IMPR Simple Winder Documentation

A&D MC PM 517. October 2000

Version 1.0

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Simple winder with free modulesfor Masterdrives MC / VC

Winder with free modules- 1 - 17. October 2000

Version 1.0


Index1 Function scope ................................................................................................................................ 32 Function description ........................................................................................................................ 4

2.1 Direct tension control by torque limiting........................................................................... 42.2 Indirect tension control by torque limiting ........................................................................ 62.3 Direct tension control by rotational speed correction....................................................... 72.4 Taper tension control ....................................................................................................... 82.5 Diameter calculation ........................................................................................................ 82.6 Moment of inertia ............................................................................................................. 82.7 Gear ratio ......................................................................................................................... 92.8 Tension operating mode .................................................................................................. 92.9 Maneuvering and jogging................................................................................................. 102.10 Line breakage detection................................................................................................... 102.11 Quick stop ........................................................................................................................ 10

3 Control ............................................................................................................................................. 123.1 Winder control- and status word ...................................................................................... 123.2 Winder interface to the automation system ..................................................................... 13

4 Comissioning ................................................................................................................................... 144.1 Standardization ................................................................................................................ 144.2 Interface adjustment ........................................................................................................ 14

4.2.1 Direct tension control with load cell (control method A) ................................... 154.2.2 Indirect tension control (control method B)....................................................... 154.2.3 Direct tension control with dancer roll (control method C) ............................... 16

4.3 Acceleration torque .......................................................................................................... 164.4 Friction characteristic ....................................................................................................... 174.5 Rotational speed controller optimization.......................................................................... 174.6 Tension controller optimization ........................................................................................ 18

5 Appendix.......................................................................................................................................... 195.1 Formulary ......................................................................................................................... 195.2 Formula symbols.............................................................................................................. 205.3 Selection criteria............................................................................................................... 215.4 List of free modules used................................................................................................. 225.5 Winder checklist ............................................................................................................... 235.6 Winder application (Masterdrive MC) .............................................................................. 25

5.6.1 Function diagrams ............................................................................................ 255.6.2 Script MC_WINDER_CELL (Control method A).............................................. Fehler! Textmarke5.6.3 Script MC_WINDER_INDIRECT (Control method B)....................................... Fehler! Textmarke5.6.4 Script MC_WINDER_DANCER (Control method C) ........................................ Fehler! Textmarke5.6.5 Specific Scripts (MC) ........................................................................................ Fehler! Textmarke

5.6.5.1 Script SC_SPEED_CONTROL_MC............................................... Fehler! Textmarke5.6.5.2 Script SC_TORQUE_COMP_MC................................................... Fehler! Textmarke5.6.5.3 Script SC_TORQUE_LIMITING_MC.............................................. Fehler! Textmarke

5.6.6 General Scripts................................................................................................. Fehler! Textmarke5.6.6.1 Script SC_TENSION_SET ............................................................. Fehler! Textmarke5.6.6.2 Script SC_ANALOG_INPUT_MC................................................... Fehler! Textmarke5.6.6.3 Script SC_TECHNO_CONTROL.................................................... Fehler! Textmarke5.6.6.4 Script SC_OVERRIDE.................................................................... Fehler! Textmarke5.6.6.5 Script SC_LINE_CORRECTION .................................................... Fehler! Textmarke5.6.6.6 Script SC_SPEED_CORRECTION................................................ Fehler! Textmarke5.6.6.7 Script SC_DIAMETER_CALC ........................................................ Fehler! Textmarke5.6.6.8 Script SC_LINE_SPEED_SET ....................................................... Fehler! Textmarke5.6.6.9 Script SC_TORQUE_LIMIT............................................................ Fehler! Textmarke5.6.6.10 Script SC_WINDER_CONTROL_WORD....................................... Fehler! Textmarke5.6.6.11 Script SC_WINDER_CONTROL .................................................... Fehler! Textmarke5.6.6.12 Script SC_WINDER_CONTROL_INDIRECT ................................. Fehler! Textmarke


Version 1.0


5.7 Wicklerapplikation (Masterdrive VC)................................................................................ Fehler! Textmarke5.7.1 Funktionspläne ................................................................................................. Fehler! Textmarke5.7.2 Script VC_WINDER_CELL (Control method A) ............................................... Fehler! Textmarke5.7.3 Script VC_WINDER_INDIRECT (Control method B) ....................................... Fehler! Textmarke5.7.4 Script VC_WINDER_DANCER (Control method C)......................................... Fehler! Textmarke5.7.5 Specific Scripts (VC)......................................................................................... Fehler! Textmarke

5.7.5.1 Script SC_ANALOG_INPUT_VC.................................................... Fehler! Textmarke5.7.5.2 Script SC_SPEED_CONTROL_VC................................................ Fehler! Textmarke5.7.5.3 Script SC_TORQUE_COMP_VC ................................................... Fehler! Textmarke5.7.5.4 Script SC_TORQUE_LIMITING_VC .............................................. Fehler! Textmarke

5.8 Legend ............................................................................................................................. Fehler! Textmarke5.9 Literature .......................................................................................................................... Fehler! Textmarke


Version 1.0


1 Function scopeThis application realizes a simple winder based on free modules for the basic units Masterdrive MCand VC.

