Notes for Centre Wind Drive Applications

These notes are intended to help avoid the common errors made when selecting drives for Centre Wind applications. Centre wind tension control systems fall into two categories; they can be either speed controlled or torque controlled. Either way the objective is to maintain material tension throughout the full diameter range and over the machine linear speed range at a controlled value commensurate with obtaining a satisfactory rewound roll of finished product. The following observations are intended to help in the choice of control philosophy and drive configuration to be used for centre wind applications. SPEED OR TORQUE CONTROL Speed control systems are only practical where direct feed back of material tension from a dancing roll mechanism is available, load cell tension feedback is not normally practical for speed controlled winders as no material storage is provided to allow for control system span. Torque control systems can be used with or without direct tension feedback, the tension feedback for torque control systems may be derived from either a dancer mechanism or load cell. The selection of speed or torque control is usually decided by the machine manufacturer, who will have had previous experience of his machine and the material being wound however some background information is always useful to the drive engineer. Torque control solutions are normally adopted when the material to be wound is nonextensible, e.g. paper, steel, non-ferrous metals. However care should be exercised where no tension feedback is to be used. It is essential that mechanical transmission losses be kept to the absolute minimum. Low-tension applications where tension powers are comparable to transmission losses should not be attempted without some form of direct tension feedback. Where tension powers are high compared to transmission losses simple predictive torque control systems with no overriding tension feedback can be completely satisfactory. Extensible materials such as certain types of plastic and polyester films or machine configurations where non-extensible material is to be drawn from a catenary e.g. a looping pit, should normally be approached with a speed control solution in mind. Because speed controlled systems always rely on a tension feedback signal they are less sensitive to the problems experienced with predictive torque control systems where inertia and transmission losses can cause tension disturbances however the transmission losses and inertia effects should still be kept to the minimum. The dancer error operates on the drive in speed mode causing any tension disturbances due to torque changes within the load system to be very quickly compensated by the effect of the speed regulator. Where large inertias are involved it may still be necessary to provide some form of compensation in order to reduce the demands on the tension control loop. The diagrams below show the basic control configuration for speed and torque controlled centre wind systems.

Winder notes

TAPER TENSION Some materials require the tension to be reduced as the rewound diameter increases; this is termed taper tension. Taper tension may be implemented on open loop torque controlled systems and closed loop torque controlled systems using load cell measurement quite simply, by modifying the system tension set point as the diameter increases. Systems using dancer feedback whether operating in speed or torque mode pose a somewhat more difficult problem if taper is to be achieved. Dancer systems rely on the preloading of the dancer mechanism to set the material tension, to achieve taper this pre-loading must be modified according to diameter changes. Solutions are possible where dancer loading is pneumatic using Electric to Pneumatic (E to P) transducers controlled via an analog output from the drive diameter calculating software. Taper may be required to start from the central core diameter or may be introduced at some diameter threshold. The slope of the reduction in tension should be adjustable and will normally be set by the operator. Taper is usually required for material with a smooth surface where there is a possibility of the outer layers slipping over the inner layers, usually resulting in the rewound roll telescoping. Materials needing high degrees of taper include coated paper and some plastic films. CONSTANT TORQUE AND FIELD WEAKENING The decision concerning the use of field weakening depends to a large extent on the power requirements of the application. For lower power applications constant torque motors used in conjunction with over sized converters are the normal solution as the control strategy and set up is simple. DC constant torque solutions have the disadvantage that they operate at very poor power factor and draw comparatively high AC currents, as they must produce maximum torque at minimum speed. This means that the motor and converter be sized using the build up ratio multiplied by the tension power, possibly resulting in an expensive power converter. By using the constant power characteristic of the motor the converter size can be reduced, on DC systems the AC current reduces accordingly and the power factor is improved as the motor operates at its optimum voltage through the diameter range. This solution should be considered where tension powers above about 50Kw are to be provided. As an example, a system requiring 20Kw of tension power over a 5:1 diameter range with no taper using a constant torque motor will require a 100Kw motor and a 100Kw converter to match. This would be economically acceptable but for DC systems the customer should be advised of the likely level of the AC currents and the abnormally low power factors when the drive is operating at maximum diameter. Obviously if the tension power is increased to 200Kw over 5:1 diameter range, the constant torque solution becomes totally unacceptable as both the motor and controller would effectively be sized at 1000Kw. A 330Kw controller with 3:1 field controller would be a far more effective solution costing less and reducing the current required at maximum diameter to one third that of the constant torque solution. Modern DC motors can normally only be operated over 3:1 or 3.5:1 range of diameter by field weakening, any larger ratio must be provided by the constant torque range of the motor and the converter oversized accordingly. Some older motors encountered on refits may have 4:1 or even 5:1 by field weakening. A modern motor with a 3.5:1 constant power range may well need a field current range in the order of 10:1, this can be troublesome as the field current reduces to a level very close to the point a which the field failure trip will be reported. Constant power solutions using field weakening on AC systems are also feasible however a limit of 2.5:1 by field weakening is suggested as the absolute maximum, constant torque with over-sizing of the converter should be used for diameter ranges above this limit. When offering constant power solutions always check with the motor supplier, these are not standard windings and should be selected by the motor designer.

