Solution Products Pre-Information: Center Winder Training

Solution Products Pre-Information
Center Winder Training

Application Software
General
Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 1 Printed 7-Dec-98
File : Solutions_Winder.ppt
Winder Basics
Common Terms and Definitions

Winder Basics
 A Center Winder,
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
Velocit
y
 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.

Winder Basics
 Common Terms
– CORE:
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: DIA The maximum roll diameter the machine is
designed for.
– BUILD-UP/ Winding ratio: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:
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
– CORE SPEED MATCH:
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:
WEB The product (material) which is to be wound by the
machine. This is also known as the “strip” in the Metals.
– EXTENSIBLE:
EXTENSIBLE This is related to the properties of the web. A
web which is elastic is considered extensible. Example: Plastic
food wrap
– NON-EXTENSIBLE:
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
– TENSION:
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:
TENSION The reduction of the reference tension as a
function of diameter. As diameter is increased the tension is
decreased.
– STALL TENSION:
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
– SPEED CONTROL:
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:
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
– 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
 Basic Winder Macro Includes

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

Winder Basics
B F
Dia Min Dia Act (D)

F= Tension Force Core Dia
M=Torque
V= Material Speed
n= Rotational Speed
JR1 + JR2
W= Angular Speed NR, WR, MR
B= Material Width
D= Diameter Gear Box
JR= Moment of Inertia
JR1= Moment of Inertia of roller
JM,
JR2= Moment of Inertia of roll NM, WM, MM
JR3= Moment of Inertia of gearbox
JM = Moment of Inertia of Motor Motor
JC = Total moment of Intertia (on motor side)

v [m/min] Strip speed

D [mm] Coil diameter
Dmin [mm] Mandrel diameter
C [1/sec] Omega Coiler shaft
M [1/sec] Omega Motor Shaft
nC [rpm] Speed Coiler
nM [rpm] Speed Motor Shaft
Z Gearratio
t [mm] Strip thickness
B [mm] Strip width
J [kgm²] Total inertia
Jfixed [kgm²] Basic inertia
[kg/dm³] Mass density
MB [Nm] Acceleration / Deceleration torque

General Formulas:
D 2*v
v= * =>  = 1
2 C C D
D v
v= *2**n => n = 2
2 C C  D
*
C
Rated to the motor shaft wZth Z =
M
M * D
Z*2*v Z*v
M = D
n = => v = 3
M *D Z*2
DZameter change (+ = TensZon reel, - = Pay off reel)
dD 2*h*
= 2*h*n = 4
dt  C *D

Winder Basics
V
F
1. Power required for winding
F m ax*V m ax
Pmax = 60000
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
Fmax*Dmax
Mm ax = 2000*Z
[Nm]
Fmin*Dmin
Mmin = 2000*Z
[Nm]

4. Maximum and minimum Motor Speeds Winder Basics
N min = V min* Z *1000
rpm Formulas for the Winder
D max* PI
V max* Z *1000
N max = D min* PI rpm
Relationship between Diameter "D" ,
Velocity "V" and rpm N
d [mm]
v [m/min]
n [rpm]
V
F
time

5. Intertia components Winder Basics
Torque available from motor is used to produce the Tension component
as well as to overcome the Inertia requirements
Fact * Dact dw
Total _ Motor _ Torque( M m ) = + Jc + Loss _ component
2000 * Z dt
Loss _ component = F ( n) = Loss0 + Loss1 * N ACT
V
F
Total inertia of System =( Inertia of Roll+ Inertia of roller+ Inertia of gear) reflected to motor side
+motor inertia

Winder Basics
V Formulas for the Winder
F
Inertia of shaft (roller)
ShaftOuterDia 2 + ShaftInnerDia 2
Intertia _ of _ roller = ShaftWt .*
2
Shaft Outer Dia

Inertia of roll ( material wound or unwound on the core)
Dia _ Act 2 + D min 2

Intertia _ of _ roll = MaterialWt .* Shaft Inner Dia
2
Dia _ Act 2 - D min 2
MaterialWt .= B * density * PI *( )
32 2 Inertia (J mec. + J coil) = f (diamter)
Dia _ Act 4 - D min 4

Inertia _ of _ roll = B * density * PI *
32
Inertia of Gearbox J [kgm²]

v [m/min]
d [mm]
Usually provided by the customer/mech supplier
Inertia of Motor
Motor Catalogues provide the motor Inertia.

time
Winder Basics
V Formulas for the Winder
Total Torque to be developed by Motor Mm=

D
F *
Mm= 2Z + MM1+MM2+MM3+Loss component
D
Mm= F *
2Z
Mm=
D 1 B * density *PI 1 Z dV
F* + f(Nm ) + ( JR1 + JR3 ) * 2 + JM ) + *(D 4 - D 4 min ) * 2 * *
2Z Z 32 Z 30 *D dt
Fixed part Variable part

Winder Basics
Acceleration torque T (acc.) = f (diamter)
T (acc.) [Nm]
v [m/min]
d [mm]
Total torque T total = f (diamter)
T total [Nm]
v [m/min]
d [mm]
time
time

Relationship of Power and material
Fmax *V
max
Pmax =
60000
Fact *V
act
Pact =
60000
Fact = Funit _ tension * B * h
Funit _ tension * B * h *V
act
Pact =
60000

Winder Basics
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

Winder Basics
Configurations
 Basic Winder Macro Includes

Dancer 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
Indirect and Direct Tension Control
Tensiometer

a) No Feedback system for Actual Tension
b) Feedback for Actual Tension is used
Winder Basics
Configurations
Winder- Application
Software Flux Code
Tension
Tension
to TQ cal
Reference
Tension Controller Torque Correction

