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The high pressure gas injection physical foam production line is the most key manufacture process for the communication cable,with the science and technology developping of the communication for the high speed train the developed 3G and 4G communication, higher performance communication cables are required on the core cable diameter and capacity, but the traditioanal control system can’t match the requirement, the key parmeters ,core diameter and capacity, are often out of tolerance during the manufacture process, to work it out I made the followings research and development in the article during the devlepment of the new production line control system on target of the invariablenes tension and stable diamer control:First, to reduce the effect of the diameter change and the wrong singal caused by the poor wire aligment on the reel, the reel diameter calculation,analog signal filter and anti-integral saturation with integral detatch function PID controller are used, in the addition,according to the character of the unwinder and rewinder system, speed and torque control ways are adopted respectively.Second, the conventional way of the speed acculation or deceleration is linear ramp way, this way will have the impact not only for the mechanical system but also for the tension stability, as a solution, the“S”shape curve is used; besides the tension system on the production line is a mutli-input,strong couple between the speed and tension, time vary system, under the feedback diameter control by speed adjustment way, there is big effect on the tension control, to search the solution, base on the Hooke’s law and the daynamic moment equilibrium, we build up the mathematical model of the drawing system and the part decouple forward feedback compensation control way is developed and the simulation result verified that the tension control is improved obviously. Third, the diameter and capacity of the cable are a system with strong couple relation and long delay character, in the past control system, only the diameter is under the control and the capacity indication is often out of tolerance, to improve it, base on the material balance law, the interactive effect between the diameter and capacity are showed and the auto disturbance rejection control technique is introduced to the production line control system, it is proved that this kind of controller has the ability of error estimation and the good performace can be got by the Simulink simulation under MATLAB system.Next, base on the theory analysis, in the different part of the article I draw out the program function figure for the PID, input/output analog signal, introduced the tune way of PID parameters, the electrical drawings for the extruder systems and feeds system, the logic program flow chart, also introduced the theory and reliazation way by calling the special S7 temperature PID controller to get the high accuracy temperature controlling.The last, in the article I presented the deisgn and reliazation way for the supervisor sytem base on SIEMENS WinccFlexible software and instrument systems with the interface of serial port communication, the whole control system based on the field bus technology. In the past, we have to use the special instrument or analog signal by connectting lots of cables to get the data from the instrument, it isn’t reliable and convenience, serial port communication is a good solution and supervisor system devleppoed on the base of Winccflexible it is with the character of friend iterface, high reliability,good compatibility and integration,easy expand.
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