IMPR Simple Winder Documentation

A&D MC PM 5 17. October 2000 Version 1.
Simple winder with free modules for Masterdrives MC / VC
Copyright (C) SIEMENS AG 2000 All Rights Reserved
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Winder with free modules 17. October 2000 Version 1.0
Index
1 Function scope ................................................................................................................................ 3 2 Function description ........................................................................................................................ 4 2.1 Direct tension control by torque limiting........................................................................... 4 2.2 Indirect tension control by torque limiting ........................................................................ 6 2.3 Direct tension control by rotational speed correction....................................................... 7 2.4 Taper tension control ....................................................................................................... 8 2.5 Diameter calculation ........................................................................................................ 8 2.6 Moment of inertia ............................................................................................................. 8 2.7 Gear ratio ......................................................................................................................... 9 2.8 Tension operating mode .................................................................................................. 9 2.9 Maneuvering and jogging................................................................................................. 10 2.10 Line breakage detection................................................................................................... 10 2.11 Quick stop ........................................................................................................................ 10 3 Control ............................................................................................................................................. 12 3.1 Winder control- and status word ...................................................................................... 12 3.2 Winder interface to the automation system ..................................................................... 13 4 Comissioning ................................................................................................................................... 14 4.1 Standardization ................................................................................................................ 14 4.2 Interface adjustment ........................................................................................................ 14 4.2.1 Direct tension control with load cell (control method A) ................................... 15 4.2.2 Indirect tension control (control method B)....................................................... 15 4.2.3 Direct tension control with dancer roll (control method C) ............................... 16 4.3 Acceleration torque .......................................................................................................... 16 4.4 Friction characteristic ....................................................................................................... 17 4.5 Rotational speed controller optimization.......................................................................... 17 4.6 Tension controller optimization ........................................................................................ 18 5 Appendix.......................................................................................................................................... 19 5.1 Formulary ......................................................................................................................... 19 5.2 Formula symbols.............................................................................................................. 20 5.3 Selection criteria............................................................................................................... 21 5.4 List of free modules used................................................................................................. 22 5.5 Winder checklist............................................................................................................... 23 5.6 Winder application (Masterdrive MC) .............................................................................. 25 5.6.1 Function diagrams ............................................................................................ 25 5.6.2 Script MC_WINDER_CELL (Control method A).............................................. Fehler! Textmarke 5.6.3 Script MC_WINDER_INDIRECT (Control method B)....................................... Fehler! Textmarke 5.6.4 Script MC_WINDER_DANCER (Control method C) ........................................ Fehler! Textmarke 5.6.5 Specific Scripts (MC) ........................................................................................ Fehler! Textmarke 5.6.5.1 Script SC_SPEED_CONTROL_MC ............................................... Fehler! Textmarke 5.6.5.2 Script SC_TORQUE_COMP_MC................................................... Fehler! Textmarke 5.6.5.3 Script SC_TORQUE_LIMITING_MC.............................................. Fehler! Textmarke 5.6.6 General Scripts ................................................................................................. Fehler! Textmarke 5.6.6.1 Script SC_TENSION_SET ............................................................. Fehler! Textmarke 5.6.6.2 Script SC_ANALOG_INPUT_MC ................................................... Fehler! Textmarke 5.6.6.3 Script SC_TECHNO_CONTROL.................................................... Fehler! Textmarke 5.6.6.4 Script SC_OVERRIDE.................................................................... Fehler! Textmarke 5.6.6.5 Script SC_LINE_CORRECTION .................................................... Fehler! Textmarke 5.6.6.6 Script SC_SPEED_CORRECTION ................................................ Fehler! Textmarke 5.6.6.7 Script SC_DIAMETER_CALC ........................................................ Fehler! Textmarke 5.6.6.8 Script SC_LINE_SPEED_SET ....................................................... Fehler! Textmarke 5.6.6.9 Script SC_TORQUE_LIMIT............................................................ Fehler! Textmarke 5.6.6.10 Script SC_WINDER_CONTROL_WORD....................................... Fehler! Textmarke 5.6.6.11 Script SC_WINDER_CONTROL .................................................... Fehler! Textmarke 5.6.6.12 Script SC_WINDER_CONTROL_INDIRECT ................................. Fehler! Textmarke
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5.7 Wicklerapplikation (Masterdrive VC)................................................................................ Fehler! Textmarke 5.7.1 Funktionsplne ................................................................................................. Fehler! Textmarke 5.7.2 Script VC_WINDER_CELL (Control method A) ............................................... Fehler! Textmarke 5.7.3 Script VC_WINDER_INDIRECT (Control method B) ....................................... Fehler! Textmarke 5.7.4 Script VC_WINDER_DANCER (Control method C)......................................... Fehler! Textmarke 5.7.5 Specific Scripts (VC)......................................................................................... Fehler! Textmarke 5.7.5.1 Script SC_ANALOG_INPUT_VC.................................................... Fehler! Textmarke 5.7.5.2 Script SC_SPEED_CONTROL_VC................................................ Fehler! Textmarke 5.7.5.3 Script SC_TORQUE_COMP_VC ................................................... Fehler! Textmarke 5.7.5.4 Script SC_TORQUE_LIMITING_VC .............................................. Fehler! Textmarke 5.8 Legend ............................................................................................................................. Fehler! Textmarke 5.9 Literature .......................................................................................................................... Fehler! Textmarke
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Function scope
This application realizes a simple winder based on free modules for the basic units Masterdrive MC and VC. Required software versions are 1.4 for the Masterdrive MC and 3.2 for the Masterdrive VC . This winder application contains the following functionality: Direct tension control by torque limiting with load cell (Control method A) Indirect tension control by torque limiting (Control method B) Direct tension control by rotational speed correction with dancer roll (Control method C) Diameter calculator Variable line width setting Variable material density setting (by parameters) Maneuvering Jog speed (1 jogging setpoint) Line breakage detection
The selection of the control method is not realized with selectors, on account of both the limited supply of free modules and the limited run-time in the frequency inverter. That means, that a download script file is available for every tension control method.
The winder can be set as follows: Winder or unwinder Over- or underwind Regarding a gear ratio Taper tension characteristic
In addition to the usual control- and statusword, theres a specific winder control- and statusword, which is directly controlled via the parameterized interface. This interface can be controlled via PROFIBUS or SIMOLINK, or also via digital inputs. Digital inputs require additional input modules (EB1 or EB2).
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Function description
For the considerations hereinafter the following is always valid: The line speed setpoint, respectively the rotational speed setpoint and the given tension force are always positive. For position controlling, the position setpoint is 0% or positive.
2.1
Direct tension control by torque limiting

