## 5 Transformer Copper Winding Stripping Methods  
### Constant-Tension Intelligent Unwinding System  
A constant-tension intelligent unwinding system is a high-precision control system designed to manage the wire-unwinding process, and it is primarily used in the production and processing of cables, fiber optic cables, and similar materials. Its design goal is to prevent wire stretching, deformation, or breakage by accurately controlling the unwinding tension, thereby ensuring product quality and production efficiency. The system mainly comprises servo motors and drives, tension sensors, and intelligent controllers. The system structure is shown in Figure 11.  
A constant-tension intelligent unwinding system achieves continuous and constant tension release of the wire from the bobbin through the collaboration of various hardware components, ensuring stability and reliability during the unwinding process. The system primarily consists of the following parts:  
1. Driven payoff reel: The primary function of the follower pulley is to release the wire by making contact with it. The follower pulley rotates with the master pulley, allowing the wire to be released from the bobbin in a slow and even manner.
2. Active payoff reel: The primary function of the active wheel is to drive the rotation of the driven payoff wheel, thereby controlling the release speed and tension of the wire. It is typically powered by a motor that adjusts its speed based on feedback from the tension signal, ensuring constant tension during the payoff process.
3. Servo motor: The servomotor enables precise speed control of the active payoff wheel based on instructions from the tension controller. By finely adjusting the rotational speed of the active payoff wheel, it effectively controls the wire's release speed, which is essential for maintaining constant wire tension.
4. Rollers: The rollers guide the wire's path and ensure a smooth release from the bobbin. Typically arranged between the driven and active payoff pulleys, they help maintain a steady course for the wire.
5. Tension sensors: The primary function of the tension sensors is to detect the real-time tension of the wire and provide feedback signals to the tension controller. Common types include pressure and load sensors, which accurately measure the wire's tension.
6. Controllers: The controller is a crucial component of the system, responsible for adjusting the rotational speed of the active payoff wheel based on feedback from the tension sensor to maintain constant wire tension. Tension controllers typically use PID algorithms or other neural network algorithms to quickly and accurately adjust the tension.  
The constant tension control algorithm is based on PID tension control, represented by the following equation:  
\[u_{\text{PID}}(t)=K_{p}e(t)+K_{i}\int_{0}^{t}e(t)dt+K_{d}\frac{de(t)}{dt} \tag{42}\]  
where \(e(t)\) is the error signal and \(K_{p}\), \(K_{i}\), \(K_{d}\) are the proportional, integral, and derivative coefficients, respectively. By using the set tension value, the tension error calculated from the tension sensor feedback enables tension stabilization control through PID. However, since wires of varying thicknesses and specifications require different settings, a single  
Figure 11: Constant-tension intelligent unwinding system structure.  
PID configuration may not provide stable control. Therefore, tension compensation is introduced as a feedforward quantity to enhance performance.