A tensioner and tensioner system with tension compensation

Abstract

The application discloses a tensioner and a tensioner system with tension compensation, characterized in that the tensioner comprises a main body, a tension rod, a tension measuring assembly and a wire conveying assembly, the tension measuring assembly and the wire conveying assembly are arranged on the main body, the wire conveying assembly is used for conveying a wire, a controller receives a tension setting parameter through a user interface, calculates a compensation proportion value according to a formula, and then calculates a wire tension value; the controller adjusts the speed of the wire conveying assembly according to a measured value of the tension measuring assembly, so that the measured tension matches the calculated value. The tension rod is designed to rotate and adapt to the wire conveying path; the compensation proportion is calculated according to the accurate formula, and real-time measurement and speed adjustment are combined, so that the accurate compensation and constant control of the wire tension are realized, and the tension control precision is improved.

Description

Technical Field

[0001] This invention relates to tension measurement, and more specifically to a tensioner and tensioner system with tension compensation. Background Technology

[0002] In the winding process of small transformers and relay coils, the winding machine and tensioner are the core supporting equipment. The core function of the tensioner is to provide appropriate wire tension for the winding process, so as to ensure that the coil is of moderate tightness and the winding is tight and full.

[0003] CN209895919U discloses a servo tensioner with a digital display function for tension measurement; it includes a base plate, a tension rod, a measuring wheel assembly, a tension sensor, a tension measurement circuit, and a main wire wheel; the tension rod is rotatably connected to the base plate, and a wire exit wheel is connected to its end; the measuring wheel assembly is located between the main wire wheel and the wire exit wheel, including a measuring wheel and a guide wheel, with the measuring wheel located below the guide wheel, and the wire is led out from the main wire wheel, passing through the measuring wheel and the guide wheel in sequence to the wire exit wheel; the rotating shaft of the measuring wheel is connected to the tension sensor through a force guide frame, which transmits the force signal of the measuring wheel to the tension measurement circuit, and displays the tension value through a display device.

[0004] As can be seen, the CN209895919U solution only uses a tension sensor to measure the tension of the measuring wheel assembly and displays the tension value. However, many users are accustomed to measuring the tension at the line inlet after the output wheel. But there are one or more wire guides between the output wheel of the tensioner and the line inlet of the wire. All wire guides will affect the final output tension value.

[0005] Therefore, it is urgent to solve how to compensate for the wire tension value based on the measured value at the tip of the wire to obtain the actual required tension value. Summary of the Invention

[0006] To address the problems existing in the prior art, this invention proposes a tensioner and tensioner system with tension compensation to solve the problem of how to compensate for the tension value of the wire based on the measured value at the end of the wire nozzle, so as to obtain the actual required tension value.

[0007] In a first aspect, this application proposes a tensioner with tension compensation, the tensioner comprising a main body, a tension rod, a tension measuring component, and a wire conveying component, wherein the main body is provided with the tension measuring component and the wire conveying component, the wire conveying component is used to convey the wire to the tension measuring component, and the tension measuring component is used to measure the tension of the wire; The main body is provided with a first base surface, and a rotating shaft is provided on the first base surface. The rotating shaft is perpendicular to the first base surface. The tension rod is connected to the rotating shaft. One side of the tension rod rotates around the rotating shaft inside or outside the first base surface. A wire output wheel is provided on the other side of the tension rod away from the rotating shaft. The wire output wheel is used to receive the wire from the tension measuring component and deliver it to the wire tip. The tensioner also includes a controller configured to perform a compensation step, specifically: The device is used to receive tension setting parameters from the user interface. The tension setting parameters include a set tension upper limit value, a set tension lower limit value, a compensation ratio value, and a wire tip tension value. The compensation ratio value is calculated as (target tension value - wire tip tension value + target tension value) / first difference value, where the first difference value is the difference between the set tension lower limit value and the set tension upper limit value, and the target tension value is user-defined. The wire tension value is calculated based on the first difference and the compensation ratio value, and the wire tension value is equal to the product of the first difference and the compensation ratio value. The first measured tension value of the tension measuring component is received in real time, and the conveying speed of the wire conveying component is adjusted to regulate the tension of the wire until the first measured tension value is equal to the wire tension value.