1 2 3 4 5 6 7 8
F V const n+ F act
M+
M
B B
V set Jog Setpoint

C
Speed Controller
Current Controller
Power Section
Maneuvering
Override J Gain-Adaption Diameter Calculator D act
n act
D
F set
Taper Tension Characteristic F act

E E
Acceleration Torque D act Friction Torque Gain-Adaption
Siemens AG A&D MC PM5

1
Datum Bearb.
15.10.00 Zelder 2
Winder with load cell; control method: torque limiting Winder concept; basic unit CUMC/VC
3 4 5 6 File pl_winder_cell.vsd 7 8
Page 1
Fig. 2.1.1: Direct tension control with load cell by torque limiting With this control method (see Appendix, figure 6.1), the material tension is measured by means of a load cell. The tension controller responds to deviations from the given tension setpoint. The tension controller is designed as a PI controller. The tension setpoint can be influenced during the wind up by means of the taper tension characteristic, dependent on the diameter. The resulting tension control component is added to the tension setpoint and weighted with the diameter D. The friction and acceleration torque with sign according to table 2.1.1 is added to this tension torque.
Type of winder Unwinder Winder
Acceleration and friction torque sign +
Tab. 2.1.1: Acceleration and friction torque sign dependent on type of winder The resulting torque works as a limiting torque at the rotational speed controller output.
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The given line speed setpoint is converted into the according rotational speed by means of the actual diameter. To be effective in tension operation, the torque limiting is switched to an additional line speed setpoint, which leads to an override of the rotational speed controller. The override for line speed is switched with sign according to table 2.1.2. Mode of winding Overwind Underwind Override sign +
Tab. 2.1.2: Override sign dependent on mode of winding
The override switching is delayed by means of a PT1 element. A small override should be chosen to build up material tension slowly. The tension setting is realized directly via torque limiting. The switching of the calculated torque limiting to the lower, respectively upper limit is realized according to table 2.1.3. Mode of winding Overwind Overwind Underwind Underwind Type of winder Unwinder Winder Unwinder Winder Torque limit lower upper upper lower
Tab. 2.1.3: Torque limit switching dependent on type of winder and mode of winding
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2.2
Indirect tension control by torque limiting

