Tension control of PE stretch film production line: a combination of intelligent technology and precise technology

In the production process of PE stretch film, the film enters the winding stage after melt extrusion, stretching and shaping, and rapid cooling. This link seems simple, but it actually contains complex technical challenges. Tension, as a key parameter in the film winding process, its control accuracy directly affects the tightness, uniformity and subsequent processing performance of the film roll. Excessive tension may cause the film to be overstretched or even broken, affecting the integrity and aesthetics of the film roll; if the tension is too small, the film roll may be loose and wrinkled, reducing packaging efficiency and protection performance.

In order to meet this challenge, modern PE stretch film production lines are equipped with advanced tension control systems. This system realizes real-time monitoring and automatic adjustment of film tension by integrating sensors, controllers and actuators. Sensors, as the "eyes" of the system, can accurately sense the tension changes of the film during the winding process and feed back real-time data to the controller. The controller dynamically adjusts the winding speed and roller pressure based on precise algorithms and efficient feedback systems to maintain a stable tension state.

Sensor technology: The sensors used in modern tension control systems, such as laser rangefinders and pressure sensors, have high precision, high sensitivity and long-term stability. They can monitor the tiny tension changes of the film material during the winding process in real time to ensure the accuracy and reliability of the data.
Controller algorithm: The controller integrates advanced algorithms such as PID (proportional-integral-differential) control algorithm and fuzzy control algorithm, which can quickly calculate the required winding speed and roller pressure adjustment according to the data fed back by the sensor. These algorithms not only take into account the current tension state, but also predict future trends, thereby achieving precise control of tension.
Actuator: Actuators, such as variable frequency motors, servo motors and pneumatic/hydraulic cylinders, are responsible for adjusting the winding speed and roller pressure according to the instructions of the controller. These mechanisms have the characteristics of fast response speed and high control accuracy, which can ensure the stable operation of the tension control system under complex working conditions.

The stability of the tension control system depends not only on accurate algorithms and efficient actuators, but also on efficient feedback systems. The feedback system compares the actual value with the set value by real-time monitoring of the film tension and winding state to form an error signal. According to the error signal, the controller fine-tunes the winding speed and roller pressure until the actual tension reaches the preset range. This process is a closed-loop control process that can continuously correct errors and improve the accuracy and stability of tension control.

With the continuous development of intelligent manufacturing technology, the tension control system of the PE stretch film production line is developing in a more intelligent and automated direction. On the one hand, by integrating the Internet of Things, big data and artificial intelligence technologies, the tension control system can achieve remote monitoring, fault diagnosis and predictive maintenance, and improve the operating efficiency and reliability of the production line. On the other hand, by optimizing algorithms and improving the performance of sensors and actuators, the control accuracy and response speed of the tension control system will be further improved to meet the production needs of higher quality and higher efficiency.

The accuracy of tension control is directly related to the quality and subsequent application effect of PE stretch film. In the field of logistics, tight and non-loose film rolls can reduce waste and downtime in the packaging process, and improve packaging efficiency and protection performance. In the fields of construction and agriculture, uniform tension distribution can ensure the flatness of the film during use, and improve the sunshade, rainproof and dustproof effects. In the electronics field, precise tension control can reduce damage to film materials during cutting and bonding, and improve product yield and reliability.