A calendering and winding constant tension control system, method and electronic device

Abstract

The application provides a calendering and winding constant tension control system, method and electronic equipment, which is applied to a calendering production line including a main traction unit, a cloth storage and buffering unit and a winding unit, and includes: a first control module, which is used for acquiring an actual main tension of a material in a winding process, and performing closed-loop adjustment on the main traction unit according to a deviation of the actual main tension from a preset target main tension; a buffering adjustment module, which is configured in the cloth storage and buffering unit, and is used for acquiring a state parameter of the cloth storage and buffering unit, and controlling an action of the cloth storage and buffering unit according to the state parameter, so as to compensate for a speed difference or a tension fluctuation between the main traction unit and the winding unit; and a winding execution module, which is used for generating a driving instruction to control the winding unit to perform a winding action according to the preset target main tension, the state parameter and a parameter related to a winding process of the winding unit. Through the multi-module cooperative control, the application improves the tension control precision and the anti-disturbance ability, and is helpful to improve the winding material quality and the production efficiency.

Description

Technical Field

[0001] This invention relates to the field of constant tension control technology for calendering and winding, and specifically to a constant tension control system, method, and electronic device for calendering and winding. Background Technology

[0002] In the calendering production of tire cord fabric, winding is a key process that determines the final product quality and production efficiency. In order to ensure uniform interlayer density, flat end face, and no damage to the physical properties of the material, it is necessary to accurately and stably control the surface tension of the material during the winding process.

[0003] Currently, conventional calendering and winding control systems mostly employ single-point, open-loop, or semi-closed-loop control methods. For example, they may only preset the output torque of the winding motor or perform open-loop following control based on a pre-set speed curve. Some improved solutions introduce simple tension sensor feedback, but their control loops remain limited to the winding unit itself and fail to effectively coordinate with upstream and downstream processes on the production line. Because the control logic only acts on the winding end, the system cannot effectively sense and suppress dynamic disturbances from upstream, such as fine-tuning of the calender speed, uneven changes in material thickness, and the mechanical inertia of the guide rollers. When such disturbances occur, the passive adjustment of the winding unit often lags behind the actual change in tension, causing significant fluctuations in material tension around the set value, and requiring a long time to recover stability. Tension fluctuations directly affect the quality of the finished coil. Excessive instantaneous tension can cause irreversible plastic stretching of the material, leading to thickness reduction or even structural damage and excessive radial stress inside the coil. Insufficient instantaneous tension can cause interlayer relaxation, air entrapment, or interlayer slippage, resulting in uneven coil end faces. Especially during equipment acceleration / deceleration or automatic roll changing, sudden tension fluctuations can easily lead to tape breakage accidents. To reduce the quality risks caused by tension fluctuations, on-site operators limit the production line speed to a low level, which restricts the release of equipment capacity. Simultaneously, frequent and severe tension impacts accelerate the wear and fatigue of bearings, guide rollers, and transmission components, shortening equipment maintenance cycles and increasing unplanned downtime and maintenance costs. Furthermore, existing control systems lack precise model compensation for key parameters such as roll diameter changes and material properties, relying heavily on operators repeatedly adjusting PID parameters or torque limit values ​​based on observation. Therefore, how to provide a constant tension control scheme that achieves full-process coordination, high precision, and rapid response has become a pressing technical problem to be solved in this field.

[0004] Therefore, existing technologies still need further development. Summary of the Invention

[0005] The purpose of this invention is to overcome the above-mentioned technical deficiencies and provide a constant tension control system, method and electronic device for calendering and winding, so as to solve the problems existing in the prior art.

[0006] To achieve the above-mentioned technical objectives, according to a first aspect of the present invention, a calendering and winding constant tension control system is provided, applied to a calendering production line including a main traction unit, a fabric storage buffer unit, and a winding unit, the system comprising: The first control module is used to acquire the actual pushing force of the material during the winding process, and to perform closed-loop adjustment of the main traction unit based on the deviation between the actual pushing force and the preset target pushing force. A buffer adjustment module is configured in the fabric storage buffer unit to acquire the status parameters of the fabric storage buffer unit and control the operation of the fabric storage buffer unit according to the status parameters, so as to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit. The winding execution module is used to generate drive instructions to control the winding unit to perform winding actions based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit.

[0007] Specifically, the fabric storage buffer unit includes a floating roller structure, and the state parameter obtained by the buffer adjustment module is the position signal of the floating roller structure.

[0008] According to a second aspect of the present invention, a method for controlling constant tension during calendering and winding is provided, the method comprising: At the main traction unit, the actual pushing force of the material during the winding process is obtained, and the main traction unit is adjusted in a closed loop according to the deviation between the actual pushing force and the preset target pushing force. The status parameters of the fabric storage buffer unit are obtained, and the operation of the fabric storage buffer unit is controlled according to the status parameters to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit. Based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit, a drive command is generated to control the winding unit to perform the winding action.

[0009] Specifically, the method for generating drive commands to control the winding unit to perform winding actions based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit includes: Acquire parameters related to the current winding process of the winding unit, and determine the current roll diameter value in real time based on the parameters related to the winding process. Based on the preset target assertion force and the current roll diameter value, the target driving parameters of the take-up unit are determined; A compensation adjustment amount is generated based on the state parameters of the storage buffer unit; Based on the target driving parameters and the compensation adjustment amount, a driving command is generated to control the winding unit to perform the winding action.

[0010] Specifically, the method for determining the target driving parameters of the winding unit based on the preset target assertion force and the current winding diameter value includes: Based on the taper tension control logic, and based on the preset target push force and the real-time changing current roll diameter value, the target drive torque required by the winding unit is calculated, and the target drive torque is the target drive parameter of the winding unit.

[0011] Specifically, the formula for calculating the target driving torque required by the winding unit is as follows: ; in, The target driving torque, For the preset target claim, This refers to the current roll diameter value.

