KR20200076451A - Real time estimatng device and method for ribbon thickness in tension control for amorphous ribbon - Google Patents

Abstract

The present invention relates to an apparatus and a method for predicting a real-time ribbon thickness. According to one embodiment of the present invention, the apparatus for predicting a real-time ribbon thickness performs winding tension control without separate additional devices and sensors. The apparatus for predicting a real-time ribbon thickness includes: a nonlinear control part varying a size of control gains in accordance with control errors of winding tension generated when a ribbon is wound by using a torque of a cooling roll; a ribbon thickness calculating part calculating the theoretical thickness of the ribbon by using a rotating speed difference between the cooling roll and a winding roll; and a ribbon thickness predicting part predicting the present ribbon thickness by using the calculated theoretical ribbon thickness and a past ribbon thickness predicted value.

Description

REAL TIME ESTIMATNG DEVICE AND METHOD FOR RIBBON THICKNESS IN TENSION CONTROL FOR AMORPHOUS RIBBON

The present invention relates to an apparatus and method for real-time winding tension control and real-time ribbon thickness prediction of ultra-thin materials such as an amorphous ribbon, and more specifically, a method for real-time prediction of ribbon thickness through precise tension control for high-speed winding of an amorphous ribbon. It is about.

Amorphous material is generally an amorphous metal. Refers to a glassy metal. Usually, a metal is a group of small crystal grains, and an amorphous metal is a metal in which the arrangement of atoms is disordered and not in a crystalline state. This is made by rapidly cooling the molten metal, and since it is in an amorphous state, it has properties different from those of ordinary crystalline metals. That is, corrosion is only one-millionth of that of stainless steel, and 400 to 500°C? There is also a characteristic of returning to a crystal when heat is applied, and it has a magnetic characteristic and is hard. It is used as a material for electric and electronic parts, a tape recorder, or a magnetic head material of a VTR, and when used as an iron core of a transformer, its power consumption is greatly reduced.

In the electronics industry, there is an active demand for high functionalization of components as well as continuous advancement of technology, and technology development using magnetic properties of the amorphous material is actively being made. In particular, due to the miniaturization, high efficiency, high reliability, low noise, and low cost of the device, miniaturization, high efficiency, high reliability, and low noise due to high-frequency and self-amplification have been realized. That is, the functionally excellent self-amplification method of the voltage control method is that when the frequency is low, the saturable core is enlarged, which has no economical attractiveness, but the core can be miniaturized according to the high frequency.

In general, a field in which amorphous functional alloys are frequently used is followed by power transformers for electronic devices. In particular, the use of amorphous functional alloys exhibiting excellent magnetic properties in the hundreds of kHz bands has been greatly promoted as small size and light weight through high frequency are actively promoted for switching power sources embedded in electronic devices such as various computers, communication devices, and office automation devices. Is increasing.

The composition of the amorphous functional alloy exhibiting soft magnetic properties is an alloy in which Si or B, which is a semi-metal based on a transition metal (Fe, Co, and Ni) is added, and the Fe and Co systems are mainstream. Fe-based amorphous alloys are generally used as magnetic core materials for high-frequency transformers and inductors due to their high saturation magnetic flux density and low magnetic loss. Co-based amorphous alloys use high magnetic permeability, low magnetic loss, and zero magnetostrictive components. Is used in

From the self-amplifying switching power supply in the frequency band of 100 to 500 kHz, the use of cobalt-based amorphous alloys having a large squareness ratio on a magnetization curve, a small coercive force, and a low frequency loss is increasing from a saturable reactor that is an output control element. In addition, a high-saturation magnetic flux density iron-based amorphous magnetic alloy is used for the smoothing choke coils that require excellent DC superimposition characteristics, and the high-permeability cobalt and high-saturation magnetic flux density and low magnetic core loss are used to reduce noise generated in the switching power supply. Iron-based amorphous magnetic alloys are used for high attenuation and high voltage pulse countermeasure respectively. In addition, in order to reduce spike noise due to the recovery characteristics of the diode in the switching power supply, cobalt-based ultra-small beads having high angle formation, high permeability, and low magnetic core loss are used.

On the other hand, there are iron-based cut cores that utilize excellent high-frequency properties of the amorphous alloy in addition to the components for the switching power supply. It is used as a transformer, reactor, etc. of a high-power inverter-type power supply of kVA class operating at 500 Hz to 20 kHz, and is used for power of high-frequency heating devices, X-ray generators, welding machines, and uninterruptible power supplies.

As a new amorphous functional alloy market, transformers and power inductors for ISDN interfaces have been developed. The interface transformer that connects the communication network and the terminal of the ISDN communication network is a high-permeability cobalt-based amorphous alloy. In electric and electronic devices for mobile communication, power inductors used to increase the efficiency of switching elements and suppress noise of power sources are required to have excellent DC superimposition characteristics, iron-based amorphous magnetic alloys are used, and the fastest growing market is expected. .

Currently, technology improvement of all electric and electronic devices is progressing toward miniaturization, energy saving, reliability improvement, and noise countermeasures. To this end, starting with the high frequency of the switching frequency, the number of parts is reduced, miniaturization of mounted parts, circuit simplification, and high-density mounting are progressing. Improvement of conversion efficiency of electrical and electronic circuits, heat generation due to miniaturization and high density. For heat resistance characteristics and noise countermeasures, it is absolutely necessary.

