The Non-sliding Drawing Structure Design And Tension Control Algorithm Of Fine Metal Wire

The fine metal wire is mainly formed by plastic deformation cold drawing process,and is widely used in advanced technical fields such as high-precision filter screen,semiconductor integrated circuit board,anti-static clothing and intelligent manufacturing.This topic comes from the horizontal project “Design and development of tension wire drawing equipment and tension control research” of XXX Co.,Ltd.and our school.The micro-wire drawing process is to combine the raw material wire by a certain proportion of the drawing eye mold,and after multiple times of combined drawing,the reduced-diameter stretching effect is obtained,which is an important part of the wire processing field.The company's existing wire drawing equipment is a traditional sliding tower wheel wire drawing machine,its tension control mode is fuzzy and the response speed is lagging.The wire drawing process is difficult to meet the requirements in important indexes such as wire cylindricity,axial direction and surface quality,and defective products.The rate is high.Based on the research of advanced drawing technology and control methods at home and abroad,this paper designs a set of drawing equipment capable of drawing 0.0118mm--0.05 mm wire diameter with high automation degree and accurate tension control,which improves the drawing.The level of technology,using a constant tension control method to improve the yield rate.1)Based on the analysis of the micro-wire drawing process and its principle,a new non-sliding linear drawing process was designed.The ultimate fracture tension verification test of monofilament is carried out,which is the critical point of tension control of drawing process.According to the principle of the influence of back tension drawing on drawing force,a load-adjustable tension mechanism is designed.It ensures the reduction of the drawing eye mask loss and the production cost while improving the drawing process.2)Design and develop the mechanical structure and electrical system of the micrometal non-sliding linear wire drawing machine,and carry out subsequent start-up experiments.The mechanical structure mainly includes a vertical tension unwinding unit,a combined drawing unit,and a traversing cable winding unit.According to the non-sliding linear drawing process,the tension isolation of the sub-units is realized,and the load-adjustable tension mechanism is provided,and the anti-tension drawing process is effectively and reliably performed,thereby improving the surface quality of the metal wires.The electrical system with Panasonic AFPX-M8N16 T as the control core is designed.The PLC and the touch screen jointly build the upper control system,which can complete the human-computer interaction functions such as drawing process parameter setting,equipment start-stop control,real-time operation monitoring and fault information alarm.The basic actuator is a 5-axis servo motor,a rotary angle encoder,a tension detecting sensor,and the like.3)Constant tension stability control algorithm based on closed-loop feedback PID control of Kalman filter is the difficulty of the whole tension control system.The accuracy of the system response is improved by properly filtering the output signal in the Kalman filtering algorithm.The load-adjustable tension mechanism adopts an openloop control mode,which provides a stable torque by the micro-magnetic powder brake to ensure that the tension swing lever is in an equilibrium position,thereby providing a reverse tension input mold on the basis of constant tension operation.The overall algorithm control optimizes the drawing process and ensures system stability and antiinterference ability under high-speed operation.In the test drawing stage,the breaking rate is not more than 1.5%,the interference test swing angle is not more than ±10°,and the self-adjusting time is less than 2s.In the tensile working area tension measurement,the initial tension is at a basic steady state in about 3s.The front end back tension steady state error is controlled at 60±20% gf,and the back end pull tension steady state error is controlled at 80±20% gf.