Winder notes

In Example 1 above the motor AC or DC would be specified as 100Kw at 1500RPM. In Example 2 the DC motor could be specified as 200 / 200 / 200Kw 300 / 500 / 1500 RPM 270 / 450 / 450 Volts The converter would need to be rated for 333Kw.ie. {200 x 450} 270 An AC option for Example 2 would possibly be 200 / 200 / 200Kw 300 / 600 / 1500 RPM 20 / 40 / 100 Hz 207 / 415 / 415 Volts The converter would need to be rated for 400Kw. The speeds and voltages selected are for example only. Ideally the motor speed should be as close to the required spindle speed as is practical, this reduces errors in tension due to transmission losses and the effect of motor rotor inertia. POWER REQUIREMENTS FOR CENTRE DRIVEN WINDERS Winder motors should always be sized from knowledge of the required winding tension and line speed.

Winding tension power (kW) = Line speed (MPM) x Total tension pull (Newtons) 60000 If constant torque control is to be employed then the motor and converter should be rated Motor/Converter (KW) = Winding tension power (Kw) x Maximum diameter Minimum diameter Motor speed (RPM) = Line speed (MPM) x Gear ratio Pi x Diameter (metres)

This will ensure that the drive can produce the torque required at maximum diameter and the speed required at minimum diameter. Constant power applications are best specified by stating the power and speed requirements at both ends of the diameter range. If a combined constant power / constant torque application is involved then the speed and power requirement at base speed should also be quoted. Any additional power required to provide for transmission losses and peaks for acceleration should be added to the above result. Winding heavier gauges of metal requires additional power to form the metal around the periphery of the coil, tighter bends occur at smaller diameters the bending effort therefore reduces with increasing diameter unlike the tension torque which increases with diameter. This means that the drive benefits from a balancing of these two torques but the control system may need to calculate the individual torque components in order to achieve accurate control over the tension.

INERTIA COMPENSATION During line speed changes energy must be supplied to or removed from the rotating masses of the rewind mechanism. The amount of energy transferred depends upon the inertia of the total system and the rate of change of speed. All rewinds and unwinds can be considered as having two inertia elements, one of fixed inertia made up of the motor and transmission components together with the core or spindle onto which the material is wound. The other is

