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Center Winder Training Application Software General. Winder Basics. Common Terms and Definitions. A Center Winder , also known as an Axial Winder, is a machine in which the rotational force is applied to the center or (axial) point of which material is wound. Tension Force. Velocity.

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Center Winder Training Application Software General

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Center winder training application software general

Center Winder Training

Application Software

General


Winder basics

Winder Basics

Common Terms and Definitions


Center winder training application software general

A Center Winder, also known as an Axial Winder, is a machine in which the rotational force is applied to the center or (axial) point of which material is wound.

Tension Force

Velocity

Winder Basics

Common Terms and Definitions

  • The objective is to regulate surface Tension of the roll. The Speed and Torque of the core must change as a function of Roll Diameter.


Center winder training application software general

Common Terms

CORE: The object the material is to be wound around. The minimum core diameter is the smallest diameter the Winder can start or the smallest diameter an Unwind can reach.

MAX ROLL DIA: The maximum roll diameter the machine is designed for.

BUILD-UP/ Winding ratio: The ratio of Max Roll Diameter to Core diameter. If the max. roll diameter is 1000mm and the core diameter is 100mm the Build-Up/ Winding ratio is 10 to 1.

FULL ROLL: In a Winding application this is the finished or completed roll diameter. In Unwind applications this is the starting roll diameter to be unwound.

Winder Basics

Common Terms and Definitions


Center winder training application software general

Common Terms

CORE SPEED MATCH: The function of trimming the speed of winder when in Speed Mode. This is typically used for continuous process lines with automatic roll change function.

WEB: The product (material) which is to be wound by the machine. This is also known as the “strip” in the Metals.

EXTENSIBLE: This is related to the properties of the web. A web which is elastic is considered extensible. Example: Plastic food wrap

NON-EXTENSIBLE: This is related to the properties of the web. A web which is rigid in length and width or one which cannot be stretched is considered non-extensible. Example: Paper

Winder Basics

Common Terms and Definitions


Center winder training application software general

Common Terms

TENSION: The force applied to the web. This is used to control the web. Units of tension are [ N ] for Newtons or [ lb ] for pounds.

TAPER TENSION: The reduction of the reference tension as a function of diameter. As diameter is increased the tension is decreased.

STALL TENSION: The meaning of “stall” is the mechanical section is at or near zero speed. When Stall Tension is activated the reference tension is reduced to a preset percentage of the tension set-point.

Winder Basics

Common Terms and Definitions


Center winder training application software general

Common Terms

SPEED CONTROL: The drive is regulating speed of the machine and the tension of the web is controlled by trimming the speed based on tension feedback.

TORQUE CONTROL: The drive is regulating torque of the machine and the tension of the web is controlled by the Torque reference. If tension feedback is used the torque reference is trimmed with the tension feedback.

Moment Of Inertia (WK2): Used for calculating torque required to change the speed of a machine. The formula includes the weight and dimensions to be accelerated. Additional components, change in speed and change in time or (n/t), are required for the calculation of torque required.

Winder Basics

Common Terms and Definitions


Center winder training application software general

Common Terms

DIAMETER CALCULATOR: The formula or process by which the diameter of a center winder are calculated. The Center Winder application is using the line velocity and actual roll rpm to calculate the roll diameter.

ROLL CHANGE: A function for continuous process lines in which the finishing roll is automatically replaced by a new roll without stopping the production process. Typically two (2) Center Winders are used.

TORQUE MEMORY: Process of storing the active actual torque of the machine. Used in Roll Change.

TORQUE BOOST: A multiplier to the Torque Memory, used for aiding the cutting of the Web when a Roll Change is performed.

Winder Basics

Common Terms and Definitions


Center winder training application software general

Basic Winder Macro Includes

Dancer Control

Indirect Tension Control

Direct Tension Control

With Correction signal used as Speed Correction (Speed Trim)

With Correction signal used as Torque correction (Torque Trim)

Selectable Winder and Unwinder modes

Common Control Functions Include

Diameter calculation

Tension torque reference

Calculation of moment of inertia

Acceleration/deceleration torque compensation

Loss Compensation

Winder Basics


Center winder training application software general

Winder Basics

Formulas for the Winder

Formulas for the Winder


Center winder training application software general

Winder Basics

Formulas for the Winder

F= Tension Force

M=Torque

V= Material Speed

n= Rotational Speed

W= Angular Speed

B= Material Width

D= Diameter

JR= Moment of Inertia

JR1= Moment of Inertia of roller

JR2= Moment of Inertia of roll

JR3= Moment of Inertia of gearbox

JM = Moment of Inertia of Motor

JC = Total moment of Intertia (on motor side)


Center winder training application software general

F

Winder Basics

Formulas for the Winder

V

1. Power required for winding

Pmax = KW

2. Relationship between Tension component and motor Torque

M = FxD/2 Nm : Winding Torque on the machine side

Mm= FxD/2Z Nm : Winding Torque on the Motor side

3. Maximum and minimum Torques (ignoring the Inertia requirements)

With respect to Tension component


Center winder training application software general

V

F

Winder Basics

Formulas for the Winder

4. Maximum and minimum Motor Speeds


Center winder training application software general

V

F

Winder Basics

Formulas for the Winder

5. Intertia components

Torque available from motor is used to produce the Tension component

as well as to overcome the Inertia requirements

Total inertia of System =( Inertia of Roll+ Inertia of roller+ Inertia of gear)reflected to motor side

+motor inertia


Center winder training application software general

V

F

Inertia of shaft (roller)

Shaft Outer Dia

Shaft Inner Dia

Inertia of roll ( material wound or unwound on the core)

Winder Basics

Formulas for the Winder

Inertia of Gearbox

Usually provided by the customer/mech supplier

Inertia of Motor

Motor Catalogues provide the motor Inertia.


