PID Control of Cable Extrusion Diameter Prediction Based on Improved Whale Optimization Algorithm

To address the issue of poor control accuracy in cable diameter due to time delays and nonlinearities in cable extrusion system, a composite control strategy was proposed, combining an improved whale optimization algorithm (IWOA) with dynamic matrix control (DMC) and proportional-integral-derivative (PID). By introducing a nonlinear convergence factor and Levy flight disturbance, global optimization capability of IWOA was enhanced, and it was utilized to optimize parameters of a DMC-PID cascade controller. A system model was established based on actual production data from a cable factory. Simulation experiments demonstrated that, compared to traditional PID and WOA-PID, the proposed strategy could reduce overshoot to 1.2%, and settling time was shortened to 7 s, while maintaining strong robustness under parameter drift and external disturbances. Validation on an actual production line showed that the method could increase the qualified rate of cable diameter from 89.3% to 98.7%, providing an effective solution for high-end cable manufacturing.