PI
Line Speed
Reference
Tension
Reference
Tension Controller
PI

Winder Basics
Configurations- Indirect Ten
Linear Speed Reference

Tension Reference
Gear Box
External DIA
Web Density
Web Width
M
VN
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
External /Internal Dia Calc
2
3
Torque
Winder/ Rewinder LossTorq= K+ N* K1 MIN
4
5 6 Ref
to DTC
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 PI
Taper Tension Generator

Tension Ref
F
M
DIA

Winder Basics
Configurations
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.
Isrecommendable
Is recommendableto
touse
useIndirect
Indirecttension
tensioncontrol
controlin
in
Directcoupled
Direct coupledwinders
winders(no
(nogearbox)
gearbox)
InInmech
mechconfigurations
configurationswhere
wherethe
themechanical
mechanicallosses
lossesare
arelow.
low.(No
(Noworm
wormgears,
gears,and
andno
noappreciable
appreciable
differencebetween
difference betweengearbox
gearboxlosses
lossesininwarm
warmororcold
coldconditions
conditions
Wherethe
Where theInertia
Inertiacomponent
componentTQ
TQtotoTension
Tensioncomponent
componentTQTQ ratio
ratioisissmall.
small.
InInprocess
 processapplications
applicationswhere
wherethe
theTension
Tensionrange
rangerequired
requiredisisrelatively
relativelysmall
small(less
(lessthan
than10:1)
10:1)

Winder Basics
Configurations
 Tension
 TensionControl
Control--Open
OpenLoop
LoopTorque
Torque
–– The
Thedrive
driveisistorque
torqueregulated.
regulated. The Theparent
parentspeed
speedreference
referenceisis
requiredfrom
required fromthe theprocess
processline
linecontroller
controllerfor
forover
overspeed
speedcontrol.
control.
–– The
Thetorque
torquereference
referenceisiscalculated
calculatedby bythe
theapplication
applicationbased
basedon on
tensionsetpoint
tension setpointand andmachine
machineparameters.
parameters.
–– The
ThePIPIcontroller
controllerisisNOTNOTactive
activeininthis
thismode
modeandandtherefore
thereforethere
there
isisnot
notany
anytrim
trimofofthe
thetorque
torquereference.
reference.
–– The
TheTension
Tensioncontrol
controlisismade
madeby bycalculating
calculatingthethetorque
torque
requirements.Careful
requirements. Carefuldimensioning
dimensioningofofthethesystem
systemwith
withthe
the
processparameters
process parametersisisrecommended.
recommended.

Winder Basics
Configurations
 Indirect
 IndirectTension
TensionControl-
Control-Open
OpenLoop
LoopTorque
Torque
–– Recommendation
Recommendationfor forUse:
Use:
Transducer--Actual
Transducer Actualtension
tensionfeedback
feedbackisisnot
notavailable
available
Webdimensions
Web dimensionsareareconstant
constantwith
withlimited
limitedvariations
variationsininwidth
width
anddensity.
and density.
Accuratesystem
Accurate systemandandmaterial
materialInertia
Inertiadata
dataisisavailable.
available.
Processtension
 Process tensionrange
rangeisissmall.
small.

Winder Basics
Configurations

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.
IsIsrecommendable
recommendableto
touse
useDirect
Direct tension
tensioncontrol
controlin
in
Processesrequiring
Processes requiringhigh
hightension
tensionaccuracy.
accuracy.
InInmech
mechconfigurations
configurationswhere
wherethe
themechanical
mechanicallosses
lossesare
arehigh
high. .
InInprocesses
processeswhere
wherethe
thetension
tensionrange
rangeisisvery
veryhigh
high(e.g
(e.g20:1)
20:1)

Winder Basics
Configurations
Directtension
Direct tensionControl
Control
withspeed
with speedTrim
Trim
Directtension
Control
Directtension
Control
withTorque
with TorqueTrim
Trim

Winder Basics
Configurations- Direct Tension Control with speed Trim
 Tension
 TensionControl
Control--Closed
ClosedLoop
LoopSpeed
SpeedTrim
Trim
–– The
Thedrive
driveisisspeed
speedregulated.
regulated. The Theparent
parentspeed
speedreference
referencecomes
comes
fromthe
from theprocess
processline
linecontroller.
controller.
–– Speed
SpeedTrimTrimisisused
usedto tocontrol
controlthe
theactual
actualtension
tensionofofthe
theweb.
web. The
The
TensionController
Tension Controllertrim
trimisisadded
addedas asaaspeed
speedcorrection.
correction.
–– Tension
TensionController
ControllerisisaaPI PIcontroller
controllerreceiving
receivingsetpoint
setpointreference
reference
froman
from anoperator
operatorcontrol
controlandandreceiving
receivingaafeedback
feedbackofofactual
actual
tensionfrom
tension fromthe
theprocess.
process.
–– Diameter
Diameterisiscalculated
calculatedby byusing
usingthe
theline
linespeed
speedandandthe
therotational
rotational
speedfeedback
speed feedbackfromfromthethedrive.
drive.
–– Inertia
Inertiacompensation
compensationmay maybe beadded
addedto toimprove
improvethethedynamics
dynamicsofof
thecontrol.(Losses
the control.(Lossesininthe theform
formofoffriction
frictionandandwindage
windageare
are
automaticallycompensated
automatically compensatedby bythe
theclosed
closedlooploopsystem)
system)

Winder Basics
nRef
F-Controller n-Controller
Tq Speed Ctl out

+ Used TQ reft
FRef
- x Speed Trim
-
Fact
F(D, V) nact
Controller
adaptation
Macc
Web type (material thickness/ material width)
Gain
Gain
D D
Block Diagram of the Direct tension Control with speed Trim

Winder Basics
 Direct
 DirectTension
TensionControl
Control-- Closed
ClosedLoop
Loop Speed
Speed
Trim
Trim
Use:
IfIfthe
thematerial
materialrange
rangeisiswide
wideand
andextensive.
extensive.
IfIfaalarge
largerange
rangeofofWeb
WebWidths
Widthsare
arepossible/required.
possible/required.
AccurateInertia
Accurate Inertiadata
dataisisnot
notavailable.
available.
IfIfaa“tight”
“tight”control
controlisisnot
notneeded.
needed.

