Triple loop control system
A method for precisely controlling the tension of a cabling assembly includes applying a triple-feedback-loop to allow the manufacture of a large number of cable pairs. The control loop may be used with any take-up and payoff assemblies and compensate for wide variations in take-up reel weight, cable weight, process line speeds, and pay-off tension. One of the loops of the triple-feedback-loop is under-damped and unstable and allows the control loop to compensate for the wide variations without changing control systems or cabling apparatus.
1 - 32 . (canceled)
33 . A method of controlling cabling equipment comprising applying a triple-loop feedback mechanism to a cabling controller.
34 . The method of claim 33 , wherein the applying the triple-loop comprises compensating for weight variations in a take-up reel by feeding back motor armature current of a take-up reel drive motor with an underdamped first feedback loop.
35 . The method of claim 34 , wherein the applying a triple loop further comprises compensating for cable line speed, take-up reel speed, or both, by feeding back take-up reel motor speed with a neutrally stable second feedback loop.
36 . The method of claim 35 , wherein the neutrally stable second feedback loop comprises critically damping or slightly underdamping a signal indicative of the take-up reel motor speed.
37 . The method of claim 35 , wherein the applying a triple loop further comprises compensating for tension differences between a wire input side of a dancer and a wire output side of the dancer by feeding back dancer position with an overdamped third feedback loop.
38 . The method of claim 33 , further comprising providing an overall loop damping ratio of 0.74 across all combinations of variations in reel weight, reel fill, and line speed.
39 . A method of controlling a cabling assembly comprising providing a triple-loop feedback mechanism.
40 . The method of claim 39 , further comprising conditioning a first loop of the triple-loop feedback mechanism with an underdamped transfer function.
41 . The method of claim 40 , wherein the first loop monitors take-up reel motor armature current and compensates for variations in take-up reel weight.
42 . The method of claim 40 , further comprising conditioning a second loop of the triple-loop feedback mechanism with a critically damped-to-slightly underdamped transfer function.
43 . The method of claim 42 , wherein the second loop monitors take-up motor speed and compensates for variations in line speed, reel speed, or both as a take-up reel fills with cable.
44 . The method of claim 42 , further comprising conditioning a third loop of the triple-loop feedback mechanism with an overdamped transfer function.
45 . The method of claim 44 , wherein the third loop monitors a dancer assembly position and compensates for differences in tension between a wire input side of the dancer and a cable output side of the dancer.
46 . The method of claim 45 , further comprising applying torque to a take-up reel to balance the differences in tension.
47 . A method of creating a cable comprising:
unreeling multiple wires to a dancer assembly at a constant rate;
applying a constant tension to the multiple wires; and
cabling the elements onto a take-up reel;
wherein the constant tension of the elements is precisely controlled by a triple-feedback-loop.
48 . The method of claim 47 , wherein the triple-feedback loop comprises an underdamped first loop feeding take-up motor armature current back to a controller and compensating for variations in take-up reel weight.
49 . The method of claim 48 , wherein the triple-feedback loop comprises a critically damped second loop feeding take-up motor speed to the controller and compensating for variations in line speed, reel speed, or both.
50 . The method of claim 49 , wherein the triple-feedback loop comprises an overdamped third loop feeding dander position to the controller and compensating for differences in tension between a wire input side of the dancer assembly and a wire output side of the dancer assembly.
51 - 54 . (canceled)
55 . A method for compensating for variations in take-up reel weight, cable weight, process line speeds and pay-off tension, comprising applying a triple loop feedback control system.
56 . The method of claim 55 , further comprising applying a fourth feedback control loop to monitor jerk.
57 . The method of claim 55 , wherein said triple loop comprises
an underdamped first feedback loop;
a critically damped to slightly underdamped second feedback loop; and
an overdamped third feedback loop.