Mikitinskiy A.P., Kravchenko O.A., Lobov B.N., Mikitinskiy K.A., Prudiy A.A. Possibility of Using Active Take-Up Devices in Electrotechnical Tension Control Systems

Abstract

Full Text

The paper is concerned with improving the efficiency of electrotechnical tension control systems (ETCS) used in the production of composite material products by the wet winding method. It is noted that traditional control systems have limited dynamic performance due to the inertia of mechanical components, particularly the slow movement of the dancer roller responsible for adjusting the tape tension. To overcome this limitation, a new approach is proposed, which is based on the use of active spoolers, strand holders equipped with electric drives and individual tension controllers. This design makes it possible to implement a dual-loop control structure: a “fast” loop controlling the spooler motor torque and a “slow” loop adjusting the dancer mechanism position. The paper presents the functional and structural diagrams of the proposed ETCS, which include permanent magnet synchronous motors, current, speed, tension, and position controllers, as well as a logical control unit coordinating the loops operation. Mathematical modeling and transient process analysis were performed under varying external conditions (e.g., changes in the material friction coefficient along the guiding elements). The simulation results demonstrated that the system transient response time with active spoolers is approximately 0.042 seconds, which is more than five times faster as compared to conventional control schemes. The proposed ETCS architecture ensures stable tape tension and high product quality despite variations in winding geometry and speed, confirming its promise for application in modern composite material manufacturing technologies.

Keywords

electrotechnical tension control systems, active spooler, composite material winding, wet winding, tensioning device electric drive, permanent magnet synchronous motor, tape tension regulation, dual-loop control system, electromechanical system modeling, control system dynamic performance

Aleksandr P. Mikitinskiy D.Sc. (Engineering), Associate Professor, Department of Electric Power Supply and Electric Drive, Platov South-State Polytechnic University, Novocherkassk, Russia, This email address is being protected from spambots. You need JavaScript enabled to view it., https://orcid.org/0000-0002-7338-9075

Oleg A. Kravchenko D.Sc. (Engineering), Professor, Rector, Tula State University, Tula, Russia

Boris N. Lobov D.Sc. (Engineering), Professor, Department of Electric Power Supply and Electric Drive, Platov South-State Polytechnic University, Novocherkassk, Russia

Konstantin A. Mikitinskiy Postgraduate Student, Department of Electrical Engineering and Electrical Apparatuses, Platov South-State Polytechnic University, Novocherkassk, Russia

Anzhela A. Prudiy Ph.D. (Engineering), Associate Professor, Department of Electric Power Supply and Electric Drive, Platov South-State Polytechnic University, Novocherkassk, Russia

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Mikitinskiy A.P., Kravchenko O.A., Lobov B.N., Mikitinskiy K.A., Prudiy A.A. Possibility of Using Active Take-Up Devices in Electrotechnical Tension Control Systems. Elektrotekhnicheskie sistemy i kompleksy [Electrotechnical Systems and Complexes], 2025, no. 4(69), pp. 54-60. (In Russian). https://doi.org/10.18503/2311-8318-2025-4(69)-54-60

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