core roll. Metallized film on one or more of the metallized film rolls is wound around multiple tension rollers before being wound onto the capacitor core roll. For each type of metallized film, at least one of the multiple tension rollers is mounted on a load cell. The signal output terminal of the load cell is connected to the signal input terminal of a processor. The control input terminal of the tension roller is connected to the control output terminal of the processor. The variable tension control method for winding large-capacity capacitor cores includes the following steps:
[0008] Step 1: Establish a tension curve in the processor for each specification of metallized film roll and the metallized film wound on it. This tension curve uses the percentage of effective turns as the x-axis and the tension value as the y-axis. The effective turn percentage represents the percentage of metallized film turns already wound on the capacitor core roll relative to the total number of metallized film turns before winding on the corresponding roll. The tension value is the control parameter used in the processor to determine the magnitude of the tension roller. This tension curve is established using the following tension mathematical model:
[0009] ,
[0010] Where T is the tension value, x is the percentage of effective turns, a is a constant determined by the winding speed and the diameter of the metallized film on the metallized film roll before winding, b is a constant determined by the width and thickness of the metallized film, c is a constant determined by the elastic modulus of the metallized film, a, b, and c are obtained from relevant experiments, and d is the starting tension value.
[0011] Step 2: Define the following parameters: T0 is the tension preset value, T x T0 is the real-time sampled tension value obtained by the weighing sensor. ΔT is the tension deviation of the equipment caused by the winding equipment, and ΔT' is the tension deviation of the material caused by the metallized film. ΔT is greater than ΔT'. T0, ΔT and ΔT' are obtained through relevant experiments.
[0012] Step 3: The processor performs the following calculations and processes: When When, the output is the same as T. x The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters are used, and the tension values in the tension curve are corrected in real time based on the above results to complete the correction; when When the alarm is cleared, an alarm signal is output and the equipment is stopped until the alarm is cleared and the process returns to step 2 until all the winding of the corresponding metallized film is completed.
[0013] Preferably, in order to update the tension mathematical model and achieve better tension control, step 3 is followed by the following steps for updating the tension mathematical model:
[0014] Step 4: Archive the tension curves completed in Steps 1-3 and transfer them to the tension curve management database on the remote terminal computer.
[0015] Step 5: Perform statistical analysis on the historical tension curves of one specification, calculate n tension curves, and obtain the tension mean Ti, standard deviation si, and coefficient of variation. Let △Tcvi be the effective variation deviation coefficient. When Tcvi≤△Tcvi, the calculated n tension curves are valid; when Tcvi>△Tcvi, the calculated n tension curves are invalid. Where i is the i-th percentage point of the tension curve, and Ti is the tension mean at the i-th percentage point.
[0016] Step 6: Using the historical tension curve data deemed acceptable in Step 5, perform mean fitting using the least squares method to obtain the updated tension mathematical model. a', b', c', and d' are the corrected constants that correspond one-to-one with a, b, c, and d, respectively; for metallized film rolls of the same specification and the metallized film wound on them, the updated tension mathematical model is used in the next winding control.
[0017] The beneficial effects of this invention are as follows:
[0018] This invention establishes a tension curve through a tension mathematical model and performs specific correction calculations and judgments based on real-time sampled tension values, preset tension values, equipment tension deviations, and material tension deviations. It outputs tension roller control parameters with smaller real-time errors, ensuring precise control and continuous output of variable tension. This avoids the problem of excessive tension fluctuations caused by deviations between the winding equipment and the metallized film, which leads to poor core winding formation and excessive capacity deviations. This improves the consistency of core winding and product quality in large-capacity capacitors. Furthermore, by learning from and updating historical tension curves of the same specification core winding, the effectiveness of the tension mathematical model is further improved, making tension control more precise and efficient. This achieves closed-loop management of the tension curve through "setting-sampling-correction-learning," further improving winding quality and product quality. Attached Figure Description
[0019] Figure 1 This is a schematic diagram of the large-capacity capacitor core winding equipment described in this invention during operation;
[0020] Figure 2 This is a three-dimensional structural diagram of the tension roller and weighing sensor of the large-capacity capacitor core winding equipment described in this invention;
[0021] Figure 3 This is a schematic diagram of the tension curve before correction in step 3 of the variable tension control method for winding large-capacity capacitor cores according to the present invention, and also a schematic diagram of the tension curve established in step 1.
