Ultra-fine Wire Warping Tension Control And Equipment Research

High precision wire mesh is mainly used in high precision filtration,high precision circuit printing and intelligent application.Ultra-fine metal wire warping machine is applied in warping of high precision wire mesh weaving.The subject comes from the development of Hangzhou Hengyi Filter Co,Ltd.They want to develop sophisticated wire mesh.Warping is a before weaving process that parallel wind certain numbers of warp yarns around the shaft according to the length and width,and maintain a certain tension.It is the most important process before weaving.The company's original wirewarping equipment is too obsolete.It has no filament tension control and accurate yarn tension control;the creel capacity is small;the lateral displacement cannot be controlled accurately.The machine can only meet the diameter of 0.025mm and above metal wire warping.In order to develop the high fine metal mesh,especially the diameter of 0.02mm and below wire mesh,it is imminent to develop super fine metal wire warping machine.Based on the study of super fine metal wire warping characteristics,warping process and the wire warping machine on the basis of the shortage,this article mainly studies the filament tension control methods of super fine metal wire warping and the structure of creel,the algorithm of yarn tension control and super fine metal wire warping machine development.(1)Filament tension control and structure design:Through the filament tension contrast test of hammer weight friction disc tension control,and hammer weight rod tension control and no filament tension control,it comes out that hammer weight friction disc tension control method is more stable than others,and it can guarantee the bobbin unwinding tension by adjusting.In view of the creel capacity,small friction requirements on the wire,the V type creel dislocation symmetrical structure can reduce the wire in friction and angle gather before they are gathered.In the design of electromagnetic brake of bobbin servo shaft brake,electromagnetic brake response time is 0.3s,it will avoid bobbin unwind when the.machine is braking.(2)Yarn tension control algorithm:By studying the principle of tension formation,double closed loop control is adopted in the yarn tension control system,which realizes constant wire speed winding and constant tension winding.PID algorithm based on Kalman Filter is used to control winding line speed.Because the coil diameter is changing all the time,servo motor must be dynamic controlled.By real-time line speed encoder detection,use the filter Kalman Filter to remove noise signal.The PID algorithm will control the quantity of output,then,the purpose of the dynamic adjusting winding speed of servo motor comes true,also the algorithm keep the line speed constant.The constant winding tension is controlled by using the integral separation PID algorithm.In the winding,the control system of speed and tension must ensure that respond rapidly,accurately,stably,moreover must ensure that there is no overshoot,which will causes physical damage to the wire.The integral separation PID algorithm meets the requirements above,and achieves the purpose of winding with constant tension,and no overshoot.(3)Structural design and electrical control system design:The 500 bobbins creel capacity and warping frame were designed and manufactured.The whole frame contains the gather mechanism,a yarn tension control mechanism,a rolling mechanism,sliding control mechanism and dividing mechanism.The creel and warping machine,realizes that the super fine metal wire constant tension winding,and the filament tension is equal,and the yarn tension is constant.