DCS800 Winder applications

PDC2 EN REVA 2008

Product notes

Different winder types

Winder congurations can be classied by different control structures. Indirect tension control The web tension is calculated by motor speed and not measured. This is the most popular winder because hardware sensors are not required. It provides a very robust control behavior and is the basis for all more sophisticated control structures.

Dancer roll controlled winder Best winding quality is possible with a dancer roll system. The dancer roll balances inaccuracies and ensures a precise tension of the web. For dancer control the dancer needs a separate controller which regulates the position of the dancer.

M
T nact Dr act dact v ref= n ref

kg

M
T nact ... nref n ref ramp

M
nact Tref dact v ref = nref

M
nact . .. nref n ref ramp

Dancer control regulation scheme

Indirect tension control regulation scheme

Direct tension control The difference between indirect and direct control is the tension feedback. To get an accurate tension signal, a load cell is needed to measure the actual tension.

Velocity control If wrapping from one roll to another is required, M the unwind roll must be equipped with a mechaT nical brake. This brake denes the web tension. n The velocity will be affected by the winder TmoT tor. d During the wrapping it is possible to split the web with a cut.
act ref act act

M
nact ... nref nref ramp

M
nact Tref Tact dact vref = n ref

M
nact . .. nref n ref ramp

T T

M
nact vact dact vref

Velocity control regulation scheme Direct tension control regulation scheme

DCS800 winder control

The DCS800 Winder WilT1.1 is used with indirect tension control. The controller calculates coil diameter. The calculated diameter is used to adapt gain and ramp times and to calculate the tension reference.
Ref. Ve lo city (lin e sp e e d ) p ro ce ssin g 23.01 R a mp x 50 .17 D ia me te r ca lcu la to r Kp , Tn Ad a p t. To rq u e sca le In e rtia co mp e n sa tio n Frictio n - /L o ss co mp e n sa tio n Sp e e d co n tro lle r 25.01 To rq u e se le cto r 26 .02 Flux x

PDC2 EN REVA 2008

mechanical losses. The control structure ts well with the accurate torque behavior of DC motors in the eld weakening range. The winder control functionality is an add-on to standard rmware with additional parameters in groups 60 to 69.
C u rre n t co n tro lle r

nact

Tref.

Te n sio n re fe re n ce

The control interface for the customer can be classic hardware I/O or serial communication or even a mixed structure. Of course all other DCS800 features (e.g. DCSlink communication, masterfollower communication and 12-pulse control) are available as well.

Requirements DCS800 training DCS800 winder training (available as eLearning) Drive Window PC tool + DWL assistant

Requirements DCS800 training DCS800 winder training (available as eLearning) DCS800 ControlBuilder training (available as eLearning) Drive Window PC tool + DWL assistant

Customer benets

Flexible structure Standard commissioning ABB tool Wide power range Based on standard rmware function E-learnings for certication available

ABB Automation Products Wallstadter Strae 59 68526 Ladenburg GERMANY Phone +49(0)6203-71-0 Fax +49(0)6203-71-7609 www.abb.com/motors&drives dc-drives@de.abb.com

Copyright 2008 ABB. All rights reserved. Specications subject to change without notice.

Product notes

List of features

Winder Function

DCS800 Firmware

Main Path of Indirect Tension Control

The speed controller is used as line speed controller and operates in window mode. Additional features include inertia compensation during ramp-up and ramp-down and compensation for

Diameter calculation Tension calculation based on diameter Torque reference calculation Control gain is adapted based on diameter Tension compensation for mechanical losses Inertia compensation for speed ramp-up and ramp-down Wide diameter ratio (up to 1:10) Wind and rewind logic included

Two different packages are available

Ready programmed SDCS-MEM-8 WilT1.1 Order code:
Id code 3ADT200007R02 (separate) or ready programmed drive pluscode (+S202, +S203)

The winder function is handled by the additional parameter groups 60-69 and DriveWindow standard PC-tool (SDCS-COM-8 required for commissioning). The winder manual, publication no. 3ADW000308, provides information about winder basics and internal calculations of control function as well as commissioning information. Small functions can be added by adaptive program.

DCS800 Control builder template of WilT1.1 The template is the function block program of SDCS-MEM-8 WilT1.1. This includes the project le and the winder library. With control builder template new functions can be added, existing connections can be opened and cycle times can be changed. Testing of new function in lab environment is strongly recommended. Extended winder manual, publication no. 3ADW000253, provides additional information about the winder blocks (diameter calculation, tension controller, etc.)