MWEDM constant tension control system

To achieve higher accuracy of Micro Wire Electrical Discharge Machining (MWEDM) and solve the problem that the wire electrode is easy to broken, this paper studies the dual-motor optimal control of wire electrode constant tension system. Aiming to eliminate the tension measurement noise caused by the vibration of wire electrode etc., Kalman filtering algorithm is proposed to fuse tension and speed sensor. The accurate dual input dual output mathematical model of wire drawing and tension wheel is established, the minimum performance index which is the sum of the wire speed and tension squared error is achieved by optimal control, which make the accuracy of the tension improved greatly. The disturbance observer is employed for the actual processing environment to cancel the modeling error and interference. The simulation results show that the expected control performances are achieved.