Required software versions are 1.4 for the Masterdrive MC and 3.2 for the Masterdrive VC .

This winder application contains the following functionality:

• Direct tension control by torque limiting with load cell (Control method A)• Indirect tension control by torque limiting (Control method B)• Direct tension control by rotational speed correction with dancer roll (Control method C)• Diameter calculator• Variable line width setting• Variable material density setting (by parameters)• Maneuvering• Jog speed (1 jogging setpoint)• Line breakage detection

The selection of the control method is not realized with selectors, on account of both the limitedsupply of free modules and the limited run-time in the frequency inverter. That means, that adownload script file is available for every tension control method.

The winder can be set as follows:

• Winder or unwinder• Over- or underwind• Regarding a gear ratio• Taper tension characteristic

In addition to the usual control- and statusword, there´s a specific winder control- and statusword,which is directly controlled via the parameterized interface. This interface can be controlled viaPROFIBUS or SIMOLINK, or also via digital inputs. Digital inputs require additional input modules(EB1 or EB2).


Version 1.0


2 Function descriptionFor the considerations hereinafter the following is always valid:

The line speed setpoint, respectively the rotational speed setpoint and the given tension forceare always positive. For position controlling, the position setpoint is 0% or positive.

2.1 Direct tension control by torque limiting

1 2 3 4 5 6 7 8

7 81 2 3 4 5 6

F

E

D

C

B

A

F

E

D

C

B

A

Datum

Bearb. Zelder

15.10.00 1

A&D MC PM5

Winder with load cell; control method: torque limitingSiemens AGFile pl_winder_cell.vsd

Page

Winder concept; basic unit CUMC/VC

Maneuvering

V set

Override

F actM

F set 1

Power SectionSpeed

ControllerCurrent

Controller

Acceleration Torque

Friction Torque

D actn act

DiameterCalculator

F act

Gain-Adaption

J

Gain-Adaption

D act

Taper TensionCharacteristic

JogSetpoint

V const n+M+F

Fig. 2.1.1: Direct tension control with load cell by torque limiting

With this control method (see Appendix, figure 6.1), the material tension is measured by means of aload cell. The tension controller responds to deviations from the given tension setpoint. The tensioncontroller is designed as a PI controller. The tension setpoint can be influenced during the wind up bymeans of the taper tension characteristic, dependent on the diameter. The resulting tension controlcomponent is added to the tension setpoint and weighted with the diameter D. The friction andacceleration torque with sign according to table 2.1.1 is added to this tension torque.

Type of winder Acceleration and friction torque signUnwinder -Winder +

Tab. 2.1.1: Acceleration and friction torque sign dependent on type of winder

The resulting torque works as a limiting torque at the rotational speed controller output.


Version 1.0


The given line speed setpoint is converted into the according rotational speed by means of the actualdiameter. To be effective in tension operation, the torque limiting is switched to an additional linespeed setpoint, which leads to an override of the rotational speed controller. The override for linespeed is switched with sign according to table 2.1.2.

Mode of winding Override signOverwind -Underwind +

Tab. 2.1.2: Override sign dependent on mode of winding

The override switching is delayed by means of a PT1 element. A small override should be chosen tobuild up material tension slowly. The tension setting is realized directly via torque limiting. Theswitching of the calculated torque limiting to the lower, respectively upper limit is realized according totable 2.1.3.