[0012] Specifically, the fabric storage buffer unit includes a floating roller structure, the state parameter of the fabric storage buffer unit is the position signal of the floating roller structure, and the method for generating a compensation adjustment amount based on the state parameter of the fabric storage buffer unit includes: Calculate the deviation of the position signal relative to a preset reference position, and calculate the compensation adjustment amount based on the deviation and a preset proportional coefficient.

[0013] Specifically, the method for determining the current roll diameter value in real time based on parameters related to the winding process includes: The linear speed signal of the calendering production line and the rotation speed signal of the winding unit are acquired, and the current roll diameter value is calculated based on the linear speed signal and the rotation speed signal.

[0014] Specifically, the method for determining the current roll diameter value in real time based on parameters related to the winding process includes: The distance value of the roll surface of the winding unit is directly obtained by a non-contact distance sensor, and the current roll diameter value is calculated based on the distance value and the preset core position parameters.

[0015] According to a third aspect of the present invention, an electronic device is provided, comprising: a memory; and a processor, wherein the memory stores computer-readable instructions, which, when executed by the processor, implement the above-described constant tension control method for calendering and winding.

[0016] Beneficial effects: This invention provides a system and method for constant tension control during calendering and winding. A first control module performs closed-loop adjustment of the main traction unit, stabilizing the tension of the material entering the winding process. Simultaneously, the winding execution module calculates driving parameters based on real-time changes in roll diameter and taper tension control logic, overcoming the tension attenuation problem caused by roll diameter variations. This ensures constant surface tension of the material throughout the winding process, avoiding quality defects such as stretching, loosening, and wrinkling caused by tension fluctuations, thus improving the internal and external quality of the roll material. By setting up a buffer adjustment module, compensation adjustment amounts are generated using the state parameters of the fabric storage buffer unit to dynamically compensate the driving commands of the winding execution module. This proactively and quickly suppresses dynamic disturbances such as speed differences and tension impacts from upstream or downstream of the production line, resulting in rapid system response and stable operation. The excellent anti-disturbance capability allows the equipment to operate stably at higher speeds, thereby improving production efficiency. By constructing a multi-module collaborative closed-loop control system, multiple key parameters such as main force, buffer state, and winding process are incorporated into a unified control model, improving the automation level of the production process and the consistency of product quality. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the composition of the constant tension control system for calendering and winding provided in a specific embodiment of the present invention; Figure 2 This is a flowchart of a method for controlling constant tension during calendering and winding, provided in a specific embodiment of the present invention. Detailed Implementation

[0018] To enable those skilled in the art to better understand the technical solutions of the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Based on the embodiments in this application, other similar embodiments obtained by those skilled in the art without creative effort should all fall within the scope of protection of this application. Furthermore, directional terms mentioned in the following embodiments, such as "up," "down," "left," and "right," are only for reference to the directions in the accompanying drawings; therefore, the directional terms used are for illustrative purposes and not for limiting the invention.

[0019] Before providing a further detailed description of the embodiments of this application, some of the nouns and terms involved in the embodiments of this application will be explained. The nouns and terms involved in the embodiments of this application are subject to the following interpretations.

[0020] (1) Main traction unit: refers to the functional unit located after the calendering host and before the cloth storage buffer unit in the calendering production line, which is used to actively traction the strip material and serve as the main execution point for upstream tension control. It is usually composed of traction rollers driven by servo motors. Its core function is to provide a material source with a stable tension reference that is not affected by upstream process fluctuations for subsequent processes. (2) Fabric storage buffer unit: refers to a device set between the main traction unit and the winding unit to store a certain length of material and absorb and compensate for the speed difference or tension fluctuation between upstream and downstream through the dynamic changes of its own structure (such as the lifting and lowering of the floating roller). It is a key physical link to achieve coordinated control and suppress disturbances. (3) Taper tension control logic: a winding control algorithm, the core of which is to dynamically adjust the tension applied to the material or the output torque of the winding motor according to the real-time change of the roll diameter, so that it follows a preset curve (taper curve) to optimize the stress distribution inside the roll material and prevent quality problems such as tight inside and loose outside or loose inside and tight outside. In this application, it mainly refers to the dynamic adjustment of the driving torque to maintain the constant surface tension of the material. (4) Compensation adjustment amount: refers to a dynamic adjustment amount generated to actively suppress system disturbances. In this application, it specifically refers to the signal value calculated based on the state parameters of the fabric storage buffer unit (such as the floating roller position deviation) and used to correct the target drive parameters of the winding unit, so as to achieve rapid feedforward compensation or feedback fine adjustment.

[0021] The present invention will be further described below with reference to the accompanying drawings and preferred embodiments.

[0022] Example 1 Please see Figure 1 This application aims to provide a calendering and winding constant tension collaborative control system to solve the problems of low winding tension control accuracy and poor anti-disturbance capability in the prior art. This system is applied to a calendering production line including a main traction unit, a fabric storage buffer unit, and a winding unit. The system includes a first control module 100, a buffer adjustment module 200, and a winding execution module 300. The first control module 100 is used to acquire the actual tensile force of the material during the winding process and to perform closed-loop adjustment of the main traction unit according to the deviation between the actual tensile force and the preset target tensile force. The buffer adjustment module 200 is configured in the fabric storage buffer unit and is used to acquire the state parameters of the fabric storage buffer unit and control the action of the fabric storage buffer unit according to the state parameters to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit. The winding execution module 300 is used to generate drive commands to control the winding unit to perform winding actions according to the preset target tensile force, the state parameters, and parameters related to the winding process of the winding unit.

[0023] It is understood that the above-mentioned technical solution of this embodiment solves the problems of large tension fluctuations, unstable roll material quality and limited production efficiency caused by isolated control logic and poor anti-disturbance capability in the prior art. The core idea of ​​this application is to construct a collaborative control architecture consisting of three parts: force control, buffer adjustment and winding execution. Through the combination of multi-point closed loop and feedforward compensation, high-precision and fast stable control of tension throughout the winding process can be achieved.

