SINAMICS DCC Winder V3.2

© Siemens AG 2012. All Rights Reserved.

SINAMICS DCC Winder V3.2

© Siemens AG 2012. All Rights Reserved. Industry Sector

Tools

Example Configuration

Function Block Overview

Scope of Functionality

Contents of the Application

Benefits when using the Application

Introduction

Converting Toolbox Introduction

The application SINAMICS DCC Winder was developed with the objective to address many of the known winder applications using one application software. If required, the application can be configured and/or also changed. Using the application SINAMICS DCC Winder allows winders and un-winders to be implemented in a wide range of applications, e.g. foil making machines, printing machines, coating machines... The winder application can be used on the following devices: SINAMICS S120, S150, G130, G150 SINAMICS DCM SINAMICS Integrated in SIMOTION D4xx-2


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Introduction

Converting Toolbox Benefits when using the Application

Shorter engineering and service times (same look & feel)

Industry standards are used

Supported by the various PM Application Centers

Continuously updated in the Intranet

Essentially open source code so that you can adapt the functions to your requirements

User Manuals in English and German

Free of Charge


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Introduction

Converting Toolbox Contents of the Application

PowerPoint presentation (English / German) Programming in CFC User Manuals (English / German) Feedback sheets (English / German)


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Introduction

Converting Toolbox Scope of Functionality

Tension

Coil

Tension

Coil

Nip

Center Winder or tandem center winder winds material around a core or mandrel the coil is driven by a motor the motor can be operated in torque or

speed controlled mode dancers or load cells for tension control are

optional Roll hardness controlled by web tension

and optional by nip pressure

Turret winder two or more centerwinds on a rotating axis Roll change on the fly A flying knife will slice the material and

automatically hold it while it starts to wrap a new coil


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Introduction


Min Diameter DMin

Max. Diameter DMax

Web Width w

Gear, Gear ratio iMoment of Inertia Jgear

Material Velocity V

External Moment of Inertia JCore

Motor Moment of InertiaJMotor

Dact Actual Diamter


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Introduction


V+, F+

Winder from above

V+, F+

Winder from below

V+, F+

Unwinder from below

V+, F+

Unwinder from above

n+

no+

Mf+

MP+

MT+

n-

no-

Mf-

MP-

MT-

n-

no+

Mf-

MP-

MT+

n+

no-

Mf+

MP+

MT-

Mf: Friction TorqueMP: Torque PrecontrolMT: Tensionn: winder speedno: speed override


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Introduction


The Winder Function Block covers the common control modes and is an open function for adjustments or build in your own Know-how! Control modes: indirect tension control dancer roll control with speed correction tension control with speed correction tension control with torque limiting constant v-control


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Introduction

Converting Toolbox Scope of Functionality – Indirect Tension Control

No tension feedback required Web speed is set via nip Tension Torque pre-controlled via torque setpoint Good Inertia and friction torque compensation required Diameter ratio app. 10:1 Tension ratio app. 6:1 Winder torque ration app. 40:1 Web speed up to app. 600 m/min Material: foil, textile, paper


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Introduction

Converting Toolbox Scope of Functionality – Indirect Tension Control

Maneuver

Vset

overcontrol

M

Fset 1

Power unitSpeed controller

Current controller

Friction momentdn/dt

Dactnact

Diameter calculation

Kp-adaptation

J

Tension taper curve

Jog set point

Vconst n+M+

F

Dact

Inertia curve


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Introduction

Converting Toolbox Scope of Functionality - Tension control with torque limiting

Tension measuring device required Web speed is set via nip Tension Torque pre-controlled via torque set point Nip required, tension capsule is very damageable Good Inertia and friction torque compensation required Diameter ratio app. 15:1 Tension ratio app. 20:1 Winder torque app. 100:1 Web velocity up to app. 2000 m/min Tension control via torque limitation Material: paper, thin film


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Introduction

Converting Toolbox Scope of Functionality - Tension control with torque limiting

Maneuver

Vset

overcontrol

FactM

Fset 1

Power unitSpeed

controllerCurrent

controller

Friction curve

dn/dt

Dactnact

Diameter calculation

Fact

Kp-adaptation

J

Kp-adaptation

Dact

Tension taper curve

Jog set point

Vconst n+M+F

Tension controller

Dact

Inertia curve


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Introduction

Converting Toolbox Scope of Functionality - Dancer position control with speed setpoint-correction