Winder Basics
Configurations- Direct Tension Control with Torque Trim
 Tension
 TensionControl
Control--Closed
ClosedLoop
LoopTorque
TorqueTrim
Trim
–– The
Thedrive
driveisistorque
torqueregulated.
regulated. TheTheparent
parentspeed
speedreference
referenceisis
requiredfrom
required fromthetheprocess
processlinelinecontroller
controllerfor
forover
overspeed
speedcontrol.
control.
–– The
Thetorque
torquereference
referenceisiscalculated
calculatedbybythe
theapplication
applicationbased
basedonon
tensionsetpoint
tension setpointand
andmachine
machineparameters
parametersentered
enteredatatthe
thekeypad.
keypad.
–– Torque
TorqueTrim
Trimisisused
usedtotocontrol
controlthetheactual
actualtension
tensionofofthe
theweb.
web. The
The
TensionController
Tension Controllertrim
trimisisadded
addedas asaatorque
torquecorrection.
correction.
–– Tension
TensionController
ControllerisisaaPI
PIcontroller
controllerreceiving
receivingsetpoint
setpointreference
reference
froman
from anoperator
operatorcontrol
controlandandreceiving
receivingaafeedback
feedbackofofactual
actual
tensionfrom
tension fromthetheprocess.
process.

Winder Basics
nRef
F-Controller n-Controller
Tq Speed Ctl out

+ Used TQ reft
FRef
- x -
Fact
F(D, V) nact
Controller
adaptation
Macc
Gain
Gain
D D
Block Diagram of the Direct tension Control with speed Trim

Winder Basics
 Direct
 DirectTension
TensionControl
Control-- Closed
Closed Loop
Loop Torque
Torque
Trim
Trim
Use:
Greaterdynamic
Greater dynamicresponse.
response.
Webdimensions
Web dimensionsare arebasically
basicallyconstant
constantwith
withminimal
minimal
variationsininwidth
variations widthand
anddensity.
density.
Accuratesystem
Accurate systemand andmaterial
materialInertia
Inertiadata
dataisisavailable.
available.
Transducerfeedback
Transducer feedbackisisrequired.
required.

Winder Basics
Configurations- Dancer Control
Dancer Control

Winder Basics
Configurations- Dancer
Mechanical Configurations
 Fixed back tension systems
 Variable back tension systems
Loading
Dancer Cylinder
Dancer
Fixed Back Tension Position Servo
Position
Feedback (I/P)
Feedback
to ACS600 Force
to ACS600 Force
0 volts +10 volts

0 volts +10 volts
Response polarity as with a Transducer
Variable Tension System

Fixed Tension System

Winder Basics
Configurations
 Dancer Control
– 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.
Loading
Dancer Cylinder
Position Servo
Feedback (I/P)
to ACS600 Force
0 volts +10 volts


Winder Basics
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
adaptation
Macc
Gain
Gain
D D

Winder Basics
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”

Winder Basics
Configurations- Dancer- variable Tension
Block Diagram of Dancer Control - Speed Control and
speed correction- Variable Tension system
nRef
Tq Speed Ctl out Used TQ reft
PRef +
- x -
Normally Fixed as Parameter
Pact
Tension Setpoint F(D, V) nact Macc
Controller
adaptation
Loading
Web type (material
thickness/ material width) Cylinder
Servo
(I/P)
Gain
Gain
Force
D D
Stall and Taper

Reference

Solution Products- Pre-Information
Winder Basics
Dimensioning
Dimensioning the Winder

Understandingthe
Understanding
 theLoad
LoadRequirements
Requirements
Selecting the correct Motor
Recommending the optimal gearbox and speeds
to mechanical supplier
Mike Vallier and Narendra Gupta/ 98-12-01

 Analyzing the Load Requirements
Winder Basics
Dimensioning- Load Requirement
How the customer specifies his load (typically)
30KW, 800rpm/1500rpm ,150% overload
General Interpretation
a) Constant Torque application , Constant Power above base speed

b) Requirement is to deliver at base speed
9550 *Pw 5252 *Pw
Torque = ( Nm) Torque = (lb - ft )
Nbase Nbase
P = KW P = HP
N = rpm N = rpm
c) Generally the required torque below base speed is same

d) Specified overload of 150% is required at all speed points

Winder Basics
Graphical Interpretation of the specified Load
30KW, 800 rpm/ 1500 rpm 150% overload
600
500
Constant TQ
400
Torque [Nm]
300
TQ requirement proportional to 1
200
Nact
100
0
0 200 400 600 800 1000 1200 1400 1600
Speed [rpm ]
max lo ad co nt load