1 2 3 4 5 6 7 8
V const
F n+
M+
M
B B
V set Jog setpoint

C
Speed controller
Current controller
Power section
Maneuvering
Override J Gain-adaption Diameter calculator D act
n act
D
F set
E
Taper tension characteristic
Acceleration torque Friction torque

1
Datum Bearb.
15.10.00 Zelder 2
Winder without load cell; control method: torque limiting Winder concept; basic unit CUMC/VC
3 4 5 6 File pl_winder_indirect.vsd 7 8
Page 1
Fig. 2.2.1: Indirect tension control by torque limiting For this control method, no signal for tension measurement is available. With the exception of the tension controller, this control structure is conform with the tension control by torque limiting. The torque limiting consists of both the torque of the tension setpoint and the friction and acceleration torque. First is realized by weighting the tension setpoint with the actual diameter. The exactness of the calculated friction and acceleration torque is essentiell for the exactness of the tension required.
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2.3
Direct tension control by rotational speed correction

1 2 3 4 5 6 7 8
V const L act D act
+ P U
M+ n+
M
B
F set
Taper tension characteristic V set Jog setpoint Speed controller
Current controller
Power section
Maneuvering
J D act n act
D
Gain-adaption
Diameter calculator
D
L set
L act
Acceleration torque D act Friction torque

F
Gain-adaption
1 Datum Bearb. 15.10.00 Zelder 2
Winder with dancer roll; control method: speed correction Winder concept; basic unit CUMC/VC
3 4 5 6 File pl_winder_dancer.vsd 7 8
Page 1
Fig. 2.3.1: Direct tension control with dancer roll by rotational speed correction For direct tension control with a dancer roll, tension is set by the dancer roll. The counter-pressure is set by the taper tension characteristic via a pneumatic power controller at the dancer. The suspension of the dancer roll must be laid out accordingly. The position setpoint, determined by the operating point, is maintained by the position controller. The actual position value is e.g. evaluated by a position or angle meter. The actual position value is compared with the position setpoint. The resulting difference is compensated with a P(I)-controller and switched to as an additional line speed setpoint. The switching of the additional line speed setpoint is realized according to table 2.3.1.
Type of winder Unwinder Winder
Rotational speed correction sign +
Tab. 2.3.1: Rotational speed correction sign dependent on type of winder This control loop might possibly lead to vibrations. An additional D component of the actual position value has cushioning effect and prohibits the predisposition for vibrating. The resulting line speed setpoint and the actual diameter are converted into a rotational speed setpoint. The rotational speed controller is pre-controlled by the friction and acceleration torque.
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2.4
Taper tension control
Taper tension control is only useful and effective while winding up. The taper tension characteristic is dependent on the actual diameter (output motorized potentiometer). The motorized potentiometer is part of the free available modules. The firmly parameterized characteristic can be dissolved with maximum 10 value pairs.
2.5
Diameter calculation
The actual diameter results from the ratio of line speed reference to actual rotational speed. The diameter value is needed to convert the line speed into the according motor rotational speed.
Dact [%] = Dmin [%]
Vset [%] nact [%]
The diameter values are scaled to the maximum diameter; likewise, the line speed and the actual rotational speed value are scaled to the maximum line speed, respectively the maximum nominal rotational speed. To reach a stable closed-loop performance, the diameter calculation must show an integral performance. This is guaranteed by the used free module motorized potentiometer. The calculated diameter value is additionally smoothed by a time constant of 100 ms. The diameter calculation is not stable until a minimum rotational speed has been reached. Until this minimum has been reached, the preset value will be used. An adaption of this minimum rotational speed preset, e.g. with a layer counter, is not scheduled within this application. The diameter calculator can be stopped with a stop-signal, respectively set with a set-signal. The setsignal is given via the interface.
2.6
Moment of inertia
The moment of inertia is composed of a constant and a variable component. The constant component consists of motor-, gearbox- and core-inertia. The variable component consists of the inertia of the wound-up material. The moment of inertia always refers to the motor shaft.
J = J motor + J gear + J core + J material """ """! " " ! J cons tan t J var iable
The motor- and gearbox-inertia can be obtained at the manufacturer. The core-inertia can be calculated by the following principle. Core-inertia
[kg m 2 ]
J core =
b 4 4 (Doutside Dinside ) 2 32 i
[m] [kg / m 3 ] [m 4 ]
Tab. 2.6.1: Core-inertia The inertia of the wound-up material can be calculated analogue.
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Inertia of wound-up material
[kg m ]
2
J material =
b 4 (D 4 Dmin ) 2 32 i
[m] [kg / m 3 ] [m 4 ]
Tab. 2.6.2: Inertia of wound-up material The moment of inertia cannot be directly calculated with the existing set of free modules. It has to be calculated in advance, dependent on the diameter, and deposited as a characteristic. This characteristic includes maximum 10 support values. The width and density of material can be changed in terms of percentage. The originator of this application is a scaled moment of inertia, that is, the calculated moment of inertia is scaled with the nominal rotational speed and the rated torque of the motor. The total moment of inertia is calculated as follows:
J [s]
MN = N
4 [m 4 ] B [m] [ kg / m 3 ] D 4 max max max 4 [%] b[%] [%] +J +J + d [%] d J core min motor gear 32 i 2 1012 """"""""""""""" """""""""""""""! J characteristic M
N N
The characteristic resolution determines the exactness of the acceleration torque, which has to be quite exact, especially in case of indirect tension control. The accelaration torque results from the moment of inertia:
M B [%] = J [ s ]
dn [% / s ] dt
Due to the different ramp function generator outputs (dn/dt) of the MC/VC converter, as well as to the inertia value range, a system-specific scaling, concerning the intermediate value range (-200% ... 200%), has to be made.
2.7
Gear ratio
This application supports a gear ratio. The gear ratio i is among other things needed to convert the line speed into the corresponding rotational speed.
k G [%] =
100% n 2 = 100% i n1
2.8
Tension operating mode
Tension operating mode can only be selected in mode operation and with no existing line breakage report. Switching from line to tension operating mode and vice versa should always be realized in stand still.
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2.9
Maneuvering and jogging
This application offers the functionality of maneuvering and jogging. The maneuvering input can e.g. be connected with an analogue input and like this allow the percental controlling of the line speed setpoint. With the signal jogging, the jog operating mode is selected. This mode can only be selected when tension operating mode is switched off. Jogging setpoint (line speed) can be set directly via interface. While jogging, maneuvering is not possible.
2.10 Line breakage detection