Winder notes

the inertia of the wound material, which obviously varies from zero to a maximum value as the diameter increases. An estimate of acceleration torque referred to tension torque at various diameters will give an indication of the degree of tension disturbance to be expected during speed changes. Systems with low inertia or slow rates of acceleration, where the acceleration torque is small compared to the tension torque will need very little or no compensation. High speed winders with rapid acceleration and high inertias where acceleration torques can be equal to or greater than the tension torques will obviously need precise inertia compensation. Deriving rate of change signals for use in the inertia compensation calculation can be troublesome. The most satisfactory system is to use an S-Ramp to set the acceleration characteristic of the line speed controller. The S-Ramp should be configured to provide not only a speed reference value but also an acceleration rate signal, this can be used in conjunction with the inertia values to produce a torque feed forward for the winder drive to compensate for inertia effects. Simple systems with acceleration torques, which are relatively constant throughout the diameter range, can use block compensation. Basically switching the compensation torque in and out on the result of a simple accel / decel detection system. More sophisticated arrangements may need some shaping of the torque related to diameter but can still rely on an acceleration switch. High performance systems should always use S-Ramp acceleration of the line speed controller with accurate speed and trapezoidal rate of change of speed signals fed forward to the winder control software. S-Ramp software is available to provide these functions. Systems have been installed and commissioned running up to 2200 MPM with acceleration rates of 20 MPM per second using both AC and DC drive technology.

LOSS COMPENSATION Transmission systems should be selected to be, as loss free as possible, worm gear boxes should be avoided. Ideally motor speeds should match winder spindle speeds with no requirement for speed reduction but on smaller machines this is normally not practical. Toothed belt or low loss inline gear boxes should be specified, some discussion with the machine manufacturer may be necessary here, not all machine builders realise the effect that the mechanical transmission system can have on winder drive performance. Losses are usually considered to split into two components, basic stiction which is considered to be constant throughout the speed range and viscuous where the loss increases with speed. Small values of both components are relatively simple to compensate for but often complications arise if the losses are comparable to the tension component. Any variation in actual loss due to temperature changes in the lubricants, general running in of machinery etc. can cause substantial disturbances to the tension. The most satisfactory solution here is to use direct measurement of tension with closed loop tension control. If this is not possible then some form of auto compensation should be considered where the machine losses are measured and stored by the control system and used to provide the compensation during production runs. These solutions are hardly ever totally satisfactory. Ideally for satisfactory open loop tension control the torque required to overcome transmission losses should be no greater than 10% of the minimum tension torque. FLUX COMPENSATION The torque produced by a motor is determined by the product of its active current and its flux. When the motor runs above base speed the relationship between active current and actual torque changes due to the reduction of flux. The Unidrive torque loop automatically corrects for this thereby ensuring that the actual torque delivered matches the torque demanded.

Winder notes

The Mentor does not provide this facility, therefore when using DC motors in torque control applications above base speed it is necessary to modify the relationship between torque demand and armature current demand to compensate for the change in motor performance. This must form an integral part of the winder control software package. A simple algorithm to achieve this is: If speed > base speed then Current = Torque x speed Base speed Else Current = Torque DRIVE SELECTION - LIMITING PARAMETERS DC motor with Mentor control This has been the traditional solution for all winder applications for many years. It has the advantage of a linear motor torque characteristic with the possibility of extending the operating range by field weakening above the motor base speed. Accuracies on simple predictive systems of between 3-5% of maximum tension are attainable with improvement to 1-2% using tension feedback. Due to the large predictable torque range available from the motor, wide ranges of tension and diameter range product are practical. Typical operating parameters for standard packages would be: Tension range Diameter range Material speed 1:10 1:10 1:20

Such a system would require a sensitive method of speed feed-back as the overall speed range of the rewind motor will be 200:1, DC tacho or a high pulse count encoder are essential to ensure performance at the low speed. The performance can easily be assessed, by logging motor current and voltage throughout the diameter range and checking for a constant power product. Corrections being made for any changes in line speed or taper tension effects during the test. The above performance figures assume minimal transmission losses. AC motor with Unidrive Vector control Since the introduction of Version 3 Unidrive with improved torque control this option has become a feasible alternative to the DC option. Torque linearity is probably not quite upto the DC version but has been proven to be quite adequate. Operation above base speed is possible with a suggested limit of 2.5 : 1, above this torque linearity becomes suspect. Typical operating parameters for standard packages would be: Tension range Diameter range Material speed 1:10 1:5 1:20