[0024] In one specific embodiment, this application provides a constant tension collaborative control system for calendering and winding. This system is applied to a calendering production line, which includes at least a calendering host, a main traction unit, a fabric storage buffer unit, and a winding unit that sequentially transfer materials. The system also includes a first control module 100, whose function is to establish a tension reference at the front end of the production line. Specifically, the first control module 100 acquires the actual tensile force of the material in real time through a main tension sensor located downstream of the main traction unit, compares the actual tensile force with a preset target tensile force, and uses the deviation calculated by PID or other control algorithms to perform closed-loop adjustment of the drive system of the main traction unit, such as the main traction motor. This can stabilize the tension of the material entering the fabric storage buffer unit at a constant reference value, thereby isolating process disturbances from upstream equipment such as the calendering host and providing a stable prerequisite for subsequent precise winding.

[0025] Furthermore, the constant tension coordinated control system for calendering and winding in this embodiment also includes a buffer adjustment module 200, which is physically or logically configured with the fabric storage buffer unit as a buffer against dynamic disturbances. The buffer adjustment module 200 acquires one or more state parameters of the fabric storage buffer unit through sensors, such as the position and speed of the movable parts or the tension magnitude inside them. Based on these real-time state parameters, the buffer adjustment module 200 controls the fabric storage buffer unit to perform corresponding actions, such as lifting, stretching, or adjusting damping. Through these actions, the fabric storage buffer unit can effectively absorb and compensate for changes in material length caused by instantaneous speed mismatch between the main traction unit and the winding unit, or absorb sudden tension impacts. This avoids the disturbance being directly transmitted to the winding point, and realizes the system's rapid dynamic response.

[0026] Furthermore, the constant tension co-control system for calendering and winding in this embodiment also includes a winding execution module 300, which is used to directly control the winding action of the winding unit. Unlike traditional open-loop control that relies on only a single set value, the winding execution module 300 in this embodiment is a decision-making and execution unit that integrates multi-source information and generates drive commands. It integrates information from multiple dimensions to generate the final drive command: First, based on a core control objective, namely the preset target force, which is the pre-set material surface tension; second, it receives and utilizes the state parameters from the buffer adjustment module 200 as a prediction or feedback signal for dynamic disturbances; finally, it also considers parameters related to the winding process of the winding unit itself, such as the continuously increasing roll diameter. Through the built-in algorithm, these three types of information are integrated to generate accurate and dynamically changing drive commands to control the drive motor of the winding unit, thereby achieving constant tension winding while coping with various static and dynamic changes.

[0027] Furthermore, in a preferred embodiment, the fabric storage buffer unit specifically includes a floating roller structure. In this structure, the material path is designed to bypass one or more floating rollers that can move freely up and down. The state parameter that the buffer adjustment module 200 needs to acquire is specifically the vertical position signal of the floating roller. This position signal can be accurately acquired by a position sensor (such as a laser displacement sensor, a wire encoder, or an ultrasonic sensor) installed on the travel path of the floating roller. The position of the floating roller directly reflects the length of the stored material in the buffer area, and its position change directly corresponds to the speed difference between the preceding and following processes. Therefore, using the position signal as a state parameter is simple to measure, the signal is stable, and the establishment and implementation of the control model are simplified.

[0028] The working principle of the calendering and winding constant tension collaborative control system in this embodiment is illustrated by a specific example below. This system is applied to a production line consisting of a calendering host, a main traction unit, a fabric storage buffer unit, and a winding unit. The core of the system is a central controller, such as a PLC controller, which is used to execute the collaborative control logic of the system in this embodiment. Specifically, the constant tension coordinated control system for calendering and winding includes a first control module 100, the functions of which are implemented by a part of the logic of the PLC controller and related hardware. Specifically, a tensile force sensor is installed after the main traction unit to measure the actual tensile force of the material and send the signal to the PLC controller. The control program running inside the PLC controller compares this actual value with a preset target tensile force (e.g., 200N) and generates a control signal based on the deviation using a PID algorithm. This control signal is sent to the driver of the main traction unit to adjust its speed, thus forming a tensile force closed-loop control. The role of the first control module 100 is to stabilize the tension of the material entering the subsequent process, providing a stable input source for the entire system, which reduces the possibility of tension fluctuations from the source.

[0029] The constant tension coordinated control system for calendering and winding also includes a buffer adjustment module 200, the function of which is also implemented by the logic of the PLC controller and related hardware. The buffer adjustment module 200 is associated with the fabric storage buffer unit, which is used to physically absorb and release material to cope with speed differences. The buffer adjustment module 200 obtains the status parameters of the fabric storage buffer unit through a sensor and transmits the signal back to the PLC controller. The PLC controller determines whether the system is disturbed based on the change of the status parameters and calculates the corresponding compensation requirements. For example, when the upstream material speed is instantaneously greater than the downstream winding speed, the fabric storage buffer unit will store more material, and its status parameters will change. The buffer adjustment module 200 senses the disturbance accordingly.

[0030] In addition, the system also includes a winding execution module 300, whose functions are also implemented by the logic of the PLC controller and related hardware. The winding execution logic in the PLC controller will comprehensively process three aspects of information: (1) the target force set by the process; (2) the status parameters provided by the buffer adjustment module 200 that reflect real-time disturbances; and (3) the parameters related to the winding unit itself that reflect the change in winding diameter. Based on this information, the PLC controller dynamically generates a series of drive instructions through the built-in collaborative control algorithm and sends them to the driver of the winding unit to control its motor to accurately execute the winding action. In this way, the winding execution module 300 can actively adapt to the global state and generate corresponding execution instructions.

[0031] These three modules work together under the unified scheduling of the PLC controller to form an organic whole. The first control module 100 is responsible for stabilizing the input source, the buffer adjustment module 200 is responsible for suppressing sudden changes, and the winding execution module 300 is responsible for precise execution. This architecture decomposes the complex tension control problem into three related but distinct sub-problems, which are linked together through a collaborative mechanism to achieve proactive, rapid, and precise suppression of tension fluctuations.