Line breakage detection is active while tension control is switched on. It is also implemented differently, depending on the control method used.
Direct tension control by torque limiting with load cell (control method A):
Line breakage is detected when tension has fallen below an adjustable minimum tension. In case of line breakage, the rotational speed controller becomes effective and controls the line speed, according to the given line speed setpoint and the adjusted overmodulation.
Direct tension control by rotational speed correction with dancer roll (control method C):
Line breakage is detected when an adjustable final position of the dancer has been exceeded. In case of line breakage, the dancer reaches the lower limit stop. The position controller reaches its limit. The rotational speed controller controls the circumferential speed according to the given line speed setpoint and the output limit of the position controller.
Indirect tension control (control method B):
Line breakage is detected when actual torque has fallen below an adjustable minimum torque, and a likewise adjustable torque limit for the difference between setpoint and actual value has been exceeded. In case of line breakage, the rotational speed controller becomes effective and controls the circumferential speed according to the given line speed setpoint and the adjusted overmodulation.
When line breakage has been detected,
the diameter calculator will be stopped, tension operating mode will be switched off and the enabling of tension control will be reset.
2.11 Quick stop

As standard, the converters MC and VC offer three different shutdown modes.
At mode OFF 1, the speed ramp brakes the motor down to standstill. Subsequently, pulse blocking is activated. At mode OFF 2, the converter is switched off at once. The motor coasts down, respectively the mecanical brake is activated.
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At mode OFF 3, the motor is braked down to standstill with maximum braking torque. Subsequently, pulse blocking is activated.
An additional quick stop with selectable ramp-down time is often required. At this implemented quick stop, ramp-down time can be preset. Quick stop is enabled by the external signal quick stop and only active in mode OFF 1.
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3
3.1
Control
Winder control- and status word
In addition to the usual system-inherent control- and status words, a winder-specific control- and status word has been defined. Bit Bit 00 Winder control word Set diameter (only while pulse blocking is activated) Hold diameter (only while in tension operating mode) Line- / Tension operating mode Jogging Quick stop ramp (OFF 1) not used n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. Mode of winding Type of winder Value 0 Value 1 D-calculator is singularly set by edge (0->1) D-calculator is held
Bit 01
Enable D-calculator
Bit 02 Bit 03 Bit 04 Bit 05 Bit 06 Bit 07 Bit 08 Bit 09 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15
Line speed control (speedcontrolled) switched off n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. overwind Unwinder
Tension control controlled) Jogging enabled n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. underwind Winder
(torque
Tab. 3.1.1: Winder control word The control word can be preset via PROFIBUS, SIMOLINK, or fixed bits, respectively via digital inputs.
Bit Bit 00 Bit 01 Bit 02 Bit 03 Bit 04 Bit 05 Bit 06 Bit 07 Bit 08 Bit 09 Bit 10 Bit 11 Bit 12 Bit 13 Bit 14 Bit 15
Value 0 Value 1 Unwinder Winder overwind underwind Line speed control (speed- Tension control (torque controlled) controlled) Jogging Jogging Status diameter-calculator inactive active Limiting of rotational speed Limit reached controller Limiting of tension controller Limit reached Line breakage Line breakage detected n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u. n.u.
Winder status word Type of winder Mode of winding Line- / Tension operating mode
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Tab. 3.1.2: Winder status word The status word is reported back to the superordinated automation system.
3.2
Winder interface to the automation system
The application requires the following settings:
Tension setpoint (control method A, B, C) Tension actual value (control method A) Position setpoint (control method C) Position actual value (control method C) Line speed setpoint (output ramp function generator) Maneuvering setpoint Jogging setpoint Diameter preset value Percental width of material Percental density of material (by parameter setting)
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4
4.1
Comissioning
Standardization
The used values for control are related, that means, all reported values - via interface to the application must primarily be standardized by the transmitter according to the following table.
Designation Diameter D Line speed v Rotational speed n
Base value Dmax i * vmax, vmax directly at the shaft i * nmax, nmax directly at the shaft
Tab. 4.1.1: Standardizations
4.2
Interface adjustment
At first the following connectors have to be adjusted independent of converter type and control method (see corresponding script file).
Connectorno. (#) U078.01 U078.02 U078.03 U078.04 U078.05 U078.15 U078.16 P402.02 P403.03 P404.04 P405.05 P406.06 P407.07 P408.08 U380 U116.02 U114.01 U114.02 P428 P426 U110.01 U115.02 P464.02 U440.01
Connector designation - Winder control word Set diameter Hold diameter Line- / tension operating mode Jogging Quick stop Mode of winding Type of winder - Fixed setpoints Gearbox factor kG Width of material [%] Constant moment of inertia Jk reduced torque limit [%] Jog line speed setpoint Density of material/Dmax [%] Lower limit [%] (Zero pulse generation) - Tension setpoint Tension setpoint [%] - Additional rotational speed setpoint Minimum diameter [%] - Diameter calculator Line speed setpoint [%] Minimum diameter [%] Setpoint diameter [%] Setpoint diameter [%] - Line speed setpoint Line speed setpoint [%] Minimum diameter [%] Ramp-down time quick stop Density of material [%]
Connector value ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ? ?
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U135
Minimum rotational speed D-calculator
The following connectors have to be adjusted for the Masterdrive MC. Connectorno. (#) Connector designation Connector value
The following connectors have to be adjusted for the Masterdrive VC. Connectorno. (#) Connector designation Connector value
The following connectors have to be adjusted dependent on the used control method.
4.2.1 Direct tension control with load cell (control method A)

Connectorno. (#) P401.01 U352 U355 U141 U140 Connector designation - Fixed setpoint Override value line speed - Tension controller Tension setpoint (tension controller) Tension actual value (tension controller) - Additional sequence control Tension actual value (line breakage) Minimum tension force Connector value ? ? ? ? ?
4.2.2 Indirect tension control (control method B)

Connectorno. (#) P401.01 U141 Connector designation - Fixed setpoint Override value line speed - Additional sequence control Torque actual value (line breakage) Connector value ? ?
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U140 U150
Minimum torque Maximum torque setpoint actual value difference
? ?
4.2.3 Direct tension control with dancer roll (control method C)