Such a system would require a sensitive method of speed feed-back as the overall speed range of the rewind motor will be 100:1, closed loop vector control is essential to ensure performance at the low speed. The performance is less easily be assessed, as there is no simple means of checking true power delivery throughout the range of the drive. The above performance figures assume minimal transmission losses. Servo Drives Brushless AC motors under Unidrive control provide a more accurate means of controlling torque than their Asynchronous counterparts. Performance obtained with such systems

Winder notes

should match those produced by a conventional DC system but no field weakening range is available. Typical operating parameters for standard packages would be: Tension range Diameter range Material speed 1:10 1:10 1:20

DESIGN STUDY (High speed paper winder) Machine Line diagram The winder has a centre driven unwind and surface driven rewind.

L O AD CELL

U N W IN D M O T O R

R E W IN D M O T O R

Winder specification (from machine builder) Maximum speed Threading speed Acceleration rate Material width Maximum tension Minimum tension Parent reel diameter Reel shell diameter Parent Inertia Reel shell Inertia Motor Inertia Mechanical Brake Torque Emergency Stop Time 2200 metres per minute 5 10 metres per minute 20 metres per minute per second (110 secs) 4.6 metres 10 Newtons per centimeter 1 Newton per centimeter 2600 mm 567 mm 33254 Kg m2 414 Kg m2 110 Kg m2 10000 Nm 30 seconds

Sizing calculations for the Unwind motor are as follows: Maximum tension force = Max tension x width = 10 x 4600/10 = 4600 Newtons = Max tension force x Max paper speed 60,000 = 168.7 Kw =1235RPM

Maximum tension power

RPM at 2200 MPM for the shell diameter = 2200 Pi x 0.567 = 1235 RPM RPM at 2200 MPM for the max diameter = 2200 Pi x 2800

=250RPM

Winder notes

Total deceleration power requirement for a normal stop with normal tension control maintained is estimated as below: Torque to decelerate the Unwind at maximum diameter during a normal stop. = (Parent reel Inertia + Shell Inertia + Motor Inertia) x 2 x Pi x RPM 60 x Deceleration time = (33253 + 414 +110) x 2 x Pi x 250 60 * 110 = 8038 Nm Equivalent deceleration power = 8038 x 250 9549 =210 Kw Total deceleration power requirement for a normal stop = Tension power + Deceleration Power = 168 + 210 = 378 Kw Torque regulating range of the motor = Max tension x Max diameter Min tension x Min diameter = 10 * 2800 1 x 567 = 49.4 : 1 Obviously this range of torque is outside the limits of normal prediction accuracies and will require closed loop tension control using the load cell. Emergency stop torque required (Assumes no tension power as the Paper will be broken) = Total U/W Inertia x 2 pi x RPM 60 x E-Stop time = 33778 x 2 x Pi x250 60 x 30 = 29477 Nm

The U/W mechanical brake provides 10,000 Nm So motor must provide 19477 Nm Emergency stop power requirement = 19477 x 250 9549 = 510 Kw

Specification for the Unwind motor will be: 169 / 169 / 169 Kw 250 / 500 / 1235 RPM Overload for Normal Stopping: 378 Kw for 110 seconds Overload for Emergency Stopping: 510 Kw for 30 seconds In this instance an AC machine was used and the final specification for building was: 169 / 169 / 169 Kw 250 / 500 / 1235 RPM 16 / 33 / 80 Hz 200 / 415 / 415 Volts