[0008] In a specific embodiment, the tension controller includes a PID controller, which is used to adjust the conveying speed of the wire conveying assembly, and includes the following algorithm: ,in The output of the PID controller is e(t), where e(t) is the tension deviation, which is the absolute value of the difference between the first measured value and the wire tension value; t is the current time. This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients; The controller has a preset reference scaling factor. Baseline integral coefficient Reference differential coefficients ; The operating condition is determined based on the conveying speed change rate, tension fluctuation rate, and tension deviation: when the conveying speed change rate is greater than or equal to the set speed change threshold, or the tension fluctuation rate is greater than or equal to the set tension change rate threshold, or the system is in the start-up or stop phase, it is determined to be a dynamic operating condition; when the conveying tension fluctuation rate is less than the set tension change rate threshold, and the tension deviation is less than the set steady-state deviation threshold for multiple consecutive sampling periods, it is determined to be a steady-state conveying operating condition. When the condition is determined to be steady-state conveying operation... , and ,in, < ; > ; < ; When the condition is determined to be dynamic, the following applies: , and ,in, > ; < ; < , > .

[0009] In a specific embodiment, the user interface is provided with a tension compensation control, which can trigger a tension segment setting interface. The tension segment setting interface can set parameter values ​​for multiple tension segments. The parameter values ​​for each tension segment include a set upper tension value, a set lower tension value, a compensation ratio value, and a tension value at the tip of the wire. The tension segment setting interface also includes a tension segment selection control for receiving the user's tension segment selection. The controller includes a storage area for storing the parameter values ​​of the multiple tension segments. The controller receives the parameters from the tension segment selection control, calls the corresponding tension segment parameter value from the storage area, and executes the compensation step according to the parameter value of the tension segment.

[0010] In a specific embodiment, if the tension segment is selected as multiple segments, the controller executes the corresponding compensation steps in the order of the tension segment numbers.

[0011] In a specific embodiment, the user interface further includes a display compensation value, wherein the display compensation value = wire tip tension value - first tension value + first tension value, the wire tip tension value is pre-measured by the customer, the first tension value is measured in real time by the tension measuring component, and the display compensation value can be dynamically displayed according to the change of the first tension value over time.

[0012] In a specific embodiment, the wire conveying assembly includes a main wire pulley and a drive motor, the tension measuring assembly includes a tension wheel and a tension sensor, the drive motor drives the main wire pulley to convey the wire to the tension wheel, and then from the tension wheel to the output pulley, the tension sensor measures the tension at the tension wheel, and the controller is connected to the drive motor and the tension sensor respectively.

[0013] In a specific embodiment, the tensioner is also equipped with an alarm device and an angle sensor. The angle sensor is also provided at the tension rod to detect the rotation angle of the tension rod relative to the rotating shaft. If it exceeds a first preset angle, the alarm device is triggered.

[0014] In a specific embodiment, when the tension rod rotates to a second preset angle, the wire conveying assembly starts conveying the wire; when the tension rod rotates to a third preset angle, the tension rod is restricted from rotating.

[0015] In a specific embodiment, the user interface is equipped with an alarm indicator light, which displays different colors when the tension rod rotates to a second preset angle or a third preset angle.

[0016] The second aspect of this application proposes a tensioner system with tension compensation, comprising a plurality of the aforementioned tensioners, the plurality of tensioners being arranged in sequence, wherein the tensioner with the first sequence number can communicate with at least one of the remaining tensioners and send the same tension setting parameter value to the remaining at least one tensioner.

[0017] It has the following beneficial effects: 1. The controller receives tension setting parameters through the user interface, calculates the compensation ratio value according to the formula, and then calculates the wire tension value. Based on the actual measured value of the tension measuring component, the controller adjusts the speed of the wire conveying component to match the actual tension with the calculated value. The tension rod rotation design adapts to the wire conveying path; by calculating the compensation ratio with a precise formula, combined with real-time measurement and speed adjustment, accurate compensation and constant control of wire tension are achieved, improving tension control accuracy.

[0018] 2. The interface includes a tension segment selection control. The controller's storage area saves parameters for multiple segments, allowing for the retrieval of the corresponding segment parameters for compensation. It supports independent parameter settings for multiple tension segments, adapting to the tension requirements of different processes. Parameters can be stored and recalled with a single click, simplifying the operation process and improving the tensioner's process adaptability and ease of operation.

[0019] 3. If multiple tension segments are selected, the controller will execute the corresponding tension compensation steps for each segment sequentially according to their number. This enables automatic sequential switching of multiple tension segments without manual intervention, adapting to the segmented tension requirements of continuous processes such as winding, and improving the level of production automation and process continuity.

[0020] 4. The displayed compensation value can be dynamically updated over time based on the real-time measurement of the first tension value. The displayed compensation value closely matches the actual tension requirements at the tip of the wire and dynamically updates to reflect tension changes in real time, allowing users to intuitively grasp the tension status at the tip of the wire and facilitating real-time monitoring and adjustment.