Mode of winding Type of winder Torque limitOverwind Unwinder lowerOverwind Winder upperUnderwind Unwinder upperUnderwind Winder lower

Tab. 2.1.3: Torque limit switching dependent on type of winder and mode of winding


Version 1.0


2.2 Indirect tension control by torque limiting

1 2 3 4 5 6 7 8

7 81 2 3 4 5 6

F

E

D

C

B

A

F

E

D

C

B

A

Datum

Bearb. Zelder

15.10.00 1

A&D MC PM5

Winder without load cell; control method: torque limitingSiemens AGFile pl_winder_indirect.vsd

Page


Maneuvering

V set

Override

M

F set 1

Power sectionSpeed controllerCurrent

controller

Acceleration torque

Friction torque

D actn act

Diametercalculator

Gain-adaption

J

Taper tensioncharacteristic

Jogsetpoint

FV const

n+M+

Fig. 2.2.1: Indirect tension control by torque limitingFor this control method, no signal for tension measurement is available. With the exception of thetension controller, this control structure is conform with the tension control by torque limiting. Thetorque limiting consists of both the torque of the tension setpoint and the friction and accelerationtorque. First is realized by weighting the tension setpoint with the actual diameter. The exactness ofthe calculated friction and acceleration torque is essentiell for the exactness of the tension required.


Version 1.0


2.3 Direct tension control by rotational speed correction

1 2 3 4 5 6 7 8

7 81 2 3 4 5 6

F

E

D

C

B

A

F

E

D

C

B

A

Datum

Bearb. Zelder

15.10.00 1

A&D MC PM5

Winder with dancer roll; control method: speed correctionSiemens AGFile pl_winder_dancer.vsd

Page


Maneuvering

V set

L act

M

L set

Power sectionSpeed controllerCurrent

controller

Acceleration torque

Friction torque

D actn act Diameter

calculator

L act

Gain-adaption

J

Gain-adaption

D act

Taper tensioncharacteristic

P U

F set 1

D act

Jogsetpoint

+

-

V constM+

n+F

Fig. 2.3.1: Direct tension control with dancer roll by rotational speed correction

For direct tension control with a dancer roll, tension is set by the dancer roll. The counter-pressure isset by the taper tension characteristic via a pneumatic power controller at the dancer. The suspensionof the dancer roll must be laid out accordingly. The position setpoint, determined by the operatingpoint, is maintained by the position controller. The actual position value is e.g. evaluated by a positionor angle meter.

The actual position value is compared with the position setpoint. The resulting difference iscompensated with a P(I)-controller and switched to as an additional line speed setpoint. The switchingof the additional line speed setpoint is realized according to table 2.3.1.

Type of winder Rotational speed correction signUnwinder -Winder +

Tab. 2.3.1: Rotational speed correction sign dependent on type of winder

This control loop might possibly lead to vibrations. An additional D – component of the actual positionvalue has cushioning effect and prohibits the predisposition for vibrating.

The resulting line speed setpoint and the actual diameter are converted into a rotational speedsetpoint. The rotational speed controller is pre-controlled by the friction and acceleration torque.


Version 1.0


2.4 Taper tension controlTaper tension control is only useful and effective while winding up. The taper tension characteristic isdependent on the actual diameter (output motorized potentiometer). The motorized potentiometer ispart of the free available modules. The firmly parameterized characteristic can be dissolved withmaximum 10 value pairs.

2.5 Diameter calculationThe actual diameter results from the ratio of line speed reference to actual rotational speed. Thediameter value is needed to convert the line speed into the according motor rotational speed.

[%][%]

[%][%] minact

setact n

VDD ⋅=

The diameter values are scaled to the maximum diameter; likewise, the line speed and the actualrotational speed value are scaled to the maximum line speed, respectively the maximum nominalrotational speed.

To reach a stable closed-loop performance, the diameter calculation must show an integralperformance. This is guaranteed by the used free module „motorized potentiometer“. The calculateddiameter value is additionally smoothed by a time constant of 100 ms.

The diameter calculation is not stable until a minimum rotational speed has been reached. Until thisminimum has been reached, the preset value will be used. An adaption of this minimum rotationalspeed preset, e.g. with a layer counter, is not scheduled within this application.

The diameter calculator can be stopped with a stop-signal, respectively set with a set-signal. The set-signal is given via the interface.

2.6 Moment of inertiaThe moment of inertia is composed of a constant and a variable component. The constant componentconsists of motor-, gearbox- and core-inertia. The variable component consists of the inertia of thewound-up material. The moment of inertia always refers to the motor shaft.

��

iableJmaterialJ

tconsJcoreJgearJmotorJJ

vartan

+++=

The motor- and gearbox-inertia can be obtained at the manufacturer. The core-inertia can becalculated by the following principle.

Core-inertia ][ 2mkg ⋅ ( )44232 insideoutsidecore DD

ibJ −⋅⋅⋅⋅= ρπ ][]/[][ 43 mmkgm ⋅⋅

Tab. 2.6.1: Core-inertia

The inertia of the wound-up material can be calculated analogue.