Japanese Open Publication Special Publication 10-34288 (Publication date: 1998. 02. 10)

Technical problem to be solved by the present invention is a control method for precisely maintaining the tension applied to the amorphous ribbon between the cooling roll and the winding roll by using the torque of the winding roll without a separate additional device or sensor using the torque of the cooling roll. In the process of applying, it is to provide an algorithm that can accurately predict the thickness of the amorphous ribbon by using the increase in the diameter of the winding roll.

Real-time ribbon thickness prediction apparatus according to an embodiment of the present invention, in a device for performing the winding tension control without a separate additional device or sensor, of the winding tension generated in the process of winding the ribbon using the torque of the cooling roll A nonlinear control unit that varies the size of the control gain according to the control error; A ribbon thickness calculator for calculating the theoretical thickness of the ribbon by using a difference in rotational speed between a cooling roll and a winding roll; And a ribbon thickness prediction unit for predicting the current ribbon thickness using the calculated theoretical thickness and the past ribbon thickness prediction value.

In addition, the real-time ribbon thickness prediction apparatus according to an embodiment of the present invention applies a ring buffer method to remove noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculator It may further include a removing portion.

In addition, the reflection coefficient for the past ribbon thickness prediction value and the reflection coefficient for the theoretical thickness of the ribbon are matrices including a plurality of coefficients as components, respectively, before the plurality of coefficients are predicted for the current ribbon thickness. Can be decided on.

Real-time ribbon thickness prediction method according to another embodiment of the present invention, in a device for performing winding tension control without a separate additional device or sensor, using the torque of the cooling roll, of the winding tension generated in the process of winding the ribbon Varying the size of the control gain according to the control error; Calculating a theoretical thickness of the ribbon using a difference in rotational speed between a cooling roll and a winding roll; And predicting the current ribbon thickness using the calculated theoretical thickness and the past ribbon thickness prediction value.

In addition, in the real-time ribbon thickness prediction method according to an embodiment of the present invention, removing noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculator by applying a ring buffer method It may further include.

According to a real-time ribbon thickness prediction apparatus and method according to embodiments of the present invention, in the process of applying a control method for precisely maintaining the tension applied to the amorphous ribbon between the cooling roll and the winding roll using the torque of the winding roll , It is possible to accurately predict the thickness of the amorphous ribbon using an increase in the diameter of the winding roll.

1 is a schematic view showing an example of a conventional winding process method.
2 and 3 are schematic diagrams showing a central wind type, which is a type of winding process.
4 is a schematic diagram showing a surface winder type, which is a type of winding process.
5 is a schematic view showing a turret winder type, which is a type of winding process.
6 is a schematic view showing the arrangement of nozzles, cooling rolls, and winding rolls in a ribbon manufacturing process.
7 is a block diagram illustrating a real-time ribbon thickness prediction apparatus according to an embodiment of the present invention.
8 is a graph for explaining a saturation function applied to a nonlinear control unit in a real-time ribbon thickness prediction apparatus according to an embodiment of the present invention.
9 and 10 are graphs showing frequency characteristics of a control output according to a nonlinear control unit of a real-time ribbon thickness prediction apparatus according to the conventional PID control (proportional integral derivative control) method and embodiments of the present invention, respectively.
11 is a schematic view for explaining a parameter for calculating the winding diameter of the winding roll.
12 is a conceptual diagram of a ring buffer method for explaining a noise removing unit of a real-time ribbon thickness prediction apparatus according to embodiments of the present invention.
13 is a block diagram illustrating a tension control and ribbon thickness prediction apparatus according to embodiments of the present invention.
14 is a graph for explaining the operation of the noise removing unit of the real-time ribbon thickness prediction apparatus according to embodiments of the present invention.
15 is a graph showing an impulse response when a dynamic model is applied to predict a ribbon thickness in a real-time ribbon thickness prediction apparatus according to embodiments of the present invention.
16 to 19 are graphs showing application results of a real-time ribbon thickness prediction apparatus according to embodiments of the present invention.
20 is a graph showing a change in cooling roll torque over time in tension control according to a winding roll torque command change method according to a conventional winding roll winding diameter.
21 is a graph showing changes over time, such as a cooling roll torque and a winding roll speed, when a real-time ribbon thickness prediction device is applied according to embodiments of the present invention.
22 is a graph showing a predicted value of ribbon thickness when tension is controlled according to a winding roll torque command change method according to a conventional winding roll winding diameter.
23 is a graph showing a predicted value of ribbon thickness when a real-time ribbon thickness prediction apparatus according to embodiments of the present invention is applied.
24 is a flowchart illustrating a real-time ribbon thickness prediction method according to embodiments of the present invention.

Specific details of other embodiments are included in the detailed description and drawings.

Advantages and features of the present invention, and methods for achieving them will be clarified with reference to embodiments described below in detail together with the accompanying drawings. However, the present invention is not limited to the embodiments disclosed below, but may be implemented in various different forms, and only the embodiments allow the disclosure of the present invention to be complete, and common knowledge in the technical field to which the present invention pertains. It is provided to completely inform the person having the scope of the invention, and the present invention is only defined by the scope of the claims. The same reference numerals refer to the same components throughout the specification.