Connectorno. (#) U352 U355 U141 U140 Connector designation - Position controller Position setpoint (position controller) Position actual value (position controller) - Additional sequence control Position actual value (line breakage) Final dancer position Connector value ? ? ? ?
4.3
Acceleration torque
The acceleration torque results from the relation:
M B [%] = J [ s ]
dn [% / s ] dt
The standardized moment of inertia with the measuring unit seconds results from the relation:
J [ s ] = J [kg m 2 ]
N MN
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Usually, the moment of inertia of the motor and the used gearbox is known. The core-inertia can be calculated according to table 2.6.1. The inertia of the wound material can be calculated likewise according to table 2.6.2. The support values needed for the characteristic must be evaluated diameter-dependent and must be entered separately. Hereby, attention has to be paid to the correct scaling as the support value range is limited to 200%. Master Drive MC: The rotational speed ramp-function generator provides a time-deducted rotational speed with the measuring unit [100%/ms]. That means the standardized moment of inertia with the measuring unit seconds must additionally be scaled with the factor 10. Master Drive VC: The rotational speed ramp-function generator provides a time-deducted rotational speed with the measuring unit [%/s]. That means the standardized moment of inertia with the measuring unit [%/s] neednt be scaled furthermore.
4.4
Friction characteristic
The frequency converter Master Drive MC is equipped with a function to report the friction characteristic. This recording is started with the parameter U219.01. Before starting, the following must be secured (see also summary 7-12):
Master drive (P587 = 0) P260 = 153 respectively P262 = 153 P228 = 152
Needed enablings:
Impulse Rotational speed controller Direction of rotation (positive and/or negative) Positive and negative rotational speed limit must be chosen in such a way that considering the enabled direction of rotation the characteristic in one rotational direction can be fully reached.
The frequency converter Master Drive VC is not equipped with a function to report the friction characteristic. Therefore the friction charcteristic must be evaluated manually by running the unloaded drive with different rotational speeds and so evaluating the related friction torque. Afterwards, the evaluated friction characteristic can be recreated with the available field characteristics (see function diagram 371).
4.5
Rotational speed controller optimization
Because of the changing moment of inertia, the proportional gain must be generally adapted while winding. The proportional gain is linearly dependent on the moment of inertia.
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Moment of
Source n-controller-adapt.. P232.B (0) K0442 inertia J of [55.A8] n-contr. gain2 0.0 ... 1000.0 P236.F (10.0) n-contr. gain1 0.0 ... 1000.0 P235.F (10.0)
x y
Gain-adaption
K p1 =
J min K p2 J max
P233.F (0.0) P234.F (100.0) 0.0 ... 200.0 % 0.0 ... 200.0 % n-contr.-adapt..1 n-contr.-adapt.2
Fig. 4.5.1: Gain-adaption rotational speed controller For optimizing the rotational speed controller, a diameter as big as possible should be chosen. The diameter is set with the command Set diameter. At a given line speed, the rotational speed controller is optimized. Optimization is realized with short steps in line speed. Line speed should therefore be chosen in such a way as not to get control into the limiting while stepping. The evaluated propotional value and the actual moment of inertia represent one of the two needed gain characteristic support values. The second support value can be deducted by using the rule of three (see figure 4.4.1).
4.6
Tension controller optimization
With direct tension control by rotational speed correction, an adaption of the position controller is not necessary. Material tension is determined by the dancer. That means that proportional value is constant for the complete control range. Because of the switching-in of the rotational speed correction, the position controller has to be configured as a P-controller. With direct tension control by torque limiting, an adaption of the proportional gain is necessary. Optimization of the tension controller is realized by short steps in tension setpoint value. Proportional gain and integral-action time should be chosen in such a way that the resulting step response (rotational speed) settles cushionedly. As above, it is also here important, that control mustnt be brought into the limiting while stepping. Optimization should be realized with different diameters. The following practically-proven values fr control setting have been evaluated:
Gain = 0.1 ... 0.3 with direct tension control by rotational speed correction (dancer). Gain = 0.1 ... 0.3 and TN = 0.5 ... 1s with direct tension control by torque correction (load cell).
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5
5.1
Appendix
Formulary
q= Dmax Dcore V V n2 = = D U perimeter MW =
Diameter ratio
Rotational speed
[min 1 ] 1
[ m] [ m] [m / min] [m]
[ N ] [ m] [ N ] [m / min]
Winder torque (motor shaft) [Nm] Winder power (motor shaft)
[W ] = [ N m / s ]
Gear ratio
F D 2i F V PW = = M W 1 60 60 D n1, max n1, max i = min = Vmax n2, max
[m] [min 1 ] [m / min] [m] [kg / m 3 ] [m 4 ]
Moment of inertia Solid cylinder
[kg m ]
2
Moment of inertia Hollow cylinder (motor shaft) (motor shaft) (motor shaft)
[kg m ]
2 2
Moment of inertia
[kg m ] [kg m ]
2
Constant moment of inertia Variable moment of inertia
[kg m ]
2
Acceleration torque (motor shaft) [Nm] Acceleration power (motor shaft) [W] Starting time TA [s]
m D2 b J2 = = D4 8 32 2 b mD 4 J2 = = D 4 DKern 8 32 J J 1 = 22 i J J K = J motor + J gear + core i2 b 4 JV = (D 4 DKern ) 2 32 i i V MB = (J K + J V ) 30 D 60 t B
[m] [kg / m 3 ] [m 4 ] [kg m 2 ] [kg m 2 ] [m] [kg / m 3 ] [m 4 ] [1] [m / min] [kg m 2 ] [ m] [ s]