Version 1.0


Inertia of wound-up material][ 2mkg ⋅ ( )4

min4

232DD

ibJmaterial −⋅⋅⋅⋅= ρπ ][]/[][ 43 mmkgm ⋅⋅

Tab. 2.6.2: Inertia of wound-up material

The moment of inertia cannot be directly calculated with the existing set of free modules. It has to becalculated in advance, dependent on the diameter, and deposited as a characteristic. Thischaracteristic includes maximum 10 support values. The width and density of material can bechanged in terms of percentage.

The originator of this application is a scaled moment of inertia, that is, the calculated moment of inertiais scaled with the nominal rotational speed and the rated torque of the motor. The total moment ofinertia is calculated as follows:

[%][%][%]4min[%]4

1210232

]3/[max][max]4[4max

][

ρ

ω

ϕ

ω

⋅⋅

⋅−

�

��

�

�

��

��

� −⋅⋅⋅

⋅⋅⋅Π+++

=⋅

b

N

NMsticcharacteriJ

ddi

mkgmBmD

coreJJJ

sJ

gearmotor

N

NM

��

The characteristic resolution determines the exactness of the acceleration torque, which has to bequite exact, especially in case of indirect tension control.

The accelaration torque results from the moment of inertia:

]/[%][[%] sdtdnsJM B ⋅=

Due to the different ramp function generator outputs (dn/dt) of the MC/VC converter, as well as to theinertia value range, a system-specific scaling, concerning the intermediate value range (-200% ...200%), has to be made.

2.7 Gear ratioThis application supports a gear ratio. The gear ratio i is among other things needed to convert theline speed into the corresponding rotational speed.

%100%100[%]1

2 ⋅==nn

ikG

2.8 Tension operating modeTension operating mode can only be selected in mode „operation“ and with no existing line breakagereport. Switching from line to tension operating mode and vice versa should always be realized instand still.


Version 1.0


2.9 Maneuvering and joggingThis application offers the functionality of maneuvering and jogging. The maneuvering input can e.g.be connected with an analogue input and like this allow the percental controlling of the line speedsetpoint.

With the signal „jogging“, the jog operating mode is selected. This mode can only be selected whentension operating mode is switched off. Jogging setpoint (line speed) can be set directly via interface.While jogging, maneuvering is not possible.

2.10 Line breakage detectionLine breakage detection is active while tension control is switched on. It is also implementeddifferently, depending on the control method used.

Direct tension control by torque limiting with load cell (control method A):

• Line breakage is detected when tension has fallen below an adjustable minimum tension.• In case of line breakage, the rotational speed controller becomes effective and controls the line

speed, according to the given line speed setpoint and the adjusted overmodulation.

Direct tension control by rotational speed correction with dancer roll (control method C):

• Line breakage is detected when an adjustable final position of the dancer has been exceeded.• In case of line breakage, the dancer reaches the lower limit stop. The position controller reaches

its limit. The rotational speed controller controls the circumferential speed according to the givenline speed setpoint and the output limit of the position controller.

Indirect tension control (control method B):

• Line breakage is detected when actual torque has fallen below an adjustable minimum torque,and a likewise adjustable torque limit for the difference between setpoint and actual value hasbeen exceeded.

• In case of line breakage, the rotational speed controller becomes effective and controls thecircumferential speed according to the given line speed setpoint and the adjusted overmodulation.

When line breakage has been detected,

• the diameter calculator will be stopped,• tension operating mode will be switched off• and the enabling of tension control will be reset.

2.11 Quick stopAs standard, the converters MC and VC offer three different shutdown modes.

• At mode OFF 1, the speed ramp brakes the motor down to standstill. Subsequently, pulseblocking is activated.

• At mode OFF 2, the converter is switched off at once. The motor coasts down, respectively themecanical brake is activated.


Version 1.0


• At mode OFF 3, the motor is braked down to standstill with maximum braking torque.Subsequently, pulse blocking is activated.

An additional quick stop with selectable ramp-down time is often required. At this implemented quickstop, ramp-down time can be preset. Quick stop is enabled by the external signal „quick stop“ andonly active in mode OFF 1.


Version 1.0


3 Control

3.1 Winder control- and status wordIn addition to the usual system-inherent control- and status words, a winder-specific control- andstatus word has been defined.