Dancer position measuring device required (e.g. potentiometer, encoder) Web speed is set via nip Web tension is controlled via additional speed setpoint Nip required, dancer influences the web path Diameter ratio up to app. 15:1 Tension ration controlled via dancer Winder torque ratio up to app. 40:1, depending on the dancer

system Web speed up to app. 2000 m/min Material: rubber, cable, textile, film and paper


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Introduction

Converting Toolbox Scope of Functionality - Dancer position control with speed setpoint-correction

Maneuver

vset

Sact

M

Sset

Power unitSpeed

controllerCurrent

controller

Friction moment

Dactnact Diameter

calculation

Sist

Kp-adaptation

J

Kp- adaptation

Dact

Tension taper curve

P U

Fset 1

Dact

Jog set point

+

-

VconstM+

n+F

Position controller

dn/dt

Dact

Inertia curve


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Introduction

Converting Toolbox Scope of Functionality – constant v-control

Web velocity input via web tachometer Web speed isn’t set via nip Tension can‘t be affected by winder No nip required Diameter ratio up to app. 15:1 Web velocity is depending on the mechanical construction Especially for sorter


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Introduction

Converting Toolbox Scope of Functionality – constant v-control

Maneuver

Vset

Vact M

Power unitspeed controller

Currentcontroller

Friction moment

Dactnact Diametercalculation

Kp-adaption

J

Jog set point

M+n+

dn/dt

Dact

Inertia curve

Vact


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Introduction

Converting Toolbox Scope of Functionality – Diameter calculation

Diameter calculation based on ratio between web velocity and winder rotational speed

The diameter is required to e.g. calculate the correct speed of the winder axis from the machine speed

optional there is an integrating calculation methode, a division method, the possibility to interconnect a diameter sensor or a methode with layer counting available


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Introduction

Converting Toolbox Scope of Functionality – Taper characteristic

Optional for rewinder, if the tension is reduced with increasing diameter Taper characteristic depends on the actual diameter Decrease can be absolute (N) or relative (% of tension setpoint) four characteristics are implemented: Hyperbolic characteristic with: Max. tension reduction at infinite diameter Max. tension reduction at specified diameter

Linear characteristic with tension reduction when maximum diameter is reached Personal characteristic using 10 points along the characteristic


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Introduction

Converting Toolbox Scope of Functionality – Controller adaption

Controller gain of the tension/position controller is adaptable based on the actual diameter

higher gain at higher diameter Controller gain of the speed controller is adaptable based on the

moment of inertia of the roll higher controller performance with high load conditions


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Introduction

Converting Toolbox Scope of Functionality – Torque pre-control

Optional compensation of the acceleration/ deceleration torque, resulting of the moment of inertia to improve the dynamic reaction of the drive Inertia compensation reduces tension fluctuation based on speed

changes Inertia compensation is required if indirect tension control is used

and recommended in tension control mode via load cell Inertia compensation is set up during commissioning Inertia compensation is calculated based on the diameter, the

web width, the gear ratio und the material density


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Introduction

Converting Toolbox Scope of Functionality – tension operation

Tension operation can only be enabled if the control is in operation and web break detection is not signaling an error It is recommended to only enable tension operation in machine

stand still Tension or position setpoint will be enabled using adaptable ramp

functions If tension operation is not active, the diameter computer and the

speed override are disabled


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Introduction

Converting Toolbox Scope of Functionality – Maneuvering input

The maneuvering input can e.g. be connected with an analog input to influence the internal speed setpoint.