[0032] Specifically, the fabric storage and buffer unit employs a mechanical structure that includes a floating roller. The floating roller is constrained by guide rails and other devices to move only in the vertical direction, with material passing underneath it. Therefore, when there is a speed difference between the main traction unit and the winding unit, the floating roller will rise or fall accordingly. A position sensor, such as a laser displacement sensor mounted on a fixed frame, continuously monitors the precise vertical position of the floating roller and sends this position signal as a key status parameter to the PLC controller. The advantage of this design is that the physical displacement of the floating roller directly reflects the change in the amount of material stored in the buffer area, providing the control system with an intuitive and reliable disturbance quantification index.

[0033] Furthermore, the control logic of the roll-up execution module 300 in the PLC controller includes: First, the PLC controller needs to calculate the current roll diameter in real time. By acquiring the linear speed signal v from the production line and the rotational speed signal n fed back from the encoder of the winding motor, and using the formula... =v / (π×n) to complete, or you can directly use an ultrasonic range sensor installed above the winding unit to measure the roll diameter. After obtaining the roll diameter, the PLC controller executes the taper tension control algorithm, the goal of which is to maintain a constant surface tension F. Specifically, it applies the formula... To calculate the target drive torque currently required Here It is the target tension value set by the operator on the human-machine interface. It is a feedforward control quantity based on a physical model, which actively compensates for the impact of increasing the roll diameter; Meanwhile, the PLC controller processes the floating roller position signal from the position sensor. It compares the current position with a set equilibrium position (center point) to obtain the deviation value ΔH. Then, based on a preset proportional gain Kp, it calculates a compensation torque ΔT=Kp×ΔH. This ΔT is a feedback or feedforward compensation amount used to quickly suppress dynamic disturbances.

[0034] Finally, the PLC controller will select the target drive torque. The output torque command is obtained by superimposing the compensation torque ΔT on the output torque. = +ΔT, this command is sent to the servo driver of the winding unit via the fieldbus, driving the winding motor to rotate with precise torque. Through this cooperative control mode of base torque plus compensation torque, the system can adapt to the increase of roll diameter and respond to disturbances in the production process to achieve constant tension control.

[0035] Below is an example based on product parameters. This embodiment of the calendering and winding constant tension collaborative control system is applied to a tire cord fabric calendering production line. The core of this system is a PLC controller, which integrates motion control and high-speed data processing functions. The key equipment and sensors on the production line are configured as follows: Both the main traction unit and the winding unit are driven by AC servo motors with built-in high-resolution absolute encoders. The main force sensor is a high-precision strain gauge tension sensor with a range of 0-500N, installed on a fixed guide roller after the main traction roller. The fabric storage buffer unit adopts a gravity-type floating roller structure with a vertical travel of 1.5 meters. A laser displacement sensor with a measurement range of 0-2000mm and an accuracy of 0.1mm is installed on its travel guide rail as a position sensor. The system is equipped with a touch screen as a human-machine interface, where operators can set key process parameters, such as the target main force. (e.g., 200N), maximum roll diameter Material thickness and selection of taper control curve type; When processing 1.5-meter-wide nylon cord fabric, the system can stabilize the production line speed at 35 meters per minute, compared to 25 meters per minute when using traditional single-point control before the upgrade, thus increasing production capacity. Throughout the winding process, through high-frequency data acquisition (control cycle less than 10ms) and collaborative control algorithms, the system can control the actual surface tension fluctuation of the material within a small range of ±5N (i.e. ±2.5%) of the set value. The final produced roll material has an end face flatness error of less than 2mm, a tight roll shape, and no defects such as chrysanthemum patterns or tower-shaped rolls, resulting in a significant improvement in product quality.

[0036] Example 2 Please see Figure 2 This embodiment also provides a constant tension collaborative control method for calendering and winding. This method can be run on the system described in Embodiment 1 above. The specific steps of this embodiment include: S1, at the main traction unit, acquiring the actual tensile force of the material during winding, and performing closed-loop adjustment of the main traction unit according to the deviation between the actual tensile force and the preset target tensile force; S2, acquiring the state parameters of the fabric storage buffer unit, and controlling the action of the fabric storage buffer unit according to the state parameters to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit; S3, generating a drive command according to the preset target tensile force, the state parameters, and parameters related to the winding process of the winding unit to control the winding unit to perform the winding action.

[0037] Specifically, at the main traction unit, the actual tension of the material during the winding process is continuously acquired by the tension sensor and compared with the preset target tension in real time. Based on the deviation between the two, the drive of the main traction unit is continuously adjusted by a closed-loop control algorithm (such as PID control), for example, by adjusting the speed or torque of its motor, so as to stably control the tension at that point near the target value and provide a stable incoming tension for downstream materials.

[0038] Simultaneously, the method executes a buffer adjustment step in parallel. In this step, the system continuously acquires the state parameters of the fabric storage buffer unit, such as the position signal of the aforementioned floating roller. Based on the changes in these state parameters, such as the magnitude and direction of the floating roller's deviation from its reference equilibrium position, the system controls the fabric storage buffer unit to perform corresponding compensation actions. For example, if the floating roller descends due to the material inlet speed being greater than the winding speed, the system can control its support structure (such as a cylinder or motor) to apply a reverse force, or directly use this position deviation signal for compensation in the downstream winding control. The core purpose is to use the fabric storage stroke to absorb the speed difference and prevent drastic tension fluctuations.

[0039] Furthermore, the method in this embodiment also includes a winding control step. In this step, the system does not simply execute a fixed winding command, but generates a drive command based on multiple dynamically changing inputs. These inputs include a preset target force as a control reference, state parameters of the fabric buffer unit reflecting dynamic disturbances of the system, and winding process-related parameters reflecting changes in the winding physical state, such as the roll diameter. By performing coordinated calculations on these three, an adaptive drive command that can simultaneously cope with the roll diameter growth effect and external disturbances is generated, and the winding unit is controlled to perform the winding action, thereby achieving the final high-precision constant tension control.