Bit Winder control word Value 0 Value 1Bit 00 Set diameter

(only while pulse blocking isactivated)

- D-calculator is singularly setby edge (0->1)

Bit 01 Hold diameter(only while in tension operatingmode)

Enable D-calculator D-calculator is held

Bit 02 Line- / Tension operating mode Line speed control (speed-controlled)

Tension control (torquecontrolled)

Bit 03 Jogging - JoggingBit 04 Quick stop ramp (OFF 1) switched off enabledBit 05 not used n.u. n.u.Bit 06 n.u. n.u. n.u.Bit 07 n.u. n.u. n.u.Bit 08 n.u. n.u. n.u.Bit 09 n.u. n.u. n.u.Bit 10 n.u. n.u. n.u.Bit 11 n.u. n.u. n.u.Bit 12 n.u. n.u. n.u.Bit 13 n.u. n.u. n.u.Bit 14 Mode of winding overwind underwindBit 15 Type of winder Unwinder Winder

Tab. 3.1.1: Winder control wordThe control word can be preset via PROFIBUS, SIMOLINK, or fixed bits, respectively via digitalinputs.

Bit Winder status word Value 0 Value 1Bit 00 Type of winder Unwinder WinderBit 01 Mode of winding overwind underwindBit 02 Line- / Tension operating mode Line speed control (speed-

controlled)Tension control (torquecontrolled)

Bit 03 Jogging - JoggingBit 04 Status diameter-calculator inactive activeBit 05 Limiting of rotational speed

controller- Limit reached

Bit 06 Limiting of tension controller - Limit reachedBit 07 Line breakage - Line breakage detectedBit 08 n.u. n.u. n.u.Bit 09 n.u. n.u. n.u.Bit 10 n.u. n.u. n.u.Bit 11 n.u. n.u. n.u.Bit 12 n.u. n.u. n.u.Bit 13 n.u. n.u. n.u.Bit 14 n.u. n.u. n.u.Bit 15 n.u. n.u. n.u.


Version 1.0


Tab. 3.1.2: Winder status word

The status word is reported back to the superordinated automation system.

3.2 Winder interface to the automation systemThe application requires the following settings:

• Tension setpoint (control method A, B, C)• Tension actual value (control method A)• Position setpoint (control method C)• Position actual value (control method C)• Line speed setpoint (output ramp function generator)• Maneuvering setpoint• Jogging setpoint• Diameter preset value• Percental width of material• Percental density of material (by parameter setting)


Version 1.0


4 Comissioning

4.1 StandardizationThe used values for control are related, that means, all reported values - via interface to theapplication – must primarily be standardized by the transmitter according to the following table.

Designation Base valueDiameter D DmaxLine speed v i * vmax, vmax directly at the shaftRotational speed n i * nmax, nmax directly at the shaft

Tab. 4.1.1: Standardizations

4.2 Interface adjustmentAt first the following connectors have to be adjusted independent of converter type and controlmethod (see corresponding script file).

Connector-no. (#)

Connector designation Connectorvalue

- Winder control word -U078.01 Set diameter ?U078.02 Hold diameter ?U078.03 Line- / tension operating mode ?U078.04 Jogging ?U078.05 Quick stop ?U078.15 Mode of winding ?U078.16 Type of winder ?

- Fixed setpoints -P402.02 Gearbox factor kG ?P403.03 Width of material [%] ?P404.04 Constant moment of inertia Jk ?P405.05 reduced torque limit [%] ?P406.06 Jog line speed setpoint ?P407.07 Density of material/Dmax [%] ?P408.08 Lower limit [%] (Zero pulse generation) ?

- Tension setpoint -U380 Tension setpoint [%] ?

- Additional rotational speed setpoint -U116.02 Minimum diameter [%] ?

- Diameter calculator -U114.01 Line speed setpoint [%] ?U114.02 Minimum diameter [%] ?P428 Setpoint diameter [%] ?P426 Setpoint diameter [%] ?

- Line speed setpoint -U110.01 Line speed setpoint [%] ?U115.02 Minimum diameter [%] ?

P464.02 Ramp-down time quick stop ?U440.01 Density of material [%] ?


Version 1.0


U135 Minimum rotational speed D-calculator ?

The following connectors have to be adjusted for the Masterdrive MC.

Connector-no. (#)


The following connectors have to be adjusted for the Masterdrive VC.

Connector-no. (#)


The following connectors have to be adjusted dependent on the used control method.

4.2.1 Direct tension control with load cell (control method A)

Connector-no. (#)


- Fixed setpoint -P401.01 Override value line speed ?

- Tension controller -U352 Tension setpoint (tension controller) ?U355 Tension actual value (tension controller) ?

- Additional sequence control -U141 Tension actual value (line breakage) ?U140 Minimum tension force ?


Connector-no. (#)



Connector-no. (#)


4.2.2 Indirect tension control (control method B)

Connector-no. (#)


- Fixed setpoint -P401.01 Override value line speed ?

