The production of textiles has undergone a considerable transformation, progressing from its primitive origins in hand-weaving to the implementation of contemporary automated systems. Weaving yarn into fabric is a crucial process in the textile industry that requires meticulous attention to output quality products, particularly in the tension control section. The efficiency of the tension controller in relation to the yarn tension significantly affects the quality of the resulting fabric, as proper tension control leads to strong, uniform, and aesthetically pleasing fabric, while poor tension control can cause defects and yarn breakage, leading to production downtime and increased costs. Maintaining the desired yarn tension during textile production is crucial, although it poses several problems, such as the continuous diameter change of the unwinder and rewinder sections leading to system change. Another problem faced by the industrial operation is maintaining proper tension on the yarn while changing the roll-to-roll operation velocity. In this paper, an optimized method for controlling yarn tension through the cascade control of tension and position, incorporating feedback controllers, feedforward, and disturbance observers, has been proposed to make the system more robust and suitable for industrial use. In addition, an optimum signal processor has been designed to obtain sensor data with reduced noise and minimal phase difference.

Frequency stability is a critical factor in maintaining the quality of the power grid system. A battery energy storage system (BESS) with quick response and flexibility has recently been used as a primary frequency control (PFC) resource, and many studies on its control algorithms have been conducted. The cyber physic system (CPS) simulator, which can perform virtual physical modelling and verification of many hardware systems connected to the network, is an optimal solution for the performance verification of control algorithms and hardware systems. This study introduces a large-scale real-time dynamic simulator that includes the national power system. This simulator comprises a power grid model, an energy management system (EMS) model, a BESS system model, and a communication model. It performs the control algorithm performance evaluation and the hardware controller’s response performance evaluation. The performance of the control algorithm was evaluated by tracking the power system’s characteristic trajectory in the transient state based on the physical response delay time between the output instruction of the frequency regulation controller (FRC), a hardware controller, and the output response of the BESS. Based on this, we examined the response performance evaluation results by linking them to the optimally designed actual FRC. As a result, we present an analysis of the BESS’s characteristic trajectories in the transient state, such as frequency, power system inertia, and power grid constant, and provide FRC response performance evaluation results at a level of 163 ms, by connecting the BESS installed at the actual site with the CPS simulator.