Winder Basics
Tooptimize
To optimizethe
theWinder
Winderititis
isimportant
importantto
toknow
knowother
otherinformation
information
ProcessParameters
Process Parameters
Tensionranges-
Tension ranges-Stall
Stalltension
tensionand
andTaper
TaperTensions
Tensionsrange
range
DiameterRatios
Diameter Ratiosfor
forspecified
specifiedmaterials
materials
Peripheralspeed
Peripheral speed--Crawl
Crawl/ /thread
threadspeed,
speed,Max
Maxspeed,
speed,
Operatingspeeds
Operating speeds
Accelerationand
Acceleration anddeceleration
decelerationrates
rates
GearRatios
Gear Ratios
MaterialSpecific
Material SpecificWtWtand
anddensity
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

Winder Basics
Calculating the Min and max values
P o we r 30 KW Vmax * Z
Nmax (rpm) =
Mo to r Ba s e S p e e d 700 rp m D min *PI
Mo to r Ma x S p e e d 1500 rp m D min (m)
Tma x 6000 N Vmax (m / min)
Nmotor
ma x rp m 1592 rp m Z = Gear Ratio( )
Nmech
min rp m 637 rp m
Ma x mo to r to rq ue 409 Nm
Vmax * Z
Ma x to rq ue to p ro ce s s 4093 Nm Nmin (rpm) =
D max *PI
D max (m) = Maximum dia
Ps * 60,000 9550 *Pw Vmax (m / min)
Fmax (N) = Torque = ( Nm)
Vmax Nbase Nmotor
Z = Gear Ratio( )
Ps (KW) P = KW Nmech
Vmax (m / min) N = rpm

Winder Basics
Calculating the minimum speed point
The minimum rotational speed point is calculated by using the minimum
linear operating speed at the maximum diameter. V *Z
N (rpm) = min
min operating speed
D max *PI
The minimum linear operation speed is the speed at which the D max (m) = Maximum dia
winder may run continuously for a extended period of time. Vmax (m / min)
This does not have any effect on dimensioning when a separately Z = Gear Ratio( N motor
)
ventilated motor is used. N mech
800
700
Nmin in this 600

Torque [Nm]
example = 125 rpm 500
400
Line stops before
300
max dia is reached !!
200
100
0
0 200 400 600 800 1000 1200 1400 1600
M2BA 315 SMA8 Speed [rpm ]
max lo ad co nt lo ad ab ilit y co nt lo ad

Winder Basics
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

Winder Basics
Calculating the Torque at different speed points Dimensioning- Load Requirement
Out d ia m. [m] 1.50 S p e e d [m/min] 300
In dia m. [m] 0.60 Te ns io n [kN] 5.0
Wid th [m] 0.80 Calculation based on Tset =Tmax conditions Acc. time [s ] 20.0
De ns ity [kg /m^3] 7800 Fa s t s to p [s ] 10.0
S trip d e n. [kg /m^3] 1100 Em. s to p [s ] 10.0
Ge a r (nmo t/ma ch.) 10.00
Co up ling [kg m^2] 5
Mo to r [kg m^2] 1
Re coile r (R) / R
Unco ile r (U)
Co ile r Em . s to p R e s ult
Dia m e te r Mo to r S p e e d J Acc. T o rq . J T e ns io n to rq ue T o t. a cc. to rq . Fa s t s to p a t b as e
[m ] [rp m ] [kg m ^ 2] [Nm ] [Nm ] [Nm ] [Nm ] s p e e d [Nm ]
0.60 1592 2 15 150 165 -31 -45 Ba s e s p e e d [rp m] 637
0.69 1384 2 14 173 186 -28 -37 Ma x.s p e e d [rp m] 1592
0.78 1224 2 13 195 208 -26 -32 Tma x(nma x) [Nm] 165
0.87 1098 2 13 218 230 -26 -29 Tte ns .(nma x) [Nm] 150
0.96 995 2 13 240 253 -26 -28 Tma x(nb a s e ) [Nm] 395
1.05 909 3 13 263 276 -26 -28 Tte n(nb a s e ) [Nm] 375
1.14 838 3 14 285 299 -28 -29 Te ns . p o we r [kW] 25
1.23 776 4 15 308 323 -30 -31 Ma x.p o we r [kW] 28
1.32 723 4 16 330 346 -33 -33 Ove rlo a d (%) 95%
1.41 677 5 18 353 371 -37 -37
1.50 637 6 20 375 395 -41 -41

Winder Basics
Out d ia m. [m] 1.50 S p e e d [m/min] 300
In dia m. [m] 0.60 Te ns io n [kN] 1.0
Wid th [m] 0.80 Acc. time [s ] 20.0
De ns ity [kg /m^3] 7800 Calculation based on Tset =Tmin conditions Fa s t s to p [s ] 10.0
S trip d e n. [kg /m^3] 1100 Em. s to p [s ] 10.0
Ge a r (nmo t/ma ch.) 10.00
Co up ling [kg m^2] 5
Mo to r [kg m^2] 1
Re coile r (R) / R
Unco ile r (U)
Co ile r Em . s to p R e s ult
Dia m e te r Mo to r S p e e d J Acc. T o rq . J T e ns io n to rq ue T o t. a cc. to rq . Fa s t s to p a t b as e
[m ] [rp m ] [kg m ^ 2] [Nm ] [Nm ] [Nm ] [Nm ] s p e e d [Nm ]
0.60 1592 2 15 30 45 -31 -45 Ba s e s p e e d [rp m] 637
0.69 1384 2 14 35 48 -28 -37 Ma x.s p e e d [rp m] 1592
0.78 1224 2 13 39 52 -26 -32 Tma x(nma x) [Nm] 45
0.87 1098 2 13 44 56 -26 -29 Tte ns .(nma x) [Nm] 30
0.96 995 2 13 48 61 -26 -28 Tma x(nb a s e ) [Nm] 95
1.05 909 3 13 53 66 -26 -28 Tte n(nb a s e ) [Nm] 75
1.14 838 3 14 57 71 -28 -29 Te ns . p o we r [kW] 5
1.23 776 4 15 62 77 -30 -31 Ma x.p o we r [kW] 8
1.32 723 4 16 66 82 -33 -33 Ove rlo a d (%) 26%
1.41 677 5 18 71 89 -37 -37
1.50 637 6 20 75 95 -41 -41