Center winder training application software general

V

F

Mm=

Winder Basics

Formulas for the Winder

Total Torque to be developed by Motor Mm=

Mm= + MM1+MM2+MM3+Loss component

Mm=

Variable part

Fixed part


Center winder training application software general

Winder Basics

Formulas for the Winder


Center winder training application software general

Relationship of Power and material


Center winder training application software general

Winder Basics

Configurations

Control Configurations for Winders and Rewinders

  • Indirect Tension Control

    • No Tension Feedback instrument is needed

  • Direct Closed loop Tension control with Tension Feedback

    • Material Tension is measured directly from

      a tension transducer.

    • Tension control may be super-imposed over the Indirect Tension

      control or used to control the drive in speed mode

  • Direct Closed loop Tension Control with Dancer rolls

    • Dancer Position feedback is used as a closed loop feebback

    • Drive remains in speed control

  • Winder is used as Speed master

    • Material Tension is controlled by back tension provided by other equipment

    • Winder is controlled in speed control with Diameter Calculation to maintain

      uniform peripheral speed


  • Center winder training application software general

    Basic Winder Macro Includes

    Dancer Control

    Indirect Tension Control

    Direct Tension Control

    With Correction signal used as Speed Correction (Speed Trim)

    With Correction signal used as Torque correction (Torque Trim)

    Selectable Winder and Unwinder modes

    Common Control Functions Include

    Diameter calculation

    Tension torque reference

    Calculation of moment of inertia

    Acceleration/deceleration torque compensation

    Loss Compensation

    Winder Basics

    Configurations


    Center winder training application software general

    Winder Basics

    Configurations

    Indirect and Direct Tension Control

    Tensiometer


    Center winder training application software general

    Winder- Application

    Software

    Flux Code

    Tension

    Reference

    Tension Controller

    PI

    Torque Correction

    Line Speed

    Reference

    Tension

    Reference

    Tension Controller

    PI

    Winder Basics

    Configurations

    a) No Feedback system for Actual Tensionb) Feedback for Actual Tension is used

    Tension

    to TQ cal


    Center winder training application software general

    Winder Basics

    Configurations- Indirect Ten

    Linear Speed Reference

    Gear Box

    Tension Reference

    External DIA

    M

    Web Density

    Web Width

    DIA CALCULATOR+ INTEGRATOR

    Macc= J*2/D*Z*dv/dt

    TORQUE REFERENCE

    Dia Preset

    t

    SELECTOR

    V

    TORQ REF SEL

    N

    0

    EXTERNAL TORQUE REFERENCE

    1

    Torque Ref

    to DTC

    External /Internal Dia Calc

    2

    3

    Winder/ Rewinder

    4

    MIN

    LossTorq= K+ N* K1

    5

    6

    Count UP EN

    TORQ REF1

    Count DN EN

    MIN DIA

    MAX

    D

    MAX DIA

    STATIC FRICTION

    +

    SPEED CONTROLLER OUTPUT

    -

    +

    TORQ REF2

    LINEAR FRICTION

    +

    I

    C+I *C1

    X

    P

    I

    Taper Tension Generator

    Tension Ref

    F

    M

    DIA


    Center winder training application software general

    Winder Basics

    Configurations

    Indirect Tension Control

    The torque is calculated according to the formulas discussed before.

    No feedback instrument is used for actual measurement of tension

    Diameter needs to be computed accurately to control the correct tension

    Friction& Windage are very crucial components to maintain accuracy of

    tension.

    • Is recommendable to use Indirect tension control in

    • Direct coupled winders (no gearbox)

    • In mech configurations where the mechanical losses are low. (No worm gears, and no appreciable

      difference between gearbox losses in warm or cold conditions

    • Where the Inertia component TQ to Tension component TQ ratio is small.

    • In process applications where the Tension range required is relatively small (less than 10:1)


    Center winder training application software general

    Winder Basics

    Configurations

    • Tension Control - Open Loop Torque

      • The drive is torque regulated. The parent speed reference is required from the process line controller for over speed control.

      • The torque reference is calculated by the application based on tension setpoint and machine parameters.

      • The PI controller is NOT active in this mode and therefore there is not any trim of the torque reference.

      • The Tension control is made by calculating the torque requirements. Careful dimensioning of the system with the process parameters is recommended.


    Center winder training application software general

    Winder Basics

    Configurations

    • Indirect Tension Control- Open Loop Torque

      • Recommendation for Use:

        • Transducer - Actual tension feedback is not available

        • Web dimensions are constant with limited variations in width and density.

        • Accurate system and material Inertia data is available.

        • Process tension range is small.


    Center winder training application software general

    Winder Basics

    Configurations

    Direct Tension Control

    The torque is calculated according to the formulas discussed before.

    A feedback device is used for actual measurement of tension. This is used as

    a superimposed control loop to correct the Torque reference.

    Diameter needs to be computed accurately to control the correct tension

    Friction& Windage are not very crucial as inaccuracies may be corrected by the presence of the feedback loop.

    • Is recommendable to use Direct tension control in

    • Processes requiring high tension accuracy.

    • In mech configurations where the mechanical losses are high .

    • In processes where the tension range is very high (e.g 20:1)


    Center winder training application software general

    Winder Basics

    Configurations

    Direct tension Control

    with speed Trim

    Direct tension Control

    Direct tension Control

    with Torque Trim


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with speed Trim

    • Tension Control - Closed Loop Speed Trim

      • The drive is speed regulated. The parent speed reference comes from the process line controller.

      • Speed Trim is used to control the actual tension of the web. The Tension Controller trim is added as a speed correction.

      • Tension Controller is a PI controller receiving setpoint reference from an operator control and receiving a feedback of actual tension from the process.

      • Diameter is calculated by using the line speed and the rotational speed feedback from the drive.

