sensors
Article
Design of Insulation Tape Tension Control System of Transformer
Winding Machine Based on Fuzzy PID
Liwei Deng * , Hongfei Suo and Haonan Ren






Citation: Deng, L.; Suo, H.; Ren, H.
Design of Insulation Tape Tension
Control System of Transformer
Winding Machine Based on Fuzzy
PID. Sensors 2021, 21, 6512. https://
doi.org/10.3390/s21196512
Academic Editor: Hossam A. Gabbar
Received: 7 July 2021
Accepted: 27 September 2021
Published: 29 September 2021
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Attribution (CC BY) license (https://
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4.0/).
Sensors 2021, 21, 6512. https://doi.org/10.3390/s21196512
Heilongjiang Provincial Key Laboratory of Complex Intelligent System and Integration, School of Automation,
Harbin University of Science and Technology, Harbin 150080, China; 13563103295@163.com (H.S.);
rhn1996@163.com (H.R.)
* Correspondence: dengliwei666@163.com; Tel.: +86-0451-8639-0863
Abstract: With the rapid development of science and technology as well as the comprehensive
societal progress, the demand for electricity in all walks of life is also increasing. As is known to
all, the mechanical structure and tension control of a transformer winding machine is the key to
improving the quality of coil winding, due to coil winding being generally considered the core
technology of transformer manufacturing. Aiming at the synchronous winding control problem
of the conductor and insulating layer of the transformer winding machine, this paper presents a
mechanical structure and tension control scheme of a new type of transformer winding machine.
Based on the dynamic analysis and modeling of the mechanical structure of the winding machine,
the speed control of the main speed roller by the fuzzy PID control rate is implemented initially.
Combined with the actual demand of the project, the feasibility and effectiveness of the control target
with different tension are verified by the simulation experiment and further compared with the
traditional PID control method. The simulation results show that the proposed fuzzy PID control rate
can realize the automatic and efficient winding of the transformer winding machine, showing that it
is superior to the traditional PID control rate in overcoming the disturbance and controlling effect.
Keywords: fuzzy PID; tension control; transformer; winding machine
1. Introduction
In recent years, with the rapid development of domestic economy, power transmission,
and distribution transformers are in noticeably booming demand in the power industry.
Transformers, as the basic equipment for power transmission and transformation, are
widely applied in transformer stations, converter stations, and power plants, playing a
significant role in the power industry [1]. The core process of transformer manufacturing
is coil winding, of which winding quality directly affects the overall performance of the
transformer. The technical level of coil winding largely depends on the technical level of the
winding machine [2]. Therefore, in order to manufacture high-performance transformers,
the priority is to boost the development of technical level of winding machines.
The mechanical structure of the tension system and constant tension control are the
core technologies of the transformer winding process. The transformer winding machine
developed by several well-known companies has a high degree of automation and produc-
tion efficiency, and also, the winding coil is constant in integrated tension and guaranteed in
quality. The MTM Company of Canada and LAE Company of Italy have achieved the syn-
chronous winding of conductor and insulating tape, remarkably improving the production
efficiency [3]. The EFECO 800 automatic winding machine, produced by Tuboly-Astronic
AG, Switzerland, has achieved fully automatic control of coil winding, automatic coil
winding without manual intervention, and precise tension control of wires and insulating
materials during the winding process [4]. As far as tension system control is concerned,
in 2001, Mahawan et al. proposed a new electromechanical control tracking system of
winding and a new online identification scheme of the general servo mechanism, which
https://www.mdpi.com/journal/sensors
Sensors 2021, 21, 6512 2 of 17

were applied to winding machine equipment, thereby assuring the constant tension control
of the whole control system even under great disturbance [5]. In 2008, Wen et al. designed
a tension control scheme by adding a flattening machine including an accumulator and
a tensioning device, which replaced the traditional energy storage device and made it
possible to vary the winding speed under a certain tension fluctuation without prejudicing
the winding quality [6]. In 2010, Ponsart et al. successfully applied the observer theory to
the transformer winding machine in order to realize the fault estimation in the winding
process of the winding machine, meanwhile adopting the LTV model to improve the control
accuracy of the web tension [7–9]. In 2015, Le-Bao et al. proposed a new multi-motor speed
tracking and synchronization control method, using multiple motors to make the speed
error and synchronization error converge to 0, and they simultaneously verified that the
control scheme had robust interference to parameter changes [10]. In 2019, Quanjin et al.
designed a mobile software for a wirelessly connected three-axis fiber winding machine.
Through Bluetooth, the parameters such as the winding angle, length, and thickness of the
three-axis fiber winding machine could be controlled in real time, so that the crux of the
matter such as the complex wiring form of the fiber winding machine could be solved. In
result, the experimental verification was in line with expectations [11].
As a result of the technical restriction caused by both foreign technology blockade and
limited development investment, the winding machine developed in China is still semi-
automatic. With the manual pedaling method, it can only wind the wire semi-automatically,
inducing several downsides of low production efficiency and low transformer core technical
parameters such as low window filling factor. The GRX-800 automatic winding machine
developed by a company in Shandong and the F-TW100 CXL transformer winding machine
produced by a company in Dongguan can both achieve the constant tension control winding
of the wire, yet the synchronous winding of the insulation belt and the wire is incapable.
Many scholars have conducted research on the tension control system of the winding
machine. Shi Yaoyao et al., centering on the winding process of the discontinuous strip,
conducted in-depth analysis and research on key technologies such as tension control,
automatic continuous step, and automatic calibration in the winding process, and they
designed a PID controller to realize the winding of a discontinuous strip [12]. Xue Bingren
from the Harbin Institute of Technology designed an automatic winding machine control
system with PLC as the control core and accordingly put forward a feasible tension control
scheme to achieve constant tension control of wire winding [13]. Hongqian et al. designed
an automatic winding control system for the textile industry, aiming at replacing the
manual winding of broken textile thread on the empty wire barrel. However, there are still
some deficiencies in the above research, such as uncooperative winding, insufficient control
accuracy at high speed, and a small tension control range; therefore, the outputs cannot
be directly applied to the research and development of a 35 kVA transformer winding
machine [14]. Zhiyong et al. brought up a creative method for cable force distribution
optimization of a cable-driven parallel robot; that is, the minimum tension of the cable
was modified based on the dynamic characteristics of the system. Different controllers
were adopted to conduct experiments on a two-cable one-DOF test bench. Experimental
results indicate that the dynamic minimum tension control (DMTC) was superior to the
traditional minimum tension method in terms of accuracy and energy consumption [15].
On account of the stated needs of enterprise for the automatic winding machine, this
paper analyzes the mathematical relationship between tension control and speed through
the mathematical modeling of the insulated belt structure of winding machines on the basis
of research results of foreign automatic winding machines. Based on the fuzzy control
theory, an innovative tension control scheme is proposed, which takes the main speed
roller as the control object. By converting a single precise digital input into a large number
of fuzzy sets, the robustness of tension control is exquisitely enhanced. By comparing the
simulation experiment to the traditional PID scheme, the efficiency of the proposed fuzzy
control rate is also detected, as well as the experimental verification carried out on the
engineering inspection machine.
 Sensors 2021, 21, x FOR PEER REVIEW 3 of 17

simulation experiment to the traditional PID scheme, the efficiency of the proposed fuzzy
Sensors 2021, 21, 6512 3 of 17
control rate is also detected, as well as the experimental verification carried out on the
engineering inspection machine.