[0022] Figure 4 This is a schematic diagram of the tension curve after correction in step 3 of the variable tension control method for winding large-capacity capacitor cores according to the present invention. Detailed Implementation
[0023] The present invention will be further described below with reference to the accompanying drawings:
[0024] like Figures 1-2As shown, the variable tension control method for winding large-capacity capacitor cores according to the present invention is implemented by a large-capacity capacitor core winding device. The large-capacity capacitor core winding device includes a metallized film roll 1, a tension roller 2, and a capacitor core roll 4. One or more (two in the figure) metallized film 3s on the metallized film roll 1 are wound around multiple tension rollers 2 and then wound onto the capacitor core roll 4. Among the multiple tension rollers 2 corresponding to each type of metallized film 3, at least one tension roller 2 is installed on a weighing sensor 5. The signal output terminal of the weighing sensor 5 is connected to the signal input terminal of a processor (not shown in the figure), and the control input terminal of the tension roller 2 is connected to the control output terminal of the processor.
[0025] refer to Figure 1 and Figure 2 The variable tension control method for winding large-capacity capacitor cores includes the following steps:
[0026] Step 1: Establish a tension curve in the processor for each specification of metallized film roll 1 and the metallized film 3 wound on it. The tension curve is plotted on the x-axis as the percentage of effective turns and on the y-axis as the tension value. The tension value is the percentage of the number of turns of metallized film 3 already wound on the capacitor core roll 4 out of the total number of turns of metallized film 3 before winding on the corresponding metallized film roll 1. The tension value is the value of the control parameter used in the processor to determine the magnitude of the tension roller 2. This tension curve is established through the following tension mathematical model:
[0027] ,
[0028] Where T is the tension value, x is the percentage of effective turns, a is a constant determined by the winding speed and the diameter of the metallized film 3 on the metallized film roll 1 before winding, b is a constant determined by the width and thickness of the metallized film 3, c is a constant determined by the elastic modulus of the metallized film 3, a, b, and c are obtained from relevant experiments, and d is the starting tension value; the tension curve established in this step is as follows. Figure 3 As shown;
[0029] Step 2: Define the following parameters: T0 is the tension preset value, T x ΔT is the real-time sampled tension value obtained by the weighing sensor 5. ΔT is the equipment tension deviation caused by the winding equipment (including various electromechanical equipment and components other than the metallized film 3). ΔT' is the material tension deviation caused by the metallized film 3. ΔT is greater than ΔT'. T0, ΔT and ΔT' are obtained through relevant experiments.
[0030] Step 3: The processor performs the following calculations and processes: When When, the output is the same as T. x The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters are used, and the tension values in the tension curve are corrected in real time based on the above results to complete the correction. The corrected tension curve is as follows: Figure 4 As shown; when When the alarm is cleared, an alarm signal is output and the equipment is stopped until the alarm is cleared and the process returns to step 2 until all the winding of the corresponding metallized film 3 is completed.
[0031] Preferably, in order to update the tension mathematical model and achieve better tension control, step 3 is followed by the following steps for updating the tension mathematical model:
[0032] Step 4: Archive the tension curves completed in Steps 1-3 and transfer them to the tension curve management database on the remote terminal computer.
[0033] Step 5: Perform statistical analysis on the historical tension curves of one specification, calculate n tension curves, and obtain the tension mean Ti, standard deviation si, and coefficient of variation. Let △Tcvi be the effective variation deviation coefficient. When Tcvi≤△Tcvi, the calculated n tension curves are valid; when Tcvi>△Tcvi, the calculated n tension curves are invalid. Where i is the i-th percentage point of the tension curve, and Ti is the tension mean at the i-th percentage point.
