Development of Wire Tension and Synchronous Velocity Controllers for Wire Winding Systems

Abstract

This dissertation presents development results of wire tension and synchronous rotational velocity controllers for a wire winding system. The wire winding system consists of a wire coil producing system (WCPS) for winding a wire coil and a wire tension system (WTS) for controlling the tension of wires. A synchronous rotational velocity controller is used for WCPS to ensure that there is neither gap nor overlapping among wire turns of wire coils. Meanwhile, a wire tension controller is used for WTS to ensure that wires used for the wire coil winding process are neither sagged nor stretched to avoid the wires to be broken. To do these tasks, the followings are done. Firstly, the system description and system modelings of WCPS consisting of a winding spindle axial system (WSAS) and a nozzle feed drive axial system (NFDAS) are presented. The system modeling of WCPS describes the mechanical and electrical behaviors. Based upon this modeling, a modified model reference system with known parameters is chosen according to the dimension of the given system and the rotational velocity outputs of WCPS to track its trapezoidal rotational velocity reference input. Then, the rotational velocity outputs of WCPS are controlled to track the rotational velocity outputs of the model reference system by designing update laws for updating the adaptive controller gains. Moreover, since the system modeling for WCPS is constructed as a recursive structure system, the modified model reference adaptive controller is designed based on backstepping approach. Secondly, a cross-coupling synchronous rotational velocity controller is designed for WCPS. Accordingly, the rotational velocity error of one axial subsystem is reflected to the other and vice versa. The cross-coupling synchronous rotational velocity controller is designed using backstepping-based model reference adaptive control theory to regulate the synchronous rotational velocity error to zero while the rotational velocity outputs of WCPS track the trapezoidal rotational velocity reference input. Thirdly, the system description of WTS, the system modeling of WTS and an analysis of winding process for circular/non-circular cross-section of bobbins are presented. Based on the result of this analysis, mechanism called as a wire accumulator using a pneumatic servo system is designed to decay the vibration of wire tension under the harsh condition of winding process for a non-circular cross section of bobbin. For a sophisticated behavior of the system's response, a novel cascade fuzzy logical controller (CC-FLC) with the fuzzy rule constructed based on a split-range method is appropriate for controlling WTS. The feedback of one control input of WTS is used as fuzzy variable input for controlling the other control input according to cascade control structure. Fourthly, the CC-FLC is implemented on a DSP TMS320F28069 microprocessor for controlling a prototype of WTS equipped with a TS1-1000cN tension sensor, a DNCI-32-200-P-A pneumatic cylinder and a MPYE-5-1/8-hf-010-b servo valve. The prototype of the WTS is tested on a BLDC winding machine for a wire winding process. Finally, simulation and experimental results shows that the back-stepping-based model reference adaptive controller can stabilize the rotational velocity output of WSAS tracking its trapezoidal rotational velocity reference input with the smaller rotational velocity error than a conventional PID controller, the cross-coupling synchronous rotational velocity controller using model reference adaptive control can stabilize the synchronous rotational velocity error to a desirable value, and the control inputs are acceptable for driving the DC motor of WSAS and NFDAS. The WTS applied by the CC-FLC can control the wire tension error within small sufficient value to avoid the wire to be broken during the wire winding process. The wire coil size is reduced by using WTS instead of a passive tension system.