Calculating the Torque at different speed points Winder Basics
P o we r 30 KW
Mo to r Ba s e S p e e d 700 rp m
Mo to r Ma x S p e e d 1500 rp m
T ma x 6000 N
ma x rp m 1592 rp m
min rp m 637 rp m
Calculating based on Tset =Tmax conditions
Ma x m o to r to rq ue 409 Nm
Ma x to rq ue to p ro c e s s 4093 Nm
450
400
350
300
250
Ac c . To rq . J
200
T e ns io n to rq ue
T o t. a c c . to rq .
150
No tha lt b a s e s p e e d
100
50
-50
-100
0 200 400 600 800 1000 1200 1400 1600 1800
S p e e d [rp m ]

Calculating the Torque at different speed points
Winder Basics
P o we r 30 KW
Mo to r Ba s e S p e e d 700 rp m
Mo to r Ma x S p e e d 1500 rp m
T ma x 6000 N
ma x rp m 1592 rp m Calculating based on Tset= Tmax conditions
min rp m 637 rp m
Ma x mo to r to rq ue 409 Nm
Ma x to rq ue to p ro c e s s 4093 Nm
450
400
350
300
250
Ac c . T o rq . J
200 T e ns io n to rq ue
150 S c hne llha lt
100
50
-50
-100
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60
D ia m e te r [m ]

Winder Basics
Calculating the Torque at different speed points Calculation based on Tset =Tmin conditions
120
100
80
60
40 Ac c . To rq . J
Te ns io n to rq ue
To t. a cc . to rq .
20 No tha lt b a s e s p e e d
-20
-40
-60
0 200 400 600 800 1000 1200 1400 1600 1800
S p e e d [rp m]

Winder Basics
Calculation based on Tset =Tmin conditions
120
100
80
60
Ac c . T o rq . J
40
T e ns io n to rq ue
S c hne llha lt
20
-20
-40
-60
0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60
D ia m e te r [m ]

Winder Basics
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

Winder Basics
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/N 2. 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.

Winder Basics
Motor Load torque and the maximum loadibility of the motor

Winder Basics
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.

Winder Basics
Selecting the motor+Gearbox
Using the same process example
Re quire d P roce s s Te ns ion 5 kN

Ma x P roce s s s pe e d 300 m/min
Min Dia me te r 0.6 m
Ma x Dia me te r 1.5 m
Ma x P roce s s rpm (ma ndre l) 159 rpm
Min proce s s rpm (ma ndre l) 64 rpm
Ca lcula te d P owe r re quire d 25 KW (ba s e d on no ove rloa ds )
S pe e d ra tio= 2.484375

Winder Basics
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
up to about 2.5 times.
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

=

Winder Basics

Winder Basics
Dimensioning
Using the Application Checklist Form

Winder Basics
Dimensioning
Application Checklist Form for Selecting Winder Applications
GENERAL
Customer Name: _____________________ Date:______________________

Application:_________________________ Machine Section:____________
APPLICATI ON REQUIREMENTS
(Che ck all that apply)
Unwind: W inder:
Tension: Dancer: Torque:
MOTOR DATA
Size: KW Nominal Speed: rpm

Supply Voltage: VAC Encoder: Yes ______ No______
Supply Frequenc y: Hz Encoder Resolut ion: ppr
Synchronous Speed: rpm Encoder Supply: 12Vdc______ 24Vdc______
(Che ck one )
OVERLOAD
Overload: % for ______ second(s) - every ______ minute(s)
MECHANICAL DATA
Unwind/ Winder: Single Posit ion:______ Turret:______ Total Gear Ratio: :1
Unwind/ Winder: Over______ Under______ (Che ck both if r e quir e d)
Number of Cores: Core # 2 O.D. ______ mm

Min. Core O.D. _____ mm Core # 3 O.D. ______ mm
Min W eb W idth: mm Min. W eb Thicknes s: mm

Max Web W idt h: mm Max. W eb Thickness: mm
Full Roll Diameter: mm Core Shaft Material:

Max. Roll W eight: kg Core Shaft Inner Dia.: mm
Core Shaft Outer Dia.: mm
MACHINE SPECIFICATIONS
Line Speed Reference: Current______ Voltage______ Communicated______

Signal Range: (0)4-20mA______ 0-10Vdc______ Isolated: Yes ______ No______
Line Speed Min: m/min Line Speed Max: m/min

Min Accel Time: secs Min Decel Time: secs
Min. Fast St op Time: secs

Winder Basics
DANCER SPECIFICATIONS
Dimensioning
Dancer Supply Source: Existing______ Drive______ Dancer Supply: Vdc
Dancer Feedback: Current______ Voltage______ None______

Signal Range: (0)4-20mA______ ______ to ______Vdc Isolated: Yes______ No______
Max Dancer Travel: mm
TENSION SPECIFICATIONS
Tension Reference: Current______ Voltage______ Communicated______

Signal Range: (0)4-20mA______ 0-10Vdc______ Isolated: Yes______ No______
Tension Feedback: Current______ Voltage______ None______

Signal Range: (0)4-20mA______ 0-10Vdc______ Isolated: Yes______ No______
Min Tension: N Stall Tension: N