Quenching and solidifying methods for producing an amorphous material (usually a ribbon shape) include a single roll method and a twin roll method, but the most common method is a single roll method. This single roll method is a method in which molten metal is ejected onto the surface of a cooling roll rotating at high speed, and rapidly cooled and solidified on the cooling roll to continuously obtain an amorphous material. When manufacturing on an industrial scale, it is usually necessary to wind up or recover this rapidly solidified amorphous material.

Normally, when the width of the amorphous ribbon is 50 mm or less, most people perform low-speed winding by hand, but in the case of 100 mm or more wide-width amorphous ribbon, it is cast at high speed of 20 m/s or more, so it is impossible to wind with human force. Therefore, an automated facility is required, and tension control during winding is required to prevent the ribbon from breaking as the diameter increases during winding.

So far, various methods and devices have been proposed as a winding method for winding an amorphous material online immediately after casting, but generally, a method and a device for winding by rotating the winding roll using a winding roll has been adopted. Here, the conventional method of winding the amorphous material includes a method of using a permanent magnet, a method of using a double-sided adhesive tape, and a method of using an electromagnet method.

When winding is performed using the winding roll, tension is generated in the cooling roll and the winding roll by the amorphous ribbon according to the control method of the winding roll, and the rotation speed of the cooling roll or the winding roll is affected by the generated tension. do. Particularly, when the tension applied to the amorphous ribbon becomes larger than a certain level, the ribbon of the sheet is torn or the rotational torque that the cooling roll takes to maintain a constant rotational speed is reduced, and when the ribbon is broken, the cooling roll speed change becomes severe and the nozzle and cooling roll A phenomenon in which a puddle formed by molten steel breaks between them occurs.

1 is a schematic view showing an example of a conventional winding process method. In the conventional winding method, as shown in FIG. 1, in order to solve the above-described problem, an unwinder, a winder, and an intermediate infeeder are included. Most of the rolls are driven by a motor, and in some cases are free-run, and the load cell or dancer roll between the unwinder and winder is an amorphous ribbon. It is used to control the tension acting on.

2 and 3 are schematic diagrams showing a central wind type, which is a type of winding process, and FIG. 4 is a schematic diagram showing a surface winder type, which is a type of winding process. 5 is a schematic diagram showing a turret winder type, which is a type of winding process. According to the arrangement of the roll between the cooling roll and the winding roll in the winding process of winding the amorphous ribbon, the winder can be classified into three types as follows.

2 and 3, the central winding method is a method in which an amorphous ribbon is wound in a central portion called a core or a mandrel. The name is given because the amorphous ribbon is wound by controlling the center of the core with a motor.

Referring to FIG. 4, the surface winding method is a method in which the main roll on which the amorphous ribbon is wound is driven by a plurality of surface winder rolls. The amorphous ribbon enters between the main roll and the surface winder roll, and various types of configurations are possible depending on the purpose.

Referring to FIG. 5, the turret winding method is a device capable of continuously winding because two or more centerwinds are connected to a rotating shaft. When one roll is wound up and passed to the next roll, the amorphous ribbon is cut and wound on the next roll. When the first centerwind (centerwind #1) is wound, the second centerwind (centerwind #2) is rotated to prepare for winding.

The method of controlling the tension applied to the amorphous ribbon during the winding process is a method of measuring tension using a tension sensor such as a load cell or a dancer roll, and feedback control based on the measured tension. The control method (Speed Control Mode), tension control method (Tension Control Mode) and open-loop control method (Open-loop Control mode) are selected.

In general, the speed control method is used in a winding system that requires quick reactivity in both speed and tension, and the tension control method has a very large inertia moment of an unwinder (a cooling roll in an amorphous manufacturing process) or a winder, and a tension. It is suitable for the case where quick reactivity of is required, and when the tension sensor is not used for cost reduction or when it is difficult to use for mechanical reasons such as attachment of the tension sensor, the open circuit control method is used. In the case of the open-loop control method, it is difficult to guarantee good performance or responsiveness compared to a closed-loop control method such as a speed or tension control method. In this case, the tension applied to the amorphous ribbon is controlled by controlling the speed using the torque limit option of the motor.

As a method of measuring the thickness of the amorphous ribbon in the winding process, two rolls are installed between the cooling roll and the winding roll, and the X-ray, laser, eddy current sensor, confocal sensor, etc. are used to measure the thickness of the ribbon during winding. Measure the thickness.

6 is a schematic diagram showing the arrangement of nozzles, cooling rolls, and winding rolls in a ribbon manufacturing process, and FIG. 7 is a block diagram showing a real-time ribbon thickness prediction apparatus according to an embodiment of the present invention. In addition, FIG. 8 is a graph for explaining a saturation function applied to a nonlinear control unit in a real-time ribbon thickness prediction apparatus according to an embodiment of the present invention, and FIGS. 9 and 10 are conventional PID control schemes and implementation of the present invention, respectively. It is a graph showing the frequency characteristics of the control output according to the nonlinear control unit of the real-time ribbon thickness prediction device according to the examples.

In general, the winding process of the amorphous ribbon is a ribbon transfer step from the cooling roll 3, an initial winding step of catching the ribbon from which the winding roll 5 flies, winding several to tens of turns, a cooling roll 3 and winding It can be divided into four steps, such as a synchronization control step of the roll 5, a tailing control step of finishing the tail portion of the ribbon being wound as a finishing step without fluttering.