[0021] 5. The angle sensor monitors the rotation angle of the tension rod in real time and will promptly alarm if the angle exceeds the preset value. This can quickly detect problems such as wire breakage and abnormal tension, enabling early warning of faults and reducing product scrap and production losses.

[0022] 6. Enables unified distribution and synchronous setting of parameters for multiple tensioners, eliminating the need for manual adjustment of individual units. This improves the debugging efficiency of multi-machine coordinated production, ensures consistency in tension control across multiple devices, and enhances the stability of product quality in batch production. After synchronous setting, individual adjustments can still be made as needed. Attached Figure Description

[0023] The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments and, together with the description, serve to explain the principles of the invention. Other embodiments and many anticipated advantages of the embodiments will be readily recognized as they become better understood through reference to the following detailed description. Elements in the drawings are not necessarily to scale. The same reference numerals refer to corresponding similar parts.

[0024] Figure 1 This is a first schematic diagram of a tensioner with tension compensation; Figure 2 This is a second schematic diagram of a tensioner with tension compensation; Figure 3 A flowchart to display the real-time first measured tension value.

[0025] Figure label: 1-Main body; 2-Tension bar; 3-Tension measurement component; 301-Tension wheel; 302-Tension sensor; 4-Wire conveying component; 401-Main wire wheel; 402-Drive motor; 101-First base surface; 201-Rotating shaft; 5-Outlet wheel; 6-Controller; 7-Angle sensor. Detailed Implementation

[0026] In the following detailed description, reference is made to the accompanying drawings, which form part of the detailed description and are illustrated by specific illustrative embodiments in which the invention may be practiced. In this regard, directional terms such as “top,” “bottom,” “left,” “right,” “up,” “down,” etc., are used with reference to the orientation of the described figures. Because components of the embodiments can be positioned in several different orientations, directional terms are used for illustrative purposes and are by no means limiting. It should be understood that other embodiments may be utilized or logical changes may be made without departing from the scope of the invention. Therefore, the following detailed description should not be taken in a limiting sense, and the scope of the invention is defined by the appended claims.

[0027] refer to Figure 1-2 The tensioner includes a main body 1, a tension rod 2, a tension measuring component 3, and a wire conveying component 4. The main body 1 is provided with the tension measuring component 3 and the wire conveying component 4. The wire conveying component 4 is used to convey the wire to the tension measuring component 3, and the tension measuring component 3 is used to measure the tension of the wire. The system features a compact layout of three core components: tension bar 2, tension measurement assembly 3, and wire conveying assembly 4. Each component has a clearly defined function and forms an upstream and downstream work link. The conveying assembly is dedicated to the directional transmission of wire, while the measurement assembly is responsible for real-time detection of wire tension. The layout of the components matches the physical trajectory of wire transmission, eliminating redundant transmission structures. This integrated design enhances the structural stability of the equipment and avoids transmission deviations and measurement errors caused by the dispersed arrangement of components. The link-like layout of the conveying and measurement components allows tension detection to be completed directly during wire transmission, reducing contact points and friction losses. It also simplifies equipment assembly and subsequent maintenance, lowers repair costs, and adapts to the basic structural requirements of high-precision wire processing.

[0028] The wire conveying assembly 4 includes a main wire reel 401 and a drive motor 402. The tension measuring assembly 3 includes a tension wheel 301 and a tension sensor 302. The drive motor 402 drives the main wire reel 401 to convey the wire to the tension wheel 301, and then from the tension wheel 301 to the output reel 5. The tension sensor 302 measures the tension at the tension wheel 301.

[0029] The detection principle of a tension sensor is as follows: Enameled wire is wound around a tension wheel at a certain angle, typically 90°-180°, according to the process path. The tension during wire transmission generates radial pressure or tension on the tension wheel; the greater the tension, the greater the pressure or tension on the tension wheel. The tension wheel is rigidly connected to the elastic sensitive element of a strain gauge tension sensor. The pressure applied to the tension wheel by the wire is directly transmitted to the sensor's elastic sensitive element, causing it to undergo a small mechanical deformation proportional to the tension. This deformation of the elastic sensitive element causes a change in the resistance value of the surface strain gauge, and the sensor outputs a corresponding electrical signal. This signal is transmitted to the tension controller in real time. The controller uses a preset force calibration curve or conversion formula to convert the electrical signal back into a specific tension value (such as g, N), and compares it with the set tension value to achieve subsequent dynamic adjustment. Miniature patch strain gauge force sensors can be used as tension sensors.

