Analysis and design of wire winding tension control system based on genetic algorithm and fuzzy PID

Wire winding is a key process in transformer manufacturing, and the accuracy of tension control directly affects the quality of the products. To achieve the requirement of constant tension winding of wire, the influence of roll diameter, speed, and other factors on the dynamic performance of tension is analyzed by establishing the dynamic model of unwinding and winding as well as the pendulum part. A control strategy combining proportional-integral-derivative (PID) control with fuzzy control is adopted, and the parameters of the fuzzy PID controller are optimized using an improved genetic algorithm. Simulation results demonstrate that the optimized fuzzy PID controller significantly reduces tension overshoot and effectively suppresses the tension fluctuation when the speed and roll diameter change, and the tension fluctuation is controlled within 2%. Finally, the feasibility of the optimized fuzzy PID controller in the tension control system is experimentally validated.