Tension control during tungsten wire winding is a key step to achieve high-quality winding. The following are several main methods to achieve tension control in tungsten wire winding:
- Traditional manual control technology
In traditional tungsten wire winding processing, most of the tension of the winding machine is manually adjusted. This method relies on the experience and skills of the operator to achieve tension control by manually adjusting the tension mechanism (such as tension wheel, counterweight, etc.). However, this control method has the disadvantages of high difficulty in operation, low precision, and susceptibility to interference from human factors.
- Electrical control technology
With the development of electrical technology, tension control technology based on the principle of electromagnetic induction has emerged. This technology uses electrical components such as induction motors or magnetic powder clutches to achieve real-time control and feedback of tension. For example, a magnetic powder clutch can use magnetic powder to convey torque according to the electromagnetic principle, and control torque by changing the magnitude of the excitation current, thereby achieving stable control of tension. Electrical control technology has the advantages of good stability and simple operation, but it is relatively expensive and easily affected by environmental factors such as temperature and humidity.
- Intelligent control technology
Intelligent control technology is currently the most advanced tungsten wire winding tension control method. It uses computer control technology to automatically adjust the output current of the tension motor according to the real-time winding process parameters to achieve precise tension control effect. Intelligent control technology not only improves the winding quality, but also significantly reduces production costs. This technology uses sensors to detect the tension state of the tungsten wire in real time and feeds the data back to the computer control system. The control system automatically adjusts the output current or voltage of the tension motor according to the preset tension range and process requirements, thereby achieving precise control of the tension. Intelligent control technology has the advantages of high precision, high stability, easy automation and intelligence.
- Wire winding machine with tension adjustment function
Some advanced wire winding machines are designed with tension adjustment function, which can realize fast and bidirectional adjustment of tungsten wire tension. This type of wire winding machine is usually equipped with a precise tension adjustment mechanism and sensor, which can automatically adjust the tension according to the actual situation during the winding process to ensure that the tungsten wire maintains a constant tension state during the winding process.
- Tangent winding plus closed-loop control
In some high-end winding equipment, the method of tangent winding plus closed-loop control is used to achieve precise tension control. This method compares the tension setting and tension feedback by calculating the torque current setting (including tension setting, inertia compensation and mechanical loss compensation) and the closed-loop control with tension sensor feedback, and outputs the tension compensation signal through the proportional-integral operation regulator. This method combines the advantages of tangent winding function and closed-loop control technology, and can achieve high-precision tension control.
- Precautions
When implementing tungsten wire winding tension control, the following points should be noted:
Ensure the accuracy and stability of the tension control equipment to avoid tension fluctuations caused by equipment failure or error.
Select appropriate tension control methods and parameters according to the material, diameter and winding requirements of the tungsten wire.
Regularly maintain and calibrate the tension control equipment to ensure its long-term stable operation.
Pay close attention to the tension state of the tungsten wire during the winding process, and adjust the tension control parameters in time to deal with emergencies.
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