Title: Development of an active wire tension system for improving the performance of brushless direct current coil winding machine

Authors: Van Tu Duong; Dae Hwan Kim; Hak Kyeong Kim; Sang Bong Kim

Addresses: Department of Mechanical Design Engineering, Pukyong National University, Busan (608-739), South Korea ' Department of Mechanical Design Engineering, Pukyong National University, Busan (608-739), South Korea ' Department of Mechanical Design Engineering, Pukyong National University, Busan (608-739), South Korea ' Department of Mechanical Design Engineering, Pukyong National University, Busan (608-739), South Korea

Abstract: This paper presents development results of an active tension system for replacing a passive tension system on a brushless direct current coil winding machine to improve the performance of the winding machine. Firstly, a comparison in winding procedure between circular and non-circular cross-section winding processes is considered to evaluate and design the proposed active tension system. Secondly, to reduce the fluctuation of wire tension in the winding process, a wire accumulator including pneumatic cylinder, servo valve and spring is used. Thirdly, in order to control the system, a fuzzy logic controller with three inputs and two outputs is employed. Finally, experimental results show that the winding machine equipped with the active tension system not only has ability to operate at high speed without wire broken but also decreases coil size in dimension.

Keywords: wire tension control; brushless DC coil winding machines; pneumatic servo systems; fuzzy logic controller; FLC; fuzzy control; three inputs two outputs.

DOI: 10.1504/IJAMECHS.2015.072817

International Journal of Advanced Mechatronic Systems, 2015 Vol.6 No.5, pp.201 - 210

Available online: 03 Nov 2015 *

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