[0030] The conveying assembly consists of a drive motor 402 and a main wire pulley 401, forming an active power structure. The motor's adjustable speed drives the main wire pulley 401 to feed the wire at a uniform speed. The measuring assembly comprises a tension wheel 301 and a tension sensor 302, a contact-type detection structure. The tension wheel 301 provides a stable force point for the wire, and the sensor precisely contacts the tension wheel 301 for detection. The wire transmission path is clearly defined as main wire pulley 401 → tension wheel 301 → output pulley 5. The wheel arrangement matches the natural transmission trajectory of the wire, ensuring uniform force distribution without bending. The speed-adjustable motor adapts to the feeding speed requirements of different wire diameters and processes. The rotation of the main wire pulley 401 reduces sliding friction of the wire, protecting the surface quality of the wire.

[0031] The main body 1 is provided with a first base surface 101, on which a rotating shaft 201 is provided. The rotating shaft 201 is perpendicular to the first base surface 101. The tension rod 2 is connected to the rotating shaft 201. One side of the tension rod 2 rotates around the rotating shaft 201 inside or outside the first base surface 101. The other side of the tension rod 2 away from the rotating shaft 201 is provided with a wire outlet wheel 5. The wire outlet wheel 5 is used to receive the wire from the tension measuring component 3 and deliver it to the wire nozzle end. The wire nozzle end refers to the part that may pass through several wire guide components after exiting from the wire outlet wheel 5 and then to the wire winding place. This wire nozzle end is usually not on the tensioner, but on the worktable closer to the user.

[0032] The tensioner also includes a controller 6, which is connected to the drive motor 402 and the tension sensor 302 respectively. The controller 6 is configured to perform a compensation step, specifically: The device is used to receive tension setting parameters from the user interface. The tension setting parameters include a set upper tension value, a set lower tension value, a compensation ratio value, and a wire tip tension value. The compensation ratio value is calculated as (target tension value - wire tip tension value + target tension value) / first difference. The first difference is the difference between the set lower tension value and the set upper tension value. The target tension value is user-defined, and the user interface can also receive the target tension value.

[0033] The wire tension value is calculated based on the first difference and the compensation ratio value. The wire tension value is equal to the product of the first difference and the compensation ratio value. The target tension value changed by the user can be received at any time, and the actual wire tension value that the tension sensor 302 should detect can be calculated. The user can also change the tension value at the wire nozzle end at any time, and the actual wire tension value that the tension sensor 302 should detect can be calculated based on the change in the tension value at the wire nozzle end.

[0034] The tension controller includes a PID controller, and the PID output is the speed adjustment of the motor. ,in The output of the PID controller is e(t), where e(t) is the tension deviation, which is the absolute value of the difference between the first measured value and the wire tension value; t is the current time. This is the proportionality coefficient. The integral coefficient is... is the differential coefficient.

[0035] The controller has a preset reference scaling factor. Baseline integral coefficient Reference differential coefficients ; Based on the rate of change of conveying speed Tension fluctuation rate The working condition is determined by the tension deviation e(t): when the rate of change of conveying speed is greater than or equal to the set speed change threshold, or the rate of tension fluctuation is greater than or equal to the set rate of change of tension threshold, or the system is in the start / stop phase, it is determined to be a dynamic working condition; when the rate of change of conveying tension is less than the set rate of change of tension threshold, and the tension deviation is less than the set steady-state deviation threshold in multiple consecutive sampling periods, it is determined to be a steady-state conveying working condition.

[0036] When the condition is determined to be steady-state conveying operation... , and ,in, < ; > ; < ; For example, the proportionality coefficient =(0.4~0.8)× Integral coefficient =(1.2~2.0)× Differential coefficients =(0.2~0.6)× ; When it is determined to be a dynamic operating condition , and ,in, > ; < ; < , > ; proportionality coefficient =(1.2~2.0)× Integral coefficient =(0.2~0.6)× Differential coefficients = (0.8~1.2)× .

[0037] Fine-tuning of steady-state conveying conditions: If there is a small static error in the tension (deviation > 0.5% × set steady-state deviation threshold for 5 consecutive sampling cycles), increase the tension appropriately. (e.g., from 1.2) Adjusted to 1.5 If slight tension fluctuations occur (within 5 consecutive sampling periods, the first tension value fluctuates around the wire tension value, with a fluctuation range between 1% and 3%), reduce the tension appropriately. (e.g. from 0.8×) Adjusted to 0.6× If there are high-frequency small fluctuations in tension (fluctuation frequency > 10Hz), reduce the tension appropriately. (e.g. from 0.6×) Adjusted to 0.4× This avoids amplifying minute fluctuations due to differential action, ensuring stable and uninterrupted steady-state tension.