[0040] In a preferred embodiment, the method of generating a drive command to control the winding unit to perform a winding action based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit includes: acquiring parameters related to the current winding process of the winding unit; determining the current roll diameter value in real time based on the parameters related to the winding process; determining target drive parameters of the winding unit based on the preset target force and the current roll diameter value; generating a compensation adjustment amount based on the state parameters of the fabric storage buffer unit; and generating a drive command to control the winding unit to perform a winding action based on the target drive parameters and the compensation adjustment amount.

[0041] It should be noted that the process of generating drive instructions to control the winding unit to perform the winding action specifically includes: First, acquiring parameters related to the current winding process of the winding unit, and determining the current roll diameter value in real time based on these parameters, denoted as . This is because in constant tension winding, the winding diameter is a key, constantly changing variable; Then, based on the pre-set target proposition. And the current roll diameter value determined in real time in the previous step To determine the target drive parameters of the winding unit, which are the theoretical drive quantities that must be applied to the core to achieve constant tension, such as target drive torque or target drive speed, this step is the core of open-loop or feedforward control, which aims to actively overcome the problem of natural tension decay caused by the increase in winding diameter. At the same time, a compensation adjustment amount is generated based on the state parameters of the storage buffer unit (such as the position deviation of the floating roller). The compensation adjustment amount is the key to closed-loop feedback or feedforward compensation. Its purpose is to quickly correct unforeseen dynamic disturbances in the system (such as sudden changes in upstream speed). The compensation adjustment amount here can be a torque compensation value or a speed compensation value. Finally, the target driving parameters and compensation adjustments calculated in the first two steps are algebraically superimposed or fused using a more complex algorithm to generate a driving command that combines static model compensation and dynamic disturbance suppression. This driving command is sent to the driver of the winding unit to precisely control its winding action. In this way, planned control for changes in winding diameter is organically combined with reactive control for random disturbances, achieving both precision and robustness in control.

[0042] Furthermore, in a preferred embodiment, the method for determining the target drive parameters of the winding unit based on the preset target assertive force and the current roll diameter value includes: calculating the target drive torque required by the winding unit based on the preset target assertive force and the real-time changing current roll diameter value according to the taper tension control logic, wherein the target drive torque is the target drive parameter of the winding unit.

[0043] It should be noted that the specific method for determining the target driving parameters of the winding unit employs tapered tension control logic. Traditional constant torque control causes the surface tension F to decrease sharply as the winding diameter D increases. Tapered tension control aims to keep the surface tension F constant throughout the winding process. Specifically, the system is based on a preset target driving force. and the current volume diameter value that changes in real time The target drive torque required by the winding unit is calculated through the taper tension control logic. This calculated target driving torque This physical model-based control method, which uses the target driving parameter of the winding unit as the control parameter, helps to solve the problem of tension caused by changes in winding diameter and is the basis for achieving constant tension control.

[0044] In a more specific implementation, the physical model for calculating the target driving torque described above is based on the fundamental principle of mechanical equilibrium (torque = force × lever arm), and the formula for calculating the target driving torque is as follows: ; in, The target driving torque; The preset target force is a constant value determined during process setup, for example, 200 Newtons. The current roll diameter is a variable that changes in real time. The physical meaning of this formula lies in maintaining the surface tension of the material. Constant driving torque applied to the core It must be according to the winding radius (i.e. The torque is increased proportionally to the increase of / 2). By applying this formula according to the real-time roll diameter in each control cycle, the system can adjust the output torque according to the real-time roll diameter to achieve constant tension control.

[0045] In another preferred embodiment, the fabric storage buffer unit includes a floating roller structure, and the state parameter of the fabric storage buffer unit is the position signal of the floating roller structure. The method for generating a compensation adjustment amount based on the state parameter of the fabric storage buffer unit includes: calculating the deviation value of the position signal relative to a preset reference position, and calculating the compensation adjustment amount based on the deviation value and a preset proportional coefficient.

[0046] It should be noted that the fabric storage buffer unit adopts a floating roller structure, and its state parameter is the position signal of the floating roller. The method for generating the compensation adjustment amount includes: first, calculating the deviation value ΔH of the real-time position signal relative to a preset reference position, such as the middle position that the floating roller should be in when the system is running stably; then, based on the deviation value ΔH and according to a preset proportional coefficient Kp, calculating the compensation adjustment amount using the formula ΔT = Kp × ΔH. This compensation adjustment amount, such as a compensation torque ΔT, is then used to correct the target drive torque. This proportional compensation based on position deviation can achieve a rapid response to disturbances: the larger the deviation, the stronger the compensation effect, thereby quickly pulling the floating roller back to the reference position and effectively suppressing tension fluctuations.

[0047] In one alternative implementation, the current roll diameter value is determined in real time. The method can be based on indirect calculation. Specifically, the actual linear velocity signal v of the calendering production line is obtained through sensors, such as linear velocity meters mounted on the guide rollers, and the real-time rotational speed signal n of the winding unit is obtained simultaneously, such as through the encoder of the winding motor. Based on the kinematic relationship: linear velocity = angular velocity × radius, the formula for calculating the current roll diameter can be derived. =v / (π×n), this method utilizes the sensor signals that are usually available on the production line, and can provide the required accuracy when there is no significant slippage between the material and the guide roller.

[0048] In another alternative implementation, to achieve higher roll diameter measurement accuracy, especially when handling smooth or slippery materials, a direct measurement method can be used. Specifically, the system directly acquires the distance value from the roll surface using a non-contact distance sensor (e.g., an ultrasonic sensor or a laser rangefinder) mounted above the winding unit. Using this real-time distance value and pre-set core geometric position parameters, such as core axis coordinates and initial radius, the system can accurately calculate the current roll diameter using simple geometric calculations. This direct measurement method is not affected by factors such as material slippage, and the measurement results are reliable, providing input data for subsequent taper tension control.

[0049] The following specific example illustrates the implementation principle of the constant tension coordinated control method for calendering and winding in this embodiment. The hardware implementation employs methods such as... Figure 1 The complete architecture shown includes a main tension closed loop consisting of a main tension sensor, a fabric storage buffer unit consisting of a floating roller and a position sensor, and a winding unit consisting of a winding motor with an encoder. These components are all coordinated and controlled by a PLC controller. Specifically, the PLC controller's control program executes the following complete workflow in a high-speed cyclic task: Step 1: Parameter acquisition.