- Additional sequence control -U141 Torque actual value (line breakage) ?


Version 1.0


U140 Minimum torque ?U150 Maximum torque setpoint – actual value difference ?


Connector-no. (#)



Connector-no. (#)


4.2.3 Direct tension control with dancer roll (control method C)

Connector-no. (#)


- Position controller -U352 Position setpoint (position controller) ?U355 Position actual value (position controller) ?

- Additional sequence control -U141 Position actual value (line breakage) ?U140 Final dancer position ?


Connector-no. (#)



Connector-no. (#)


4.3 Acceleration torqueThe acceleration torque results from the relation:

]/[%][[%] sdtdnsJM B ⋅=

The standardized moment of inertia with the measuring unit seconds results from the relation:

N

N

MmkgJsJ

ω⋅= ][][ 2


Version 1.0


Usually, the moment of inertia of the motor and the used gearbox is known. The core-inertia can becalculated according to table 2.6.1. The inertia of the wound material can be calculated likewiseaccording to table 2.6.2. The support values needed for the characteristic must be evaluateddiameter-dependent and must be entered separately. Hereby, attention has to be paid to the correctscaling as the support value range is limited to ±200%.

Master Drive MC:

The rotational speed ramp-function generator provides a time-deducted rotational speed with themeasuring unit [100%/ms]. That means the standardized moment of inertia with the measuring unitseconds must additionally be scaled with the factor 10.

Master Drive VC:

The rotational speed ramp-function generator provides a time-deducted rotational speed with themeasuring unit [%/s]. That means the standardized moment of inertia with the measuring unit [%/s]needn´t be scaled furthermore.

4.4 Friction characteristicThe frequency converter Master Drive MC is equipped with a function to report the frictioncharacteristic. This recording is started with the parameter U219.01. Before starting, the followingmust be secured (see also summary 7-12):

• Master drive (P587 = 0)• P260 = 153 respectively P262 = 153• P228 = 152

Needed enablings:

• Impulse• Rotational speed controller• Direction of rotation (positive and/or negative)• Positive and negative rotational speed limit must be chosen in such a way that – considering the

enabled direction of rotation – the characteristic in one rotational direction can be fully reached.

The frequency converter Master Drive VC is not equipped with a function to report the frictioncharacteristic. Therefore the friction charcteristic must be evaluated manually by running the unloadeddrive with different rotational speeds and so evaluating the related friction torque. Afterwards, theevaluated friction characteristic can be recreated with the available field characteristics (see functiondiagram 371).

4.5 Rotational speed controller optimizationBecause of the changing moment of inertia, the proportional gain must be generally adapted whilewinding. The proportional gain is linearly dependent on the moment of inertia.


Version 1.0


y

x

n-contr. gain10.0 ... 1000.0P235.F (10.0)

n-contr. gain20.0 ... 1000.0P236.F (10.0)

P233.F (0.0)0.0 ... 200.0 %

n-contr.-adapt..1

P234.F (100.0)0.0 ... 200.0 %n-contr.-adapt.2

y

xP232.B (0)K0442

Source n-controller-adapt..Gain-adaption

Moment of inertia J

of [55.A8]

2max

min1 pp K

JJK ⋅=

Fig. 4.5.1: Gain-adaption rotational speed controller

For optimizing the rotational speed controller, a diameter as big as possible should be chosen. Thediameter is set with the command „Set diameter“.

At a given line speed, the rotational speed controller is optimized. Optimization is realized with shortsteps in line speed. Line speed should therefore be chosen in such a way as not to get control into thelimiting while stepping.

The evaluated propotional value and the actual moment of inertia represent one of the two neededgain characteristic support values. The second support value can be deducted by using the rule ofthree (see figure 4.4.1).

4.6 Tension controller optimizationWith direct tension control by rotational speed correction, an adaption of the position controller is notnecessary. Material tension is determined by the dancer. That means that proportional value isconstant for the complete control range. Because of the switching-in of the rotational speedcorrection, the position controller has to be configured as a P-controller.

With direct tension control by torque limiting, an adaption of the proportional gain is necessary.Optimization of the tension controller is realized by short steps in tension setpoint value. Proportionalgain and integral-action time should be chosen in such a way that the resulting step response(rotational speed) settles cushionedly. As above, it is also here important, that control mustn´t bebrought into the limiting while stepping. Optimization should be realized with different diameters.

The following practically-proven values für control setting have been evaluated:

• Gain = 0.1 ... 0.3 with direct tension control by rotational speed correction (dancer).• Gain = 0.1 ... 0.3 and TN = 0.5 ... 1s with direct tension control by torque correction (load cell).