[0038] Dynamic operating condition fine-tuning: If the tension response lags (after a sudden speed change, the tension deviation > 3% × the set steady-state deviation threshold and continues for more than 3 sampling periods), appropriately increase the [weight / adjustment]. (e.g. from 1.2×) Adjusted to 1.8× If overshoot occurs (tension exceeds the wire tension value by more than 2%), increase the tension appropriately. For example, from 0.8× Adjusted to 1.0× If the tension deviation continues to accumulate during the dynamic process and cannot be quickly corrected (the deviation does not decrease after 8 consecutive sampling periods), appropriately increase the [weight / size]. (e.g. from 0.2×) Adjusted to 0.4× ), while avoiding Excessive size can exacerbate overshoot; a balance must be struck between response speed and adjustment accuracy.

[0039] In this embodiment, the tension controller employs PID closed-loop control, using speed adjustment as output and tension deviation as input. Combined with a reference coefficient and an adaptive switching strategy based on operating conditions, it significantly improves the accuracy and stability of tension control. It presets a reference coefficient and dynamically adjusts the PID parameters according to operating conditions, employing a small reference coefficient in steady state. ,big ,Small Effectively eliminates static error and avoids oscillation; in dynamic situations, large... ,Small ,middle It responds quickly to changes in speed and suppresses overshoot. Simultaneously, targeted fine-tuning rules can optimize parameters in real time based on tension fluctuations, static error, and response lag, adapting to different operating scenarios. The overall design achieves precise and rapid tension control, reducing wire tension fluctuations, avoiding wire damage caused by unstable tension, improving equipment operating efficiency and product quality. Furthermore, parameter adjustments can be engineered and implemented, adapting to various wire specifications and conveying conditions, making it highly practical and widely adaptable.

[0040] The first measured tension value of the tension measuring component 3 is received in real time, and the conveying speed of the wire conveying component 4 is adjusted to regulate the tension of the wire until the first measured tension value is equal to the wire tension value.

[0041] Real-time reception of the first measured tension value from tension measuring component 3; see details below. Figure 3The specific steps are as follows: Step 1: Determine whether a target tension value has been set. If it is determined that no target tension value has been set, proceed directly to Step 7, output the real-time first measured tension value corresponding to the pressure sensor value, and the process ends. If the target tension value has been set: proceed to the pressure sensor creep correction process and execute step 2.

[0042] The purpose of this step is to: add a pre-judgment mechanism for the target tension value to achieve process diversion and control; and in the case where no target tension value is set, directly skip the entire creep correction process, quickly output real-time tension data, simplify the invalid calculation process, reduce system computing power consumption, improve data response speed, and take into account the basic real-time measurement needs in uncalibrated scenarios.

[0043] Step 2: Start the pressure sensor creep correction process, read the output data of the pressure sensor in real time, and obtain the raw tension data currently being detected.

[0044] The beneficial effects of this step are: to initiate the sensor creep correction process and collect raw tension data in real time, to capture the real raw output signal of the pressure sensor, and to provide the raw data basis for subsequent filtering, error analysis and model correction, thus locking in the raw data source of sensor creep drift from the source.

[0045] Step 3: Filter the real-time data to eliminate random noise interference, and record the difference between the current tension value and the preset target tension value after filtering.

[0046] The beneficial effects of this step are: filtering and noise reduction of the raw real-time data effectively eliminates data fluctuations caused by external random noise and electromagnetic interference, improving the stability and authenticity of the raw tension data; at the same time, it records the difference between the measured value and the target value, quantifies the magnitude of the sensor deviation, and provides a reliable comparison basis for subsequent accuracy judgment and error correction.

[0047] Step 4: Determine whether the recorded difference value meets the preset precision threshold (within 3% in this embodiment): If the difference is within 3%: the correction is deemed complete, proceed to step 7, output the real-time first measured tension value, and the process ends; If the difference exceeds 3%, it is determined that error correction is required, and step 5 is executed.

[0048] A 3% accuracy threshold is set as the calibration termination criterion to automatically identify calibration needs; calibration ends directly and enters the output stage when the deviation meets the standard, avoiding over-calibration; when the deviation exceeds the standard, the subsequent error correction process is triggered, balancing measurement accuracy requirements and system operating efficiency, and preventing invalid loop calculations.

[0049] The benefits of this step are as follows: setting a 3% accuracy threshold as the calibration termination criterion enables automatic identification of calibration needs; when the deviation meets the standard, the calibration ends directly and enters the output stage, avoiding over-calibration; when the deviation exceeds the standard, the subsequent error correction process is triggered, balancing measurement accuracy requirements with system operating efficiency and preventing invalid loop calculations.

