Roll Diameter Requirements in Converting Processes 2802.16.17 29 PDF

Roll Diameter Requirements in
Converting Processes
www.siemens.com/converting
© Siemens Industry, Inc. 2016 All rights reserved. Answers for industry.
Roll Diameter in Converting Processes
Roll diameter accuracy is critical in many converting processes
v n
D ???
Roll diameter accuracy = Increased machine performance

Restricted © Siemens Industry, Inc. 2013 All rights reserved.
Center Driven Tension Control
Starting Diameter
Running Diameter

Center Driven Tension Control (Torque)

Diameter
Tension set point
Taper tension Tension setpoint
Acceleration
Acceleration torque
Diameter
Taper Tension Acceleration precontrol
J total
Drive
Inertia Calc Gain
V Speed setpoint
Web velocity
– –
Diameter Diameter
Override
Winder rotational speed

v n M
D
Web velocity Diameter

Diameter Calc

Center Driven Tension Control (Speed)

Web velocity Torque precontrol
J total
Inertia Calc
Gain
V Speed setpoint
Web velocity
– –
Diameter Diameter
PID
Dancer position fb
– Winder rot. speed
M
v n
D
Web velocity Diameter
Diameter Calc
Diameter
Tension setpoint Tension setpoint / Dancer Load

Taper tension
Restricted © Siemens Industry, Inc. 2013 All rights reserved. Taper Tension
Unwind Flying Splice
Web Direction
Bump Roll
Knife
Splice Mark
Unwind flying splice requires actual
Rotating roll diameter for firing the bump roll
Turret
and knife at their correct positions
and speed matching of new roll.

Turret Indexing
Stopping positions of the rolls.
Modification of the spindle velocity

setpoint during indexing.

Zero Speed Splice Splice

New Roll
Tail Cutters Zero speed splicing is diameter dependent

for auto splicing at the required minimum
diameter.
Nip
Tail Cutters
Depleting Roll
Gap and Lay-on Rolls
Lay on rolls applied in gap

winding must precisely
follow the roll diameter
accurately throughout the
winding process.

Surface Wind Rider Rolls
Rider Roll
Rider rolls on surface winders require roll

diameter to apply the correct specified
pressure throughout the roll build.

Common Diameter Determination Methods
How to get it?
Measurement - Sensor
Calculation

Measurement - Sensor
• Lay-on Roll Measuring Arm

• Diameter Sensor

Lay-on Roll Measuring Arm

Unwind
Layon Roll
Advantages
 Simple and robust.

 Relatively low maintenance.
 Diameter value does not require spindle or web
Rotary Diameter motion.
Sensor Tension
Controller

Lay-on Roll Measuring Arm

Unwind
Layon Roll
Disadvantages
 Must contact the roll

 Out-of-round rolls
 The output signal may require filtering
Rotary Diameter  Angle must be transformed to a linear distance.
Sensor Tension  Must be loaded against the roll
Controller  Roll changing / mechanics

Diameter Sensor
Unwind
Ultrasonic Diameter
Sensor
Advantages
 Linear output proportional to roll diameter.

 No material contact with the roll.
Diameter  The diameter value does not require motion.
Tension
Controller

Diameter Sensor
Unwind
Ultrasonic Diameter
Sensor
Disadvantages
 Measurement can be affected by moving air

and temperature drift (ultrasonic).
Diameter  Periodic maintenance and calibration.
 Susceptible to dirt and dust.
 Low density materials absorb the signal.
Tension
Controller  Damage from roll changes.
 Does not work well with out of round rolls.
 Signal typically requires filtration.

Diameter Sensors
SENSOR LAY-ON ROLL
vset ωset vset ωset
A/D A/D
Acceptable for starting diameter but neither are practical for providing a
process running diameter

How to Calculate?
Calculation
• Web Velocity / Winder Shaft RPM (V/n)

• Roll Turns & Web Thickness

Web Velocity / Winder Shaft RPM (V/n)
Web Velocity / Winder Shaft Rpm (V/n) is the most common method of determining
Running roll diameter for center driven spindles.
Diameter (D) is determined by using the relationship between surface web velocity (v)
and the angular velocity of the spindle (ω ) with the calculation v/n.


Web Transport
Unwind
(n)
(V)
Tension Controller
(V/n) = Diameter
(V), (n)
Drive System
Set D
filter ms
0 - 100% 0 - Dmin% D
Vact hold
D(min%) - 100%
D(min%) &
n < D(min%)
filter ms
D(min%) - 100%
nact
Legend:
V: Line speed
n: Rotational speed
D: Diameter
Advantages
 Requires no additional machine hardware.

 Simple calculation, directly proportional.
 Provides acceptable steady state diameter status.
Disadvantages
 Must be above minimum line speed for calculation (diameter hold).

 Filters required for output smoothness.
 Filter changes may be required for changes in material thickness.
 Poor accuracy during acceleration and deceleration.

Roll Turns & Web Thickness

Web
Thickness
Turns
Drive System Diameter (New = Diameter Old + (Thickness *2)
Web
Tension Thickness
Controller
Turns

Roll Turns & Web Thickness
Advantages
 Theoretically the most accurate diameter calculator.