2. Mechanical Structure and Dynamics Model

2.
The automatic winding machine includes the automatic winding winding of of aa conductor
conductor and and
insulating layer. The
insulating The tensile
tensile capacity
capacity ofof the
the insulation
insulation layer
layer is
is limited
limited soso that
that itit can
can be
be
difficult to
difficult to control.
control. The winding tape is too easy to bend and and break;
break; hence,
hence, itit becomes
becomes the the
core problem
core problem of of the
the whole
whole winding
winding machine
machine design and control. Taking Taking the the insulating
insulating
tape system
tape system as an example, this paper studies the constant tension control algorithm. algorithm. The The
mechanical structure of the insulating tape system
mechanical system isis shown
shown in in Figure
Figure 1, 1, including
including the the
unwinding area,
unwinding area, processing
processing area,
area, and rewinding area. In the winding
winding areaarea and
and unwinding
unwinding
area, the
area, the DC motor is used as the actuator
actuator to
to control
control the
the production
production of of these
thesetwo twoparts.
parts.
During the winding process, the electromagnetic
During electromagnetic brake
brake roller,
roller, the
the main
main speed
speed roller,
roller, and
and
the
the guide
guide roller in the processing area control the tension of the reel. Using Using an an ACAC servo
servo
motor
motor as the actuator,
actuator, the speed control of the main speed roller is is carried
carried out
out through
through thethe
speed
speed control of the AC servo motor [16–18].

Unwinding Processing area Winding area

area v
v
v

Figure 1.
Figure 1. Mechanical structure of insulating tape system.

The main devices of the transformer winding winding machine

machine inin the
the winding
winding process
process areare
shown
shown in Figure
Figure 2.
2. There are three devices in total, whose characteristics
characteristics are are shown
shown in in
Table
Table 1. TheThecontrol
controlsystem
systemcancan control
control the the tension
tension and speed
and speed of theof the insulation
insulation tape
tape wind-
winding by adjusting
ing by adjusting the output
the output of three
of three different
different driven
driven rollers,
rollers, namely,the
namely, thetorque
torqueofof the
the
Sensors 2021, 21, x FOR PEER REVIEW 4 of 17
unwinding
unwinding roller, the torque of the magnetic powder powder brake
brake roller,
roller, and
and thethe speed
speed ofof the
the
driving
driving roller
roller [19].
In the first stage, the unwinding roller (driven by a torque motor) generates a reverse
forceUnwinding
to apply a pretension Electromagnetic
on the winding coil, which is set Mainto a speed
smaller value to reduce
roll brake roll roll
the influence of the time-varying radius of the unwinding coil and periodic oscillations on
the preset tension. Coming to the second stage, the electromagnetic brake takes advantage
of the fact that it can generate torque over a wide range without introducing significant
tension interference to control tension. In the final stage, when the tension of the winding
u
coil is restored to set the tension value, the speed of the winding coil is controlled by con-
trolling the speed of the main speed roller, which tracks the linear speed of the winding
coil and uses it as the reference speed and adjusts the speed to maintain the expected value
of the tension [20,21].
Figure 2.
Figure 2. Main
Main devices
devices in
in the
the winding
winding process
process of
of insulating
insulatingtape.
tape.

Table1.1. Characteristics
Table Characteristics of
of three
three devices.
devices.

Device Device Characteristic

Characteristic
Apply small tension;
Apply small tension;
Minimize tension deviations due to
Unwinding roller
Unwinding rollerMinimize tension deviations due to changes in velocity
changes in velocity acceleration, ra-
acceleration, radius, and inertia.
dius, and inertia.
Apply high tension;
Apply high tension;
Electromagnetic brake roller
Prevent the introduction of greater tension interference.
Electromagnetic brake roller Prevent the introduction of greater
Adjust the tension totension
get theinterference.
target tension;
Main speed roller
Adjust the speed and track the
Adjust the tension tocoil
getspeed.
the target
tension;
Main speed roller
Adjust the speed and track the coil
speed.

According to the mechanical structure of the transformer winding machine and the
winding characteristics of the insulating tape in Figure 1, a mathematical model of the
 Sensors 2021, 21, 6512 4 of 17

In the first stage, the unwinding roller (driven by a torque motor) generates a reverse
force to apply a pretension on the winding coil, which is set to a smaller value to reduce
the influence of the time-varying radius of the unwinding coil and periodic oscillations on
the preset tension. Coming to the second stage, the electromagnetic brake takes advantage
of the fact that it can generate torque over a wide range without introducing significant
tension interference to control tension. In the final stage, when the tension of the winding
coil is restored to set the tension value, the speed of the winding coil is controlled by
controlling the speed of the main speed roller, which tracks the linear speed of the winding
coil and uses it as the reference speed and adjusts the speed to maintain the expected value
of the tension [20,21].
According to the mechanical structure of the transformer winding machine and the
winding characteristics of the insulating tape in Figure 1, a mathematical model of the
whole insulating tape tension control system is established. Taking the insulated belt system
as an example, mathematical modeling is carried out for winding roll, electromagnetic
brake roll, main speed roll, and guide roll, respectively [22].

2.1. Dynamic Model of Roller

Figure 3 shows the mechanical structure side view of the unwinding part of the
transformer winding machine and the unwinding roller. There is an insulated core arranged
on the unwinding shaft which is driven by a torque motor. In the unwinding process, the
relationship between coil winding tension and velocity is as follows:

T0 R0 = Iα + Tn + Tb
d (1)
dt ( J0 ( t ) w0 ) = T0 R0 − n20 U0 − bω0

where T0 , Tn , and Tb are the tension, friction torque, and load torque of the unwinding
insulation tape and the motor, respectively. R0 is the radius of the unwinding coil, I is the
moment of inertia, and α is the angular acceleration during unwinding. J0 (t) is the moment
Sensors 2021, 21, x FOR PEER REVIEW of inertia, ω0 is the initial angular velocity, U0 is the input torque of the torque motor, n0 5isof 17
the mechanical transmission ratio between the torque motor and the unwinding roller, and
b is the friction coefficient.

The structure of the unwinding section Side view of the unwinding roller
Insulated tape

Unwinding reel
V0
T0

The torque
motor R0
r0

Running Running roller

roller
U0

V0

Figure 3. 3.
Figure Mechanical
Mechanicalstructure
structureof
ofunwinding part and
unwinding part andside
sideview
viewofofthe
theunwinding
unwinding roller.
roller.

At any moment, the moment of inertia of the unwinding roller is composed of three
parts:
𝐽 (𝑡) = 𝐽 + 𝐽 + 𝐽 (𝑡) (2)
where 𝐽 is the moment of inertia of the torque motor, 𝐽 is the moment of inertia of the
 Sensors 2021, 21, 6512 5 of 17

At any moment, the moment of inertia of the unwinding roller is composed of

three parts:
J0 (t) = Jm + Jc + Jω (t) (2)
where Jm is the moment of inertia of the torque motor, Jc is the moment of inertia of the
winding shaft, and Jω (t) is the moment of inertia of the insulating belt.
Due to the real-time change of the coil diameter during the winding process of the
unwinding roller, Jω (t) will also change in real time. The analysis is expressed as follows:

J = 21 m R22 + R21




m = ρπl R22 − R
21 (3)
Jω (t) = 2 ρW R20 − r02 R20 + r02 = R40 − r04
 π

π


2 ρW

where ρ is the density of the insulating strip, W is the width of the insulating strip, R0 is
the radius of the unwinding roll, and r0 is the radius of the insulating strip core. Therefore,
Equation (1) can be written as:
. .
J 0 ω0 + J0 ω 0 = T0 R0 − n20 U0 − bω0 . (4)

Thereinto: ( . .
J 0 = 2πρWR30 R0
. (5)
ω0 = v 0 R 0
Therefore, Equation (4) can be written as:
. . .
T0 R0 = 2πρWv0 R40 R0 + J0 v0 + J0 v0 R0 + n20 U0 + bv0 R0 . (6)

The above expression illustrates the relationship between the tension T0 , the rate of
.
change R0 , and the velocity differential expression in the unwinding process [23,24].