[0050] Step 5: Periodically calculate the current tension value data at a preset time interval (50ms in this embodiment); calculate the arithmetic mean of every 20 sampled data points as a group, and use the average value as the effective error value of the group for error comparison with the target tension value.

[0051] The beneficial effects of this step are as follows: sampling is performed at a fixed period of 50ms, and the arithmetic mean of 20 sampled data is calculated as the effective error value. This smooths out random fluctuations in a single sampling, weakens the influence of instantaneous interference data, extracts the true creep error characteristics, makes the error comparison results more objective and accurate, and avoids interference from single-point abnormal data with the correction results.

[0052] Step 6: Repeat the sampling and averaging process of Step 5, accumulating 3 sets of valid error values; based on the 3 sets of error values, correct the tension calculation model of the pressure sensor, update the correspondence between the pressure sensor value and the tension value, and complete the creep compensation. After the correction is completed, jump back to Step 4, re-execute the accuracy threshold determination, form a closed-loop correction circuit, until the difference value meets the accuracy requirement of within 3%.

[0053] The beneficial effects of this step are as follows: three sets of effective error values ​​are collected for model correction, and the tension conversion model is corrected by comprehensively fitting multiple sets of samples to complete sensor creep compensation, which greatly reduces the measurement drift error caused by long-term creep of the pressure sensor; at the same time, the closed loop jumps back to the accuracy judgment step, forming a closed loop of repeated verification and correction, and continuously iterating until the accuracy index is met, ensuring long-term accurate and stable tension measurement under all working conditions.

[0054] Step 7: Convert the output value of the pressure sensor into the corresponding tension value, display and output the real-time first measured tension value, and the process ends.

[0055] The benefits of this step are: it completes the standard conversion between sensor values ​​and tension values, and finally visualizes and outputs the real-time first measured tension value, realizing complete and accurate real-time tension measurement output, and providing a reliable real-time data source for subsequent equipment tension control and monitoring feedback.

[0056] Adjusting the speed of the drive motor to regulate wire tension is essentially achieved by changing the wire's feed speed to balance the speed difference between the wire at the tensioner output and the winding machine or processing end, thereby altering the tension on the wire. This allows for precise tension control. The entire process involves the controller 6 dynamically controlling the tension in a closed loop based on real-time data from the tension sensor 302. The controller 6 receives the measured values ​​from the tension sensor 302 in real time and continuously compares them with the user-set target tension value (the wire tension value after compensation calculation). Based on the difference, it adjusts the drive motor speed (wire feed speed) in real time, forming a closed-loop control system of measurement, comparison, speed adjustment, and re-measurement. The controller 6 features a built-in standardized tension compensation program, executing in four steps: parameter reception, proportional calculation, tension value calculation, and real-time adjustment. The compensation ratio and wire tension value are precisely calculated using a fixed formula, incorporating user-defined target tension and actual wire tip tension. A closed-loop mode of real-time measurement and dynamic speed adjustment continuously compares the measured value with the target value until they match. The standardized program avoids subjective errors from manual adjustments, improving compensation consistency. The formula, combined with process objectives and actual working conditions, ensures the calculation results better match processing requirements. Closed-loop dynamic adjustment quickly captures tension fluctuations and stabilizes the tension at the target value through speed adjustment, effectively preventing wire breakage and loosening due to abnormal tension, thus improving processing quality.

[0057] In a specific embodiment, the user interface is provided with a tension compensation control, which can trigger a tension segment setting interface. The tension segment setting interface can set parameter values ​​for multiple tension segments. The parameter values ​​for each tension segment include a set upper tension value, a set lower tension value, a compensation ratio value, and a tension value at the tip of the wire. The tension segment setting interface also includes a tension segment selection control for receiving the user's tension segment selection. The controller 6 includes a storage area for storing the parameter values ​​of the multiple tension segments. The controller 6 receives the parameters from the tension segment selection control, calls the corresponding tension segment parameter value in the storage area, and executes the compensation step according to the parameter value of the tension segment.

[0058] The user interface features tension compensation controls, allowing for one-click triggering of the tension segment setting interface. It supports independent configuration of multiple tension segments, each with complete tension setting parameters. A tension segment selection control is also included; the controller's built-in storage area can permanently store parameters for multiple segments. Upon receiving a selection command, it automatically and accurately recalls the corresponding parameters and executes the compensation steps without manual intervention. Independent multi-segment configuration allows the equipment to adapt to the segmented tension requirements of complex processing techniques, significantly improving process adaptability. Parameter storage and one-click recall functions avoid repetitive debugging, save production preparation time, and reduce operator workload. Automated parameter recall and compensation execution reduce human error and improve the stability and ease of operation of tension control.