[ m / min] [ Nm] [ m]
PB =
i V MB 30 D
TA =
N J1 zp M N
[ s 1 ] [kg m 2 ] [ Nm]
U here is the perimeter of the cylinder.
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5.2
Formula symbols
Meaning Minimum diameter Maximum line speed Mass Nominal speed Material width Material density Gear ratio Gearbox factor Rated torque Moment of inertia Pole pair number Tension force Angular frequency Starting time Measuring unit [m] [m/min] [kg] [U/min] [m] [kg/m^3] [--] [--] [Nm] [kgm^2] [--] [N] [rad/s] [s]
Formula symbol
Dmin Vmax m nN b i kG
MN J zp
TA
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5.3
Selection criteria
The following tables content decision criteria, respectively practically-proven values for the various, possible tension control methods. Realized within this application are the control methods edged black. Because of the simplified realization with free modules, the maximum torque control range for this application is limited to the factor 30 for the time beeing, until further practically-proven values are available.
Method
Indirect tension control
Direct tension control with load cell

Correction by torque limiting Calculation or measuring Correction by rotational speed correction Calculation or measuring
Way of implementation Diameter acquisition Tension actual value acquisition Diameter ratio Dmax/Dcore
Correction by torque limiting Calculation or measuring
No acquisition necessary
No intervention into the line run, sensitive to overload
No intervention into the line run, sensitive to overload
Appr. 10:1, good compensation of acceleration torque and friction necessary

Appr. 6:1 at good compensation of acceleration torque and friction Appr. 40:1
Appr. 15:1, good compensation of acceleration torque necessary Appr. 20:1 at good compensation of acceleration torque Appr. 100:1 dependent on the quality of the tension actual value signal Up to 2000 m/min at good compensation of the acceleration torque Paper, thin films
Tension ratio Fmax/Fmin Torque ratio Mmax/Mmin Line speed
Up to 600 m/min at good compensation Sheet metal, textile, paper
? Useful for elastic, extremely stretchable material Necessary
Field of application Speed master
Necessary
Necessary
Line speed tachometer
Not necessary
Not necessary
Not necessary
Tab. 5.3.1: Selection criteria for indirect and direct tension control with load cell
- 22 -
Method
Direct tension control with dancer roll

Correction by rotational speed correction Calculation or measuring Correction by torque limiting Calculation or measuring
Way of implementation Diameter acquisition Tension actual value acquisition Diameter ratio Dmax/Dcore Tension ratio Fmax/Fmin Torque ratio Mmax/Mmin Line speed
Intervention into the line run
Intervention into the line run
Appr. 15:1 ?
Changeable with adjustable dancer loading Appr. 40:1 dependent on the quality of the dancer loading Up to 2000 m/min
Changeable with adjustable dancer loading
Field of application Speed master
Rubber, cable, wire, textile, film, paper Necessary
Useful for brittle, sensitive, hard and unflexible material Necessary
Line speed tachometer
Not necessary
Not necessary
Tab. 5.3.2: Selection criteria for direct tension control with dancer
5.4
List of free modules used