The present invention passes the initial winding step of winding several to several tens of times by catching the flying ribbon, constantly controlling the tension applied to the amorphous ribbon during winding to solve the instability of the puddle formed between the amorphous nozzle and the cooling roll, and winding up In order to solve the problem that the ribbon is broken, the tension applied to the amorphous ribbon between the cooling roll and the winding roll is received by receiving the torque of the motor for cooling roll rotation without a separate roll and sensor for measuring the tension applied to the amorphous ribbon. It provides a control method for precisely maintaining the torque of the. Also, while maintaining the tension of the amorphous ribbon, an algorithm capable of accurately predicting the thickness of the amorphous ribbon using an increase in the diameter of the winding roll is provided.

To this end, referring to FIG. 7, the real-time ribbon thickness prediction apparatus 10 according to an embodiment of the present invention includes a nonlinear control unit 100, a ribbon thickness calculation unit 200, and a ribbon thickness prediction unit 300. Can. According to another embodiment of the present invention, in addition to this, a noise removing unit 250 may be further included.

The non-linear control unit 100 varies the magnitude of the control gain according to the control error of the winding tension generated in the process of winding the ribbon, so that the chattering occurs in a general PID integral (proportional integral derivative control) method. By minimizing the tension change applied to the amorphous ribbon.

To this end, the nonlinear control unit 100 calculates the control input of the winding roll in a sliding mode method that compensates for the nonlinear component of the proposed control system as shown in [Equation 1] below.

는 시스템의 제어 입력으로서 실제 권취기의 보빈의 토크로 환산되어 제어 시스템에 지령값으로 사용된다.

는 과거의 제어 입력이고,

는 현재의 제어 입력을 의미한다.

는 제어 이득 행렬을 의미하며,

는 상태변수 백터의 이득이고,

는 e(제어 오차)+Kv(상태변수의 속도 이득)*e'(제어 오차의 1차 미분항)으로 표현되는 상태변수이다.

는 시스템 행렬을 의미하고,

는 시스템 지배 방정식에서의 비선형 성분의 합과 모델링되나, 실제 알 수 없는 비선형 성분의 합이다.

는 원하는 제어 지령의 상태값이고,

는 이득을 의미한다. From here,

Is the control input of the system, which is converted into the torque of the bobbin of the actual take-up and used as a command value in the control system.

Is the past control input,

Means the current control input.

Is the control gain matrix,

Is the gain of the state variable vector,

Is a state variable expressed as e (control error) + Kv (speed gain of the state variable) * e'(first differential term of the control error).

Means system matrix,

Is the sum of the nonlinear components in the system governing equation and the nonlinear components that are modeled, but not actually known.

Is the status value of the desired control command,

Means gain.

,

,

,

는 비선형 항목들로서 이들 비선형 항목들에 의해 순간 토크 변화율이 커지게 되면 퍼들 진동을 유발할 수 있다. 따라서, [수학식 1]에서 포화 함수(saturation function), 즉 sat(s)는 아래 [수학식 2]와 같이 정의됨으로써, 제어 시스템의 비선형 성분을 보상한다. In [Equation 1]

,

,

,

As non-linear items, when the instantaneous torque change rate is increased by these non-linear items, puddle vibration may be caused. Therefore, in [Equation 1], the saturation function (ie, sat(s)) is defined as [Equation 2] below, thereby compensating for the nonlinear component of the control system.

는 상태 변수의 허용 오차(tolerance)로서, 상태 변수가

이상일 경우 +1 또는 -1로 스위칭되고, 상태 변수가

미만일 경우 포화 함수가

보다 작은 값으로 변하게 하여, 상태 변수가 일정 범위(

) 내로 줄어들면 자동으로 제어 이득이 줄어드는 효과가 있다. 본 발명의 일 실시예에 따라 비선형 제어부(100)가 적용하는 포화 함수는 도 8에서 도시하는 바와 같이 장력제어 오차에 따라 오차함수의 크기를 가변하는 역할을 수행한다. From here,

Is the tolerance of the state variable, where the state variable

If it is abnormal, it switches to +1 or -1, and the state variable

If less than, the saturation function

By changing it to a smaller value, the state variable

), the control gain is automatically reduced. According to an embodiment of the present invention, the saturation function applied by the nonlinear controller 100 serves to vary the size of the error function according to the tension control error as shown in FIG. 8.

As a result, the nonlinear control unit 100 of the real-time ribbon thickness prediction apparatus 10 according to an embodiment of the present invention can solve the chattering problem that may occur in the control process by introducing a saturation function such as [Equation 2].

As shown in FIGS. 9 and 10 comparing the frequency characteristics of the control output of the proposed nonlinear controller with the classical PID method, the amorphous ribbon according to the method applied by the nonlinear controller 100 according to an embodiment of the present invention It can be seen that the amount of instantaneous tension fluctuation is much smaller, which has the effect of reducing the instantaneous tension change.

11 is a schematic diagram for explaining a parameter for calculating the winding diameter of a winding roll, and FIG. 12 is a conceptual diagram of a ring buffer method for explaining a noise removing unit of a real-time ribbon thickness prediction apparatus according to embodiments of the present invention. 13 is a block diagram showing an apparatus for tension control and ribbon thickness prediction according to embodiments of the present invention. In addition, Figure 14 is a graph for explaining the operation of the noise removing unit of the real-time ribbon thickness prediction device according to embodiments of the present invention, Figure 15 is a ribbon of the real-time ribbon thickness prediction device according to embodiments of the present invention This graph shows the impulse response when applying a dynamic model to predict thickness.