Winder notes

Inertia Compensation Analysis The torque required to accelerate the Paper component of the Unwind may be calculated using: Accl Torque = Pi x max line speed (mpm) x width x density x ( Actual diam 4 Shell diam 4 ) (Paper) 960 x acceleration time to max line speed The torque required for the fixed inertia component is simply: Accl torque = (Shell inertia + Motor inertia) x 2 x Pi x Unwind RPM at the actual diameter (Mechanics) 60 x acceleration time to max line speed Total acceleration torque is the sum of these two components. Tension torque = Total tension force x Actual Unwind diameter 2 Final torque for accelerating = Acceleration torque - Tension torque Final torque for decelerating = -1 x Acceleration torque - Tension torque The level of power needed to accelerate the Unwind compared to the power required to maintain constant tension through the diameter range is shown below. It can be seen that considerable disturbances in tension levels will occur if no Inertia compensation is provided. In fact when compared to the tension torques at the probable normal running tension of 6 N/cm the acceleration torque exceeds the tension torque at all diameters above 1700mm. Implying that the unwind will be required to motor during acceleration periods.This emphasises the need for an accurate Inertia Compensation system if acceptable tension control is to be achieved, calculation of inertia and prediction of acceleration torque must be accurate with no jitter. This in turn places great demands on the quality of the diameter calculation and measurement of acceleration rate, any errors in these functions will result in large disturbances in tension.

Effect of Inertia
100.00 50.00 0.00 -50.00 0 -100.00 -150.00 -200.00 -250.00 -300.00 -350.00 -400.00 -450.00 Diameter

1000

2000

3000 Tension power Total Accl power Toatl Dccl power

The system normally adopted on modern high-speed paper winders is to accept the manufacturers quoted values for the fixed inertia components. eg. the shell and the motor. The variable inertia component is continuously calculated knowing the paper density, roll

Winder notes

U/W Power

width and diameter. These two components can then be combined and multiplied by the acceleration rate to give a precise value of required acceleration torque. No loss compensation is required on these machines as the friction component is almost negligible and any tension error due to losses is corrected by the load cell tension loop. The block diagram of the Tension control software for this Unwind is shown below, this operates in conjunction with an S-Ramp housed in the associated rewind drive which provides both speed and acceleration reference signals.

On a DC system a Flux compensation factor would be introduced to change the effect of the drive torque scaler as the motor operates through its field weakening range. Paper has a relatively constant density but the overall density of a roll can vary depending on how tightly it has been wound and what quantity of air has been trapped between the layers. By checking the rate of increase in volume of the rewound roll, which is surface driven and has the air excluded. Compared to the reduction in volume of the Unwind roll some indication of relative densities can be achieved and used to provide online correction of the value used in the unwind calculation. This assumes that an accurate of signal of rewind diameter is available, most modern machines have an Lv/Dt device to provide this signal. The minimum line speed required for threading is 5 metres per minute this means that the minimum speed of the Unwind will be as low as 250 RPM x 5 = 0.57 RPM 2200 Accurate speed control with diameter compensation must be provided at this level in order to match the unwind pay off speed to the surface speed of the rewind to allow trouble free threading of paper through the machine. Tension control is invoked by the winder control system slightly above this speed as the machine accelerates, at these low RPMs the speed feedback signal provided by the drive is not adequate for accurate diameter computation resulting in problems with the tension control. An additional high precision, speed measurement task using an extended count period was implemented to overcome this problem.

Winder notes

Due to the very wide speed range of this machine and the requirement for very smooth control of line speed with no overshoot during jogging and threading of the rewind some considerable attention was paid to the rewind speed controller. In order to achieve the desired performance of the rewind two torque feed forward components should be provided. One to provide acceleration torque the other to provide a torque proportional to the tension setting at the unwind. This means that the required torque at the rewind is predicted fairly accurately, hence reducing the span required from the speed control loop itself. Accel torque = Rewind drum Inertia x 2 x Pi x RPM at Max line speed 60 x Accel time It was not considered necessary to provide inertia compensation for the Paper component but if the Rewound diameter is known this would be practical.

Tension torque = Total tension force x Rewind drum diameter 2 The provision of these torque feed forward signals into the rewind speed controller ensures that the rewind drive gain parameters can be set up to give no overshoot and smooth control. The requirement for accurate torque feed forward at the Unwind and Rewind of these machines imposes a requirement for an accurate S-Ramp generator with precise values of acceleration rate and line speed as its output. It was found necessary to provide these signals at the resolutions stated below: Line speed Accel rate 0 - 2200 metres per minute in 22000 increments 0 - 20 metres per minute per second in 200 increments

This was primarily to ensure correct operation of the Unwind torque feed forward calculations.

Winder notes

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