Version 1.0


5 Appendix

5.1 Formulary

Diameter ratio

coreDDq max=

][][

mm

Rotational speed ][min 1− 1

perimeterUV

DVn =⋅

=π2 ][

min]/[m

m

Winder torque (motor shaft)[Nm] i

DFMW ⋅⋅=

2][][ mN ⋅

Winder power (motor shaft)]/[][ smNW ⋅= 16060

ω⋅=⋅= WW MVFPmin]/[][ mN ⋅

Gear ratio

max,2

max,1

max

max,1min

nn

VnD

i =⋅⋅

=π

min]/[][min][ 1

mm −⋅

Moment of inertiaSolid cylinder ][ 2mkg ⋅

42

2 328DbDmJ ⋅⋅⋅=⋅= ρπ ][]/[][ 43 mmkgm ⋅⋅

Moment of inertiaHollow cylinder ][ 2mkg ⋅ ( )44

2

2 328 KernDDbDmJ −⋅⋅⋅=⋅= ρπ ][]/[][ 43 mmkgm ⋅⋅

Moment of inertia(motor shaft) ][ 2mkg ⋅ 2

21 i

JJ = ][ 2mkg ⋅

Constant moment of inertia(motor shaft) ][ 2mkg ⋅ 2i

JJJJ coregearmotorK ++= ][ 2mkg ⋅

Variable moment of inertia(motor shaft) ][ 2mkg ⋅ ( )44

232 KernV DDi

bJ −⋅⋅⋅⋅= ρπ ][]/[][ 43 mmkgm ⋅⋅

Acceleration torque(motor shaft) [Nm] ( )VK

BB JJ

tV

DiM +⋅

⋅∆⋅

⋅=

6030][

][min]/[

][]1[ 2mkg

sm

m⋅⋅⋅

Acceleration power(motor shaft) [W] BB M

DViP ⋅⋅

⋅=30

][][

min]/[ Nmm

m ⋅

Starting time TA [s]1J

MzT

Np

NA ⋅

⋅=

ω][

][][ 21

Nmmkgs ⋅⋅−

1 U here is the perimeter of the cylinder.


Version 1.0


5.2 Formula symbols

Formula symbol Meaning Measuringunit

minD Minimum diameter [m]

maxV Maximum line speed [m/min]

m Mass [kg]

Nn Nominal speed [U/min]

b Material width [m]ρ Material density [kg/m^3]i Gear ratio [--]

Gk Gearbox factor [--]

NM Rated torque [Nm]

J Moment of inertia [kgm^2]

pz Pole pair number [--]

F Tension force [N]ω Angular frequency [rad/s]

AT Starting time [s]


Version 1.0


5.3 Selection criteriaThe following tables content decision criteria, respectively practically-proven values for the various,possible tension control methods. Realized within this application are the control methods edgedblack. Because of the simplified realization with free modules, the maximum torque control rangefor this application is limited to the factor 30 for the time beeing, until further practically-proven valuesare available.

Method Indirect tension control Direct tension controlwith load cell

Way ofimplementation

Correction by torquelimiting


Correction by rotationalspeed correction

Diameteracquisition

Calculation or measuring Calculation or measuring Calculation or measuring

Tension actualvalue acquisition

No acquisition necessary No intervention into the linerun, sensitive to overload

No intervention into the linerun, sensitive to overload

Diameter ratioDmax/Dcore

Appr. 10:1, goodcompensation of

acceleration torqueand frictionnecessary

Appr. 15:1, goodcompensation ofacceleration torquenecessary

?

Tension ratioFmax/Fmin

Appr. 6:1 at goodcompensation ofacceleration torque andfriction

Appr. 20:1 at goodcompensation ofacceleration torque

?

Torque ratioMmax/Mmin

Appr. 40:1 Appr. 100:1 dependent onthe quality of the tensionactual value signal

?

Line speed Up to 600 m/min at goodcompensation

Up to 2000 m/min at goodcompensation of theacceleration torque

?

Field ofapplication

Sheet metal, textile, paper Paper, thin films Useful for elastic, extremelystretchable material

Speed master Necessary Necessary Necessary

Line speedtachometer

Not necessary Not necessary Not necessary

Tab. 5.3.1: Selection criteria for indirect and direct tension control with load cell


Version 1.0


Method Direct tension controlwith dancer roll

Way ofimplementation

Correction by rotationalspeed correction


Diameteracquisition

Calculation or measuring Calculation or measuring

Tension actualvalue acquisition

Intervention into the linerun

Intervention into the linerun

Diameter ratioDmax/Dcore

Appr. 15:1?