When manufacturing the amorphous ribbon, in the tension control method proposed in the present invention, since there is little change in the cooling roll torque due to an increase in the diameter during winding, there is almost no speed change of the cooling roll, and the instantaneous speed change rate of the winding roll is very small, so a separate sensor Without using the diameter and rotational speed of the cooling roll and the calculated diameter and rotational speed of the winding roll, the ribbon thickness can be accurately predicted in the manner suggested below.

The ribbon thickness calculator 200 calculates the theoretical thickness of the ribbon through Equation 3 below using the difference in rotational speed between the cooling roll and the winding roll.

은 상기 리본두께 계산부에 의해 계산된 상기 리본의 이론적인 두께를 의미하고,

는 상기 권취롤이 상기 리본을 권취하는 동안 리본두께를 계산하는 시간 간격을 의미하며,

은

기간 전의 상기 권취롤의 보빈의 권경을 의미하고,

는 현재의 상기 권취롤의 보빈의 권경을 의미하며,

는 상기 냉각롤의 회전 각속도를 의미한다. From here,

Means the theoretical thickness of the ribbon calculated by the ribbon thickness calculator,

Is a time interval for calculating the ribbon thickness while the winding roll is winding the ribbon,

silver

Means the bobbin diameter of the winding roll before the period,

Means the bobbin diameter of the current winding roll,

Means the angular speed of rotation of the cooling roll.

및

는 아래 [수학식 4]를 통해 계산된다. And, in [Equation 3]

And

Is calculated through [Equation 4] below.

는 상기 권취롤의 보빈의 권경을 반지름으로 환산한 값을 의미하고,

는 상기 냉각롤의 반지름으로서 주조 시 변하지 않는 고정값이며,

는 상기 권취롤의 모터와 상기 권취롤의 보빈축 간의 감속비를 의미하며,

는 상기 권취롤의 보빈의 회전 각속도를 의미한다. From here,

Means a value obtained by converting the diameter of the bobbin of the winding roll into a radius,

Is a radius of the cooling roll and is a fixed value that does not change during casting,

Means a reduction ratio between the motor of the winding roll and the bobbin shaft of the winding roll,

Means the rotational angular velocity of the bobbin of the winding roll.

,

,

,

등은 일반적인 비정질 리본제조 공정에서 계측을 통해 얻을 수 있는 값들이며, 리본두께 계산부(200)는 이들 값들을 통해 [수학식 3]과 [수학식 4]를 활용하여 리본의 이론적인 두께를 계산한다.

,

,

,

Etc. are values that can be obtained through measurement in a general amorphous ribbon manufacturing process, and the ribbon thickness calculator 200 calculates the theoretical thickness of the ribbon using [Equation 3] and [Equation 4] through these values. do.

The ribbon thickness predicting unit 300 predicts the current ribbon thickness using the theoretical thickness of the ribbon calculated by the ribbon thickness calculating unit 200 and the predicted values of past ribbon thickness. The ribbon thickness prediction unit 300 may predict the current ribbon thickness through a dynamic model of ribbon thickness expressed as Equation 5 below.

는 리본두께 동적모델을 통해 최종적으로 예측된 리본두께를 의미하고,

는 과거 리본두께 예측값을 의미하며,

는 리본두께 계산부에 의해 계산된 리본의 이론적인 두께를 의미하며,

은 과거 리본두께 예측값에 대한 동적특성을 반영하기 위한 가중치를 반영한 계수이고,

은 리본두께 계산부에 의해 계산된 리본의 이론적인 두께에 대한 동적특성을 반영하기 위한 가중치를 반영한 계수를 의미한다. From here,

Means the ribbon thickness finally predicted through the dynamic model of the ribbon thickness,

Means the past ribbon thickness prediction,

Is the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit,

Is a coefficient reflecting the weight to reflect the dynamic characteristics of the past ribbon thickness prediction,

Is a coefficient reflecting the weight to reflect the dynamic characteristics of the ribbon's theoretical thickness calculated by the ribbon thickness calculator.

) 및 리본의 이론적인 두께에 대한 반영계수(

)는 각각 복수의 계수들을 성분으로 포함하는 행렬로서, 이들 복수의 계수들은 현재의 리본두께를 예측하기 이전에 리본두께를 결정하는 동적특성을 반영하여 설계되어 사전에 결정된다. 즉, 이들 행렬에 포함된 계수들은 리본두께 예측 프로세스 이전에, 계수값의 입력, 입력된 계수값에 따른 결과 확인, 계수값의 변경, 변경된 계수값의 입력 및 결과 재확인 등의 과정을 거치면서 최적의 수치를 조율하여 선택한 값들일 수 있다. Here, the reflection coefficient for the past ribbon thickness prediction value (

) And the reflection coefficient for the theoretical thickness of the ribbon (

) Is a matrix each containing a plurality of coefficients as components, and these plurality of coefficients are designed and determined in advance by reflecting the dynamic characteristic of determining the ribbon thickness before predicting the current ribbon thickness. That is, the coefficients included in these matrices are optimal through the process of inputting the coefficient values, checking the results according to the inputted coefficient values, changing the coefficient values, and reconfirming the results before the ribbon thickness prediction process. It may be selected values by adjusting the value of.