[0059] In a specific embodiment, if the tension segment is selected as multiple segments, the controller 6 executes the corresponding compensation steps according to the sequence number of the tension segments. Multiple segments mean that different target tension values ​​can be set with different compensation ratios and wire end tension values, which can be stored. When the user needs the parameters of a certain segment, i.e., a certain target tension value, the parameters of the corresponding segment can be directly called to calculate the actual wire tension value, that is, until the first measured value equals the wire tension value.

[0060] In a specific embodiment, the user interface further includes a display compensation value, which is calculated as: (Nose tip tension value - First tension value + First tension value). The nozzle tip tension value is pre-measured by the customer, and the first tension value is measured in real-time by the tension measuring component 3. The display compensation value dynamically changes over time according to changes in the first tension value. The user interface adds a dedicated digital display area to show the compensation value. The value is calculated using a fixed formula, integrating the pre-measured nozzle tip tension value and the real-time sensor measurement value. The display compensation value is linked to the first tension value and can be dynamically updated in real-time with subtle changes in tension, without delay. The simplified formula calculation logic ensures fast update speed.

[0061] In a specific embodiment, the tensioner is further equipped with an alarm device and an angle sensor 7. The angle sensor 7 is also installed at the tension rod 2 to detect the rotation angle of the tension rod 2 relative to the rotating shaft 201. If the rotation angle exceeds a first preset angle, the alarm device is triggered. When the tension rod 2 rotates to a second preset angle, the wire conveying assembly 4 starts conveying the wire. When the tension rod 2 rotates to a third preset angle, the rotation of the tension rod 2 is restricted. The restriction of rotation can be achieved by stopping the operation of the drive motor 402. The user interface is equipped with an alarm indicator light, which displays different colors when the tension rod 2 rotates to the second or third preset angle.

[0062] The angle sensor 7 can be a Hall-type non-contact angle sensor. The permanent magnet is fixed to the rotating shaft 201 of the tension rod and rotates synchronously with the tension rod. The Hall sensing chip is fixed next to the rotating shaft 201 of the tensioner body 1 and remains stationary. The two have no mechanical contact and only maintain a small gap of 0.5-2mm.

[0063] The angle sensor 7 can also be a potentiometer-type angle sensor, in which the rotating shaft of the potentiometer is coaxially and rigidly connected to the rotating shaft of the tension rod. The housing of the potentiometer is fixed on the tension rod body, and the rotation of the tension rod directly drives the rotating shaft of the potentiometer to rotate synchronously.

[0064] The second aspect of this application proposes a tensioner system with tension compensation, comprising multiple tensioners as described above. These tensioners are arranged by serial number, and the tensioner with the first serial number can communicate with at least one other tensioner, sending the same tension setting parameter value to the remaining tensioners. The tensioner system consists of multiple high-precision tensioners as described above, with all devices numbered sequentially according to the production workstation layout. The tensioner with the first serial number is designated as the master control unit, with a built-in communication module and parameter sending program. It can send complete and consistent tension setting parameters to the remaining subordinate tensioners with a single click via a stable wired or wireless link, supporting one-to-one and one-to-many communication.

[0065] It is evident that those skilled in the art can make various modifications and alterations to the embodiments of the present invention without departing from the spirit and scope of the invention. In this way, the invention is also intended to cover such modifications and alterations if they fall within the scope of the claims and their equivalents. The word "comprising" does not exclude the presence of other elements or steps not listed in the claims. The simple fact that certain measures are described in mutually different dependent claims does not indicate that a combination of these measures cannot be used for profit. Any reference numerals in the claims should not be considered as limiting the scope.

Claims

1. A tensioner with tension compensation, characterized in that, The tensioner includes a main body, a tension rod, a tension measuring component, and a wire conveying component. The main body is provided with the tension measuring component and the wire conveying component. The wire conveying component is used to convey the wire to the tension measuring component, and the tension measuring component is used to measure the tension of the wire. The main body is provided with a first base surface, and a rotating shaft is provided on the first base surface. The rotating shaft is perpendicular to the first base surface. The tension rod is connected to the rotating shaft. One side of the tension rod rotates around the rotating shaft inside or outside the first base surface. A wire output wheel is provided on the other side of the tension rod away from the rotating shaft. The wire output wheel is used to receive the wire from the tension measuring component and deliver it to the wire tip. The tensioner also includes a controller configured to perform a compensation step, specifically: The device is used to receive tension setting parameters from the user interface. The tension setting parameters include a set tension upper limit value, a set tension lower limit value, a compensation ratio value, and a wire tip tension value. The compensation ratio value is calculated as (target tension value - wire tip tension value + target tension value) / first difference value, where the first difference value is the difference between the set tension lower limit value and the set tension upper limit value, and the target tension value is user-defined. The wire tension value is calculated based on the first difference and the compensation ratio value, and the wire tension value is equal to the product of the first difference and the compensation ratio value. The first measured tension value of the tension measuring component is received in real time, and the conveying speed of the wire conveying component is adjusted to regulate the tension of the wire until the first measured tension value is equal to the wire tension value.

