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# Center Winder Training Application Software General - PowerPoint PPT Presentation

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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Presentation Transcript

Application Software

General

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

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.

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

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

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

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

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

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

Formulas for the Winder

Formulas for the Winder

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)

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

F

Winder Basics

Formulas for the Winder

4. Maximum and minimum Motor Speeds

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

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.

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

Formulas for the Winder

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

• 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

Configurations

Indirect and Direct Tension Control

Tensiometer

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

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

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)

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.

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.

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)

Configurations

Direct tension Control

with speed Trim

Direct tension Control

Direct tension Control

with Torque Trim

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)

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

Macc

Web type (material thickness/ material width)

Gain

Gain

D

D

Block Diagram of the Direct tension Control with speed Trim

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.

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.

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

Macc

Web type (material thickness/ material width)

Gain

Gain

D

D

Block Diagram of the Direct tension Control with speed Trim

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.

Configurations- Dancer Control

Dancer Control

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

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.

Dancer

Position

Feedback

to ACS600

Servo (I/P)

Force

+10 volts

0 volts

Response polarity as with a Transducer

Winder Basics

Configurations

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

Macc

Web type (material thickness/ material width)

Gain

Gain

D

D

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”

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

Web type (material

thickness/ material width)

Servo (I/P)

Gain

Gain

Force

D

D

Stall and Taper

Reference

### Dimensioning the Winder

Winder Basics

Dimensioning

• Selecting the correct Motor

• Recommending the optimal gearbox and speeds

• to mechanical supplier

How the customer specifies his load (typically)

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

Graphical Interpretation of the specified Load

30KW, 800 rpm/ 1500 rpm 150% overload

Constant TQ

TQ requirement proportional to

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

Calculating the Min and max values

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

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

Calculating the Torque at different speed points

Calculation based on Tset =Tmax conditions

Calculating the Torque at different speed points

Calculation based on Tset =Tmin conditions

Calculating the Torque at different speed points

Calculating based on Tset =Tmax conditions

Calculating the Torque at different speed points

Calculating based on Tset= Tmax conditions

Calculating the Torque at different speed points

Calculation based on Tset =Tmin conditions

Calculating the Torque at different speed points

Calculation based on Tset =Tmin conditions

• 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

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.

Dimensioning- Selecting the Motor

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.

Selecting the motor+Gearbox

Using the same process example

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

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

=

Selecting the motor+Gearbox

Dimensioning

Using the Application Checklist Form

Dimensioning

Dimensioning

Application Software

Implementation

Integration of the Winder Application

Standard and Multidrive

Winder Application Configuration

Winder Application consists of the macros :

Winder Ten

Winder Dan

Unwinder Ten

Unwinder Dan

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.

Dancer

Position

Feedback

to ACS600

Servo (I/P)

Force

+10 volts

0 volts

Response polarity as with a Transducer

Winder Application Configuration

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

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

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

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

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

PI

Winder Application Configuration

Motor

RPM

DTC

Diameter

Calculator

Line Speed

div

Dancer

Feedback

Dancer

Setpoint

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

62:11 Center Offset

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

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

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 (%)

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

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

Macc

Web type (material thickness/ material width)

Gain

Gain

D

D

PI

Winder Application Parameters

Motor

RPM

DTC

Diameter

Calculator

Torque Ref.

Line Speed

Spd Ref.

div

mul

Tension

Feedback

Torque Control

Tension

Setpoint

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

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

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

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

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

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

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

+

+

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

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

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

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

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

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

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

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

Actual formula for Flux control

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

Winder Application Parameters

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.

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

Winder Application Parameters

Single Position Winder

Under Winding

Winding

Under Winding

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 2 AI 3 XT AI1 XT AI2 FIELDBUS DI3, DI4 FBus b4,5

61:2 Spd Match W/Trim

Scaling &

Digital

Operated

Pot Rate

mul

23:4

0

Line Speed Ref

61:3 Spd Match Range

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

Turret Winder Roll Change Continued

Winder Application Parameters

Winder Application Parameters

Turret Winder - 2 Position

Indexing

Winding Position

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

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

Winder Application Configuration

Winder Application consists of the macros :

Selectable from Parameter 99.2

Winder Ten

Winder Dan

Unwinder Ten

Unwinder Dan

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

• 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

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

DDCS Interface

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

DDCS Interface - Inputs

Parameter Group 6

DDCS Interface - Inputs

Parameter Group 6

DDCS Interface - Inputs

Parameter Group 6

DDCS Interface - Outputs

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

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.

1 NAIO-01 is not supported by the application software

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)

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