The reflection coefficients selected in this way are values selected in consideration of the stability of the control system. Therefore, as a result of applying these reflection coefficients, they are stabilized within a certain period (τ, for example, 10 seconds) as shown in FIG. 15.

는 복수회의 계산을 통해 획득될 수 있으며 이는

및

에 반영될 수 있다. 예를 들어, 아래 [표 1]은 2회에 걸쳐 동적 모델을 통한 예측값을 구하기 위해 반영계수

및

의 성분들이다. Also, it is calculated through [Equation 5]

Can be obtained through multiple calculations, which

And

Can be reflected in. For example, [Table 1] below shows the reflection coefficient to obtain the predicted value through the dynamic model twice.

And

It is a component of.

Primary Secondary A01, B01 One One A02, B02 One One A11, B11 2 -1.065 A12, B12 2 -0.968 A21, B21 One 0.638 A22, B22 One 0.276

According to another embodiment of the present invention further comprises a noise removing unit 250 to remove noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit by applying a ring buffer (ring buffer) method can do.

기간 동안 상대속도차에 의해 발생한 권취 리본의 면적을 냉각롤의 주조속도에 동기화 시 리본두께로 환산된 값으로 환산된 리본두께(

)에는 냉각롤 및 권취롤의 속도제어를 위한 인버터의 통신주기의 불규칙성에 따라 미분 노이즈가 포함되어 있다. [Equation 3] and [Equation 4] described above

When the area of the winding ribbon generated by the relative speed difference during the period is synchronized with the casting speed of the cooling roll, the ribbon thickness converted to the value converted to the ribbon thickness (

) Contains differential noise according to the irregularity of the communication cycle of the inverter for speed control of the cooling roll and the winding roll.

가 변수로서, 권취롤 인버터 내 권취롤 회전용 모터의 엔코더(Encoder)를 값을 읽는 카운트 드라이버(Count Driver)의 통신주기의 불규칙성에 따라 계단 형태의 데이터로 획득되기 때문에 권경 계산 시 샘플링 주기에 따른 오차가 유발될 수 있다. 14, the ribbon thickness geometric model in the present invention is

As a variable, the encoder of the winding roll rotating motor in the winding roll inverter is obtained as stair-shaped data according to the irregularity of the communication cycle of the count driver that reads the value. Errors can be caused.

을 [수학식 5]에 적용하여 리본두께를 예측할 수 있다.The noise removing unit 250 may remove the influence of the differential noise component by introducing the concept of a ring buffer as shown in FIG. 12 to remove it. Subsequently, the ribbon thickness prediction unit 300 removes noise components.

Can be applied to [Equation 5] to predict the ribbon thickness.

13, the ribbon thickness prediction apparatus according to the embodiments of the present invention is described as a whole. In the method for predicting the ribbon thickness among the windings proposed in the present invention, the inverter for cooling roll rotation for rapid cooling of the amorphous ribbon operates in a speed control mode to match the set casting speed, and the inverter for winding roll rotation rotates with the cooling roll setting torque. Using the measured torque value, the control input value calculated in the nonlinear tension control logic (ie, [Equation 1] and [Equation 2] described above) is input to the winding roll rotating inverter as a command value. At this time, the winding roll rotating inverter performs control to reach a control input value in a torque control mode. At this time, the ribbon thickness geometry (ie, [Equation 3] and [Equation 4] described above) is calculated by using the current angular velocity output from the cooling roll rotation inverter and the winding roll rotation inverter and the set cooling roll radius and the winding machine reduction ratio. After calculating and compensating for the speed change in the winding roll transfer section, the ribbon thickness predicted value is fed back through the ribbon thickness dynamic model (ie, [Equation 5]).

The estimated ribbon thickness predicted value proposed in the present invention is utilized to adjust the thickness of the amorphous ribbon during casting by finely adjusting the nozzle-mounted tundish drive device up and down.

16 to 19 are graphs showing application results of a real-time ribbon thickness prediction apparatus according to embodiments of the present invention. 20 is a graph showing a change in cooling roll torque over time in tension control according to a winding roll torque command change method according to a conventional winding roll winding, and FIG. 21 is cooling when applying a real-time ribbon thickness prediction device according to embodiments of the present invention It is a graph showing changes over time such as roll torque and winding roll speed. In addition, Figure 22 is a graph showing the predicted value of the ribbon thickness when tension control according to the winding roll torque command change method according to the conventional winding roll diameter, Figure 23 is a real-time ribbon thickness prediction apparatus according to embodiments of the present invention It is a graph showing the predicted value of ribbon thickness.

In general, during the initial winding in the amorphous ribbon manufacturing process, in order to stably wind the flying ribbon, catching is attempted at a position close to the cooling roll. After the ribbon is caught on the winding roll, the winding is rolled while traversing the winding roll in a direction away from the cooling roll for cooling the amorphous ribbon. At this time, since the speed change occurs while the winding roll is being transported, it affects the predicted value of ribbon thickness. 16 to 19 are examples of the results when the winding roll speed change compensation logic is applied to the winding roll transfer section.

