Modeling and Experimental Validation of a Tension Control System for Wire Winding Machines

This paper presents a comprehensive study of tension control in the winding of rectangular bobbins, a process that inherently induces high frequency disturbances due to the bobbin's geometric properties. A tension control system integrating servo motors and a dancer pulley constrained by a spring is proposed to address these disturbances. An analytical model of the system, including the wire behavior and the influence of rectangular bobbins, is developed, and the system's performance is validated through simulations in MATLAB® Simulink. The model is then tested experimentally using a prototype, with wire tension measured and analyzed in both time and frequency domains. The results demonstrate that the tension control system effectively attenuates tension oscillations and maintains wire tension within the desired range, despite the challenges posed by rectangular bobbins. The findings confirm the system's ability to mitigate tension disturbances and improve winding precision.