数控纤维缠绕机精密张力控制系统的实验研究

纤维缠绕是目前树脂基复合材料成型的最主要工艺手段之一,而缠绕过程中,张力的控制是缠绕技术的关键所在。文章在实验的基础上,对以磁粉离合器为执行元件的数控纤维缠绕机精密张力控制系统进行了深入的探讨与研究。     

基于模糊PID控制的张力位置闭环伺服控制系统的研究

为使纤维缠绕张力控制系统性能得到提高,通过分析张力系统的受力不确定性,引用自适应模糊PID优化控制方法,并将其应用于纤维缠绕张力控制系统。结果表明,模糊自适应PID控制方法简单实用,适用于该张力控制系统,并且使纤维缠绕张力控制系统的控制性能得到显著改善。     

缠绕张力对环缠绕复合材料气瓶应力的影响

提出了一种等效降温法,将缠绕张力产生的预应力等效模拟为复合材料层降温产生的预应力,通过理论推导得到了缠绕预应力与复合材料层降温量之间的计算公式,基于等效降温法并利用通用有限元软件研究了缠绕张力对环缠绕复合材料气瓶应力的影响。结果表明：随着缠绕预应力的增大,环缠绕复合材料气瓶内胆工作应力减小、复合材料层工作应力增大;缠绕张力预应力较大时会抵消自紧工艺效果,气瓶工作应力和纤维应力比主要受缠绕张力影响,在进行有限元应力分析和纤维应力比计算时应考虑缠绕张力作用。     

五轴联动数控纤维缠绕机及其张力系统的设计

五轴联动数控纤维缠绕机的研制成功,对缠绕工艺而言是一次技术性的飞跃。在一些复合材料缠绕成型工艺的研究中,一项重要的内容就是对施加在纤维上的张力进行精准地控制,以防止缠绕制品因张力的不合适而引起制品变形过大,从而降低制品强度和抗疲劳性能,影响制品的质量。本文的目的是研发一种新型的五轴数控纤维缠绕机,通过对五轴联动数控纤维缠绕机的整体结构的设计,以及对缠绕机张力控制系统的工作原理的分析和研究,设计了五轴联动数控纤维缠绕机的张力系统。该系统采用曲线拟合的数学描述方法实现对张力传感器的标定,再通过复合滤波消除干扰。该缠绕机在实际的使用过程中,精确且稳定,制品满足使用要求。     

火箭发动机壳体缠绕过程中纤维张力控制系统的研究

分析了发动机壳体纤维缠绕过程中张力变化规律及影响因素,并给出了大张力计算机控制的程序框图、控制原理及实现方法。该控制方法还可用于天然气气瓶、航天航空和核工业等行业的纤维缠绕张力的控制,具有广泛的适应性。     

变频器在纤维缠绕张力控制中的应用

介绍了缠绕设备张力控制系统的组成和一般概念,基本控制方式和目前发展状况,分析了设计过程中要考虑的主要问题.针对纤维缠绕中张力控制的特点,提出用变频器控制的方法,并说明其基本原理,讨论了变频器在纤维缠绕中应用的实用性.     

精密张力控制系统及其控制精度的研究

文中通过对数控纤维缠绕机精密张力控制系统的工作原理及其控制精度因素的分析与研究,建立了系统的数学模型,并采取了张力补偿技术。经运行证明,该系统技术先进,合理,提高了纤维缠绕中张力的控制精度。     

基于神经网络的缠绕过程张力积分鲁棒控制

纤维缠绕系统是典型的非线性系统,缠绕过程张力控制精度决定了缠绕制品成型品质,然而系统非线性特性、摩擦及外干扰等严重制约了缠绕过程张力控制性能的提升。目前现有方法主要以收/放卷两轴同步控制为基础,通过解耦等复杂操作展开张力控制研究,计算量大且不利于控制算法的应用。为了避免上述问题并准确描述缠绕系统张力产生机理和实际的摩擦特性,建立简化的缠绕系统非线性数学模型。同时以自适应作为神经网络权值训练方法,基于自适应神经网络设计出干扰量的逼近函数,在基于连续积分鲁棒（RISE）控制器设计的控制律中补偿扰动的影响,并基于Lyapunov稳定性理论证明了系统的渐近稳定性。最后,给出所提出控制器与现有方法的对比验证实例,结果表明所提出基于神经网络扰动补偿的积分鲁棒控制显著增强了系统抑制外干扰的能力,提升了张力控制精度。     

缠绕张力模糊控制的研究

缠绕张力是影响缠绕制品质量的主要因素之一,本文针对金属丝编绕张力控制器反应速度快、控制稳定性以及鲁棒性强等方面的要求,提出一种基于PID和模糊控制理论的缠绕张力控制方法,在张力控制下进行了编绕缠绕试验,结果表明,缠绕张力的控制质量明显改善,并对结果进行了分析.     