2. The tensioner with tension compensation according to claim 1, characterized in that, The tension controller includes a PID controller, which is used to adjust the conveying speed of the wire conveying assembly. Including the following algorithms: ,in The output of the PID controller is e(t), where e(t) is the tension deviation, which is the absolute value of the difference between the first measured value and the wire tension value, and t is the current time. This is the proportionality coefficient. The integral coefficient is... These are the differential coefficients; The controller has a preset reference scaling factor. Baseline integral coefficient Reference differential coefficients ; The operating condition is determined based on the rate of change of conveying speed, the rate of fluctuation of tension, and the tension deviation. When the rate of change of conveying speed is greater than or equal to the set speed change threshold, or the rate of fluctuation of tension is greater than or equal to the set rate of fluctuation of tension, or the system is in the start-up or stop phase, it is determined to be a dynamic operating condition. When the rate of fluctuation of conveying tension is less than the set rate of fluctuation of tension, and the tension deviation is less than the set steady-state deviation threshold in multiple consecutive sampling periods, it is determined to be a steady-state conveying operating condition. When the condition is determined to be steady-state conveying operation... , and ,in, < ; > ; < ; When the condition is determined to be dynamic, the following applies: , and ,in, > ; < ; < , > .

3. The tensioner with tension compensation according to claim 1, characterized in that, The user interface is equipped with a tension compensation control, which can trigger a tension segment setting interface. The tension segment setting interface can set parameter values ​​for multiple tension segments. The parameter values ​​for each tension segment include a set upper tension value, a set lower tension value, a compensation ratio value, and a tension value at the tip of the wire. The tension segment setting interface also includes a tension segment selection control for receiving the user's tension segment selection. The controller includes a storage area for storing the parameter values ​​of the multiple tension segments. The controller receives the parameters from the tension segment selection control, calls the corresponding tension segment parameter value from the storage area, and executes the compensation step according to the parameter value of that tension segment.

4. The tensioner with tension compensation according to claim 3, characterized in that, If the tension segment is selected as multiple segments, the controller executes the corresponding compensation steps in the order of the tension segment numbers.

5. The tensioner with tension compensation according to claim 1, characterized in that, The user interface also includes a display compensation value, which is equal to the tension value at the tip of the wire - the first tension value + the first tension value. The tension value at the tip of the wire is pre-measured by the customer, and the first tension value is measured in real time by the tension measuring component. The display compensation value can be dynamically displayed according to the change of the first tension value over time.

6. The tensioner with tension compensation according to claim 1, characterized in that, The wire conveying assembly includes a main wire pulley and a drive motor. The tension measuring assembly includes a tension wheel and a tension sensor. The drive motor drives the main wire pulley to convey the wire to the tension wheel, and then from the tension wheel to the output pulley. The tension sensor measures the tension at the tension wheel. The controller is connected to the drive motor and the tension sensor respectively.

7. The tensioner with tension compensation according to claim 1, characterized in that, The tensioner is also equipped with an alarm device and an angle sensor. The angle sensor is also installed at the tension rod to detect the rotation angle of the tension rod relative to the rotating shaft. If it exceeds a first preset angle, the alarm device will be triggered.

8. The tensioner with tension compensation according to claim 1, characterized in that, When the tension rod rotates to the second preset angle, the wire conveying assembly starts conveying the wire; when the tension rod rotates to the third preset angle, the tension rod is restricted from rotating.

9. The tensioner with tension compensation according to claim 8, characterized in that, The user interface is equipped with an alarm indicator light. When the tension rod rotates to a second preset angle or a third preset angle, the alarm indicator light displays different colors respectively.

10. A tensioner system with tension compensation, characterized in that, It includes multiple tensioners as described in any one of claims 1 to 9, the multiple tensioners are arranged in sequence, and the tensioner with the first sequence number can communicate with at least one other tensioner and send the same tension setting parameter value to at least one other tensioner.

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