2.2. Dynamic Model of Electromagnetic Brake Roller

Sensors 2021, 21, x FOR PEER REVIEW The electromagnetic brake roller of the transformer winding machine, which consists 6 of 1
of one driving roller and two driven rollers, can exert large tension on the insulating tape
during winding. The analysis diagram of the electromagnetic brake is shown in Figure 4.

Ti + 2

Vi + 2

Ti- 1

V i

Li + 1

Vi + 1
Ti + 1

Ti

Driving
roller α

U i +1

Figure4.4.Analysis
Figure Analysisof of
electromagnetic brake.
electromagnetic brake.

The relationship between the preset tension 𝑇 of the insulating tape and the maxi
mum tension 𝑇 allowed to be applied during winding is as follows:
𝑇
=𝑒 (7
𝑇
where 𝑢 is the friction coefficient between the driving roller and the insulating belt, and
𝛼 is the central angle. In general, 𝛼 and u are important for achieving high tension: th
Sensors 2021, 21, 6512 6 of 17

The relationship between the preset tension Ti of the insulating tape and the maximum
tension Timax allowed to be applied during winding is as follows:

Timax
= euα (7)
Ti

where u is the friction coefficient between the driving roller and the insulating belt, and α is
the central angle. In general, α and u are important for achieving high tension: the greater
the value of α and u, the greater the maximum tension applied by the electromagnetic brake.
Meanwhile, the driving roller provides the main tension in the winding process. The
dynamic modeling of the driving roller is shown in Equation (8):

dωi
Ji = ( Ti+1 − Ti ) Ri − nUi − bωi (8)
dt
where Ji is the rotational inertia of the driving roller, ωi is the angular velocity of the driving
roller, Ti is the input tension, Ti+1 is the output tension, Ri is the radius of the driving roller,
Ui is the input torque of the driving roller motor, n is the mechanical transmission ratio of
the driving roller and the motor, and b is the friction coefficient.
The mathematical relationship between the tension and speed on the driving roller is
obtained by further derivation, as shown in Equation (9):

d( Ti+1 )
L i +1 = AE(vi+2 − vi+1 ) + Ti vi+1 − Ti+1 vi+2 (9)
dt
where Li+1 is the stretching amount of the insulating strip, E is the elastic modulus of the
insulating strip, A is the cross-sectional area of the insulating strip, and vi+1 and vi+2 are
the velocities before and after the insulating strip stretching, respectively.
The incremental model of the driving roller is expressed as:
. .q
    
r q q q
Ji vi + vi = Tir+1 + Ti+1 − Tir − Ti R2i − nUir Ri − b ωir + ωi Ri (10)

.r .q
where vi is the reference velocity, vi is the velocity increment, Tir is the reference tension,
q
Ti is the tension increment, and Uir is the reference torque. At equilibrium, the increment
of tension and velocity could be regarded as zero.
.r
 
q
Tir+1 − Ti+1 R2i − nUir Ri − bωir Ri − Ji vi = 0 (11)

Therefore, Equation (10) can be written as:

.q
 
q q q
Ji vi = Ti+1 − Ti R2i − bωi . (12)

q q
Ti+1 and Ti can be expressed as Equation (13):
.q q
q Ji v bω q
Ti+1 = 2i + 2i + Ti . (13)
Ri Ri

The above equation shows that as the radius and torque decrease, the increment of
tension also decreases, and the increment of tension is independent of the reference torque;
hence, the increase in tension can be achieved without introducing interference [25,26].

2.3. Dynamic Model of Main Speed Roller

The main speed roller of the transformer winding machine is driven by a servo motor
to track the unwinding speed and adjust tension. Its cross-section is shown in Figure 5. The
Dancer mechanism is introduced to reduce tension and velocity interference. The floating
roller in Dancer can move freely on the linear slider. A cylinder installed between them
 [25,26].

2.3.2.3. Dynamic
Dynamic Model
Model of Main
of Main Speed
Speed Roller
Roller
TheThe main
main speed
speed roller
roller of the
of the transformer
transformer winding
winding machine
machine is driven
is driven by aby a se
servo
Sensors 2021, 21, 6512 to to track
track thethe unwinding
unwinding speed
speed andand adjust
adjust tension.
tension. Its cross-section
Its cross-section is 17
is 7shown
of shown in
in Fig
TheThe Dancer
Dancer mechanism
mechanism is introduced
is introduced to reduce
to reduce tension
tension andand velocity
velocity interfer
interferenc
floating
floating roller
roller in Dancer
in Dancer cancan move
move freely
freely on on
thethe linear
linear slider.
slider. A cylinder
A cylinder installed
installed be
them
them increases
increases thethe Dancer’s
Dancer’s response
response time.
time. In the
In the steady
steady state,
state, the the floating
floating roller
increases the Dancer’s response time. In the steady state, the floating roller is in equilibrium,
equilibrium,
equilibrium, andand thethe tension
tension control
control is within
is within thethe predetermined
predetermined range.
range. TheThecha
and the tension control is within the predetermined range. The change in speed will cause
speed
speed will cause
will cause thethe
change
change in tension,
in tension, causing
causingthethe
roller deviating
roller deviating from the the
from balanba
the change in tension, causing the roller deviating from the balance position, eventually
sition,
sition,eventually
eventually resulting
resulting in the
in main
the mainspeed
speedroller adjusting
roller
resulting in the main speed roller adjusting the speed so as to make the floating roller the
adjusting speed
the so
speed assoto
as ma
to
floating
return to the floatingroller
balance return
roller
position.returnto the
Dancerto thebalance
balance
deviates position.
from the Dancer
position. Dancer
equilibriumdeviates from
deviates
position thethen
from
and equilibrium
the equilibr
tion and
tion andthen returns
then returns to the
to equilibrium
the equilibrium
returns to the equilibrium position to maintain stable tension [27]. position to
position maintain
to maintainstable tension
stable tension[27].[27]

Dancer
Dancer Vi-1 Vi-1
Main
Mainspeed roller
speed roller Ti-1 Ti-1
Linear slider
Linear slider
Vi-2 Vi-2
Ti+1 Ti+1
Ti-4 Ti-4 Vi-1 Vi-1 Vi Vi
Ti-2 Ti-2
Vi-4 Vi-4 Ti Ti
Vi-5 Vi-5
Ti-3 Ti-3
Ti-5 Ti-5

Vi-3
Vi-3

Figure
Figure 5. Cross-section 5. Cross-section
view
Figure view
of Cross-section
5. the main speed of the
roller.
view main
of the speed
main roller.
speed roller.