Max Tension: N Max Taper: %
Max Tension Variation @ Steady State: kg Loadcell Type:

Max Ttension Variation During Accel/Decel: kg
COMMUNICATIONS
(Che ck one )
Modbus: Modbus +: Device Net:
CS31: Profibus: Advant :
None:
COMMENTS:

Center Winder Training

Application Software
Implementation
Winder Application
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

Winder Application
Configuration
 Dancer Control
– 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: Loading
Dancer Cylinder
• To create Isolation of sections. Position Servo
Feedback (I/P)
• Typical Unwind Applications. to ACS600 Force
0 volts +10 volts


Winder Application
Configuration
 Tension Control - Closed Loop Speed Trim
– 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
 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.
• Transducer feedback is required.
Transducer;
Actual
Tension
Feedback

Winder Application
Configuration
 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 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
 Tension Control - Closed Loop Torque Trim
• 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
 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 therefor there is
not any trim of the torque reference.
• 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
 Dancer Controller
Motor
RPM
DTC
Diameter
Calculator
Line Speed
div add
Dancer
Feedback
Dancer PI
Setpoint
Winder Application
Parameters
– 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.
62:5 Dancer Ctl Enable
NOT SEL Running PI
ENABLE Regulator Release
DI 2 &
DI 3 Reference
62:7 Dancer FDBK Input DI 4 Feedback
DI 5
DI 6
AI 1 XT DI1
AI 2 FIELDBUS
AI 3
62:10 Max Dancer Travel
XT AI1 0V div
XT 2
AI2 0V add
XTAI2 -10V 62:11 Center Offset

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.
Stall Mode Enable
62:13 Web
Selection 62:1 P- PI
Gain 1 Min 62:14 P- K K
Gain 2 Min 62:2 P-
Gain 1 Max 62:15 P- X
Diameter
Gain 2 Max 62:3 I
Integ Time 1 62:16
Integ Time 2
62:4 Range Adjust

Winder Application
Parameters
– 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.
Stall Tension Enable
62:9 Max Taper/%Taper ACS600
KEYPAD % Taper Analogue
AI 1 R
AI 2 e Output
AI 3 f
XT AI1 Diameter Loading
XT 62:6 Dancer Setpoint Cylinder
AI2 Servo
AI 1 (I/P)
FIELDBUS AI 2 Force
AI 3
XT AI1 mul
XT 62:18 Stall Setpnt
AI2 (%)
FIELDBUS

Winder Application
Parameters
– 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
62:17 Stall Enable

If = 3 then
1) DISABLE &
2) NORMAL GAIN 62:20 Stall P-Gain
3) STALL GAIN If NOT = 1 then
Line Speed Ref A1

A1 < B1 & 62:20 Stall Integ
62:19 Stall Speed B1

Winder Application
Parameters
Dancer / Tension Trim - Speed Control

nRef
Tq Speed Ctl out

+ Used TQ reft
PRef
- x -
Pact
F(D, V) nact
Controller
adaptation
Macc
Gain
Gain
D D

Winder Application
Parameters
 Tension Controller
Motor
RPM
DTC
Diameter
Calculator
Torque Ref.
Line Speed Spd Ref.
div add
Tension mul
Torque Control
Feedback
Tension PI
Setpoint

Winder Application
Parameters
– 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
 Tension Controller Parameters
63:5 Tension Ctl Enable
NOT SEL Running
ENABLE &
DI 2
DI 3
DI 4 63:9 Max Taper/%Taper
DI 5 KEYPAD
DI 6 AI 1
XT DI1 AI 2
FIELDBUS AI 3
63:6 Tension Setpoint XT AI1
XT AI2 PI
AI 1 Stall Tension Enable
FIELDBUS Regulator Release
AI 2
AI 3 Reference
XT AI1
XT AI2 % Taper Feedback
FIELDBUS
R
63:7 Tension FDBK Input e
f
AI 1
Diameter
AI 2
AI 3
XT AI1 mul
XT AI2 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.
and WEB 2 are (infinitely) adjustable.
• Two (2) sets of PI gains for Dancer controllers.
Stall Mode Enable
63:16 Web
Selection 63:1 P- PI
Gain 1 Min 63:17 P- K K
Gain 2 Min 63:2 P-
Gain 1 Max 63:18 P- mul
Diameter
Gain 2 Max 63:3 I
Integ Time 1 63:19
Integ Time 2
63:4 Range Adjust

Winder Application
Parameters
– 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
1) DISABLE If = 3 then &
2) NORMAL GAIN 63:23 Stall P-Gain
3) STALL GAIN If NOT = 1 then
Line Speed Ref A1

63:24 Stall Integ
A1 < B1 &
63:22 Stall Speed B1

Winder Application
Parameters
 Tension Controller - Torque
– 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
63:11 Tension Ctrl Mode
Torque Ctrl Algorithm for determining
Torque Reference Selection:
Speed Ctrl
When in Speed Control the selections
Torque Reference
[TenTorq Trim] & [Torque NoTrim] do
63:12 Torque Trim Sel Selector
not operate. In this mode torque can TORQ REF SEL
TenTorq Trim only be commanded with DI or FBA.
Torque NoTrim The Torque mode is without trim. 0
Torque
2 1
DI1 (NoTrim) 3 Ref to
When in Torque Control the [Torque MIN
4
5 6 DTC
DI2 (NoTrim) Trim Sel] determines if the Tension
DI4 (NoTrim) feedback trims the torque or if the MAX
XDI1 (NoTrim) torque is not trimmed. If an input is

