Precision tension control technology of composite fiber tape winding molding

During the composite fiber tape winding process, tension fluctuation has a serious impact on the performance parameters of winding products, such as strength, compactness, resin content, fatigue resistance, and stress uniformity. Because of the influence of dynamic performance of tension control system caused by the torque motor, external disturbance, sensitivity of the parameter variation, inverter dead zone, ripple torque, cogging torque, nonlinear friction, and measurement noise, a fuzzy proportion integral derivative (PID) controller based on robust extended Kalman filter (REKF) is proposed, which considers membership function optimization of nonlinear dynamic fuzzy control system as systematic identification through designating activated membership function of input and output variable in each control step, and then, online adjustment of the activated membership functions is used to reduce the control error by REKF. By adjusting the shape and position of membership function, the designed controller can be adapted to the dynamic conditions. Simulation and experimental results show that overall performance of the control system has been significantly improved. Compared with traditional fuzzy PID, the fuzzy PID controller based on REKF has strong anti-interference performance and robustness, and the winding tension control precision has been increased by 40–42%.