The
The dynamic dynamic
model
The dynamicmodel
of the main
modelof the
speed main
roller
of the mainspeed
is roller
asspeed
follows: is asisfollows:
roller as follows:
( )
d( Ti+1𝐿) 𝐿 ( =) 𝐴𝐸(𝑣 − 𝑣− 𝑣) +)𝑇+𝑣 𝑇 𝑣− 𝑇− 𝑇𝑣 𝑣.
L i +1 = AE(vi+2 −=v𝐴𝐸(𝑣
i +1 ) + Ti vi +1 − Ti +1 vi +2 .
. (14)
dt
2.4. Dynamic Model of Guide Roller
2.4. Dynamic 2.4.
ModelDynamic
of GuideModel
Roller of Guide Roller
There are many idling rollers called guide rollers in the working process of the
There are many There arerollers
idling manycalled
idling rollers
guide called
rollers guide
in the rollers
working in theofworking
process the insula-process o
lation belt of the transformer winding machine. Since the acceleration of the guide
lation
tion belt of the belt of the
transformer transformer
winding machine. winding
Since the machine. Since
acceleration of the guide
acceleration
roller isof the gu
is verysteady-state
very small inisthe
small in the steady-state process, the influence of the guide roller in the tran
very small in process, the influence
the steady-state of thethe
process, guide roller inofthe
influence transmission
the guide roller in the
sion
process can be process
ignored. can be ignored. However, if the acceleration and decelerationthe are are
fre
sion processHowever, if the acceleration
can be ignored. However,and deceleration
if the acceleration are and
frequent,
deceleration
movementthe movement
ofthe
the movement
of the
guide roller will
of
guide
thealso roller
have
guide
will also
a great
roller impact
will
have the
alsoon
a great impact
have atension. Theon
great impact
the tension.
section view
on the
The s
tension. T
view of
of the guide roller the guide roller is shown in Figure 6.
view isofshown in Figure
the guide roller6.is shown in Figure 6.
Vi Vi+1
Li0
Vi Vi+1 Ti+1
Ti-1 Li0
Ti-1 Ti+1

E A Ti
E A Ti
ωi ωi+1
ωi Ri Ji
ωi+1 Ri+1 Ji+1
Ri Ji Ri+1 Ji+1
Mi Mi+1
The i frame Mi+1 The i+1 frame
Mi The i+1 frame
The i frame
Figure 6. Sectional view ofFigure
guide 6.roller.
Sectional view of guide roller.
Figure 6. Sectional view of guide roller.
In the winding process of the transformer winding machine, the tension of the insu-
In the winding process of the transformer winding machine, the tension of the
lating strip at sectionIn thei is winding
Ti , the linear velocitythe
process is Vi , the angularwinding
velocity is ωi , the length
lating strip at section i is 𝑇 , theoflineartransformer machine,
velocity is 𝑉 , the angular
before and after stretching is Li0 and Li , the radius of the i-th roll is Ri , the moment of
the istension
velocity 𝜔 , theo
lating
before strip at section i is 𝑇 , the
is 𝐿 and linear velocity
𝐿 ,isthe is 𝑉
of the i-th roll is 𝑅 , theismom
, the angular velocity 𝜔,
inertia of the roll isand afterthe
Ji , and stretching
electromagnetic torque Mi radius
.
before
inertia of and after
the roll is stretching
𝐽 , and the is 𝐿 and 𝐿 , the
electromagnetic radius
torque is of . i-th roll is 𝑅 , the m
𝑀 the
inertia of the roll is 𝐽 , and the ∆L
electromagnetic
L − Li0 torque is 𝑀.
Ti = EAεi = EA i = EA i (15)
Li0 Li0

The time interval between the two guide rollers is ti .

Z t
i
∆Li − Li0 = (Vi − Vi−1 )dt (16)
0
 𝐿 −𝐿 𝛥𝐿
𝑇 = 𝐸𝐴 = 𝐸𝐴 = 𝐸𝐴 (15)
𝐿 𝐿
Sensors 2021, 21, 6512
The time interval between the two guide rollers is 𝑡 . 8 of 17

𝛥𝐿 − 𝐿 = (𝑉 − 𝑉 ) 𝑑𝑡 (16)

Therefore,
Therefore, Equation (17) can
Equation (17) canbe
bederived
derivedfrom
fromEquations
Equations (15)
(15) and
and (16):
(16):
𝑇 = Z(𝑉 − 𝑉 ) 𝑑𝑡 = Z 𝑅
(𝜔 − 𝜔 𝑅 ) 𝑑𝑡. (17)
EA ti EA ti
Ti = (Vi+1 − Vi )dt = (ωi Ri+1 − ωi Ri )dt. (17)
As can be seen from Li0the0above equation, whenLi0 0 the speed of the adjacent guide rollers
remains constant, the tension of the insulating belt will not be affected. If the speed of the
As can be seen from the above equation, when the speed of the adjacent guide rollers
back guide roller is less than that of the front guide roller, the tension will increase. If the
remains constant, the tension of the insulating belt will not be affected. If the speed of
speed of the
the back back
guide guide
roller roller
is less thanisthat
greater
of thethan
frontthat of roller,
guide the front guide roller,
the tension the tension
will increase. If
becomes smaller [28,29].
the speed of the back guide roller is greater than that of the front guide roller, the tension
becomes smaller [28,29].
3. Design of Fuzzy Control System for Winding Machine
3. Design
3.1. of Fuzzy
Fuzzy PID Control System for Winding Machine
Control
3.1. Fuzzy PID Control
In view of the synchronous winding of the conductor and the insulating layer of the
In view of the synchronous winding of the conductor and the insulating layer of
transformer winding machine, the idea of fuzzy control is introduced, and a fuzzy tension
the transformer winding machine, the idea of fuzzy control is introduced, and a fuzzy
control scheme is proposed, as shown in Figure 7. The preset tension is taken as the input
tension control scheme is proposed, as shown in Figure 7. The preset tension is taken as
of the transformer winding machine, and the input variable is expressed as 𝑥(𝑘). In order
the input of the transformer winding machine, and the input variable is expressed as x (k ).
toInensure
order tothe smooth
ensure the start of the
smooth startsystem, we adopt
of the system, we the speed
adopt and tension
the speed double
and tension closed-
double
loop
closed-loop adjustment. The actual tension of the outer loop is the feedback value, andfuzzy
adjustment. The actual tension of the outer loop is the feedback value, and a a
controller is designed
fuzzy controller for speed
is designed correction
for speed to convert
correction the the
to convert original feedback
original feedbackof of
a single
a singlepre-
cise digital
precise quantity
digital into
quantity a fuzzy
into a fuzzyset.set.The
Thefeedback
feedback value
value ofofthe
theinner
innerclosed
closedlooploop is the
is the
reference
referencespeed,
speed, and
and the sum
sum of of the
thereference
referencespeed
speedand andthethe output
output speed
speed of of
thethe controller
controller
isisthe
theinput
inputcommand
command of the main main speed
speedroller,
roller,sosothat
thatthe
the conductor
conductor and
and thethe insulation
insulation
beltcan
belt canbebewound
wound synchronously
synchronously [30].[30].

Electromagnetic de/dt
Unwind brake roll Fuzzy
ing roll control

Preset Preset
- PID + PID Main
tension tension Driven
+ controll controll speed
+ roller
- Actual er er roll
tension Reference speed

Figure
Figure 7.
7. Tension controlbased
Tension control basedon
onfuzzy
fuzzyPID.
PID.

