A constant residual tension control method for the precision winding of yarns

A mechanical model for the precision winding of yarns was established to address uneven residual tension in wound packages during precision winding. Based on the precision winder, a constant residual tension control method was proposed to ensure uniform residual tension in precision winding, which improved package quality and consistency. A proportional–integral–derivative (PID) control strategy was used to regulate the overfeed roller motor’s speed, and the winding tension was adjusted based on the speed difference between the overfeed and take-up rollers. This ensured consistent circumferential tension of yarns on the inner winding layer, which achieved optimal tensile strength for each layer during precision winding. Compared with constant winding tension control, this method prevented yarn slippage due to negative tension. It also offset the relaxation effect of newly wound yarns on previously wound layers. Packages wound with the constant residual tension had a more stable and uniform winding density than those with the constant winding tension.