[0050] At the start of each control cycle, the PLC controller acquires multiple key signals in parallel through its input modules, including the actual tension value from the force sensor. The real-time position of the floating roller of the position sensor The linear velocity v of the production line speed meter and the rotational speed n of the winding motor encoder; Step 2: Propose closed-loop adjustment of the driving force.

[0051] The PLC will collect the data. With the pre-set target proposition By comparing the values, an independent PID function block calculates the adjustment amount and adjusts the drive output of the main traction unit in real time to ensure that the tension of the material entering the fabric buffer unit remains stable at the preset target tension. about; Step 3: Real-time roll diameter calculation.

[0052] The PLC uses the acquired linear velocity v and winding speed n, according to the formula... = v / (π×n), calculate the real-time roll diameter of the current roll unit. ; Step 4: Calculate the target drive torque.

[0053] The PLC uses the real-time roll diameter obtained in the previous step. and the established goals and propositions According to the core taper tension control formula The theoretically required basic driving torque to maintain constant tension was calculated. ; Step 5: Calculate the compensation adjustment amount.

[0054] The PLC will collect the real-time position of the floating roller. With the preset balance median By comparison, the positional deviation is obtained. Then, based on an online adjustable proportional coefficient Kp (e.g., 0.5), the compensation torque ΔT = Kp × ΔH is calculated; Step 6: Generate the final driver instructions.

[0055] The PLC calculates the target drive torque in step 4. The final output torque command is obtained by algebraically summing the calculated compensation torque ΔT from step 5. .

[0056] Step 7: Execution and Monitoring.

[0057] The PLC will then execute the final output torque command. The system sends data to the servo driver of the take-up unit via a high-speed bus for execution. At the same time, the system displays the actual tension curve, roll diameter change curve, and floating roller position curve in real time on the human-machine interface for operator monitoring.

[0058] Suppose the speed of the calender suddenly increases, leading to an increase in upstream material supply. This disturbance will immediately cause the floating roller in the fabric storage rack to be pulled downwards. The position sensor detects this change and immediately sends a position deviation signal ΔH to the PLC. The PLC completes the calculations in steps 4-6 above within 10 milliseconds, that is, within the original target torque... Based on this, a compensation torque ΔT calculated from ΔH is superimposed to generate a dynamically adjusted final torque command. The signal is sent to the winding machine, whose driver instantly increases its output torque to accelerate winding and consume excess material. This entire process forms a negative feedback loop, stabilizing the position of the floating roller and suppressing fluctuations in the actual tension of the material.

[0059] The following example, using tire cord winding, illustrates the specific application process of the real-time winding diameter calculation and taper tension control algorithm: The core of this embodiment lies in constructing a multi-level, collaborative, closed-loop tension control system. Through the dual effects of precise control of the main traction tension and dynamic compensation of the storage fabric buffer tension, constant tension is achieved throughout the winding process. Specifically, it includes a two-level tension collaborative control architecture: (1) Main traction control loop: A high-precision tension detector (such as a tension sensor) is set at the outlet of the main traction roller or calendering machine to form a main closed loop. The controller (such as a PLC or a dedicated tension controller) adjusts the torque or speed of the main traction motor in real time and accurately according to the deviation between the set tension and the actual tension. (2) Fabric storage tension buffer circuit: A position or tension sensor is set at the fabric storage rack (or floating roller). Its function is to absorb and buffer the tension impact caused by the speed difference between the upstream (calender) and the downstream (winding machine). By controlling the speed of the fabric storage rack lifting motor or the cylinder pressure, its position is maintained in a reasonable middle position, thereby maintaining the tension stability of this section. By employing real-time roll diameter calculation (via encoder or ultrasonic sensor) and combining it with a taper tension control algorithm, the winding motor torque is automatically reduced according to a preset curve (linear, quadratic, etc.) as the roll diameter increases to maintain constant material surface tension and prevent external tightness and internal looseness. The main force setpoint is used as the primary input for winding tension control. Simultaneously, the storage rack status signal (such as position deviation) is introduced as feedforward or fine-tuning compensation to achieve dynamic decoupling and coordination. Taking tire cord fabric winding as an example, the specific application process is as follows: (1) Equipment configuration: Initial winding diameter (empty drum): = 500mm; Material thickness: δ=1mm; Target surface tension: =200N (constant); Taper control method: linear taper, tension decreases linearly as the roll diameter increases; Rated torque of the winding motor: =100 N·m; (2) Process requirements: The surface tension of the material remains constant (200N±5N) during the winding process. To avoid a tight outer layer and a loose inner layer, the internal stress of the roll material should be uniform. The traditional method uses constant torque control: the take-up motor is set to output a fixed torque, such as T=50N·m, without considering changes in the roll diameter; Tension changes with varying roll diameter: Initial roll diameter When the surface tension is 500mm, the surface tension F = T / ( / 2)= 50 / 0.25=200N; The diameter of the roll is increased to When the surface area is 1000 mm, the surface tension F = 50 / 0.5 = 100 N (tension decreases by 50%). The diameter of the roll is increased to When the surface area is 1500mm, the surface tension is: F = 50 / 0.75≈67N (the tension is severely insufficient). Problem symptoms: The outer ring of the roll material is loose, forming a bird's nest or tower-shaped roll, causing slippage between layers, making subsequent unwinding difficult, and resulting in uneven internal stress of the material, which affects product quality; The execution process using the taper tension control algorithm is as follows: Step 1: Real-time roll diameter calculation: The system monitors the winding motor speed n (rpm) and material linear velocity v (m / min) in real time via an encoder to calculate the current roll diameter. Current volume =v / (π×n) [unit: mm]; Actual calculation example: Material linear velocity v = 30 m / min = 0.5 m / s; The winding motor speed n = 19.1 rpm = 0.318 rps; Current volume =0.5 / (3.14×0.318)≈0.5m=500mm; As winding progresses, the roll diameter gradually increases, and the system samples every 100ms and updates in real time. ; Step 2: The taper tension control algorithm is executed, which automatically reduces the motor output torque according to the change in roll diameter in order to maintain constant surface tension; Target torque N·m; Example of linear taper control, the calculation process for roll diameters from 500mm to 1500mm is shown in Table 1: Table 1 shows the calculation process for roll diameters from 500mm to 1500mm. As shown in the table above, when the roll diameter increases by 50%, the torque needs to increase by 50%, and when the roll diameter increases by 200%, the torque also needs to increase by 200% to keep the surface tension constant at 200N.

