| Wire rope is the spiral wire bundle, which is twisted by a number of steel wire or strand according to certain rules. Besides its good tensile strength, fatigue strength, and impact toughness, it can also withstand heavy load and impact load. Furthermore, it has good reelability, relatively light weight, diversified structures and complete specifications. Consequently, it has become an essential part or material in metallurgy, mining, oil and gas drilling, mechanical, chemical, aerospace and other fields. Many industries at home and abroad have paid much attention to its quality, and devote a great deal of manpower and material resources to its use research and product development. After study and analysis, it is found that the tension control of wire or strand during wire twisting has an important influence on the quality of steel wire rope.The strander is one of the main equipment in the production of wire rope. The current tubular stranding machines in industrial production result in non-constant tensioning forces, which is not desired to control the result. This article designs a constant tension control system based on the research and analysis of tension control model and algorithm.Firstly, the research background and the significance of this study are introduced. In this part, the development of wire rope and the research status of tension control at home and abroad are summarized. The production process of wire rope, the equipment used, the control principle and method are introduced. It is pointed out that constant tension control is extremely important in the twisting process of wire rope.Secondly, a mathematical model for the control system of tube strander is developed based on tension control system. The influence of the change of the roll diameter, rotational inertia and the angular velocity on tension in the process of unwinding is analyzed. It is found that the change of roll diameter is the main factor that results in the tension fluctuation. On the basis of the commonly used measuring method of coil diameter, this article develops a new method to calculate the roll diameter according to the coil model and time. Because the rolling tension control system of strander is a nonlinear, time-varying, multiple interference system, the research of the control strategy is also an important content in this article. The analysis of the respective features of various kinds of PID control algorithm lays a solid foundation for the design of the tension controller.Thirdly, a complete set of tension control device is developed, which includes the tension sensor as detecting element, magnetic powder brake as the execution component, and a fuzzy PID controller based on neural network. The design of the controller includes the hardware circuit design, software design and control algorithm design.Finally, the tests show that the calculating result of the roll diameter consists with the measured value, which proves the effectiveness of the proposed method. The simulation of the control strategy in the system is also conducted using MATLAB/Simulink. The results show that the fuzzy PID control system based on neural network is better than conventional PID algorithm in dynamic and static performance and robustness, etc. Additionally, the device is applied in real industrial production. According to the test results, the device is easy to operate, and the system works stably because of its strong anti-jamming capability. The constant tension pay-off is realized, which ensures the quality of the product and the safety requirement in production. |
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