16 to 19, in a common situation in which the bobbin of the winding roll rotates from a point of about 70 seconds to a point of about 140 seconds (see FIG. 18), the result values when the embodiments of the present invention are applied are shown. have. Referring to FIG. 19, embodiments of the present invention are intended to prevent an error that may occur due to a change in the primary differential term of the bobbin when the bobbin of the take-up roll starts to rotate and cause such a change. As shown in FIG. 16, the ribbon thickness predicted by the real-time ribbon thickness prediction device according to the embodiments of the present invention is stabilized over a period of time (τ) from a point of about 70 seconds, and has a thickness of approximately 37 μm. The predicted value is being output. In addition, referring to FIG. 17, it can be confirmed that the ribbon thickness value of about 0.07 um was corrected even though it was a minute value during the period during which the bobbin of the winding roll rotated.

FIG. 20 shows the change of the winding roll torque over time when the winding roll torque command change method according to the winding roll winding diameter-open-loop control mode tension control, and this method is during the catching state and winding of the initial amorphous ribbon Depending on the ribbon thickness, the amount and tendency of the change in the cooling roll torque must be different each time, and the amount of change in the cooling roll torque according to the diameter is large, which is inevitable to affect the puddle between the nozzle and the cooling roll. In addition, as shown in FIG. 20, when the winding roll moves backward after the initial catching, an intermittent amorphous ribbon is cut off due to excessive tension or tension change in the traverse section.

On the other hand, Figure 21 shows the change over time, such as the cooling roll speed, torque, winding roll speed and increase in diameter when applying the tension control method of the cooling roll torque feedback-based open-loop control mode proposed in the present invention As shown in FIG. 21, the difference between the cooling roll torque before and after winding acts as a tension applied to the amorphous ribbon, and the torque of the cooling roll is constantly controlled to increase the tension of the amorphous ribbon despite the increase in diameter during winding. It can be seen that it remains almost unchanged.

As described above, as the tension of the ribbon is kept constant through the amorphous ribbon tension control among the windings proposed through the embodiments of the present invention, the rate of change in the speed difference between the cooling roll and the winding roll is very small, so that the ribbon thickness can be predicted stably. .

22 and 23 compare the ribbon thickness prediction value and actual value during winding before and after applying the tension control method proposed in the present invention for each casting cycle. As shown in FIG. 22, before applying the tension control method proposed in the present invention, it can be confirmed that the prediction value of the ribbon thickness is 22-40 um, and the prediction accuracy is very low. On the other hand, referring to FIG. 23 and Table 2 below, it can be seen that after applying the tension control method proposed in the present invention, the measurement error of the ribbon thickness is predicted very accurately to 1 micro or less. This is lower than the error that occurs due to the vibration of the roll for measurement and the measurement precision of the sensor compared to the method of measuring the thickness of the ribbon using an X-ray, laser, or confocal sensor.

Lot Number Measured value Forecast Deviation One 27.60㎛ 27.22㎛ -0.38㎛ 2 32.00㎛ 32.03㎛ -0.03㎛ 3 36.95㎛ 36.95㎛ 0.00㎛ 4 30.33㎛ 30.35㎛ -0.02㎛

When manufacturing the amorphous ribbon proposed in the present invention, the tension control method during winding is very simple compared to the conventional method for measuring tension using a sensor such as a load cell. Likewise, the method for predicting the ribbon thickness proposed in the present invention is very simple and accurate in the ribbon thickness prediction because the configuration of the device is very simple because no separate device is required compared to the conventional method using a sensor such as X-ray. As described above, the present invention is a method of constantly controlling the tension of the amorphous ribbon by feeding back the cooling roll torque value without a roll or sensor for measuring the amorphous ribbon tension between the cooling roll and the winding roll, or by installing an extra roll to cool the roll. Of course, the same can be applied to improving the cooling of the ribbon by sufficiently securing the distance between the winding rolls.

24 is a flowchart illustrating a real-time ribbon thickness prediction method according to embodiments of the present invention.

A real-time ribbon thickness prediction method according to an embodiment of the present invention comprises the steps of varying the size of the control gain according to a control error of the winding tension generated in the course of winding the ribbon (S100); Calculating the theoretical thickness of the ribbon using the difference in rotational speed between the cooling roll and the winding roll (S200); And predicting the current ribbon thickness using the calculated theoretical thickness and the past ribbon thickness prediction value (S300).

In addition, in the real-time ribbon thickness prediction method according to an embodiment of the present invention, removing noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculator by applying a ring buffer method (S250) may be further included.

For a detailed description of a method for predicting a real-time ribbon thickness according to embodiments of the present invention, reference may be made to FIGS. 1 to 7 to 23 and a description of a corresponding real-time ribbon thickness prediction device, in which detailed description is made to avoid repetition. Is omitted.

On the other hand, the term'~ unit' used in this embodiment, that is,'~ module' or'~ table' is hardware such as software, FPGA (Field Programmable Gate Array) or application specific integrated circuit (ASIC). A component, and a module performs some functions. However, modules are not limited to software or hardware. The module may be configured to be in an addressable storage medium or may be configured to reproduce one or more processors. Thus, as an example, a module includes components such as software components, object-oriented software components, class components and task components, and processes, functions, attributes, procedures, subroutines. Fields, segments of program code, drivers, firmware, microcode, circuits, data, databases, data structures, tables, arrays, and variables. The functionality provided within the components and modules can be combined into a smaller number of components and modules or further separated into additional components and modules. In addition, components and modules may be implemented to reproduce one or more CPUs in the device.

