A Study on Tension Control and Disturbance Suppression for High-Speed Winding System

[[abstract]]高速盤捲系統在工業界應用日漸廣泛，但技術門檻高，主要是盤捲系統在高速盤捲時，必須維持穩定的張力，同時由於薄片在盤捲時會因為各滾輪存在些微偏斜而擠向盤捲輪之一側，導致盤捲失敗，因此糾偏控制亦是盤捲系統不可或缺的一部分。 本研究針對具糾偏控制之盤捲系統的張力控制及其干擾抑制深入探討其控制特性及改善對策，由於盤捲系統大都是由盤捲馬達直接帶動盤捲，而盤捲輪之慣性矩遠大於馬達慣性矩，亦即馬達的負載慣量比很大，導致盤捲馬達反應頻寬大幅下降，若盤捲張力由盤捲馬達來控制，則盤捲中的張力干擾將無法迅速有效地抑制。而張力干擾的因素有許多，如:供料輪或盤捲輪偏心或前製程盤捲成橢圓、張力不均等，在高速盤捲時就會有約20Hz以上的張力干擾出現，若張力控制的反應頻寬不足，此張力干擾將使得張力控制相當不穩定，甚至造成盤捲帶材斷裂。 前期研究所提出來之糾偏控制機構係以其頂輪兩端一上一下的位移來達成盤捲時橫向偏移的抑制，然而藉由該頂輪同時上下位移時，亦可控制盤捲張力，由於該機構的反應頻寬遠高於盤捲輪的反應頻寬，預期可更有效抑制高頻張力干擾的影响，因此本研究即藉此糾偏控制機構的同時上下位移來控制盤捲張力，模擬及實驗皆証實此頂輪張力控制對高頻的張力干擾可有效抑制，但系統暫態時兩輪線速度維持不易，導致頂輪位移量超過螺桿行程以至張力控制效果不佳，本研究最後提出結合盤捲輪張力控制與頂輪張力控制而成雙迴路張力控制，模擬與實驗証實可有效抑制高頻張力干擾又可在系統暫態時有不錯的張力控制[[abstract]]Tension control as well as aligning control is indispensable in a high-speed winding system This research is aiming at improving the performance of the tension control and its disturbance suppression capability in a high-speed winding system with aligning control In general the winding wheel in a winding system has a guide slow response characteristics due to its big load inertia comparing to the driving motor inertia As a result it is not easy to control the winding tension in a small stablized region by adjusting the torque or speed of the winding wheel when some high frequency tension disturbance exist which might be higher then 20Hz The approach adopted in this research is to utilize the aligning wheel to control the winding tension as well The high frequency disturbance can be effectively reduced due to the fast response characteristics of the aligning wheel However due to stroke limitation this approach does not perform well in the speed up/down transient stage Consequently a dual loop tension control which combines winding wheel and aligning wheel for tension control was proposed The effectiveness of the approach has been shown with simulation and experimentatio