XDI2 (NoTrim) selected the operation is Torque Trim +
FBA (NoTrim) when the input is 0 and Torque NO trim +
when the input is 1.
Over / Under Sel The selections of Over / Under and

Pull / Holdback determine the selection
in Torque Control for the Torque
Pull / HoldBack Reference Selector [ Min or Max ]

Winder Application
Parameters
– Frictional Losses: Static Friction for constant losses of the
machine and Linear Friction for frictional loss change as a
function of roll diameter.
Tension Reg Output Inertia Compensation

63:10 Maximum Tension mul
63:4 Range %
Roll Diameter
Torque
Friction
+
Torque Reference Ref to
Selector DTC
63:14 Linear Friction
TORQ REF SEL
Diameter
3
0
2 1
+
Tension Reference Torq Ref 1 4
*/ +
MIN 5 6
Gear Ratio
Roll Diameter MAX
63:13 Static Friction Torq Ref 2 +

Winder Application
Parameters
Tension Trim - Torque Control
Winder- Application Diameter Flux Code
Software Calculation
Tension
Tension
Reference to TQ cal
Tension Controller Torque Correction

PI
Speed
Line Speed Reference
Reference
Tension Flux
Reference
Tension Controller Accelerate

PI Torque

Winder Application
Parameters
 Inertia Compensation - WK²
– 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.
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
• Required for all torque control modes and recommend for
improved performance in speed control modes.

Winder Application
Parameters
 Diameter Calculation
– 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
t Diameter Calculator
Line Speed Reference
Actual Core Speed Diameter

V
t
Diameter Reset
Dancer / Tension Enable N
Unwinder / Rewinder
Count UP Enable
Count DOWN Enable Min Core Dia

Max Roll Dia
Web Thickness

Winder Application
Parameters
– 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.

Digitally operated potentiometer
REF select
11.4 Enable
DI4
FB_SPD_DEC
>
+20,000 units
DI3
DEC
>
FB_SPD_INC INC
>
TON
POT Rate 1
POT rate 2 R
Emergency stop
& -20,000 units
Run Enable

Winder Application
Parameters
 Additional Features
 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.
100
90
80
70 Required
Motor 60 Motor
Flux % 50 Torque %
40
Flux
30
20
10 Torque
0
Time

Winder Application
Parameters
 Active Flux Control
– Actual formula for Flux control
– Torque depends on flux vectors: T = c (s x r)
y
U 3 U 2
U4
U1
U 6
U 5
s

 r
x

Winder Application
Parameters
 Over / Under wind selection
– 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.
• Web Loss Delay Timer adjustable at the keypad.
• 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
Single Position Winder
Under
Winding
Winding
Transducer;
Actual
Tension Under
Feedback Winding
Winder Application
Parameters
 Turret Winder Roll Change
– 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.
61:1 Spd Mtch Ref Sel 61:4 Spd Match Rate
No SpdMtch
AI 1 61:2 Spd Match W/Trim
AI 2 Scaling &
AI 3 Digital
XT AI1 Operated Additive Spd Ref
mul
XT AI2 Pot Rate
23:4
FIELDBUS 0
DI3, DI4 Line Speed Ref
FBus b4,5 61:3 Spd Match Range
Winder Application
Parameters
 Turret Winder Roll Change
– 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
Turret Winder - 2 Position
Indexing
Transducer;
Actual
Tension
Feedback
Winding
Position
Winder Application
Parameters
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
Roll Change in Process
Torque Sample Memorized
Torque Memory Active
Indexing
Activate Boost Torque
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
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
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 DIy high
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 speed 1 control
is required
 Parameter 62.5 should be connected to one of the DIy inputs
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
e.g. : Needed after a web break to wind the material into the core
Winder Application
Winder Application
DDCSInterface
DDCS Interface
50 ms DATASET 1 WoRD1 : Command Word
10 ms DATASET 1 WORD 2 Speed Reference
Fieldbus
50 ms DATASET 1 WORD3 : Application CW
Narendra Gupta & Michael Vallier / 98-12-01

50 ms DATASET 3 WoRD1 : Dancer / Tension
FieldbusAdapters
50 ms DATASE 3 WORD2 : Taper Set-point
50 ms DATASET 3 WORD 3 : Speed match
Adapters(External
50 ms DATASET 5 WoRD1 : Percent Draw Trim
100 ms DATASET 5 WORD 2 : Selectable Pointer
External
(Externalprotocol
100 ms DATASET 5 WORD 3: Selectable Pointer
ExternalPLC
PLC
protocoltotoDDCS DATASET 2 WoRD1 : Selectable Pointer
SLIDE 112
DATASET 2 WORD 2 : Selectable Pointer
50 ms
DATASET 2 WORD 3: Selectable Pointer

Winder Application in ACx6xx
DDCSprotocol)
protocol)
DATASET 4 WoRD1 : Percent Draw Trim

100 ms
Printed 7-Dec-98 DATASET 4 WORD 3: Selectable Pointer
DATASET 6 WoRD1 : Percent Draw Trim

100 ms
DATASET 6 WORD 3: Selectable Pointer

Winder Application
DDCS Interface - Inputs
Parameter Group 6
DATASET COMM (if USED)