[0060] Step 3: Coordinated control of propulsion and storage rack The setpoint for the tension serves as the primary reference for winding control, while a tension sensor located behind the traction roller continuously monitors the actual tension of the strip material. The system uses a preset principal tension target value. With 200N as the baseline, the traction motor is controlled in a closed loop using PID regulation, thereby stabilizing the material push force entering the fabric storage buffer unit at around 200N. Simultaneously, the system acquires the position signal of the floating roller in the fabric storage buffer unit as the basis for feedforward compensation, assuming the normal center position of the floating roller is... =500mm, the actual position of the floating roller is detected in real time by a position sensor. And calculate the positional deviation ΔH= - .

[0061] The collaborative control logic performs the following judgments and adjustments based on the magnitude of the position deviation ΔH: When |ΔH|>10mm, it indicates that the fabric storage rack deviates significantly from the center position, requiring rapid compensation adjustment of the winding unit. In this case, the winding torque compensation amount ΔT=Kp×ΔH is calculated based on the preset proportional coefficient Kp, and this compensation amount is superimposed on the target driving torque obtained based on the taper tension control algorithm. Above, i.e., actual output torque ; When |ΔH|≤10mm, it indicates that the fabric storage rack is within the normal fluctuation range, and the system switches to integral compensation mode for smooth fine-tuning. At this time, the actual output torque... = +Ki×∫ΔH dt, where Ki is the integral coefficient.

[0062] The following example illustrates a specific dynamic disturbance response process: Suppose the calender machine suddenly increases its operating speed, causing a sudden increase in the amount of material coming in from upstream. Under this disturbance, the floating roller of the fabric storage rack is pulled downwards, and the position sensor detects the actual position. The system descends, resulting in a positional deviation ΔH = -15mm, which is 15mm below the midpoint. The system determines that |ΔH| > 10mm, triggering a rapid compensation mechanism. Based on a proportional coefficient Kp = 0.5, the compensation torque ΔT = 0.5 × (-15) = -7.5 N·m is calculated. At this point, assuming the current winding diameter of the winding unit... =800mm, according to the taper tension control formula Calculate the target driving torque =200×(0.8 / 2)=80N·m, after adding the compensation torque, the actual torque command output to the winding motor is... =80-7.5=72.5N·m; The take-up motor executes the reduced torque command, instantly decreasing the drive torque. This allows the take-up unit to quickly consume excess material accumulated upstream, effectively suppressing the upward trend of material tension. As the take-up unit accelerates its consumption, the fabric storage rack floating roller gradually rises, returning to near the midpoint position within approximately one second. At this point, the position deviation ΔH approaches zero, and the compensation torque ΔT correspondingly returns to zero. The take-up torque then recovers to the target value determined by the taper tension control algorithm. The system re-enters steady-state coordinated control, and the actual control effect is shown in Table 2: Table 2 Comparison of Actual Control Effects It is understood that the above technical solution in this embodiment is based on the principle of torque balance. The algorithm model is simple and has clear physical meaning. The roll diameter calculation cycle is short and the response speed is fast. The taper curve (linear, quadratic, exponential) can be flexibly selected according to the material properties. It advocates force closed loop + fabric storage frame feedforward + roll diameter compensation to form a multi-level anti-disturbance structure suitable for materials with different thicknesses and elastic moduli. Step 4: The closed-loop dynamic adjustment process is as follows: (1) During normal operation: the main traction tension closed loop ensures the stability of the tension of the material entering the storage area; the storage rack absorbs small speed differences by floating according to the change of winding speed, and its own position closed loop ensures the constant buffer tension. (2) When a disturbance occurs (such as acceleration): The instantaneous acceleration of the winding machine causes the fabric storage rack to be pulled down, and the tension tends to rise. The system immediately detects the downward movement of the fabric storage rack and at the same time detects the signal of increased main force. The controller will combine these two signals and command the main traction motor to accelerate slightly, while commanding the winding motor to reduce torque slightly, so as to quickly smooth out the tension fluctuation and restore the fabric storage rack to the neutral position.

[0063] It should be noted that this embodiment provides a constant tension collaborative control method for calendering and winding. It stabilizes the input source through a force closed loop, compensates for the foreseeable increase in roll diameter through taper torque feedforward, and corrects unforeseen dynamic disturbances through floating roller position feedback. The combination of these three elements improves tension control accuracy, ensuring that tension fluctuations remain below a certain range throughout the entire winding cycle and during acceleration and deceleration. Regarding dynamic response speed, the introduction of a compensation adjustment based on the floating roller position as a fast feedback loop shortens the system's response time to disturbances, avoiding instantaneous quality defects caused by disturbances. In terms of production efficiency and equipment protection, stable tension allows the production line to operate at higher speeds, leading to increased capacity. Simultaneously, a smooth, shock-free tension environment effectively reduces downtime due to strip breakage, wrinkles, and other malfunctions, and helps reduce impact and wear on mechanical transmission components, extending equipment lifespan and improving the automation level of production management.