      • Inertia compensation may be added to improve the dynamics of the control.(Losses in the form of friction and windage are automatically compensated by the closed loop system)


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with speed Trim

    nRef

    F-Controller

    n-Controller

    Tq Speed Ctl out

    +

    Used TQ reft

    FRef

    x

    Speed Trim

    -

    -

    Fact

    F(D, V)

    nact

    Controller

    adaptation

    Macc

    Web type (material thickness/ material width)

    Gain

    Gain

    D

    D

    Block Diagram of the Direct tension Control with speed Trim


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with speed Trim

    • Direct Tension Control - Closed Loop Speed Trim

      • Recommendation for Use:

        • If the material range is wide and extensive.

        • If a large range of Web Widths are possible/required.

        • Accurate Inertia data is not available.

        • If a “tight” control is not needed.


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with Torque Trim

    • Tension Control - Closed Loop Torque Trim

      • The drive is torque regulated. The parent speed reference is required from the process line controller for over speed control.

      • The torque reference is calculated by the application based on tension setpoint and machine parameters entered at the keypad.

      • Torque Trim is used to control the actual tension of the web. The Tension Controller trim is added as a torque correction.

      • Tension Controller is a PI controller receiving setpoint reference from an operator control and receiving a feedback of actual tension from the process.


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with Torque Trim

    nRef

    F-Controller

    n-Controller

    Tq Speed Ctl out

    +

    Used TQ reft

    FRef

    x

    -

    -

    Fact

    F(D, V)

    nact

    Controller

    adaptation

    Macc

    Web type (material thickness/ material width)

    Gain

    Gain

    D

    D

    Block Diagram of the Direct tension Control with speed Trim


    Center winder training application software general

    Winder Basics

    Configurations- Direct Tension Control with Torque Trim

    • Direct Tension Control - Closed Loop Torque Trim

      • Recommendation for Use:

        • Greater dynamic response.

        • Web dimensions are basically constant with minimal variations in width and density.

        • Accurate system and material Inertia data is available.

        • Transducer feedback is required.


    Center winder training application software general

    Winder Basics

    Configurations- Dancer Control

    Dancer Control


    Center winder training application software general

    Loading Cylinder

    Dancer

    Position

    Feedback

    to ACS600

    Servo (I/P)

    Dancer

    Position

    Feedback

    to ACS600

    Fixed Back Tension

    Force

    Force

    +10 volts

    0 volts

    Response polarity as with a Transducer

    +10 volts

    0 volts

    Response polarity as with a Transducer

    Winder Basics

    Configurations- Dancer

    • Mechanical Configurations

    • Fixed back tension systems

    • Variable back tension systems

    Variable Tension System

    Fixed Tension System


    Center winder training application software general

    Dancer Control

    The drive is speed regulated. The parent speed reference comes from the process line controller.

    Speed Trim is used to Control Dancer Position. The Dancer Controller trim is added as a speed correction.

    The Dancer Controller is a PI controller receiving a set-point reference which is a constant from the keypad and receiving a feedback of Dancer position from the process.

    Loading Cylinder

    Dancer

    Position

    Feedback

    to ACS600

    Servo (I/P)

    Force

    +10 volts

    0 volts

    Response polarity as with a Transducer

    Winder Basics

    Configurations


    Center winder training application software general

    Winder Basics

    Configurations

    Block Diagram of Dancer Control - Speed Control and

    speed correction- Fixed Tension system

    nRef

    P-Controller

    n-Controller

    Tq Speed Ctl out

    +

    Used TQ reft

    PRef

    x

    -

    -

    Pact

    F(D, V)

    nact

    Controller

    adaptation

    Macc

    Web type (material thickness/ material width)

    Gain

    Gain

    D

    D


    Center winder training application software general

    Winder Basics

    Configurations- Dancer - Fixed Tension

    How is Tension regulated ?

    Tension of the Winder is regulated indirectly by regulating the

    the position of the Dancer and adjusting the “restraining forces”


    Center winder training application software general

    Winder Basics

    Configurations- Dancer- variable Tension

    Block Diagram of Dancer Control - Speed Control and

    speed correction- Variable Tension system

    nRef

    P-Controller

    n-Controller

    Tq Speed Ctl out

    +

    Used TQ reft

    PRef

    x

    -

    -

    Normally Fixed as Parameter

    Pact

    Macc

    F(D, V)

    nact

    Tension Setpoint

    Controller

    adaptation

    Loading Cylinder

    Web type (material

    thickness/ material width)

    Servo (I/P)

    Gain

    Gain

    Force

    D

    D

    Stall and Taper

    Reference


    Dimensioning the winder

    Dimensioning the Winder

    Winder Basics

    Dimensioning

    • Understanding the Load Requirements

    • Selecting the correct Motor

    • Recommending the optimal gearbox and speeds

    • to mechanical supplier


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    • Analyzing the Load Requirements

    How the customer specifies his load (typically)

    30KW, 800rpm/1500rpm ,150% overload

    General Interpretation

    a) Constant Torque application , Constant Power above base speed

    b) Requirement is to deliver at base speed

    c) Generally the required torque below base speed is same

    d) Specified overload of 150% is required at all speed points


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Graphical Interpretation of the specified Load

    30KW, 800 rpm/ 1500 rpm 150% overload

    Constant TQ

    TQ requirement proportional to


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    To optimize the Winder it is important to know other information

    Process Parameters

    Tension ranges- Stall tension and Taper Tensions range

    Diameter Ratios for specified materials

    Peripheral speed - Crawl / thread speed, Max speed,

    Operating speeds

    Acceleration and deceleration rates

    Gear Ratios

    Material Specific Wt and density

    E.g.

    Tension range : Material type 1 : 5 KN, material thickness =3mm

    Material type 2 : 1 KN ,material thickness =0.5mm

    Diameter Ratio : Min 600 mm Max :1500 mm

    Line speed max = 300 mpm, Minimum speed = 60 mpm

    Operating speed= 250 mpm

    Acceleration rates= 20 sec to full speed / fast stop =10sec from full speed

    material width = 800 mm, density= 1100 kg/m3


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Min and max values


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the minimum speed point

    The minimum rotational speed point is calculated by using the minimum

    linear operating speed at the maximum diameter.

