Tension Control in Coiling of Hot-rolled Composite Strips

XU Licui; LIU Siyu; LYU Jun; PAN Changshuai; WANG Zhenmin; LIU Shankui

doi:10.3969/j.issn.1674-6457.2026.02.009

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Journal of Netshape Forming Engineering ›› 2026, Vol. 18 ›› Issue (2) : 91-100. DOI: 10.3969/j.issn.1674-6457.2026.02.009

Composites Forming

Tension Control in Coiling of Hot-rolled Composite Strips

XU Licui, LIU Siyu, LYU Jun, PAN Changshuai, WANG Zhenmin^*, LIU Shankui

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Abstract

Focusing on multilayer copper foil composite hot rolling, the work aims to address the challenge of direct tension measurement caused by insufficient initial bonding strength and limited copper strip bendability by proposing an innovative control method to enhance coiling stability. A tension control mathematical model was established to analyze influencing factors and examined motor coiling characteristics to identify key tension fluctuation variables. For dynamic coil diameter measurement, an integrated approach combining encoder-based measurements with linear speed calculations was developed to fuse results through weighted averaging. A Kalman filter was introduced to optimize encoder signals for handling time-varying characteristics, with performance systematically compared against weighted averaging. Real-time tension was indirectly calculated via motor current, while a fuzzy PID controller adjusted rotational speed to maintain constant tension. Simulations on MATLAB/Simulink demonstrated the Kalman filter's superior performance: faster dynamic response, improved abrupt change handling, average coil diameter error <2 mm, and maximum error of 13.12 mm, significantly lower than weighted averaging. In conclusion, the roll diameter result obtained based on the Kalman filter is more accurate. The fuzzy PID control strategy can effectively enhance process stability, providing a reliable technical solution for multilayer copper foil composite rolling.

Key words

coil diameter estimation / laminated composite strips / Kalman filter / tension control / hot-rolling process

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XU Licui, LIU Siyu, LYU Jun, PAN Changshuai, WANG Zhenmin, LIU Shankui. Tension Control in Coiling of Hot-rolled Composite Strips[J]. Journal of Netshape Forming Engineering. 2026, 18(2): 91-100 https://doi.org/10.3969/j.issn.1674-6457.2026.02.009

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