Baustein Fsp1 Fsp9 DFsp1
Blatt Bausteintyp 705 FSP DFSP St.bit C.displ. B.displ.. 710 715 720 725 C-B converter B-C converter Add DAdd Sub SI SSI
Fsp2 DFsp2
Fsp3 DFsp3
Fsp4 DFsp4
Fsp5 DFsp5
Fsp6 DFsp6
Fsp7 DFsp7
Fsp8 DFsp8
CB1 BC1 Add1 DAdd1 Sub1 SI1 SSI1
CB2 BC2 Add2 DAdd2 Sub2 SI2
CB3 BC3 Add3 DAdd3 Sub3 SI3 Add4 DAdd4 DSub1
DSub2
- 23 -
730 732 734 735 740 750 755 760 765
Mul MulDiv Diff AVG Limit AS Charact. AND
Mul1 MulDiv1 DMulDiv Diff1 AVG1 Limit1 AS1 DAS1 Charact1 AND1 AND9 AND17 OR1 OR9 Inv1 Inv9 NAND1 XOR1 T1 Counter SRFG1
Mul2 MulDiv2 P1 AVG2 Limit2 AS2 DAS2 Charact2 AND2 AND10 AND18 OR2 OR10 Inv2 Inv10 NAND2 XOR2 T2
Mul3 MulDiv3 P2 AVG3 DLimitG AS3 DAS3 Charact3 AND3 AND11 OR3 OR11 Inv3 NAND3 XOR3 T3
DMul1
Div1
Div2
DDiv1
DAVG1 DLimit AS4 DAS3
Limiter1 AS5 DAS4
Limiter2
DLimiter
DAS5
AND4 AND12 OR4 OR12 Inv4 NAND4
AND5 AND13 OR5
AND6 AND14 OR6
AND7 AND15 OR7
AND8 AND16 OR8
OR
770
Inv NAND XOR
Inv5 NAND5
Inv6 NAND6
Inv7 NAND7
Inv8 NAND8
775 780 785 790 791 792 793 794 795 797 798
Time element Counter SRFG
T4
T5
T6
5.5
Winder checklist
The fields shaded white must be recorded according to the measuring units. The data in the fields shaded grey can be calculated with aid of the formulary (see chapter 5.1).
Designation Minimum diameter Dmin Maximum diameter Dmax -> Diameter ratio Dmax / Dmin Minimum tension force Fmin Maximum tension force Fmax -> Tension ratio Fmax / Fmin -> Minimum torque Mmin -> Maximum torque Mmax -> Torque ratio Mmax / Mmin Type of motor (asynchronous/synchronous, order
no. )
Value
Measuring unit [m] [m] [--] [N] [N] [--] [Nm] [Nm] [--] [--] [Nm] [Hz] [U/min] [--] [kg*m^2] [kg*m^2] [--] [m/min]
Motor rated torque MN Motor rated frequency fN Motor nominal speed nN -> Pole pair number If known Motor moment of inertia JM If known Gearbox moment of inertia JG Motor speed sensor type (Resolver, Impuls,
Encoder)
Maximum line speed vmax

- 24 -
-> Maximum winding speed for vmax, Dmin Gear ratio i = n1 / n2 -> Maximum rotational speed motor for vmax, Dmin -> Maximum field weakening Converter type (MC/VC, order no.) Plug-in modules (SBM, CBP2, SLB, EB1/2, ...) Tension measuring system (dancer/load cell,
control-/measuring range)
[U/min] [--] [U/min] [--] [--] [--] [--] [%] [--] [m] [m] [m] [kg/m^3] [kg*m^2] [--]
Required exactness of tension F / Fmax Diameter sensor (Yes/No) Material to be wound width B Material to be wound length L Material to be wound thickness D Material to be wound density -> Maximum moment of inertia winding JV Flying splice (Yes/No)
- 25 -
5.6
Winder application (Masterdrive MC)
5.6.1 Function diagrams
- 26 -

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IMPR Simple Winder Documentation

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A&D MC PM 5 17. October 2000 Version 1.

Simple winder with free modules for Masterdrives MC / VC

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Winder with free modules 17. October 2000 Version 1.0

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Direct tension control by torque limiting

V set Jog Setpoint

Override J Gain-Adaption Diameter Calculator D act

Taper Tension Characteristic F act

Acceleration Torque D act Friction Torque Gain-Adaption

Siemens AG A&D MC PM5

Type of winder Unwinder Winder

Acceleration and friction torque sign +

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Tab. 2.1.2: Override sign dependent on mode of winding

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Indirect tension control by torque limiting

V set Jog setpoint

Override J Gain-adaption Diameter calculator D act

Taper tension characteristic

Acceleration torque Friction torque

Siemens AG A&D MC PM5

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Direct tension control by rotational speed correction

V const L act D act

Taper tension characteristic V set Jog setpoint Speed controller

Acceleration torque D act Friction torque

Type of winder Unwinder Winder

Rotational speed correction sign +

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Taper tension control

Dact [%] = Dmin [%]

Vset [%] nact [%]

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Inertia of wound-up material

Tension operating mode

Winder with free modules 17. October 2000 Version 1.0

Maneuvering and jogging

2.10 Line breakage detection

Indirect tension control (control method B):

When line breakage has been detected,

2.11 Quick stop

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Winder interface to the automation system

The application requires the following settings:

Copyright (C) SIEMENS AG 2000 All Rights Reserved

Winder with free modules 17. October 2000 Version 1.0

Designation Diameter D Line speed v Rotational speed n

Tab. 4.1.1: Standardizations

Copyright (C) SIEMENS AG 2000 All Rights Reserved