    The minimum linear operation speed is the speed at which the

    winder may run continuously for a extended period of time.

    This does not have any effect on dimensioning when a separately

    ventilated motor is used.

    Nmin in this

    example = 125 rpm

    Line stops before

    max dia is reached !!

    M2BA 315 SMA8


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    If the minimum operating speed was about 200rpm the selected motor

    could have been reduced by 1 frame size !!

    Motor selected = M2BA 280 SMB 6


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculation based on Tset =Tmax conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculation based on Tset =Tmin conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculating based on Tset =Tmax conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculating based on Tset= Tmax conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculation based on Tset =Tmin conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    Calculating the Torque at different speed points

    Calculation based on Tset =Tmin conditions


    Center winder training application software general

    Winder Basics

    Dimensioning- Load Requirement

    • Results:

    • The max and minimum required load torques for the process

    • demand are

    • 30 Nm to 395 Nm depending on the tension set-point

    • and the acceleration/deceleration phases.

    • Overload requirements can be accurately identified.

    • All the speeds (base and maximum speeds are accurately determined)

    • The maximum and minimum load torque has to be supplied by the

      same drive+motor set. Minimum resolutions and accuracy of control

      will start to be important considerations

    • Overload and minimum operating speeds affect the motor selection


    Center winder training application software general

    Winder Basics

    Dimensioning- Selecting the Motor

    Rule 1 : The motor should not be over-dimensioned. Over- Dimensioned

    motors will increase the inverter size which in turn effects the current

    resolution of the drive.

    Wide tension ranges will not be attainable

    The ability of the inverter to maintain the requested motor torque is stated as

    a % of the nominal torque of the motor. Increasing the motor torque way beyond

    the load requirements reduces the accuracy of tension/torque control

    Rule 2 : Motor overload characteristics are proportional to I/N2. Load torque

    requirements are proportional to 1/N.

    Therefore the overload requirements may often lead to the next frame size of the

    motor. Check the overload requirements carefully such a case. Generally Winders

    overloads are needed during the fastest stop or acceleration and can be calculated!

    Reducing (Convincing the customer)the acceleration/deceleration rates by a small percentage

    may be a better solution then over-dimensioning the motor to fulfil this requirement.


    Center winder training application software general

    Winder Basics

    Dimensioning- Selecting the Motor

    Motor Load torque and the maximum loadibility of the motor


    Center winder training application software general

    Winder Basics

    Dimensioning- Selecting the Motor

    Rule 3 : Check the minimum rotational speed of the motor. This criteria leads to a

    bigger motor in self ventilated motors.

    Minimum rotational speed for the motor is at minimum operational speed and

    at the maximum diameter.

    The problem with the motor loadibility curve is only when the maximum tension is

    requested and the maximum designed diameter is used.


    Center winder training application software general

    Winder Basics

    Selecting the motor+Gearbox

    Using the same process example


    Center winder training application software general

    Winder Basics

    Selecting the motor+Gearbox

    We are free to choose the gearbox !!!

    We know the power requirement - say 30KW, 150% overload

    We know the speed ratio = 2.48

    this implies that the motor runs into field weakening

    up to about 2.5 times.

    Choose the motor based on

    Easiest availability

    Best torque curve fitting

    <Best motor is the one whose base speed can

    be as close to our process base speed>

    Choose the gearbox based on the speeds

    =


    Center winder training application software general

    Winder Basics

    Selecting the motor+Gearbox


    Center winder training application software general

    Winder Basics

    Dimensioning

    Using the Application Checklist Form


    Center winder training application software general

    Winder Basics

    Dimensioning


    Center winder training application software general

    Winder Basics

    Dimensioning


    Center winder training application software general

    Center Winder Training

    Application Software

    Implementation


    Center winder training application software general

    Winder Application

    Integration of the Winder Application

    Standard and Multidrive


    Center winder training application software general

    Winder Application Configuration

    Winder Application consists of the macros :

    Winder Ten

    Winder Dan

    Unwinder Ten

    Unwinder Dan


    Center winder training application software general

    Dancer Control

    The drive is speed regulated. The parent speed reference comes from the process line controller.

    Speed Trim is used to Control Dancer Position. The Dancer Controller output is added as a speed correction.

    The Dancer Controller is a PI controller receiving a setpoint reference which is a constant from the keypad and receiving a feedback of Dancer position from the process.

    Recommendation for Use:

    To create Isolation of sections.

    Typical Unwind Applications.

    Loading Cylinder

    Dancer

    Position

    Feedback

    to ACS600

    Servo (I/P)

    Force

    +10 volts

    0 volts

    Response polarity as with a Transducer

    Winder Application Configuration


    Center winder training application software general

    Tension Control - Closed Loop Speed Trim

    The drive is speed regulated. The parent speed reference comes from the process line controller.

    Speed Trim is used to control the actual tension of the web. The Tension Controller output is added as a speed correction.

    Tension Controller is a PI controller receiving setpoint reference from an operator control and receiving a feedback of actual tension from the process.

    Winder Application Configuration


    Center winder training application software general

    Tension Control - Closed Loop Speed Trim

    Recommendation for Use:

    If the material range is wide and extensive.

    If a large range of Web Widths are possible/required.

    Accurate Inertia data is not available.

    Transducer feedback is required.

    Transducer; Actual Tension Feedback

    Winder Application Configuration


    Center winder training application software general

    Tension Control - Closed Loop Torque Trim

    The drive is torque regulated. The parent speed reference is required from the process line controller for over speed control.

    The torque reference is calculated by the application based on tension setpoint and machine parameters entered at the keypad.

    Torque Trim is used to control the actual tension of the web. The Tension Controller output is added as a torque correction.

    Tension Controller is a PI controller receiving setpoint reference from an operator control and receiving a feedback of actual tension from the process.

    Winder Application Configuration


    Center winder training application software general

    Tension Control - Closed Loop Torque Trim

    Recommendation for Use:

    Greater dynamic response.

