Fault Analysis Of Electrolytic Capacitor Winding Process And Realization Of Its Control System

In the production process of high-voltage and large-capacity aluminum electrolytic capacitors,the winding process is an extremely important section.The false short-circuit failure of the finished aluminum electrolytic capacitor is mainly caused by the contact between the positive and negative electrodes when the capacitor core is wound.During the winding process,tension control is crucial.The purpose of tension control is to make the film materials inside the capacitor wind according to a certain force law,making the capacitor core appear tight inside and loose outside,and avoiding deviation,core pulling and other forms.The winding tension control system of film materials is a system with time-varying parameters,hysteresis and non-linearity.The low efficiency and low degree of automation existing in traditional tension control systems on the market are no longer suitable for the production of aluminum electrolytic capacitors.manufacture.The tension control system applied in the winding process of aluminum electrolytic capacitors in this subject research not only improves the production efficiency and quality of aluminum electrolytic capacitors,but also further enhances the automation of the production process.Therefore,the research of this subject has very great practical significance and application value.This subject first analyzes and studies the manufacturing process and production process of aluminum electrolytic capacitors,establishes a dynamic model of the winding mechanism,and finds the root cause of the tension change;then uses the theoretical knowledge of elastic mechanics to analyze the internal tension distribution of the capacitor core,selects the taper tension method for winding.Secondly,the overall design and analysis of the tension control system are carried out.In view of the low efficiency and low degree of automation existing in the current aluminum electrolytic capacitor winding control system,select the appropriate tension control method,select the peripheral device of the system,and then compare the traditional industrial control programmable logic controller,and propose the tension control system based on the digital signal controller,which has abundant interface resources and convenient implementation of various algorithms.Meanwhile,hardware and software design are carried out around the controller.In the design of the hardware circuit of the system,based on the scalability requirements and strong anti-interference ability of the system,the emphasis is on the design and implementation of the hardware circuit used in the control system.Before software design,in order to solve the problem of time-varying and lagging parameters of the control process,a fuzzy control algorithm was added to the traditional PID control,and the improved Smith predictive model was used to solve the lagging problem in the system,making full use of their respective advantages,and the algorithm simulation is verified in MATLAB.In terms of software design,starting from the stability of the system,the ?C/OS-II operating system is added to realize core algorithms such as curling radius calculation and fuzzy PID control.At the same time,in order to make the control system operability,this design also added a man-machine interface based on the serial port screen.Finally,a comprehensive test was performed on the entire system.According to the manufacturer's feedback results,the control system achieved the expected control effect,approached the goal of high efficiency and low power consumption,and improved the product quality of the capacitor.The tension control system designed in this subject is not only suitable for the winding manufacturing process of aluminum electrolytic capacitors,but also has certain reference value for industries that require winding tension control such as the paper industry,printing industry,and packaging industry.