Research On Yarn Tension Control Strategy And Novel Controller In Winder

It is a basic requirement to ensure constant yarn tension during the process of automatic winding, otherwise, the fluctuation of yarn tension will affect the follow-up process and even affect the final quality of textile products. According to the yarn overfeed tension control system with high speed and yarn tension hard to control, the paper study the yarn tension control strategy in winder and develop a novel tension controller to adapt to the modernization of industrial production. The major work is as following:(1) In order to realize the high speed winding and yarn overfeed in winder, the BLDCM used to drive the yarn feeding wheel, and proposed yarn rotary positive feed control system, through the yarn tension constant value control can reduce the friction during yarn winding, and improve the quality of yarn winding.(2) Through the mathematical modeling of yarn tension control system, the speed of the wind motor and BLDCM, the radius of the cone yarn and yarn feeding wheel radius affect the yarn tension, discusses the nonlinear factors in winder tension control system,some uncertain factors are also analyzed, finally the yarn tension closed-loop control scheme is proposed.(3) This paper puts forward the solutions for the key problems. First is how to keep the BLDCM speed and spindle winding motor speed synchronization at startup stage. Second, because of the yarn tension control system is a nonlinear control system, so how to ensure the control algorithm with adaptive become critical. Using MATLAB simulink toolbox to modeling and simulation the yarn tension control system, and finally design the fuzzy adaptive PID control algorithm and starting algorithm, and verify their effectiveness.(4) This paper design the overall structure of the yarn tension controller, and implement the tension detection module, motor drive module, wireless communication module, temperature detection module, human-computer interaction module, complete hardware and software. Besides, a remote monitoring software developed to realize remote monitoring, trouble shooting and production task distribution online and improve production efficiency.Through the experiment under the condition in low wind speed and high wind speed to validate the the dynamic response performance and steady-state control error of the controller. The experimental results show that this novel yarn tension controller can achieve tension setting value within 0.4s, the yarn tension control error within 5%, and realize the online monitoring of the controller, meet the expected objectives.