ThePID
The PID controller
controller isisaafuzzy
fuzzylogic controller,
logic andand
controller, the the
adaptive fuzzyfuzzy
adaptive controller can becan
controller
described by Equation (18):
be described by Equation (18):
𝑥(𝑘)
x (k=) =𝑒(𝑘)/𝐾
[e(k)/K， 1 ,∆𝑒(𝑘)/𝐾
∆e(k)/K2 ] T

⎧ 
𝑒(𝑘)e= = t(−k)𝑡−(𝑘)
(k)𝑡(𝑘) tr (， , ∆e(k) =
k )∆𝑒(𝑘) e(k) −
= 𝑒(𝑘) (k −−11)
− e𝑒(𝑘 ) (18)(18)
⎨  u(k) = [∆Kp(k), ∆Kd (k )]
⎩ 𝑢(𝑘) = ∆𝐾𝑝(𝑘)，∆𝐾 (𝑘)
where 𝑥(𝑘)
where x (k) isis the
the input variable,e(𝑒(𝑘)
inputvariable, k) is the
is thedifference
differencebetween
between thethe
preset
preset andandthethe
actual
actual
tension, ∆e ( k ) is the difference between the preset and
tension, ∆𝑒(𝑘) is the difference between the preset and the actual tension,the actual tension, K is the scaling
1 𝐾 is the scal-
factor
ing of eof
factor (k)𝑒(𝑘),
, K2 is 𝐾the is
scaling factor of
the scaling ∆e(kof
factor ), t∆𝑒(𝑘),
(k) is the𝑡(𝑘)
inputis tension,
the inputtr (tension,
k ) is the reference
𝑡 (𝑘) is the
tension, u ( k ) is the output variable, ∆Kp ( k ) is the change in
reference tension, 𝑢(𝑘) is the output variable, ∆𝐾𝑝(𝑘) is the change in the scale the scale factor, and ∆K d ( kfactor,
) is
the change in the differential factor. The output u(k) has three phases: fuzzification, fuzzy
and ∆𝐾 (𝑘) is the change in the differential factor. The output 𝑢(𝑘) has three phases:
rule, and defuzzification, which are explained in detail below.
fuzzification, fuzzy rule, and defuzzification, which are explained in detail below.
3.2. Fuzzification
The basic domain is the actual range of parameter changes. Refer to the actual situation
to set the basic domain of e(k) to [−6, 6], and the basic domain of ∆e(k) to [−3, 3]. The
quantities in the basic domain are exact values, as are the input and output of the controller.
 3.2. Fuzzification
3.2.The basic domain is the actual range of parameter changes. Refer to the actual situa-
Fuzzification
tion to The
set the basic
basic domaindomain
is theofactual 𝑒(𝑘) range
to [–6,of6], and the changes.
parameter basic domain
Refer of ∆𝑒(𝑘)
to the to [–3,
actual situa-3].
Sensors 2021, 21, 6512 Thetionquantities
to set theinbasic
the domain
basic domain of 𝑒(𝑘)are to exact
[–6, 6],values,
and the asbasic
are the inputofand
domain output
∆𝑒(𝑘) to of 3].
9 of[–3,
17 the
controller.
The quantities in the basic domain are exact values, as are the input and output of theis
Yet the fuzzy control algorithm needs fuzzy quantity [31,32]. As a result, it
crucial to introduce
controller. Yet the fuzzification
fuzzy controltoalgorithm convert the needsprecise
fuzzy input quantity
quantity intoAs
[31,32]. fuzzy quantity.
a result, it is
The key
crucial of
to fuzzification
introduce is to
fuzzificationinput to it into
convert the
thefuzzy set
precise by
inputmembership
quantity into function.
fuzzy Figures
quantity.
Yet the fuzzy control algorithm needs fuzzy quantity [31,32]. As a result, it is crucial to
8 and
The 9key
respectively
introduce represent
of fuzzification
fuzzification to the
is convert
to input membership
it precise
the functions
into theinput
fuzzy set byofinto
quantity input 𝑒(𝑘),
membership
fuzzy ∆𝑒(𝑘).
function.
quantity. The
The keymem-
Figures
bership
8 and 9function ofisthe
respectively
of fuzzification output
torepresent
input isthe
it into the same
fuzzyas
membership
the setthat
by of the input,
functions
membership and𝑒(𝑘),
of input
function. ∆𝑒(𝑘).range
theFigures
value 8The
andmem-9of the
output
bershipis [–5,
respectively 5].represent
function the membership
of the output is the same functions
as thatof ofinput e(k), ∆e
the input, (k)the
and . The membership
value range of the
function
output of the
is [–5, 5].output is the same as that of the input, and the value range of the output is
[−5, 5].

Figure 8. Membership function of 𝑒(𝑘).

Figure
Figure8. 8.Membership function of e𝑒(𝑘).
Membershipfunction ( k ).

Figure 9. 9.
Figure
Figure Membership
9. Membership
Membership functionofof∆𝑒(𝑘).
function
function ∆e
∆𝑒(𝑘).
( k ).

3.3. Fuzzy Rule

3.3. Fuzzy
3.3. Rule
Fuzzy Rule
The core content of fuzzy control is the formulation of fuzzy rules, including rule
The
The core
core content
content ofoffuzzy
fuzzy control
control isis the
the formulation
based on K pof
formulation (k)fuzzy
and Krules,
fuzzy rules, including
includingrule
rule
base and fuzzy reasoning [33,34]. The rule bases d ( k ) are shown in
base and
baseTables fuzzy
and fuzzy reasoning [33,34]. The rule bases
reasoning [33,34]. The rule bases based
2 and 3. based on 𝐾 (𝑘)
(𝑘) and 𝐾
and 𝐾 (𝑘)
(𝑘) are shown
are shown
in in Tables
Tables 2 and3.3.
2 and
Table 2. Rule base of ∆Kp(k).
Table
Table 2.
2.∆e ∆𝐾𝑝(𝑘).
Rule base of∆𝐾𝑝(𝑘).
Rule
\e base of
NB NM NS ZO PS PM PB
∆𝒆\𝒆
∆𝒆\𝒆NB NB
NBNB NM
NB
NM NS
NB
NS ZO
NB
ZO NMPS
PS NMPM
PM NS PB
PB
NB NM
NB NBNB
NB NB
NB
NB NM
NB
NB NM
NB
NB NM
NM
NM NSNM
NM NS NS
NS
NMNS NB
NB NM
NB NM
NM NS
NM NS
NM NSNS ZO NS
NM ZO NBNM NB
NM NM
NS NM
NS NM
ZO PS NS PS NS
NSNSPS NB
NBNS
NM
NM
NS
NM
NM
ZO
NS
NS
PS
NS
PSNS
NS
PM NS
ZO
PM ZO
ZO NM NM NS NS ZO PB PS PB PS
ZO PM NMPS NMPS PM
NS PM
NS PMZO PS PS
PS NS NS ZO PS PBPS PBPM PB PM
PS PB NSPM PM
NS PM
ZO PB
PS PS PM PM
PM PS PS PM PM PM PB PB
PM PS PS PM PM PM PB PB
PB PM PM PM PB PB PB PB
PB PM PM PM PB PB PB PB
Sensors 2021, 21, x FOR PEER REVIEW 10 of 17
Sensors 2021, 21, x FOR PEER REVIEW 10 of 17