    Web dimensions are basically constant with minimal variations in width and density.

    Accurate system and material Inertia data is available.

    Transducer feedback is required.

    Winder Application Configuration


    Center winder training application software general

    Tension Control - Open Loop Torque

    The drive is torque regulated. The parent speed reference is required from the process line controller for over speed control.

    The torque reference is calculated by the application based on tension setpoint and machine parameters.

    The PI controller is NOT active in this mode and therefor there is not any trim of the torque reference.

    Recommendation for Use:

    Transducer - Actual tension feedback is not available

    Web dimensions are constant with limited variations in width and density.

    Accurate system and material Inertia data is available.

    Stall tension is not required.

    Winder Application Configuration


    Center winder training application software general

    Dancer Controller

    PI

    Winder Application Configuration

    Motor

    RPM

    DTC

    Diameter

    Calculator

    Line Speed

    div

    add

    Dancer

    Feedback

    Dancer

    Setpoint


    Center winder training application software general

    Dancer Controller

    Activation of the Dancer Controller is selected via parameter.

    Parameter selectable Dancer Position Feedback.

    Automatic Centering of the Dancer. The Dancer position of regulation is defaulted to the center of it’s maximum travel. This may be adjusted with the Center Offset parameter.

    Winder Application Parameters

    62:5 Dancer Ctl Enable

    NOT SEL ENABLE DI 2 DI 3 DI 4 DI 5 DI 6 XT DI1 FIELDBUS

    PI

    Running

    Regulator Release

    Reference

    Feedback

    &

    62:7 Dancer FDBK Input

    AI 1 AI 2 AI 3 XT AI1 0V XT AI2 0V XTAI2 -10V

    62:10 Max Dancer Travel

    2

    div

    add

    62:11 Center Offset


    Center winder training application software general

    Dancer Controller

    P-Gain Min and P-Gain Max: P-Gain of controllers are adjusted as a function of diameter. As diameter increases the P-Gain of the Controller is increased linearly to P-Gain Max for improved regulation as diameter is changed.

    Two selectable web configurations. Each parameter for WEB 1 and WEB 2 are (infinitely) adjustable.

    Two (2) sets of PI gains for Dancer controllers.

    Winder Application Parameters

    Stall Mode Enable

    62:13 Web Selection 62:1 P-Gain 1 Min 62:14 P-Gain 2 Min 62:2 P-Gain 1 Max 62:15 P-Gain 2 Max 62:3 Integ Time 1 62:16 Integ Time 2

    PI

    K

    K

    X

    Diameter

    I

    62:4 Range Adjust


    Center winder training application software general

    Dancer Controller

    Dancer Setpoint: Used in applications where Stall Tension and/or Tension Taper functions are required. In these modes a servo (I/P) must be used to adjust the tension applied to the web. An analogue output is used to control the servo.

    Taper Tension: Reduction of tension reference as a function of diameter.

    Winder Application Parameters

    Stall Tension Enable

    62:9 Max Taper/%Taper

    ACS600

    Analogue

    Output

    KEYPAD AI 1 AI 2 AI 3 XT AI1 XT AI2 FIELDBUS

    % Taper

    Ref

    Loading Cylinder

    Diameter

    62:6 Dancer Setpoint

    Servo (I/P)

    AI 1 AI 2 AI 3 XT AI1 XT AI2 FIELDBUS

    Force

    mul

    62:18 Stall Setpnt (%)


    Center winder training application software general

    Dancer Controller

    Stall Tension: If selected, is automatically activated when the line speed falls below a parameter set value. At this time the Tension reference is reduced to a parameter set percentage of setpoint tension. Stall PI gains are available for separate PI controller adjustment when in stall tension.

    Winder Application Parameters

    Stall Mode Enable

    62:17 Stall Enable

    If = 3 then

    1) DISABLE 2) NORMAL GAIN 3) STALL GAIN

    &

    62:20 Stall P-Gain

    If NOT = 1 then

    Line Speed Ref

    62:19 Stall Speed

    A1

    B1

    62:20 Stall Integ

    A1 < B1

    &

    Stall Tension Enable


    Center winder training application software general

    Winder Application Parameters

    Dancer / Tension Trim - Speed Control

    nRef

    P-Controller

    n-Controller

    Tq Speed Ctl out

    +

    Used TQ reft

    PRef

    x

    -

    -

    Pact

    F(D, V)

    nact

    Controller

    adaptation

    Macc

    Web type (material thickness/ material width)

    Gain

    Gain

    D

    D


    Center winder training application software general

    Tension Controller

    PI

    Winder Application Parameters

    Motor

    RPM

    DTC

    Diameter

    Calculator

    Torque Ref.

    Line Speed

    Spd Ref.

    div

    add

    mul

    Tension

    Feedback

    Torque Control

    Tension

    Setpoint


    Center winder training application software general

    Tension Controller

    Activation of the Tension Controller is selected via parameter.

    Parameter selectable Tension Setpoint.

    The actual Tension Reference is a calculation including selection of Tension Setpoint, Stall Tension, and Taper Tension based on roll diameter.

    Taper Tension: Reduction of tension reference as a function of diameter.

    Parameter selectable Tension Feedback (Transducer). Actual Feedback signals must be connected via Analogue Inputs.

    Winder Application Parameters


    Center winder training application software general

    Tension Controller

    63:5 Tension Ctl Enable

    NOT SEL ENABLE DI 2 DI 3 DI 4 DI 5 DI 6 XT DI1 FIELDBUS

    Running

    &

    63:9 Max Taper/%Taper

    KEYPAD AI 1 AI 2 AI 3 XT AI1 XT AI2 FIELDBUS

    63:6 Tension Setpoint

    PI

    AI 1 AI 2 AI 3 XT AI1 XT AI2 FIELDBUS

    Stall Tension Enable

    Regulator Release

    Reference

    Feedback

    % Taper

    Ref

    63:7 Tension FDBK Input

    AI 1 AI 2 AI 3 XT AI1 XT AI2

    Diameter

    mul

    63:21 Stall Setpnt (%)

    Winder Application Parameters


    Center winder training application software general

    Tension Controller

    P-Gain Min and P-Gain Max: P-Gain of controllers are adjusted as a function of diameter. As diameter increases the P-Gain of the Controller is increased linearly to P-Gain Max for improved regulation as diameter is changed.