多向纤维缠绕小样机的研制

首先对多向纤维缠绕制品的特性进行了分析。然后以实现多向纤维缠绕为基础,从总体结构、芯模零部件设计、传动系统设计以及控制系统设计等几个方面介绍了多向纤维缠绕小样机的研制。这些将为开发功能更完备的大型多向纤维缠绕机械提供很好的实践基础。     

Design and Analysis of a Novel Tension Control Method for Winding Machine

Filament winding has emerged as the main process for carbon fiber reinforced plastic(CFRP) fabrication, and tension control plays a key role in enhancing the quality of the winding products. With the continuous improvement of prod?uct quality and e ciency, the precision of the tension control system is constantly improving. In this paper, a novel tension control method is proposed, which can regulate the fiber tension and transport speed of the winding process by governing the outputs of three di erent driven rollers(the torque of the unwind roll, the torque of the magnetic powder brake roller, and the speed of the master speed roller) in three levels. The mechanical structures and dynamic models of the driven rollers and idle rollers are established by considering the time?varying features of the roller radius and inertia. Moreover, the influence of parameters and speed variation on fiber tension is investigated using the increment model. Subsequently, the control method is proposed by applying fiber tension in three levels accord?ing to the features of the three driven rollers. An adaptive fuzzy controller is designed for tuning the PID parameters online to control the speed of the master speed roller. Simulation is conducted for verifying the performance and sta?bility of the proposed tension control method by comparing with those of the conventional PID control method. The result reveals that the proposed method outperforms the conventional method. Finally, an experimental platform is constructed, and the proposed system is applied to a winding machine. The performance and stability of the tension control system are demonstrated via a series of experiments using carbon fiber under di erent reference speeds and tensions. This paper proposes a novel tension control method to regulate the fiber tension and transport speed.     

一种新型张力控制系统的研究

提出了一种新型的纤维张力控制系统，它以交流数字伺服电机为执行元件，具有结构简单、门动化程度高、回纱能力强和保持张力恒定等特点。     

薄膜张力控制系统的建模与设计

鉴于薄膜收换卷时的张力大小及平稳性对收卷质量具有决定性的影响,针对流涎机收卷系统的动态过程,分析了张力与收卷线速度、卷径及转速之间的动力学关系,提出了张力控制原理,并分析了薄膜在收换卷时收卷电机转速的变化补偿规律。在此基础上,设计了薄膜在收换卷时的张力控制系统,通过控制速度差对张力进行间接控制,同时采用BP神经网络PID控制器调节收卷转速对张力进行直接补偿。仿真对比结果表明,该控制器动态响应好,抗干扰能力强。实际应用实例也证明该控制方法张力控制精度高,控制高效可靠, 对改善系统的动态特性和提高薄膜的收卷质量有着重要意义。     

A taper tension profile maker in a converting machine

Winding is an integral operation in almost every web handling process, and a center-wound roll is one of the suitable and general schemes in a winding system. However, improper internal stresses within a center-wound roll can cause damage such as buckling, spoking, cinching, etc. Wound roll quality and performance are known to be related to the distribution of in-roll stresses. It is therefore necessary to analyze the relationship between taper tension in the winding section and internal stress distribution within the center-wound roll to prevent winding failure. But it is hard to compensate for an undesirable winding roll shape such as starring, buckling, and telescoping. This is because the winding section is the final process in a roll to roll system and has no feedback control system to correct winding roll shape directly. A time varying tension profile and accurate control of it in a winding section is one way to shape the fail-safe in-roll stress distribution of a winding roll. In this study, a new taper tension profile making method is aimed for designing high quality wound rolls. A new method to determine the proper taper tension profile was designed by analyzing the winding mechanism which includes the stress model in center-wound rolls, nip induced tension model, relationship between taper tension profile and telescoping, relationship between taper tension type and internal stress distribution. An auto taper tension profile making method was proposed not only to optimize radial stress distribution but also to minimize lateral error (telescoping). Simulation results show that the proposed method is very useful for determining the desirable taper tension profile during the winding process and preventing defects of winding roll shape such as telescoping, starting, and dishing and so on.     