Sensors 2021, 21, 6512 10 of 17

Table 3. Rule base of ∆𝐾 (𝑘).
Table 3. Rule base of ∆𝐾 (𝑘).
∆𝒆\𝒆 NB NM NS ZO PS PM PB
∆𝒆\𝒆
Table NBof ∆Kd (k)NM
NB3. Rule base
NB .NB NS
NB ZO
NB PS
NB PM
NB PB
NM
NB
NM NB
NB NB
NB NB
NB NB
NB NB
NM NB
NM NM
NM
∆e\e NB NM NS ZO PS PM PB
NM
NS NB
NB NB
NM NB
NM NB
NS NM
NS NM
ZO NM
ZO
NB
NS NB
NB NB
NM NB
NM NB
NS NB
NS NB
ZO NM
ZO
ZO
NM NS
NB NS
NB ZO
NB ZO
NB PS
NM PS
NM PM
NM
ZO
PS NS
NS NS
NS ZO
ZO ZO
PS PS
PM PS
PM PM
PM
NS NB NM NM NS NS ZO ZO
PS
PMZO NS
PS
NS NS
PS
NS ZO
PS
ZO PS
PM
ZO PM
PM
PS PM
PM
PS PM
PB
PM
PMPS
PB PS
NS
PM PS
NS
PM PS
ZO
PB PM
PS
PB PM
PM
PB PM
PM
PB PB
PM
PB
PB
PM PM
PS PM
PS PB
PS PB
PM PB
PM PMPB PB
PB
PB
3.4. DefuzzificationPM PM PB PB PB PB PB
3.4. Defuzzification
The control quantity 𝑢 obtained by fuzzy decision is a matrix, which cannot be di-
rectlyDefuzzification
3.4. The control
applied quantity 𝑢 obtained
to engineering. Therefore,by 𝑢fuzzy
needsdecision is a matrix,aswhich
to be interpreted cannot
a specific be di-
behavior
rectly applied
The to
control engineering.
quantity u Therefore,
obtained by 𝑢 needs
fuzzy to be
decision interpreted
is a as
matrix, a specific
which
in practice, that is, defuzzification operation [35,36]. At present, several of the most com- behavior
cannot be
directly
monly applied
in practice,
usedthat to engineering.
is, defuzzification
defuzzification Therefore,
operation
methods u
are asneeds to
[35,36]. be interpreted
At present,
follows: maximum as
severala specific behavior
of the most
membership com-
degree
in practice,
monly
method, used that
gravity is, defuzzification
defuzzification
center method, methodsoperation [35,36].
are asaverage
and weighted follows: At present,
maximum
method several
[37]. In of thethe
membership
this paper, most
degree
cen-
commonly
method, used
gravity defuzzification
center method, methods
and weightedare as follows:
average maximum
method [37]. membership
In
ter of gravity method is selected. The formula of the center of gravity method is shown this paper, degree
the cen-
as
method, gravity center method, The
and formula
weighted average method [37]. In this paper, the
Equation (19) [38], and the output results of ∆𝐾 (𝑘) and ∆𝐾 (𝑘) are shown in Figures 10
ter of gravity method is selected. of the center of gravity method is shown as
center of gravity method is selected. The formula of the center of gravity method is
11. (19) [38], and the output results of ∆𝐾 (𝑘) and ∆𝐾 (𝑘) are shown in Figures 10
Equation
and
11. as Equation (19) [38], and the output results of ∆Kd (k) and ∆K p (k) are shown in
shown
and
Figures 10 and 11. ∑𝑢 𝑢 𝑢
𝑢(𝑘) = 𝐾 ∑ 𝑢 𝑢 𝑢
(19)
𝑢(𝑘)
u(k=)=𝐾 Kout ∑∑u𝑢 u j u j (19)
(19)
∑∑ 𝑢u
j

Figure 10. The change of ∆𝐾 (𝑘).

Figure 10. The change of ∆K (k).
Figure 10. The change of ∆𝐾 d(𝑘).

Figure 11. The change of ∆K p (k).

Figure 11. The change of ∆𝐾 (𝑘).
Figure 11. The change
4. Simulation and Result (𝑘).
of ∆𝐾 Analysis
4.4.1.
Simulation and Result
System Mechanical Analysis
Parameters
4. Simulation and Result Analysis
4.1. System Mechanicalparameters
The mechanical Parameters of the system are shown in Table 4.
4.1. System Mechanical Parameters
The mechanical parameters of the system are shown in Table 4.
The mechanical parameters of the system are shown in Table 4.
 Sensors 2021, 21, 6512 11 of 17

Table 4. System mechanical parameters.

Parameter Device Numerical Value

J1 The moment of inertia of the unwinding roller 0.09 kgm2
R1 The radius of the unwinding roller 0.08 m
J2 The moment of inertia of the electromagnetic brake 0.002 kgm2
R1 The radius of the electromagnetic brake 0.06 m
J3 The moment of inertia of the guide roller 0.00005 kgm2
Ri The radius of the guide roller 0.025 m
Li Span 0.5 m
b Friction coefficient 0.0015
L Unwinding length 0.02 m

4.2. Analysis of Simulation Result

We try our best to establish the simulation environment for the paper under the
debugging state of the engineering prototype. The simulation parameters involved in this
paper are mainly from relevant references and actual parameters that are closer to the
real state. According to the set mechanical parameters, the rationality of the design of a
fuzzy PID control scheme for the transformer winding machine is verified. The rewinding
Sensors 2021,
Sensors 2021, 21,
21, xx FOR
FOR PEER
PEER REVIEW
REVIEWspeed is set as 1 m/s, and the reference tension is 10 N, 30 N, and 50 N to carry12 12 of 17
out
of 17
multiple groups of simulation experiments. The tension responses obtained were shown in
Figure 12a, Figure 13a, and Figure 14a.

(a)
(a) (b)
(b)
Figure
Figure 12.
Figure12. Tension
12. Tension response at
Tension response at 10
10 N
10 N reference
N referencetension.
reference tension.(a)
tension. (a)Tension
(a) Tensionofof
Tension ofunwinding
unwindingroller
unwinding roller
roller and
and
and electro-
electro-
electro-
magnetic
magnetic brake; (b) Tension of take-up roll.
magnetic brake;
brake; (b)
(b) Tension of take-up
Tension of take-uproll.
roll.

(a)
(a) (b)
(b)
Figure 13.
Figure13.
Figure Tension response at
Tension response
13. Tension at 30
30 N
30 N reference
N referencetension.
reference tension.(a)
tension. (a)Tension
(a) Tensionofof
Tension ofunwinding
unwindingroller
unwinding roller and
and
roller electro-
electro-
and electro-
magnetic brake;
magnetic brake;
magnetic (b)
brake; (b) Tension
(b) Tension oftake-up
Tension of
of take-uproll.
take-up roll.
roll.
 (a) (b)
Sensors 2021, 21, 6512 12electro-
Figure 13. Tension response at 30 N reference tension. (a) Tension of unwinding roller and of 17
magnetic brake; (b) Tension of take-up roll.

(a) (b)
Figure
Figure 14. Tension responseat
Tension response at50
50NNreference
referencetension.
tension.(a)
(a)Tension
Tensionofof unwinding
unwinding roller
roller and
and electro-
electro-
magnetic brake; (b) Tension of take-up roll.
magnetic brake; (b) Tension of take-up roll.

