Research on Unwinding Mechanism Design and Tension Control Strategy for Winding Machines

During the winding process of a coil winding machine, excessive tension can cause wire deformation, over-stretching, or breakage, while insufficient tension may lead to slackness, accumulation, and wrinkling. The magnitude of winding tension directly affects product quality and operational performance. This paper addresses the challenges of inadequate constant-tension control accuracy and excessive fluctuations in the unwind system of winding machines under disturbances. By integrating specific operational scenarios, a fuzzy PID control strategy suitable for actual production environments is designed. Based on an established coupling model relating unwind tension to roll diameter, unwind speed, and moment of inertia, conventional PID and fuzzy PID control simulation models are developed in the MATLAB/Simulink platform. These models evaluate both control strategies under noise disturbances and abrupt tension changes. A systematic comparative analysis examines the dynamic response characteristics, steady-state accuracy, and anti-interference capabilities. Results demonstrate that the fuzzy PID control, integrated with actual winding machine conditions, effectively suppresses tension fluctuations induced by nonlinear disturbances, reducing adjustment time by 3 s compared to conventional PID control. This indicates that the production-condition-integrated fuzzy PID control exhibits smaller overshoot, enhanced robustness, and superior dynamic response and better meets precision requirements for wire winding tension control.