    Two selectable web configurations. Each parameter for WEB 1 and WEB 2 are (infinitely) adjustable.

    Two (2) sets of PI gains for Dancer controllers.

    Winder Application Parameters

    Stall Mode Enable

    63:16 Web Selection 63:1 P-Gain 1 Min 63:17 P-Gain 2 Min 63:2 P-Gain 1 Max 63:18 P-Gain 2 Max 63:3 Integ Time 1 63:19 Integ Time 2

    PI

    K

    K

    mul

    Diameter

    I

    63:4 Range Adjust


    Center winder training application software general

    Tension Controller

    Stall Tension: If selected, is automatically activated when the line speed falls below a parameter set value. At this time the Tension reference is reduced to a parameter set percentage of setpoint tension. Stall PI gains are available for separate PI controller adjustment when in stall tension.

    Stall Mode Enable

    63:20 Stall Enable

    If = 3 then

    1) DISABLE 2) NORMAL GAIN 3) STALL GAIN

    &

    63:23 Stall P-Gain

    If NOT = 1 then

    Line Speed Ref

    63:22 Stall Speed

    A1

    B1

    63:24 Stall Integ

    A1 < B1

    &

    Stall Tension Enable

    Winder Application Parameters


    Center winder training application software general

    Tension Controller - Torque

    Tension Control Mode selection.

    (Speed Trim, Torque Trim, or Torque No-Trim)

    The selections for Tension Control Mode are (Torque Ctrl or Speed Ctrl). An additional parameter selection is required to select the operation of Torque Ctrl.

    Torque Control can be activated in Open Loop when Speed Control is the selected control mode. This is for special applications which require Tension trim in Speed ctrl and an additional Torque only mode, (Special load share applications).

    When in speed control the normal selection of the Torque Trim Sel parameter is [Tentorq Trim].

    Winder Application Parameters


    Center winder training application software general

    Tension Controller - Torque

    Torque Reference Selector

    TORQ REF SEL

    0

    Torque Ref to DTC

    1

    2

    3

    4

    MIN

    5

    6

    MAX

    +

    +

    Winder Application Parameters

    63:11 Tension Ctrl Mode

    Torque Ctrl

    Speed Ctrl

    Algorithm for determining Torque Reference Selection:

    When in Speed Control the selections [TenTorq Trim] & [Torque NoTrim] do not operate. In this mode torque can only be commanded with DI or FBA. The Torque mode is without trim.

    When in Torque Control the [Torque Trim Sel] determines if the Tension feedback trims the torque or if the torque is not trimmed. If an input is selected the operation is Torque Trim when the input is 0 and Torque NO trim when the input is 1.

    The selections of Over / Under and Pull / Holdback determine the selection in Torque Control for the Torque Reference Selector [ Min or Max ]

    63:12 Torque Trim Sel

    TenTorq Trim Torque NoTrim DI1 (NoTrim)DI2 (NoTrim) DI4 (NoTrim)XDI1 (NoTrim) XDI2 (NoTrim) FBA (NoTrim)

    Over / Under Sel

    Pull / HoldBack


    Center winder training application software general

    Tension Controller - Torque

    Frictional Losses: Static Friction for constant losses of the machine and Linear Friction for frictional loss change as a function of roll diameter.

    Winder Application Parameters

    Inertia Compensation

    Tension Reg Output

    63:10 Maximum Tension

    63:4 Range %

    Roll Diameter

    mul

    Torque Ref to DTC

    +

    Torque Reference Selector

    Friction

    63:14 Linear Friction

    TORQ REF SEL

    +

    Diameter

    0

    1

    2

    3

    Tension Reference

    Gear Ratio

    Roll Diameter

    +

    * /

    Torq Ref 1

    4

    MIN

    5

    6

    MAX

    63:13 Static Friction

    Torq Ref 2

    +

    +


    Center winder training application software general

    Tension

    Reference

    Tension Controller

    PI

    Winder Application Parameters

    Tension Trim - Torque Control

    Winder- Application

    Software

    Diameter

    Calculation

    Flux Code

    Tension

    to TQ cal

    Tension

    Reference

    Tension Controller

    PI

    Torque Correction

    Speed

    Reference

    Line Speed

    Reference

    Flux

    Accelerate

    Torque


    Center winder training application software general

    Inertia Compensation - WK²

    The calculation for Torque required due to speed change per time change (n/t).

    Parameters for Motor and Gearing inertia.

    Parameters for calculation constant system inertia.

    Can be deactivated in Speed control mode.

    Two selectable web configurations. Each parameter for WEB 1 and WEB 2 are (infinitely) adjustable. Selection of Web 2 is done in the Dancer or Tension parameters.

    Two (2) Web width parameters

    Two (2) Web density parameters

    Recommendation for Use:

    Required for all torque control modes and recommend for improved performance in speed control modes.

    Winder Application Parameters


    Center winder training application software general

    Diameter Calculation

    The calculation of the diameter is a function of line speed and winding roll rpm.

    Starting Diameter Values:

    The starting diameter can be preset using digital inputs or FieldBus. These inputs can be used to trigger a selection of three (3) parameter preset diameters. The first being Minimum core for a Winder or Maximum roll for an Unwind.

    The starting diameter can also be set by DI’s or FieldBus to manually increase or decrease the diameter value (Digital Operated Potentiometer).

    An ultrasonic sensor or mechanical measurement can also be implemented through XT AI2 and triggered through DI or FBus.