小型金属窄带恒张力卷绕控制系统设计

针对金属窄带材卷绕质量要求,设计了一套恒张力控制系统。分析了金属窄带材卷绕生产工艺过程控制中张力产生及其影响因素,在保持恒张力控制的基础上,提出、设计、制作了窄带材卷绕的双闭环、串级、动态控制系统。采用单片机为核心控制单元实现信号采集与控制信号输出,以三相交流力矩电机为主执行机构,结合转速、张力双闭环控制,实现了基于力矩电机的带材卷绕可控恒张力机构;同时以步进电机为辅执行器,以位移检测为反馈量的盘绕机构横移控制;以及以带材厚度为前馈信号的超前控制。通过设计电路图、制作电路板、系统集成应用效果表现出,带材卷绕过程用力均匀,张力稳定,匝间间隙合适,层间松紧适度,盘绕平整、均匀,保证了生产质量。     

Variable tension control for discontinuous tape winding of composites based on constant extension ratio

Discontinuous tape winding, which has obvious advantages in large extension ratio winding, is widely used in the molding of composites. Therefore, the research on technological parameters becomes the focus of many scholars. However, how to accomplish the variable tension control is usually not fully considered. Accordingly, the constant extension ratio and the smoothness of winding process cannot be ensured. Aiming at the problem of tension control, this paper first gives a comparatively deep research on the control method and the interaction mechanism of tension, extension ratio, automatic lap and automatic rectification. Then, according to the winding process features, the mechanical device and the mathematical model of tension control system are established respectively. With regard to the characteristics of PID controller and fuzzy controller, the fuzzy self-tuning PID controller is designed. As a result, the variable tension control is realized during the winding and lapping process, and the constant extension ratio is guaranteed. Finally, a sample application is presented for demonstration. By presenting the variable tension control techniques for discontinuous tape winding, the constant extension ratio of tapes is achieved, the consecution and the automation degree of winding process is improved as well. Thus, the quality of wound products is guaranteed.     

Effect of taper tension profile on the telescoping in a winding process of high speed roll to roll printing systems

Winding is an integral operation in almost every roll to roll system. A center-wound roll is one of the suitable and general schemes in a winding mechanism. In general, the quality of wound roll is known to be related to the lateral displacement error and starring defect of a wound roll. Especially, a telescoping within a center-wound roll can cause damages such as misalignment between layers, folding, wrinkle, etc. Taper tension is known to be one of the major factors which affect the shape of a wound roll. It is therefore necessary to analyze the relationship between taper tension profile and telescoping within the center-wound roll to prevent winding failure and to sustain high quality of the printed materials. It is hard to compensate for undesirable winding roll shapes such as telescoping, because a winding is commonly a final process in roll to roll systems and has no feedback control mechanism to correct winding roll shape directly during winding operation. Therefore, an optimal taper tension profile and the accurate control of it in a winding section could be one way to shape the fail-safe of a wound roll. Through the correlation between taper tension profile and telescoping in a winding process, a mathematical model for the telescoping due to tension distribution in cross machine direction was developed, and verified by experimental study. A new logic to determine the proper taper tension profile was designed by combining and analyzing the winding mechanism which includes nip induced tension model, relationship between taper tension profile and telescoping, relationship between taper value and telescoping. Numerical simulations and experimental results show that the proposed method is very useful for determining the desirable taper tension profile during the winding process and preventing defects of winding roll shape such as telescoping.     

细丝拉丝机张力控制系统设计与仿真

拉丝机卷绕张力是细丝拉丝生产过程中的重要因素.为解决钢丝拉丝过程中张力过大时易拉断、张力过小时卷绕效果差等问题,将基于PID控制算法的PLC技术应用到细丝拉丝机张力控制系统中,开展了张力产生原因及控制方法分析,建立了收卷速度与细丝拉力之间的关系及模型,提出了以PLC为核心控制器的张力控制方法;最后,基于Matlab Simulink对上述细丝张力控制系统进行了评价,并开展了相应的仿真试验.研究结果表明,该张力控制系统可以对拉丝机实现良好的控制效果,其响应快、超调小,具有较高的精度和稳定性.     

多智能体技术在张力协调控制中的应用

在纤维、造纸、塑料及金属镀膜工业中,对线状、带状及面状弹性材料卷取张力的控制是关系其产品质量的关键技术。介绍了一种动态贝叶斯网络训练算法的多智能体技术,该方法有效地减弱了张力控制系统中各轴速度、张力之间的耦合作用。仿真结果表明,该算法具有良好的自学习和自适应性能。     

基于神经网络的张力控制系统

在纤维,造纸,塑料及金属镀膜工业中,对线状,带状及面状弹性材料卷取张力的控制的是关系其产品质量的关键技术,介绍了一种带有反向传播训练算法的人工神经网络,该方法克服了传统PI控制方法的缺点,有效地减弱了张力控制系统中速度和张力之间的耦合作用,仿真结果表明该种控制议程有良好效果。