Those of ordinary skill in the art to which the present invention pertains will appreciate that the present invention may be implemented in other specific forms without changing its technical spirit or essential features. Therefore, it should be understood that the embodiments described above are illustrative in all respects and not restrictive. The scope of the present invention is indicated by the scope of the claims, which will be described later, rather than the detailed description, and all the changed or modified forms derived from the meaning and scope of the claims and their equivalent concepts are included in the scope of the present invention. Should be interpreted.

10: real-time ribbon thickness prediction device
100: nonlinear control
200: ribbon thickness calculation unit
250: noise removing unit
300: ribbon thickness prediction unit

Claims (12)

In the device for performing the winding tension control without a separate additional device or sensor,
A nonlinear control unit that varies the magnitude of the control gain according to a control error of the winding tension generated in the process of winding the ribbon using the torque of the cooling roll;
A ribbon thickness calculator for calculating the theoretical thickness of the ribbon by using a difference in rotational speed between a cooling roll and a winding roll; And
Comprising a ribbon thickness predicting unit for predicting the current ribbon thickness using the calculated ribbon thickness and the past ribbon thickness prediction value,
Real-time ribbon thickness prediction device.
According to claim 1,
The ribbon thickness prediction unit predicts the current ribbon thickness through a dynamic model of ribbon thickness expressed by the following equation,

From here,

Means the ribbon thickness finally predicted through the dynamic model of the ribbon thickness,

Means the past ribbon thickness prediction value,

Is the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit,

Is a reflection coefficient for the past ribbon thickness prediction value,

Is a reflection coefficient for the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit,
Real-time ribbon thickness prediction device.
According to claim 2,
The reflection coefficient for the past ribbon thickness prediction value and the reflection coefficient for the theoretical thickness of the ribbon are each a matrix including a plurality of coefficients as components,
The plurality of coefficients are predetermined before predicting the current ribbon thickness,
Real-time ribbon thickness prediction device.
According to claim 1,
Further comprising a noise removing unit for removing noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit by applying a ring buffer (ring buffer) method,
Real-time ribbon thickness prediction device.
According to claim 1,
The ribbon thickness calculation unit calculates the theoretical thickness of the ribbon through the following equation,

From here,

Means the theoretical thickness of the ribbon calculated by the ribbon thickness calculator,

Means the total period during which the winding roll winds the ribbon,

silver

Means the bobbin diameter of the winding roll before the period,

Means the bobbin diameter of the current winding roll,

Means the rotational angular speed of the cooling roll,
Real-time ribbon thickness prediction device.
The method of claim 5,

And

Is calculated by the following equation,

From here,

Means the winding diameter of the bobbin of the winding roll,

Is a radius of the cooling roll and is a fixed value that does not change during casting,

Means a reduction ratio between the motor of the winding roll and the bobbin shaft of the winding roll,

Means the rotational angular speed of the bobbin of the winding roll,
Real-time ribbon thickness prediction device.
In an apparatus for performing winding tension control without a separate additional device or sensor, varying the magnitude of the control gain according to a control error of the winding tension generated in the process of winding the ribbon using the torque of the cooling roll;
Calculating a theoretical thickness of the ribbon using a difference in rotational speed between a cooling roll and a winding roll; And
And predicting the current ribbon thickness using the calculated theoretical thickness and the previous ribbon thickness prediction value,
Real-time ribbon thickness prediction method.
The method of claim 7,
The step of predicting the current ribbon thickness using the calculated theoretical thickness and the past ribbon thickness prediction value of the ribbon, predicts the current ribbon thickness through a dynamic model of the ribbon thickness represented by the following equation,

From here,

Means the ribbon thickness finally predicted through the dynamic model of the ribbon thickness,

Means the past ribbon thickness prediction value,

Is the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit,

Is a reflection coefficient for the past ribbon thickness prediction value,

Is a reflection coefficient for the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit,
Real-time ribbon thickness prediction method.
The method of claim 8,
The reflection coefficient for the past ribbon thickness prediction value and the reflection coefficient for the theoretical thickness of the ribbon are each a matrix including a plurality of coefficients as components,
The plurality of coefficients are predetermined before predicting the current ribbon thickness,
Real-time ribbon thickness prediction method.
The method of claim 7,
Further comprising the step of removing the noise included in the theoretical thickness of the ribbon calculated by the ribbon thickness calculation unit by applying a ring buffer (ring buffer) method,
Real-time ribbon thickness prediction method.
The method of claim 7,
The step of calculating the theoretical thickness of the ribbon using the difference in rotational speed between the cooling roll and the winding roll, calculate the theoretical thickness of the ribbon through the following equation,

From here,

Means the theoretical thickness of the ribbon calculated by the ribbon thickness calculator,

Means the total period during which the winding roll winds the ribbon,

silver

Means the bobbin diameter of the winding roll before the period,

Means the bobbin diameter of the current winding roll,

Means the rotational angular speed of the cooling roll,
Real-time ribbon thickness prediction method.
The method of claim 11,

And

Is calculated by the following equation,

From here,

Means the winding diameter of the bobbin of the winding roll,

Is a radius of the cooling roll and is a fixed value that does not change during casting,

Means a reduction ratio between the motor of the winding roll and the bobbin shaft of the winding roll,

Means the rotational angular speed of the bobbin of the winding roll,
Real-time ribbon thickness prediction method.

Images