    Winder Application Parameters


    Center winder training application software general

    Winder Application Parameters

    Diameter Calculator

    t

    Line Speed Reference

    Actual Core Speed

    Diameter

    V

    t

    Diameter Reset

    N

    Dancer / Tension Enable

    Unwinder / Rewinder

    Count UP Enable

    Min Core Dia

    Max Roll Dia

    Web Thickness

    Count DOWN Enable


    Center winder training application software general

    Diameter Calculation

    Running Diameter Memory: The actual calculated diameter is stored in flash prom when power is lost to the drive. When power is restored the diameter is preset to the stored value.

    Web Thickness is used in the diameter calculation algorithm only as a maximum change limiter, to prevent unexpected speed change if a calculation error occurs.

    Diameter calculation inhibit functions:

    Diameter calculation is stopped when the line speed is below parameterized value.

    Diameter calculation decrease can be inhibited in Winders.

    Diameter calculation increase can be inhibited in Unwinds.

    Diameter calculation is stopped when torque mem is active.

    Winder Application Parameters


    Center winder training application software general

    Diameter Calculation

    The Diameter Calculator can be bypassed if an external device such as an Ultrasonic sensor is preferred. The Diameter calculator can be disabled with a parameter.

    There are available two (2) supervisory parameters for indication of diameter reached. In winder applications the indication is the preset diameter has been exceeded. In unwind applications the indication is the actual diameter is less than the presets.

    Winder Application Parameters


    Center winder training application software general

    Digitally operated potentiometer

    REF select

    Enable

    11.4

    DI4

    >

    FB_SPD_DEC

    +20,000 units

    DI3

    DEC

    >

    FB_SPD_INC

    INC

    >

    TON

    POT Rate 1

    POT rate 2

    R

    -20,000 units

    &

    Emergency stop

    Run Enable


    Center winder training application software general

    Additional Features

    Active Flux Control

    The automatic reduction of motor flux dependant on torque required. As the machine torque requirement is reduced the motor flux is reduced to improve current resolution.

    Winder Application Parameters

    100

    90

    80

    70

    60

    50

    40

    30

    20

    10

    0

    Required

    Motor

    Torque %

    Motor

    Flux %

    Flux

    Torque

    Time


    Center winder training application software general

    Active Flux Control

    Actual formula for Flux control

    Torque depends on flux vectors:T = c (sxr)

    Winder Application Parameters


    Center winder training application software general

    Over / Under wind selection

    Over or Under Wind selection can be made with the Forward / Reverse selection parameter. Over wind = Forward. To select Under wind the the reverse mode must be activated with a DI or FieldBus.

    Web Loss Detection

    Web Loss detection is calculated in the application. If web loss detection is desired, a Relay Output can be assigned to this function. The actions taken if a web loss occurs is dependant upon external controls provided by the end user.

    Web Loss Delay Timer adjustable at the keypad.

    Dancer & Tension Control:Web Loss trip point is an adjustable.

    Torque Control:Web Loss if speed actual is 10% greater than speed reference.

    Winder Application Parameters


    Center winder training application software general

    Transducer; Actual Tension Feedback

    Winder Application Parameters

    Single Position Winder

    Under Winding

    Winding

    Under Winding


    Center winder training application software general

    Turret Winder Roll Change

    The following functions were intended for use in Turret Winder applications in which automatic roll change is used.

    Core Speed Match: Used in pure speed control to trim the speed of the core. Trimming the speed of the core is done to adjust the web transfer to the new core during roll change. This may also be used to adjust the speed of the core when the core diameter varies in small percentages per the same standard core size.

    Winder Application Parameters

    61:1 Spd Mtch Ref Sel

    61:4 Spd Match Rate

    No SpdMtch AI 1 AI 2AI 3XT AI1 XT AI2 FIELDBUSDI3, DI4FBus b4,5

    61:2 Spd Match W/Trim

    Scaling &

    Digital

    Operated

    Pot Rate

    Additive Spd Ref

    mul

    23:4

    0

    Line Speed Ref

    61:3 Spd Match Range


    Center winder training application software general

    Turret Winder Roll Change

    Torque Memory is used to memorize the actual torque of the motor. The torque is memorized in order to maintain stable tension regulation during a continuous process roll change. The function is triggered through DI’s or FieldBus.

    Before indexing the finishing roll from the wind position a Sample of the actual torque is stored in the application.

    As indexing begins the Torque Memory is enabled. The drive changes to direct torque control independent of the normal operating mode. The memorized torque is then used as the torque reference.

    When the indexing is near the web transfer point the Boost Torque function may be activated to increase the actual tension of the web to aid in knife cut. The boost torque can be triggered form DI, Field-Bus, or a time delay function.

    Winder Application Parameters


    Center winder training application software general

    Turret Winder Roll ChangeContinued

    Winder Application Parameters


    Center winder training application software general

    Transducer; Actual Tension Feedback

    Winder Application Parameters

    Turret Winder - 2 Position

    Indexing

    Winding Position


    Center winder training application software general

    Winder Application Parameters

    Turret Winder - 2 Position

    Roll Change in Process, The Layon Roll moves to Position

    Torque Sample Memorized

    Activating Torque Memory

    Indexing

    Layon Roll

    Transducer; Actual Tension Feedback


    Center winder training application software general

    Winder Application Parameters

    Turret Winder - 2 Position

    Roll Change in Process

    Torque Sample Memorized

    Torque Memory Active

    Activate Boost Torque

    Indexing

    Transducer; Actual Tension Feedback


    Center winder training application software general

    Winder Application Configuration

    Winder Application consists of the macros :

