TY - GEN
T1 - Empirical Investigation and Feed-Forward Control of Wire Tension in Needle Winding Processes
AU - Kohler, Markus
AU - Herrera, Christian
AU - Gerngroß, Martin
AU - Kennel, Ralph
AU - Endisch, Christian
N1 - Publisher Copyright:
© 2024 IEEE.
PY - 2024
Y1 - 2024
N2 - In the evolving landscape of electric motor manufacture, needle winding technology has emerged as a viable solution, offering precision in producing orthocyclic round wire windings. The practicality of this technology, however, depends significantly on stable wire tension during the winding process. To facilitate this stability, a comprehensive model describing the forces exerted on the wire at various winding stages becomes indispensable. This paper primarily focuses on developing a model-based feed-forward wire brake torque control profile. This new approach ensures steady wire tensile forces at the wire deposit point, presenting practitioners with an alternative to or enhancement of feedback control systems, avoiding the need for intricate wire tension measurements in production. Leveraging previous research, we utilize neural networks to approximate the bending forces at the winding needle while using a simplified linear model for the preceding wire guiding system. Further, through meticulous analysis of measured tensile force signals, we introduce an empirical model to approximate the wire's dynamic force variations. Force measurements were then used to evaluate the generated model-based braking torque profile. The findings revealed a reduction of measured median absolute deviation by more than 50%, demonstrating effective stabilization of the wire tension compared to a constant brake torque control.
AB - In the evolving landscape of electric motor manufacture, needle winding technology has emerged as a viable solution, offering precision in producing orthocyclic round wire windings. The practicality of this technology, however, depends significantly on stable wire tension during the winding process. To facilitate this stability, a comprehensive model describing the forces exerted on the wire at various winding stages becomes indispensable. This paper primarily focuses on developing a model-based feed-forward wire brake torque control profile. This new approach ensures steady wire tensile forces at the wire deposit point, presenting practitioners with an alternative to or enhancement of feedback control systems, avoiding the need for intricate wire tension measurements in production. Leveraging previous research, we utilize neural networks to approximate the bending forces at the winding needle while using a simplified linear model for the preceding wire guiding system. Further, through meticulous analysis of measured tensile force signals, we introduce an empirical model to approximate the wire's dynamic force variations. Force measurements were then used to evaluate the generated model-based braking torque profile. The findings revealed a reduction of measured median absolute deviation by more than 50%, demonstrating effective stabilization of the wire tension compared to a constant brake torque control.
KW - automation
KW - electric machines
KW - manufacturing
KW - modeling
KW - production
UR - http://www.scopus.com/inward/record.url?scp=85199623583&partnerID=8YFLogxK
U2 - 10.1109/ISIE54533.2024.10595747
DO - 10.1109/ISIE54533.2024.10595747
M3 - Conference contribution
AN - SCOPUS:85199623583
T3 - IEEE International Symposium on Industrial Electronics
BT - 2024 33rd International Symposium on Industrial Electronics, ISIE 2024 - Proceedings
PB - Institute of Electrical and Electronics Engineers Inc.
T2 - 33rd International Symposium on Industrial Electronics, ISIE 2024
Y2 - 18 June 2024 through 21 June 2024
ER -