Tension ratioFmax/Fmin

Changeable withadjustable dancer loading

Changeable with adjustabledancer loading

Torque ratioMmax/Mmin

Appr. 40:1 dependent onthe quality of the dancerloading

?

Line speed Up to 2000 m/min?

Field ofapplication

Rubber, cable, wire,textile, film, paper

Useful for brittle, sensitive,hard and unflexible material

Speed master Necessary Necessary

Line speedtachometer

Not necessary Not necessary

Tab. 5.3.2: Selection criteria for direct tension control with dancer

5.4 List of free modules used

Blatt Bausteintyp Baustein705 FSP Fsp1 Fsp2 Fsp3 Fsp4 Fsp5 Fsp6 Fsp7 Fsp8

Fsp9DFSP DFsp1 DFsp2 DFsp3 DFsp4 DFsp5 DFsp6 DFsp7 DFsp8St.bitC.displ.B.displ..

710715 C-B –

converterCB1 CB2 CB3

720 B-C –converter

BC1 BC2 BC3

725 Add Add1 Add2 Add3 Add4DAdd DAdd1 DAdd2 DAdd3 DAdd4Sub Sub1 Sub2 Sub3 DSub1 DSub2SI SI1 SI2 SI3SSI SSI1


Version 1.0


730 Mul Mul1 Mul2 Mul3 DMul1 Div1 Div2 DDiv1MulDiv MulDiv1 MulDiv2 MulDiv3

732 DMulDiv P1 P2734 Diff Diff1735 AVG AVG1 AVG2 AVG3 DAVG1 Limiter1 Limiter2 DLimiter740 Limit Limit1 Limit2 DLimitG DLimit750 AS AS1 AS2 AS3 AS4 AS5

DAS1 DAS2 DAS3 DAS3 DAS4 DAS5755 Charact. Charact1 Charact2 Charact3760765 AND AND1 AND2 AND3 AND4 AND5 AND6 AND7 AND8

AND9 AND10 AND11 AND12 AND13 AND14 AND15 AND16AND17 AND18

OR OR1 OR2 OR3 OR4 OR5 OR6 OR7 OR8OR9 OR10 OR11 OR12

770 Inv Inv1 Inv2 Inv3 Inv4 Inv5 Inv6 Inv7 Inv8Inv9 Inv10

NAND NAND1 NAND2 NAND3 NAND4 NAND5 NAND6 NAND7 NAND8XOR XOR1 XOR2 XOR3

775780 Time element T1 T2 T3 T4 T5 T6785 Counter Counter790791 SRFG SRFG1792793794795797798

5.5 Winder checklistThe fields shaded white must be recorded according to the measuring units. The data in the fieldsshaded grey can be calculated with aid of the formulary (see chapter 5.1).

Designation Value Measuringunit

Minimum diameter Dmin [m]Maximum diameter Dmax [m]-> Diameter ratio Dmax / Dmin [--]Minimum tension force Fmin [N]Maximum tension force Fmax [N]-> Tension ratio Fmax / Fmin [--]-> Minimum torque Mmin [Nm]-> Maximum torque Mmax [Nm]-> Torque ratio Mmax / Mmin [--]Type of motor (asynchronous/synchronous, orderno. )

[--]

Motor rated torque MN [Nm]Motor rated frequency fN [Hz]Motor nominal speed nN [U/min]-> Pole pair number [--]Motor moment of inertia JM If known [kg*m^2]Gearbox moment of inertia JG If known [kg*m^2]Motor speed sensor type (Resolver, Impuls,Encoder)

[--]

Maximum line speed vmax [m/min]


Version 1.0


-> Maximum winding speed for vmax, Dmin [U/min]Gear ratio i = n1 / n2 [--]-> Maximum rotational speed motor forvmax, Dmin

[U/min]

-> Maximum field weakening [--]Converter type (MC/VC, order no.) [--]Plug-in modules (SBM, CBP2, SLB, EB1/2, ...) [--]Tension measuring system (dancer/load cell,control-/measuring range)

[--]

Required exactness of tension ∆F / Fmax [%]Diameter sensor (Yes/No) [--]Material to be wound width B [m]Material to be wound length L [m]Material to be wound thickness D [m]Material to be wound density ρ [kg/m^3]-> Maximum moment of inertia winding JV [kg*m^2]Flying splice (Yes/No) [--]


Version 1.0


5.6 Winder application (Masterdrive MC)

5.6.1 Function diagrams


Version 1.0


Documents

IMPR Simple Winder Documentation