Modeling, simulation and tension control of a coil winding machine

It is necessary to control the tension of materials such as string or wire having very small diameter to length ratio during production or winding from big spools to small spools after production to avoid breaking or damage. It is desirable for the winding tension of the small spools to be at a certain value in order to ensure that the various characteristics such as magnetic field and resistance are in an optimum level during usage. Besides, the tension of the material during winding to be greater than the yield point of material causes plastic deformation and shrink in diameter of the wire without breaking. In the section where the wire diameter is shrunk, the cross-sectional area will narrow and cause to bear less currents than that of a normal wire section can carry and induce to break due to overheating. In this study, computer control of a system designed and manufactured for winding enameled copper wire from big spools to small spools at a desired tension and a proper shape has been investigated both theoretically and practically. Satisfactory results have been obtained and presented giving a great number of graphics. Recommendations have been made for further studies.