As can
In be seen from
summary, underFigure 12a, Figure
the action 13a, and Figure
of different 14a, when
reference the winding
tensions, the fuzzy machine
control
is just started,
scheme the tension
has a better controlofeffect
the unwinding roller and
than the traditional the electromagnetic
scheme on the influence brake roller
of real-time
fluctuate of
changes greatly aroundofthe
the radius the reference
unwindingvalue. There
roller arethe
and tworewinding
possible reasons
roller for
on this: (1) The
tension, with
tension fluctuations generated by the interaction of
smaller fluctuation and faster progress to the stable state.velocities are susceptible to the variation
of the
Intime
orderderivative
to furtherof study
velocities. (2) The periodic
the effectiveness swing
of the fuzzyof the unwinding
control schemeroller
of a will
trans-
produce tension instability. Under the action of fuzzy control, the tension
former winding machine in eliminating speed interference, step interference of the generated byre-
the unwinding roller is small, and the tension disturbance of the magnetic brake roller is
winding speed was introduced after the winding machine was started for 2 s. The param-
small as well. Therefore, the controller can reach the steady state faster than the traditional
eters of speed and tension in the simulation experiment are shown in Table 5, and the
PID controller while diminishing the error in the steady state. The controller is designed to
simulation results are shown in Figures 15–17.
take a certain amount of time to track the reference tension, and the greater the reference
In Figures 15a, 16a and 17a, when the winding speed is increased from 0.2 to 0.5 m/s,
tension, the shorter the time required.
the sudden increase
The tension in theofspeed
response causes fluctuations
the rewinding roller underinthe
winding tension.
traditional In the traditional
PID control scheme
and the fuzzy PID control scheme is compared, and the reference tensions are 10 N, 30 N,
and 50 N. The tension responses are shown in Figures 12b, 13b and 14b.
As shown in Figures 12b, 13b and 14b, after the winding machine is started, the
rewinding roller rewinds, and the radius of the coiling material suddenly increases, re-
sulting in the fluctuation of rewinding tension. The tension of the winding roll obtained
by the traditional control scheme fluctuates within the range [8 18], [10 40], and [12 65],
respectively, while the tension obtained by the fuzzy control rate fluctuates within the
range [9 11], [29, 32], and [48 51], respectively. It can be seen from the figure that the tension
curve of the rewinding roller is more stable under the fuzzy control rate. Combined with
the actual engineering, the winding radius of the transformer winding machine increases
steadily in the winding process, and the fuzzy PID tension control scheme is consistent with
the actual situation. The longitudinal comparison of Figure 12b, Figure 13b, and Figure 14b
suggests that under the traditional control scheme, the tension curve is gradually smooth
and the tension control effect is gradually better as the reference tension increases after
the winding machine is started. Under the fuzzy control scheme, with the increase in the
reference tension, the fluctuation range of the tension curve is consistent with the reference
tension after the winding machine starts, and the tension control is stable and not affected
by the reference tension.
In summary, under the action of different reference tensions, the fuzzy control scheme
has a better control effect than the traditional scheme on the influence of real-time changes
of the radius of the unwinding roller and the rewinding roller on tension, with smaller
fluctuation and faster progress to the stable state.
In order to further study the effectiveness of the fuzzy control scheme of a transformer
winding machine in eliminating speed interference, step interference of the rewinding
speed was introduced after the winding machine was started for 2 s. The parameters of
speed and tension in the simulation experiment are shown in Table 5, and the simulation
results are shown in Figures 15–17.
 fuzzy PID control scheme, the tension curve shows no sign of obvious fluctuation.
Tosum
To sumup,
up,the
thesimulation
simulationconclusion
conclusioncan
canbe
bedrawn:
drawn:Under
Underdifferent
differentreference
referenceten-
ten-
sion, compared with the traditional control scheme, the fuzzy control scheme can
sion, compared with the traditional control scheme, the fuzzy control scheme can reduce reduce
theinterference
the interferenceof
ofspeed,
speed,and
andthe
theexperimental
experimentalresult
resultshows
showsaasmooth
smoothcurve,
curve,which
whichisisless
less
affectedby
affected bythe
thereference
referencetension.
tension.
Sensors 2021, 21, 6512 13 of 17

Table5.5.Speed
Table Speedand
andtension
tensionparameters.
parameters.

Label Reference Tension (N) Initial

InitialVelocity
Velocity(m/s)
(m/s) Final
FinalVelocity
Velocity(m/s)
(m/s)
TableLabel Reference
5. Speed and tension Tension (N)
parameters.
Figure 15a
Figure 15a 10
10 0.2
0.2 0.5
0.5
Figure
Figure 15b
Label15b 10
Reference Tension
10 (N) Initial 0.5
Velocity
0.5 (m/s) Final 11 (m/s)
Velocity
Figure 16a
Figure 15a
16a 30
1030 0.2
0.20.2 0.5
0.50.5
Figure15b
Figure
Figure 16b
16b 30
1030 0.5
0.50.5 1 11
Figure
Figure 16a
16a
Figure 16a 50
3050 0.2
0.20.2 0.5
0.50.5
Figure 16b
Figure16b16b 3050 0.5 0.5 1 1
Figure 50 0.5 1
Figure 16a 50 0.2 0.5
Figure 16b 50 0.5 1

(a)
(a) (b)
(b)
Figure15.
Figure 15. Theinfluence
influence of stepwhen
whenthe
thereference
referencetension
tension is 10N.N.(a)
(a)Situation
Situation1;1;(b)
(b)Situation
Situation2.2.
Figure 15.The
The influence of step when the reference tension isis1010N. (a) Situation 1; (b) Situation 2.

Sensors 2021, 21, x FOR PEER REVIEW (a) (b) 14 of 17

(a) (b)
Figure16.
Figure 16.The
Theinfluence
influenceof
influence ofstep
of stepwhen
step whenthe
when thereference
the referencetension
reference tension
tensionisisis 30
3030N.N.
N.(a)(a) Situation
Situation
(a) Situation 1;(b)
1; 1;
(b) (b) Situation
Situation 2. 2.2.
Situation

(a) (b)
Figure 17. The
Figure 17. The influence
influenceof
ofstep
stepwhen
whenthe
thereference
referencetension
tension
is is
5050
N.N.
(a)(a) Situation
Situation 1; (b)
1; (b) Situation
Situation 2. 2.

