Multi-Bundle Winding Tension Control With Fractional-Order PID
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Solution Overview
Problem
Traditional fiber winding equipment has a low automation degree and winding efficiency, with inadequate tension control capabilities, leading to issues like broken yarns, deformation, and non-uniform product quality due to tension fluctuations, especially in multi-bundle winding processes where high precision and real-time control are required.
Innovation Solution
A tension control method for multi-bundle winding equipment using a fractional order mathematical model and a time-varying fractional order PID controller to establish a robust and dynamic control system that adjusts tension in real-time, compensating for external interferences and ensuring stable target tension values.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional single-bundle winding equipment is used, then device complexity is low, but winding efficiency is low
Solution Approach 1:
The patent divides the winding system into multiple independent drive units, each capable of controlling a separate fiber bundle. This segmentation allows parallel processing of multiple bundles simultaneously, significantly improving winding efficiency while maintaining manageable complexity through modular architecture
Solution Approach 2:
The multi-bundle winding equipment is designed with universal control capabilities that can handle different bundle configurations and winding patterns. The system integrates multiple functions (spiral winding, hoop winding, tension control) into a single platform, improving productivity without proportionally increasing complexity
2Extent of automation
If simple control system is used, then ease of operation is high, but automation degree is low
Solution Approach 1:
The control system incorporates real-time feedback mechanisms that monitor tension, speed, and position parameters. This feedback enables automatic adjustment of control parameters to maintain optimal winding conditions, significantly improving automation degree while the modular feedback architecture keeps system complexity manageable
Solution Approach 2:
The control system dynamically adapts parameters such as tension and speed based on real-time operating conditions. This dynamic control enables high automation by automatically responding to changes in the winding process, while the parameter-based adaptation approach keeps the control logic relatively simple
3Manufacturing precision
If simple control system is used, then device complexity is low, but manufacturing precision is low
Solution Approach 1:
The system achieves high tension control precision by dynamically adjusting control parameters such as PID gains, tension setpoints, and speed ratios. This parameter-based control approach enables precise tension management without requiring complex hardware modifications, resolving the contradiction between precision and complexity
4Productivity
If multi-bundle winding is implemented, then productivity is improved, but control difficulty increases
Solution Approach 1:
The multi-bundle system is divided into independent drive units with individual control loops. This segmentation allows each bundle to be controlled separately, improving productivity through parallel processing while keeping the control difficulty manageable through modular, decoupled control architecture
Solution Approach 2:
The control system independently manages tension and speed parameters for each bundle, allowing optimization of control strategies for each specific bundle without affecting others. This selective control approach improves overall productivity while reducing the complexity of coordinating all bundles simultaneously
5Manufacturing precision
If high real-time control is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system achieves high tension stability through real-time parameter adjustment using fractional-order PID control. By dynamically changing control parameters based on error signals and system state, the patent achieves precise tension control without requiring overly complex control architecture
Data Source
AI summary
The present application relates to the technical field of fiber winding control, and provides a tension control method of a multi-bundle winding equipment combined driving system, which solves the problem that the tension fluctuates greatly and cannot be output constantly in the fiber winding process. The method includes: establishing a tension control system fractional order mathematical model; establishing a time-varying fractional order PID controller; inputting a target tension value and an unknown external interference to the tension control system fractional order mathematical model, and outputting a real-time tension value; and calculating a difference between the target tension value and the real-time tension value and then inputting the difference into the time-varying fractional order PID controller, inputting an output value of the time-varying fractional order PID controller and the unknown external interference into the tension control system fractional order mathematical model, and outputting a real-time tension value until the real-time tension value output by the tension control system fractional order mathematical model approaches the target tension value. The tension value output by the control system according to the present application can be well stabilized near the target tension value; and the system has high robustness when the tension changes suddenly.