Optimizing Yarn Tension in Textile Production with Tension-Position Cascade Control Method Using Kalman Filter

Area of Science:

• Textile Engineering
• Control Systems Engineering

Background:

• Textile production relies heavily on precise yarn tension control for fabric quality.
• Challenges include changing unwinder/rewinder diameters and variable operational speeds.
• Inconsistent tension leads to fabric defects, yarn breakage, and increased manufacturing costs.

Purpose of the Study:

• To develop an optimized and robust method for controlling yarn tension in automated textile production.
• To improve the quality and efficiency of fabric manufacturing through precise tension management.
• To address challenges associated with varying operational conditions and system dynamics.

Main Methods:

• Implementation of a cascade control strategy combining tension and position control.
• Integration of feedback controllers, feedforward mechanisms, and disturbance observers.
• Design of an optimal signal processor for noise reduction and phase difference minimization in sensor data.

Main Results:

• The proposed method enhances the robustness of the yarn tension control system.
• Achieved precise and stable yarn tension, leading to improved fabric quality.
• Reduced defects and potential for yarn breakage, optimizing production efficiency.

Conclusions:

• The optimized cascade control method is suitable for industrial textile applications.
• The system effectively manages yarn tension despite dynamic changes in operational parameters.
• This approach contributes to higher quality fabric production and reduced manufacturing costs.