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Introduction

Converting Toolbox Scope of Functionality – Jog

Jog operation is only enabled when tension operation is disabled Jog speed setpoint either via fixed setpoint or via connectable

input During jog operation, the maneuvering mode is disabled separate ramp function generator


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Introduction

Converting Toolbox Scope of Functionality – Velocity master, synchronize and stop web setpoint

winder can operate as velocity master for the whole machine stop the winder on continuing web, e.g. after flying roll change synchronize a stopped winder to the web, e.g. before splicing

- WI1111 -Function diagram

87654321Wickler DCC V3 1 en.VSDDO: SERVO, VECTOR, DC CTRL

SINAMICS12.06.12 V03.01.00Setpoint Computer Part 2 (Speed setpoint calculation; Master; Stop)

<1> If winder is used as speed master, the internal setpoint for web speed is used for the diameter calculation

<2> tension operation is deactivated when „Stop“ is selected, if a fixed web velocity is set and this value is also used as speed setpoint for the speed master, p22060 has to be set to „1"

When the winder is set as speed master, r21626 shows the reaching of the upper velocity limit, r21627 the reaching of the lower velocity limit.

1

0

0 %

(0)

BI: Synchronize/stop web setpoint[ 0 = synchr.; 1 = stop]

p21621

Ramp-up time, webvelocity catch up [ms]

p21622 (5000ms)

BO: Web velocity synchronizedr21626

BO: Web velocity stoppedr21627

≥1stop after splice active

stop after web length braking active

[WI1020.4]

[WI1020.4]

p21000[3]SetpointComputer

[WI1010.2]

[WI1010.2]

<2>

RUT

STSTSTSTSTSTSTST

RDT

Tup_eff Tdn_eff

Web velocity ramp functiongeneratorx

y

t

y

dy/dt

y

1

&1

winderas speed master

1

1

rampstop speed master

fast stopspeed master

10

Ramp-down time, webvelocity, fast stop [ms]p21624 (2500ms)

Ramp-down time, webvelocity, stop [ms]p21623 (5000ms)

1

0100 %CI: Velocity setpointmaterial web

(setpoint/actual valuenip position)

(0)p21515

<1>

x

y

1

0

1

0

Smoothing time rampfunction generatorweb velocity [ms]p21625 (200ms)

lower limit velocity master [%]p21629 (-2.0 ≙ -200%)

upper limit velocity master [%]p21628 (2.0 ≙ 200%)

100%

0%

r21630

CO: velocitysetpoint RFG

velocitymaster [%]

Stopp am Antrieb aktiv[WI1030.7]

r21512CO: Motor speed, actual value [rpm]

r21547

CO: Multiplier setpoint channel [1/m]

Normierung Bahngeschwindigkeit

RFG follow up when external stop

r21517CO: Material web velocity,

actual [m/min]

[WI110x.3]

[WI110x.3]

[WI110x.7]

[WI1010.2]

[WI1010.2]

[WI110x.1]

[WI1010.2]

[WI1110.3]


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Introduction

Converting Toolbox Scope of Functionality – web length and braking distance

calculation of the actual web length by integration of the material web velocity stop the winder when reaching a set web length setpoint


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Introduction

Converting Toolbox Scope of Functionality – Splice control

flying roll change with optional application splice control (precondition is active position controller for position sensing) cam outputs to control knife and splice roll “rewinding after splice” for unwinder

New

Old Knife

Rotating turret

Splice roll

Splice position


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Introduction

Converting Toolbox Scope of Functionality – Execution groups

The required components of the application are enabled via execution groups:


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Introduction

Converting Toolbox Scope of Functionality – Execution groups

The execution groups “Diameter computer”, “Setpoint calculator”, “Control unit” are always required, the execution group “TensionDancerContr” not for indirect closed-loop tension control, the execution groups “Winding hardness calculator”, “Integrating diameter computer” and “Web break detection” - only if the functions are actually required. For drive systems with the CU320-2 Control Unit, sampling times

of 4ms are recommended; for standard settings, this corresponds to the clock cycles of the execution group “BEFORE speed setpoint channel” for servo - or “BEFORE position controller” for servo and vector (This execution group is available independent of the activated basic positioner function module). Sampling times of 8ms or 16ms are recommended for the

SINAMICS DCM drive system.


Tools






Introduction

Converting Toolbox Function Block Overview

The winder functionality is part of the application SINAMICS DCC Winder.

The application is implemented in DCC.

The documentation is based on function plans.