[0034] Step 6: Using the historical tension curve data deemed acceptable in Step 5, perform mean fitting using the least squares method to obtain the updated tension mathematical model. a', b', c', and d' are the corrected constants that correspond one-to-one with a, b, c, and d, respectively; for the metallized film roll 1 and the metallized film 3 wound on it of the same specification, the updated tension mathematical model is used in the next winding control.
[0035] The above embodiments are merely preferred embodiments of the present invention and are not intended to limit the technical solutions of the present invention. Any technical solution that can be implemented based on the above embodiments without creative effort should be considered to fall within the scope of protection of the patent of the present invention.
Claims
1. A variable tension control method for winding large-capacity capacitor cores, implemented using a large-capacity capacitor core winding device, the large-capacity capacitor core winding device comprising a metallized film roll, tension rollers, and a capacitor core roll, wherein a metallized film on one or more of the metallized film rolls is wound around a plurality of tension rollers before being wound onto the capacitor core roll, wherein at least one of the plurality of tension rollers corresponding to each type of metallized film is mounted on a load cell, the signal output terminal of the load cell is connected to the signal input terminal of a processor, and the control input terminal of the tension roller is connected to the control output terminal of the processor, characterized in that: The variable tension control method for winding large-capacity capacitor cores includes the following steps: Step 1: Establish a tension curve in the processor for each specification of metallized film roll and the metallized film wound on it. This tension curve uses the percentage of effective turns as the x-axis and the tension value as the y-axis. The effective turn percentage represents the percentage of metallized film turns already wound on the capacitor core roll relative to the total number of metallized film turns before winding on the corresponding roll. The tension value is the control parameter used in the processor to determine the magnitude of the tension roller. This tension curve is established using the following tension mathematical model: ， Where T is the tension value, x is the percentage of effective turns, a is a constant determined by the winding speed and the diameter of the metallized film on the metallized film roll before winding, b is a constant determined by the width and thickness of the metallized film, c is a constant determined by the elastic modulus of the metallized film, a, b, and c are obtained from relevant experiments, and d is the starting tension value. Step 2: Define the following parameters: T0 is the tension preset value, T x T0 is the real-time sampled tension value obtained by the weighing sensor. ΔT is the tension deviation of the equipment caused by the winding equipment, and ΔT' is the tension deviation of the material caused by the metallized film. ΔT is greater than ΔT'. T0, ΔT and ΔT' are obtained through relevant experiments. Step 3: The processor performs the following calculations and processes: When When, the output is the same as T. x The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters, when At that time, the output is the same as The corresponding tension roller control parameters are used, and the tension values in the tension curve are corrected in real time based on the above results to complete the correction; when When the alarm is cleared, an alarm signal is output and the equipment is stopped until the alarm is cleared and the process returns to step 2 until all the winding of the corresponding metallized film is completed.
2. The variable tension control method for winding large-capacity capacitor cores according to claim 1, characterized in that: Step 3 is followed by the following steps for updating the tension mathematical model: Step 4: Archive the tension curves completed in Steps 1-3 and transfer them to the tension curve management database on the remote terminal computer. Step 5: Perform statistical analysis on the historical tension curves of one specification, calculate n tension curves, and obtain the tension mean Ti, standard deviation si, and coefficient of variation. Let △Tcvi be the effective variation deviation coefficient. When Tcvi≤△Tcvi, the calculated n tension curves are valid; when Tcvi>△Tcvi, the calculated n tension curves are invalid. Where i is the i-th percentage point of the tension curve, and Ti is the tension mean at the i-th percentage point. Step 6: Using the historical tension curve data deemed acceptable in Step 5, perform mean fitting using the least squares method to obtain the updated tension mathematical model. a', b', c', and d' are the corrected constants that correspond one-to-one with a, b, c, and d, respectively; for metallized film rolls of the same specification and the metallized film wound on them, the updated tension mathematical model is used in the next winding control.