1 DATASET 1 WORD 1 50ms DT1 WRD1 (Command Word)
Bit 0 Drive Enable (Drv Contactor – DCS)
Bit 1 E-STOP NOT
Bit 2 Reserved
Bit 3 Run Command
Bit 4 Direction
Bit 5 Constant Speed 1 Act
Bit 6 Constant Speed 2 Act
Bit 7 Fault Reset
Bit 8 Inching Speed Act
Bit 9 Payout Speed Act
Bit 10 Remote Command (Profibus only)
Bit 11 Relay Output 1 Act
Bit 14 CH0 Comm Heartbeat (Return Signal from Master)
Bit 15 Reserved
2 DATASET 1 WORD 2 10ms DT1 WRD2 Speed Reference
Winder Application
Parameter Group 6 DDCS Interface - Inputs
3 DATASET 1 WORD 3 50ms DT1 WRD3 Application Command Word
Bit 0 Dancer / Tension Enable
Bit 1 Dancer / Tension Gain2 Sel
Bit 2 Tension Trim Off (Open Loop Torque) In Tension Mode – Commands Open loop
Torque – No Tension Fdbk required
Bit 3 Dancer / Tension Zero Integ Time Zero’s the Integration Time of the PI-regulators.
Regulators act a P-regulator
Bit 4 Core Speed Increase Increase Core Speed Match
Bit 5 Core Speed Decrease Decrease Core Speed Match
Bit 6 Diameter Setpoint 1 Bit 6 & Bit 7 both on will activate Diameter
Setpoint 3
Bit 7 Diameter Setpoint 2
Bit 8 Diameter Hold Stop the Diameter Calculator form Changing
Bit 9 Diameter Increase For adjusting starting diameter – Off when in
Dancer or Tension Mode
Bit 10 Diameter Decrease For adjusting starting diameter – Off when in
Dancer or Tension Mode
Bit 11 Torque Sample Sample the running Torque for Roll Change
Torque Memory circuit.
Bit 12 Torque Memory Enable Enable Memorized (Sampled) Torque – the
drive will operate in Torque mode
Bit 13 Boost Torque ON Multiply the Memorized Torque by the Boost
Torque % to increase tension at Knife Cut
Bit 14 Reserved
Bit 15 Reserved
Winder Application
DDCS Interface - Inputs
Parameter Group 6
4 DATASET 3 WORD 1 50ms DT3 WRD1 Dancer / Tension Setpoint

5 DATASET 3 WORD 2 50ms DT3 WRD2 Taper Setpoint
6 DATASET 3 WORD 3 50ms DT3 WRD3 Speed Match Setpoint
7 DATASET 5 WORD 1 50ms DT5 WRD1 Percent Draw Trim – for progressive Draw
from over-riding controller (x100)
8 DATASET 5 WORD 2 100ms DT5 WRD2 Selectable – pointer
9 DATASET 5 WORD 3 100ms DT5 WRD3 Selectable – pointer
Winder Application
DDCS Interface - Outputs
Dataset Comm Out No Parameter Short Name Description

DATASET 2 WORD 1 50ms Selectable – pointer
Winder Application
Additional Hardware
 Analogue Inputs
– 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
Winder Application
Additional Hardware
 Analogue Inputs
– 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
Winder Application
Additional Hardware
 Digital Inputs - Standard (6) 24vdc
 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
• 9) TORQUE MEMORY SAMPLE - (Not available for Unwind)
• 10) TORQUE MEMORY ENABLE - (Not available for Unwind)
Winder Application
Additional Hardware
– 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
• 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
Winder Application
Additional Hardware
– Most Winder Applications typically require at least
(1) NDIO module.
– Turret Winder Applications with roll change requirements
typically require (2) NDIO modules.
– Unwind Applications can typically be done with standard
DI - Depending on Customer requirements.

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Solution Products Pre-Information: Center Winder Training

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Center Winder Training

Common Terms and Definitions

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 2 Printed 7-Dec-98

 The objective is to regulate surface Tension of the roll.

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 3 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 4 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 5 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 6 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 7 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 8 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 9 Printed 7-Dec-98

Formulas for the Winder

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 10 Printed 7-Dec-98

Dia Min Dia Act (D)

JC = Total moment of Intertia (on motor side)

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 11 Printed 7-Dec-98

v [m/min] Strip speed

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 12 Printed 7-Dec-98

DZameter change (+ = TensZon reel, - = Pay off reel)

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 13 Printed 7-Dec-98

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)

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 14 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 15 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 16 Printed 7-Dec-98

Shaft Outer Dia

Dia _ Act 2 + D min 2

Dia _ Act 4 - D min 4

Inertia of Gearbox J [kgm²]

Motor Catalogues provide the motor Inertia.

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 17 Printed 7-Dec-98

Total Torque to be developed by Motor Mm=

Fixed part Variable part

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 18 Printed 7-Dec-98

Total torque T total = f (diamter)

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 19 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 20 Printed 7-Dec-98

 Indirect Tension Control

 Direct Closed loop Tension Control with Dancer rolls

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 21 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 22 Printed 7-Dec-98

Indirect and Direct Tension Control

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 23 Printed 7-Dec-98

Tension Controller Torque Correction

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 24 Printed 7-Dec-98

Linear Speed Reference

DIA CALCULATOR+ INTEGRATOR

Taper Tension Generator

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 25 Printed 7-Dec-98

Indirect Tension Control

The torque is calculated according to the formulas discussed before.

Diameter needs to be computed accurately to control the correct tension

Friction& Windage are very crucial components to maintain accuracy of

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 26 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 27 Printed 7-Dec-98

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 28 Printed 7-Dec-98

Direct Tension Control

Diameter needs to be computed accurately to control the correct tension

Friction& Windage are not very crucial as inaccuracies may be corrected by

Narendra Gupta & Michael Vallier / 98-12-01 SLIDE 29 Printed 7-Dec-98

Customer Name: _ Date:__

Overload: % for second(s) - every minute(s)

Unwind/ Winder: Single Posit ion: Turret: Total Gear Ratio: :1

Unwind/ Winder: Over Under (Che ck both if r e quir e d)