Normalization web velocity [m/min] p21516 (30)

Actual web velocity(0)

p21515

Normalization,speed [rpm] (r2700)

p21511

speed act. valuemotor encoder (r63)

p21510

Diameter computer

r21517Web velocity actual value [m/min]

r21512actual motor speed [rpm]

<>0

=0

Setting valuefixed diameter [m]

p21522 (0.1)

Setting valuediameter normalizedto maximum diameter

(0)p21523

r21524

Setting value,diameter effective [m]

Maximumdiameter

p21534 (2 m)

Minimum diameterp21535 (0.1m)

π•=

∫motor speed

gear factor ∫ web velocityDiameter

r21545Calculated diameter, absolute [m]

r21547Multiplier, setpoint channel[1/m]

set diameterhold diameter

winding from bottom

[WI1030.7]

[WI1010.4][WI1030.7]

Diameter is limited to the maximum diameter Diameter is limited to the minimum diameter

[WI1020.4]

[WI1020.4]

Normalization web velocity

Speed normalization

gear factor

- WI1101 -Function diagram

87654321Wickler_DCC_V3_en.VSDDO: SERVO, VECTOR, DC_CTRL

SINAMICS29.11.10 V03.00.00Diameter computer integrating method (p21538=1, p21540=0, p21541=0)

1

0

r21548

Diameter value saved(retentively) [m]

Saved diameter value validr21549

saved diameter valueas setting value

[WI1010.5]

Diameter setting value

Non-volatile (retentive) memory for the diameter

value

Balancing time web velocityintegrating method p21536 (0 ms)

Smoothing time diameter integratingmethod [ms] p21537 (100.000)

(0)

BI: smoothing diameter out-put integrating method

[1=OFF; 0=ON]

p21539

Wound roll revolutions per integration interval

p21525 (1)Δt (integration interval)

r21546

Calculated diameter, relative [%]

Dmax

p21000[0]integratingDiaComp

p21000[1]Diameter Computer

minimumdiameter

maximumdiameter

motor speed

material web velocityactual diameter

gear factorM

xy

Gear factor, load revolutionsp21520 (1)

Gear factor, motor revolutionsp21521 (1)


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Introduction

Converting Toolbox Example Configuration

Example Configuration: • SINAMICS CU310 DP/PN • SINAMICS S120 PM340 AC/AC • TM31 (analog input) • Breaking resistor (optional) • e.g. 1PH8 motor Standards: SINAMICS DCC Winder

Benefits: Cost effective and simple „stand alone“ solution Integrated I/O and Safety functions (STO) Integrated TTL/HTL/SSI encoder interface No PLC required for simple applications

Winder e.g. 1PH8

SIN

AMIC

S C

U31

0 D

P

PROFIBUS

HMI

PM340



SIMATIC S7

Machine control

PROFIBUS

HMI Web handling

TM31

SINAMICS CU310 DP DCC SINAMICS S120 AC/AC

1PH8

Winder Dancer system (or load cell)

Nip


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Introduction


Example Configuration: • SINAMICS CU320 (1 Winder / CU) • SINAMICS S120 DC/AC • TB30 or TM31 • e.g. 1PH8 motor Standards: SINAMICS DCC Winder SINAMICS DCC Load Sharing (Tandem Winder)

Benefits: Modular solution based on standard products High hardware integration (no external traversing controller required) No programming necessary No PLC required for simple applications

SIN

AMIC

S C

U32

0

PROFINET / PROFIBUS

SIMATIC S7 (Machine control)

Mot

or m

odul

e

Winder (Master) e.g. 1PH8

Slave



HMI

Web handling

TM31

SINAMICS CU320 / DCC SINAMICS S120 DC/AC

1PH8

Winder Dancer system (or load cell)

Nip

PROFINET / PROFIBUS

1PH8

SIMATIC S7

Machine control

CU

320

Infe

ed

Mot

or M

odul

es


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Introduction

Converting Toolbox Tools

© Siemens AG 2012. All Rights Reserved.

Application Center I DT MC PMA APC Frauenauracher Str. 80 D-91056 Erlangen E-Mail: [email protected]

Thank you for your attention!

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SINAMICS DCC Winder V3.2