 Not susceptible to acceleration / deceleration / speed disturbances.
 Does not require filtration.
 Does not require a diameter hold
Disadvantages
 Open Loop System.

 Web thickness variable must be accurate.
 Requires an accurate starting diameter

Improved Methods of Diameter Calculation
Two improved methods can utilized and offer several benefits over the
common diameter determination methods
Integration of Web Velocity /

Spindle RPM
Web Position / Spindle Angle

Integration of Web Velocity / Spindle RPM
In this method of diameter calculation, velocity is integrated over time to

determine a linear position change of the web and a angular displacement of the
spindle.
S
r= ,D = 2*r
θ
The diameter is calculated based on calculated web length (S) and calculated
angular displacement of the spindle (Ɵ)

Revolution(s) Reset >

𝜋𝜋 1
0
Nact Fine
interpolator
Sampling Time
Vact
Calculating with a web length and a spindle angle provides an increased stability of the
measurement and does not require the filtering that is used in v/n. The added stability of
this method is especially seen during acceleration and deceleration.
Advantages
 More accurate than (v/n) during acceleration / deceleration / speed disturbances.

 Does not require filtration.
 Can be used to also determine starting diameter (Actual position mode).
 Diameter hold not required.
Disadvantages
 Integral update time must be fast.

Actual Web Position / Actual Spindle Angle Calculation
Motion controllers and some drive control systems can provide the actual positions of
drives controlling the web and spindle
Revolution(s) Reset >

1
0
Spindle Angle Fine
interpolator
Web Length
Starting Diameter
Direct operator input (subject to errors)

Sensor Measurement
2x
r≈
θ
Starting diameter DIAMETER
+
with Position D
θ
TECHNOLOGY
F
CONTROL
x x
High degree of accuracy!
Only possible with a position based
control

Performance Review - Diameter Calculation Methods
Comparing the Calculation Methods
Next Step, Evaluation of the actual results.

The following analysis will look at the three
calculation modes under different conditions.
 Constant speed operation

 Speed changes & update frequency of the diameter
calculator logic

RED - V/n diameter Constant web speed: 100 m/min

GREEN - INTEGRAL diameter
BLUE - POSITION diameter

RED - V/n diameter Acceleration profile: 50 m/min > 300 m/min > 10 m/min
Update (sampling) time: 6 ms
BLACK - Web Velocity
RED - V/n diameter Acceleration profile: 50 m/min > 300 m/min > 10 m/min
Update (sampling) time: 1 ms
BLACK - Web Velocity
Web Velocity over Winder Shaft Velocity (V/n)
V
Web Velocity
Sample
Actual
t
n
Winder Shaft
Velocity
Sample
Actual
t
v1 v2 v3
Sample Periods
Integration of Web Velocity & Position Based Calculation

ACCELERATION
V ERROR
CONSTANT SPEED
V
∆t t
∆s ∆s ∆s ∆s
∆t ∆t ∆t ∆t t
Interpolation error does not exist in a

position based controller
∆t t
Increased Sampling rate
Conclusions
Roll diameter is critical in many converting processes.
By utilizing new techniques and new technologies we can

more accurately determine diameter and help converting
machines and converting processes to reach higher
performance levels.

Thank You
William Gilbert
Siemens Industry, Inc.
5300 Triangle Parkway
Norcross, GA 30092
Mobile: +1 (678) 314-4222

E-mail: william.gilbert@siemens.com
Website: www.siemens.com/converting

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Roll Diameter Requirements in

Roll diameter accuracy is critical in many converting processes

Roll diameter accuracy = Increased machine performance

Center Driven Tension Control

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Center Driven Tension Control (Torque)

Taper tension Tension setpoint

Inertia Calc Gain

Winder rotational speed

Web velocity Diameter

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Center Driven Tension Control (Speed)

Web velocity Diameter

Tension setpoint Tension setpoint / Dancer Load

Unwind Flying Splice

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Stopping positions of the rolls.

Modification of the spindle velocity

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Zero Speed Splice Splice

Tail Cutters Zero speed splicing is diameter dependent

Gap and Lay-on Rolls

Lay on rolls applied in gap

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Surface Wind Rider Rolls

Rider rolls on surface winders require roll

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

How to get it?

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

• Lay-on Roll Measuring Arm

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Lay-on Roll Measuring Arm

 Simple and robust.

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Lay-on Roll Measuring Arm

 Must contact the roll

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

 Linear output proportional to roll diameter.

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

 Measurement can be affected by moving air

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

SENSOR LAY-ON ROLL

vset ωset vset ωset

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• Web Velocity / Winder Shaft RPM (V/n)

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Web Velocity / Winder Shaft RPM (V/n)

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Web Velocity / Winder Shaft RPM (V/n)

Web Velocity / Winder Shaft RPM (V/n)

Web Velocity / Winder Shaft RPM (V/n)

 Requires no additional machine hardware.

 Must be above minimum line speed for calculation (diameter hold).

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Roll Turns & Web Thickness

Drive System Diameter (New = Diameter Old + (Thickness *2)

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Roll Turns & Web Thickness

 Theoretically the most accurate diameter calculator.

 Open Loop System.

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Integration of Web Velocity /

Web Position / Spindle Angle