Tension control is a main event during the formation of a flexible-oriented three-dimensional composite preform, which determines the forming quality of preform. However, control error and fluctuation of existing carbon fiber control system cannot meet the needs of weaving flexible-oriented three-dimensional preforms, which is prone to cause poor consistency of the edge of preform. In this research, a novel tension control mechanism is proposed, which including rewind roll, piezoelectric ceramic actuator, idle roller and tension sensor. The influence of structural and process parameters are investigated using the established tension control mechanism model. Considering the modified Euler formula and micro-deformation behavior of carbon fiber, a tension control model for the unsteady-state moving carbon fiber is then proposed. An adaptive fuzzy controller is designed for tuning the PID parameters to control the moving distance of piezoelectric ceramic actuator. Furthermore, the proposed mechanism and control method are applied to a digital tension control system. Simulations and experiments show that the system can achieve high-precision control of tension with a target of 500 mN, residual error and control error rate of tension control system are within 3 mN and 0.6%, respectively. Application of the established system to flexible-oriented woven process significantly improves the consistency of edge of preform.

中文翻译：

---

柔性定向三维复合材料预制件成型张力数字化控制系统

张力控制是柔性定向三维复合预制件成型过程中的重头戏，它决定了预制件的成型质量。但现有碳纤维控制系统的控制误差和波动无法满足柔性定向三维预制棒编织的需要，容易造成预制棒边缘一致性差。本研究提出了一种新型张力控制机构，包括收卷辊、压电陶瓷执行器、惰辊和张力传感器。利用建立的张力控制机构模型研究了结构和工艺参数的影响。考虑修正的欧拉公式和碳纤维的微变形行为，提出了非稳态移动碳纤维的张力控制模型。设计了自适应模糊控制器，通过调整PID参数来控制压电陶瓷执行器的移动距离。此外，所提出的机制和控制方法应用于数字张力控制系统。仿真和实验表明，该系统能够实现目标为500 mN的高精度张力控制，张力控制系统的残余误差和控制误差率分别在3 mN和0.6%以内。将所建立的系统应用到柔性定向编织工艺中，显着提高了预成型件边缘的一致性。