[0064] Example 3 In a preferred embodiment, this application also provides an electronic device, the electronic device comprising: The computer device includes a memory and a processor. The memory stores computer-readable instructions that, when executed by the processor, implement the described constant tension collaborative control method for calendering and winding. This computer device can be broadly categorized as a server, terminal, or any other electronic device with the necessary computing and / or processing capabilities. In one embodiment, the computer device may include a processor, memory, network interface, communication interface, etc., connected via a system bus. The processor of the computer device can be used to provide the necessary computing, processing, and / or control capabilities. The memory of the computer device may include a non-volatile storage medium and internal memory. The non-volatile storage medium may store an operating system, computer programs, etc. The internal memory can provide an environment for the operation of the operating system and computer programs in the non-volatile storage medium. The network interface and communication interface of the computer device can be used to connect and communicate with external devices via a network. When the computer program is executed by the processor, it performs the steps of the method of the present invention.

[0065] This invention can be implemented as a computer-readable storage medium having a computer program stored thereon, which, when executed by a processor, causes the steps of the methods of embodiments of the invention to be performed. In one embodiment, the computer program is distributed across multiple network-coupled computer devices or processors, such that the computer program is stored, accessed, and executed in a distributed manner by one or more computer devices or processors. A single method step / operation, or two or more method steps / operations, may be executed by a single computer device or processor or by two or more computer devices or processors. One or more method steps / operations may be executed by one or more computer devices or processors, and one or more other method steps / operations may be executed by one or more other computer devices or processors. One or more computer devices or processors may execute a single method step / operation, or execute two or more method steps / operations.

[0066] It should be noted that the terms "first," "second," etc., in the specification, claims, and accompanying drawings of this application are used to distinguish similar objects and are not necessarily used to describe a specific order or sequence. It should be understood that such data can be interchanged where appropriate so that the embodiments of this application described herein can be implemented in orders other than those illustrated or described herein. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion; for example, a process, method, system, product, or apparatus that comprises a series of steps or units is not necessarily limited to those steps or units explicitly listed, but may include other steps or units not explicitly listed or inherent to such processes, methods, products, or apparatus.

[0067] The technical features described above can be combined arbitrarily. Although not all possible combinations of these technical features are described, any combination of these technical features should be considered to be covered by this specification, provided that such combination does not contain contradictions.

[0068] The specific embodiments of the present invention described above do not constitute a limitation on the scope of protection of the present invention. Any other corresponding changes and modifications made in accordance with the technical concept of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A constant tension control system for calendering and winding, applied to a calendering production line including a main traction unit, a fabric storage buffer unit, and a winding unit, characterized in that, The system includes: The first control module (100) is used to acquire the actual pushing force of the material during the winding process, and to perform closed-loop adjustment of the main traction unit based on the deviation between the actual pushing force and the preset target pushing force. A buffer adjustment module (200) is configured in the fabric storage buffer unit to acquire the status parameters of the fabric storage buffer unit and control the action of the fabric storage buffer unit according to the status parameters, so as to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit. The winding execution module (300) is used to generate drive instructions to control the winding unit to perform winding actions based on the preset target force, the state parameters and parameters related to the winding process of the winding unit.

2. The constant tension control system for calendering and winding according to claim 1, characterized in that, The fabric storage buffer unit includes a floating roller structure, and the state parameter obtained by the buffer adjustment module (200) is the position signal of the floating roller structure.

3. A method for controlling constant tension during calendering and winding, characterized in that, The method, applied to the constant tension control system for calendering and winding according to claim 1 or 2, comprises: At the main traction unit, the actual pushing force of the material during the winding process is obtained, and the main traction unit is adjusted in a closed loop according to the deviation between the actual pushing force and the preset target pushing force. The status parameters of the fabric storage buffer unit are obtained, and the operation of the fabric storage buffer unit is controlled according to the status parameters to compensate for the speed difference or tension fluctuation between the main traction unit and the winding unit. Based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit, a drive command is generated to control the winding unit to perform the winding action.

4. The constant tension control method for calendering and winding according to claim 3, characterized in that, The method for generating drive commands to control the winding unit to perform winding actions based on the preset target force, the state parameters, and parameters related to the winding process of the winding unit includes: Acquire parameters related to the current winding process of the winding unit, and determine the current roll diameter value in real time based on the parameters related to the winding process. Based on the preset target assertion force and the current roll diameter value, the target driving parameters of the take-up unit are determined; A compensation adjustment amount is generated based on the state parameters of the storage buffer unit; Based on the target driving parameters and the compensation adjustment amount, a driving command is generated to control the winding unit to perform the winding action.

5. The constant tension control method for calendering and winding according to claim 4, characterized in that, The method for determining the target driving parameters of the winding unit based on a preset target assertion force and the current winding diameter value includes: Based on the taper tension control logic, and based on the preset target push force and the real-time changing current roll diameter value, the target drive torque required by the winding unit is calculated, and the target drive torque is the target drive parameter of the winding unit.

6. The constant tension control method for calendering and winding according to claim 5, characterized in that, The formula for calculating the target drive torque required for the winding unit is as follows: ； in, The target driving torque, For the preset target claim, This is the current roll diameter value.

7. The constant tension control method for calendering and winding according to claim 4, characterized in that, The fabric storage buffer unit includes a floating roller structure, and the state parameter of the fabric storage buffer unit is the position signal of the floating roller structure. The method for generating a compensation adjustment amount based on the state parameter of the fabric storage buffer unit includes: Calculate the deviation of the position signal relative to a preset reference position, and calculate the compensation adjustment amount based on the deviation and a preset proportional coefficient.

8. The constant tension control method for calendering and winding according to claim 4, characterized in that, The method for determining the current roll diameter value in real time based on parameters related to the winding process includes: The linear speed signal of the calendering production line and the rotation speed signal of the winding unit are acquired, and the current roll diameter value is calculated based on the linear speed signal and the rotation speed signal.

9. The constant tension control method for calendering and winding according to claim 4, characterized in that, The method for determining the current roll diameter value in real time based on parameters related to the winding process includes: The distance value of the roll surface of the winding unit is directly obtained by a non-contact distance sensor, and the current roll diameter value is calculated based on the distance value and the preset core position parameters.

10. An electronic device, characterized in that, include: Memory; The processor, wherein the memory stores computer-readable instructions that, when executed by the processor, implement the constant tension control method for calendering and winding according to any one of claims 3 to 9.

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