    Selectable from Parameter 99.2

    Winder Ten

    Winder Dan

    Unwinder Ten

    Unwinder Dan


    Center winder training application software general

    Winder Application Configuration

    • Selecting Dancer modes automatically uses Speed Control

      • Group 63 is hidden

      • 62.5 = Enable or DIy high

      • when DIy goes low pure speed control is selected

  • If Tension modes are selected further configuration is required

    • To select Indirect Torque Control

      • 63.5 = Enable or DIy

      • when DIy goes low pure speed control is selected

      • 63.11 = Torque ctrl

      • 63.12 = Torque no trim or DIx high


  • Center winder training application software general

    Winder Application Configuration

    • If Tension modes are selected further configuration is required

      • To select Direct Tension control with Speed Trim

        • 63.5 = Enable or selectable by DIy high

        • when DIy goes low pure speed control is selected

        • 63.11 = Speed Ctrl

        • 63.12 = Tension Torque Trim or DIx low

        • when DIx goes high system goes to pure torque

      • To select Direct tension control with Torque trim

        • 63.5 = Enable or selectable by DIyhigh

        • when DIy goes low pure speed control is selected

        • 63.11= Torque Ctrl

        • 63.12 = Tension torque Trim or DIx low

        • when DIx goes high system goes to pure torque


    Center winder training application software general

    Winder Application Configuration

    • If a Switch between Dancer mode Speed trim and pure speed1 control

      is required

      • Parameter 62.5 should be connected to one of the DIy inputs

        • 62.5 = Enable or DIy high

        • when DIy goes low pure speed control is selected

          e.g. : Needed after a web break to wind the material into the core

    • If a Switch between Torque mode and pure speed1 control

      is required

      • Parameter 62.5 should be connected to one of the DIy inputs

        • 62.5 = Enable or DIy high

        • when DIy goes low pure speed control is selected

          e.g. : Needed after a web break to wind the material into the core


    Center winder training application software general

    Winder Application

    DDCS Interface


    Center winder training application software general

    Winder Application in ACx6xx

    DATASET 2 WORD 2 : Selectable Pointer

    DATASET 5 WORD 2 : Selectable Pointer

    DATASET 2 WORD 3: Selectable Pointer

    DATASET 5 WORD 3: Selectable Pointer

    DATASET 4 WORD 2 : Selectable Pointer

    DATASET 6 WORD 2 : Selectable Pointer

    DATASET 5 WoRD1 : Percent Draw Trim

    DATASET 4 WORD 3: Selectable Pointer

    DATASET 4 WoRD1 : Percent Draw Trim

    DATASET 6 WORD 3: Selectable Pointer

    DATASET 2 WoRD1 : Selectable Pointer

    DATASET 6 WoRD1 : Percent Draw Trim

    DATASET 1 WORD 2 Speed Reference

    DATASET 1 WoRD1 : Command Word

    DATASET 3 WoRD1 : Dancer / Tension

    DATASE 3 WORD2 : Taper Set-point

    DATASET 1 WORD3 : Application CW

    DATASET 3 WORD 3 : Speed match

    50 ms 100 ms 100 ms

    50 ms

    50 ms

    100 ms

    100 ms

    50 ms

    50 ms

    50 ms

    10 ms

    50 ms

    Fieldbus Adapters (External protocol to DDCS protocol)

    External PLC

    External PLC


    Center winder training application software general

    Winder Application

    DDCS Interface - Inputs

    Parameter Group 6


    Center winder training application software general

    Winder Application

    DDCS Interface - Inputs

    Parameter Group 6


    Center winder training application software general

    Winder Application

    DDCS Interface - Inputs

    Parameter Group 6


    Center winder training application software general

    Winder Application

    DDCS Interface - Outputs


    Center winder training application software general

    Analogue Inputs

    Standard AI (Qty 1 : 0-10v) (Qty 2 : 0-20ma)

    Dancer Mode Requirements

    Speed Reference

    Draw Set-point

    Dancer Set-point

    Taper Set-point

    Dancer Feedback

    Winder Application Additional Hardware


    Center winder training application software general

    Analogue Inputs

    Tension Mode Requirements

    Line Speed Reference

    Draw Setpoint

    Tension Setpoint

    Transducer Feedback

    Taper Setpoint

    If more than (1) input 0-10v - NAIO-021 req.

    Potentiometers require 0-10v

    If all listed Tension Inputs selected- NAIO-021 req.

    Winder Application Additional Hardware

    1 NAIO-01 is not supported by the application software


    Center winder training application software general

    Digital Inputs - Standard (6) 24vdc

    Maximum of 10DI and 5AI, 4AO and 5DO

    2 NDIO units and 1 NAIO-02 modules

    Normal DI Selections for Winder Applications

    1) RUN

    2) ENABLE

    3) FAST STOP

    4) REVERSE - (Over/Under Winding)

    5) FAULT RESET

    6) TENSION ENABLE / DANCER ENABLE

    7) DIAMETER RESET 1

    8) DIAMETER RESET 2

    9) TORQUE MEMORY SAMPLE - (Not available for Unwind)

    10) TORQUE MEMORY ENABLE - (Not available for Unwind)

    Winder Application Additional Hardware


    Center winder training application software general

    Digital Inputs - Standard (6) 24vdc

    Possible DI Selections for Winder Applications

    1) RUN

    2) ENABLE

    3) FAST STOP

    4) REVERSE (Over / Under)

    5) RAMPED SPEED 1

    6) RAMPED SPEED 2

    7)INCHING SPEED

    8) FAULT RESET

    9) TENSION ENABLE / DANCER ENABLE

    10) DIAMETER RESET 1

    11) DIAMETER RESET 2

    12) TORQUE MEMORY SAMPLE - (Not available for Unwind)

    13) TORQUE MEMORY ENABLE - (Not available for Unwind)

    14) TORQUE BOOST ENABLE - (Not available for Unwind)

    15) P-GAIN 2 SELECT

    Winder Application Additional Hardware


    Center winder training application software general

    Digital Inputs - Standard (6) 24vdc

    Most Winder Applications typically require at least (1) NDIO module.

    Turret Winder Applications with roll change requirements typically require (2) NDIO modules.

    Unwind Applications can typically be done with standard DI - Depending on Customer requirements.

    Winder Application Additional Hardware


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