In Figures
Figures 15a,16b
15b, 16aandand17b
17a,are
when
thethe winding
tension speed
curves is increased
when from 0.2
the winding to 0.5
speed m/s,
increases
the sudden increase in the speed causes fluctuations in winding tension. In the
from 0.5 to 1 m/s. By comparison with Figures 15a, 16a and 17a, it can be seen that the traditional
control scheme,
tension curve ofwhen the winding
the traditional machine
PID controlstarts for 2fluctuates
scheme s, the tension curve fluctuates
significantly when the
winding machine is just started and 2 s started. However, the tension of theBy
greatly at the reference tension, which makes it difficult to restore stability. using
fuzzy PID
control scheme has almost no fluctuation, which further verifies that the fuzzy PID control
scheme has a nice inhibitory effect on the speed interference. The peak values of the ten-
sion overshooting and downregulation in six situations are shown in Figure 18.
Sensors 2021, 21, x FOR PEER REVIEW 14 of 17

Sensors 2021, 21, 6512 14 of 17

the fuzzy PID control scheme, the tension response curve is remarkably smooth at the
beginning of the winding machine’s running, and it fluctuates very little 2 s after starting
and soon restores stability. By comparing Figures 15a, 16a and 17a, it can be found that
in the traditional control scheme, the tension curve of the winding machine after starting
fluctuates and the amplitude (a) decreases with the increase in the reference (b) tension, while in
the fuzzy PID control scheme, the tension curve shows no sign of obvious fluctuation.
Figure 17. The influence of step when the reference tension is 50 N. (a) Situation 1; (b) Situation 2.
(a)
To sum up, the simulation conclusion can be drawn: Under different (b) reference tension,
compared
Figure
with
17. The 15b,
the
influence
traditional
of step
control
when
scheme, the fuzzy control scheme can Situation
reduce the
Figures 16b and 17b arethe
thereference
tensiontension
curvesiswhen
50 N. (a)
theSituation
winding 1; (b) 2.
speed increases
interference of speed, and the experimental result shows a smooth curve, which is less
from 0.5 to 1 m/s. By comparison with Figures 15a, 16a and 17a, it can be seen that the
affected by the
Figures reference
15b, 16b and tension.
17b are PID
the tension curves when the winding speed increases
tension curve
Figures
of 16b
15b,
the andtraditional
17b are the
controlcurves
tension
scheme fluctuates
when the17a,
significantly
winding speed
when the
increases
from
winding0.5 to 1
machinem/s. By
is comparison
just started with
and 2 Figures
s started.15a, 16a
However,and the it
tensioncan be
of seen
the that the
fuzzy PID
from
tension0.5 to
curve1 m/s.
of the By comparison
traditional PID with Figures
control 15a,
scheme 16a and
fluctuates 17a, it can
significantly be seen
when that
the
control
the scheme
tension curve has
of almost
the no fluctuation, whichscheme
furtherfluctuates
verifies that the fuzzy PID control
winding
scheme machine
has a nice is justtraditional
inhibitory started and
effect
PID
on scontrol
2 the started.
speed However, theThe
interference.
significantly
tension
peak of when
the fuzzy
values of the
the
PID
ten-
winding machine is just started and 2 s started. However, the tension of the fuzzy PID
control
sion scheme hasand
overshooting almost no fluctuation,inwhich
downregulation six further verifies
situations are that the
shown in fuzzy PID
Figure 18. control
control scheme has almost no fluctuation, which further verifies that the fuzzy PID control
scheme has a nice inhibitory effect on the speed interference. The peak values of the ten-
scheme has a nice inhibitory effect on the speed interference. The peak values of the tension
sion overshooting and downregulation in six situations are shown in Figure 18.
overshooting and downregulation in six situations are shown in Figure 18.

Figure 18. Six situations of tension fluctuation.

Figure 18. Six situations of tension fluctuation.
Figure 18. Six situations of tension fluctuation.
Combined with engineering practice, the transformer winding machine in the pro-
Combined with engineering practice, the transformer winding machine in the process
cess of windingwith
Combined will adopt different process
the parameters and use amachine
differentinnumber pro-of
of winding will adoptengineering practice,
different process transformer
parameters and usewinding
a different number ofthe
guide
guide rollers; therefore,
cess of therefore,
winding will this paper studies the response effect of the system to tension
rollers; this adopt differentthe
paper studies process
responseparameters andsystem
effect of the use a to
different
tensionnumber
when the of
when
guide the
number ofnumber
rollers;
guide of guide
therefore,
rollers this rollers
paper
varies. varies. in
As studies
shown As shown
theFigure
responsein the
19, Figure
effect of19,
tensionthethe tension
system
response to response
tension
curves of
curves
guide of guide
when rollers
the number
withrollers withnumbers
of guide
different different numbers
rollers varies.
are are by
As shown
simulated simulated
in Figure
increasing by19,
increasing
the the the load
loadtension
mass. mass.
response
curves of guide rollers with different numbers are simulated by increasing the load mass.

(a) (b)
(a) (b)
Figure 19.
Figure 19. Tension
Tensionresponse
responseofofthe
thedifferent
differentnumber
numberofofguide
guide rollers.
rollers. (a)(a) Situation
Situation 1; 1;
(b)(b) Situation
Situation 2. 2.
Figure 19. Tension response of the different number of guide rollers. (a) Situation 1; (b) Situation 2.
As shown in Figure 19a, when the reference tension is 30 N and the winding speed
increases from 0.2 to 0.5 m/s, after the winding machine starts, when the number of guide
rollers n = 21, the overpunch value is 2.8 N, which is larger than the overpunch values 2.1 N
and 2 N when n = 14 and n = 17, and the time of overpunch vanishing is longer when n = 21.
Sensors 2021, 21, 6512 15 of 17

In Figure 19b, the winding speed is increased from 0.5 to 1 m/s. When the number of
guide rollers N = 21, the overpunch value is 4 N, which is larger than 3.0 N and 2.8 N when
N = 14 and N = 17, but the disappearance time of overpunch is shorter. In conclusion, the
number of guide rollers will affect the tension response. Since the simulation environment
is more ideal than the real operating environment of the winding prototype, the simulation
error in this paper is better than the real operating error of the prototype.
It can be seen from the above simulation experiment that compared with the traditional
PID control, the fuzzy control scheme has a shorter response time, less influence of reference
tension and speed interference, and better system stability when the number of guide rollers
changes. From a comprehensive perspective, it can be regarded as a winding scheme of the
transformer winding machine with finer overall performance.

5. Conclusions
In summary, a new tension control scheme of the transformer winding machine is
presented in this paper, meanwhile realizing the synchronous winding control of the
conductor and insulating layer of the transformer winding machine. In the case of constant
tension, the control algorithm of the insulator belt system is studied, based on which a
reasonable dynamic model is established accordingly. For the first time, the design idea
of fuzzy control is integrated into the tension control system of an insulation belt, thus
turning the precise speed control of the main speed roller into reality by using a fuzzy
control rate. Through the simulation experiment, the comparison experiment with the
traditional control scheme is presented in the form of curves. The experimental results
suggest that the fuzzy PID tension control system can reach the stable state faster under
different constant tension conditions. In addition, the proposed fuzzy PID control scheme
compared with the traditional PID control scheme can restrain velocity disturbance more
effectively for introducing the disturbance velocity step and modifying the number of
guide rollers, thereby stabilizing the system when different reference tensions fluctuate
less, which verifies the feasibility and superiority of the proposed scheme.
Through the unremitting efforts of the team, we have completed the simulation work
in general, although there are still some remaining issues: due to professional limitations,
we have not designed the transformer winding machine automatic shear system and
automatic spray glue control system. In addition during the winding process of the
transformer winding machine, how to control the high-speed flexible winding of wire
generation is still a key point that requires further improvement. In the future, we will
conduct more experiments so as to apply the fuzzy-PID tension winding technology to an
actual winding system.

Author Contributions: Methodology, H.R.; software and simulation, H.R.; writing—original draft
preparation, H.S.; writing—review and editing, H.S.; supervision, L.D.; project administration, L.D.;
All authors have read and agreed to the published version of the manuscript.
Funding: This research was funded by National Science Foundation for Natural Science Foundation
of Heilongjiang Province (Grant No. LH2019F024) and Heilongjiang Province Applied Technology
Research and Development (Grant No. GA20A401).
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: This study did not report any data.
Conflicts of Interest: The authors declare no conflict of interest.

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