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Applikationen & ToolsAnswers for industry.

Cover

Application Winder with DCCSINAMICS

Application description April 2013

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Industry Automation and Drive Technologies Service & Support Portal

This article is taken from the Service Portal of Siemens AG, Industry Automationand Drive Technologies. The following link takes you directly to the download pageof this document:

http://support.automation.siemens.com/WW/view/en/38043750

CautionThe functions and solutions described in this article confine themselves to therealization of the automation task predominantly. Please take into accountfurthermore that corresponding protective measures have to be taken up in thecontext of Industrial Security when connecting your equipment to other parts of theplant, the enterprise network or the Internet. Further information can be foundunder the Content-ID 50203404.

http://support.automation.siemens.com/WW/view/en/50203404

If you have any questions concerning this document please e-mail us to thefollowing address:

[email protected]

You can also actively use our Technical Forum from the Service & Support Portalregarding this subject. Add your questions, suggestions and problems and discussthem together in our strong forum community:

http://www.siemens.com/forum-applications
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DCC Winder3.2.0, Entry-ID: 38043750 3

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s

SINAMICS

DCC Winder

Basic information 1

Functions of the winderapplication 2

Automation solution 3

Installing the hardwareand software 4

Selecting the controlconcept 5

Winder checklist 6Short collection offormulas 7

Control and status wordsof the winder 8

Control and status wordof the splice 9

Function charts 10

Parameter description 11

Faults and alarms 12

Commissioning the

function 13General information onthe application 14

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Warranty and Liability

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Warranty and LiabilityNote The Application Examples are not binding and do not claim to be complete

regarding the circuits shown, equipping and any eventuality. The ApplicationExamples do not represent customer-specific solutions. They are only intended

to provide support for typical applications. You are responsible for ensuring thatthe described products are used correctly. These application examples do notrelieve you of the responsibility to use safe practices in application, installation,operation and maintenance. When using these Application Examples, yourecognize that we cannot be made liable for any damage/claims beyond theliability clause described. We reserve the right to make changes to these

Application Examples at any time without prior notice.If there are any deviations between the recommendations provided in theseapplication examples and other Siemens publications e.g. Catalogs thecontents of the other documents have priority.

We do not accept any liability for the information contained in this document.

Any claims against us based on whatever legal reason resulting from the use ofthe examples, information, programs, engineering and performance data etc.,described in this Application Example shall be excluded. Such an exclusion shallnot apply in the case of mandatory liability, e.g. under the German Product Liability

Act (Produkthaftungsgesetz), in case of intent, gross negligence, or injury of life,body or health, guarantee for the quality of a product, fraudulent concealment of adeficiency or breach of a condition which goes to the root of the contract(wesentliche Vertragspflichten). The damages for a breach of a substantialcontractual obligation are, however, limited to the foreseeable damage, typical forthe type of contract, except in the event of intent or gross negligence or injury tolife, body or health. The above provisions do not imply a change of the burden ofproof to your detriment.

Any form of duplication or distribution of these Application Examples or excerptshereof is prohibited without the expressed consent of Siemens Industry Sector.

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Foreword


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Foreword

Objective of the application

The standard winder application for SINAMICS based on DCC was developed with

the objective to address many of the known winder applications including splicingfunctionality

1using just one application software. When required, the application

can be configured or also changed as a result of its openness. It is possible to usethe application on different versions of the SINAMICS series such as SINAMICSDCM, SINAMICS S120 and S150, SINAMICS G130 and G150.

Using the appropriate devices and equipment, the standard winder application forSINAMICS based on DCC allows winders and unwinders to be implemented for thewidest range of applications. For instance, these include foil making machines,printing machines, coating machines, coilers for wire-drawing machines and textilemachines.

In many technological processes, winders are an essential component of a

complete machine or system.

Depending on the machine or system, sometimes a finishing process starts with anunwinder or ends with a winder.

Depending on the process and the material being wound, different windingtechniques are used.

Core contents of this application

The following core issues are discussed in this application:

Description, important basics of winder technology

Description of the splicing functionality

Commissioning the standard application

Scope of the document

This application does not include information or a description

About the basic commissioning of the SINAMICS S120 drive system

Configuring using the DCC Editor

It is assumed that readers have basic know-how about these topics.

1The splice control can only be used on SINAMICS S units with activated position controller

function module. In order to save memory space and to make it easier for users to integrate the

function, in the drive project of this example there is a version with splice and a version withoutthe splice - otherwise the functionality is identical.

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Table of Contents

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Table of ContentsWarranty and Liability ................................................................................................. 4Foreword ....................................................................................................................... 51 Basic information .............................................................................................. 9

1.1 Prerequisites ........................................................................................ 91.1.1 Technical environment ......................................................................... 91.2 Winder solution design and structure ................................................... 91.2.1 General design ..................................................................................... 91.2.2 Winding techniques ............................................................................ 11

Center winder ..................................................................................... 11Surface winder ................................................................................... 12

1.2.3 Control techniques ............................................................................. 13Indirect tension control ....................................................................... 13Tension control ................................................................................... 14Dancer roll position control ................................................................. 15Constant v control .............................................................................. 16

1.2.4 Diameter calculation technique .......................................................... 171.2.5 Overview of the features of the winding techniques .......................... 181.2.6 Solution using the standard "winder" application ............................... 181.2.7 Advantages of the standard application winder ............................... 191.3 Structure of a splice solution .............................................................. 201.3.1 General structure ................................................................................ 201.3.2 Functions ............................................................................................ 21

Splice point calculation ....................................................................... 22Script support to calculate the splice parameters .............................. 27

2 Functions of the winder application .............................................................. 312.1 Tasks that can be implemented using this application ....................... 312.2

Characteristics and features of the "winder" application .................... 32

Diameter computer ............................................................................. 32Winding hardness characteristic ........................................................ 33Controller adaptation .......................................................................... 33Inertia compensation (acceleration pre-control) ................................. 33Friction compensation ........................................................................ 33Tension operation ............................................................................... 33Maneuvering and jogging ................................................................... 34Synchronizing and stopping ............................................................... 34Web speed ramp function generator .................................................. 34Web length braking ............................................................................ 34Web break detection .......................................................................... 35Fast stop 36Execution groups ................................................................................ 37

Notes regarding the computation time requirement ........................... 39Notes for use with SINAMICS S120 ................................................... 39

3 Automation solution ........................................................................................ 413.1 Hardware and software components required ................................... 41

4 Installing the hardware and software ............................................................ 434.1 For your safety ................................................................................... 434.1.1 Safety information and instructions .................................................... 434.1.2 Responsibilities of the operator .......................................................... 43

5 Selecting the control concept ........................................................................ 455.1 Control concepts ................................................................................ 45

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5.1.1 Indirect tension control ("tension control") .......................................... 455.1.2 Direct control with dancer roll and speed correction .......................... 455.1.3 Direct tension control with tension transducer via the torque

limits ................................................................................................... 465.1.4 Direct tension control with tension transducer and speed

correction ............................................................................................ 46

5.1.5 Constant v control .............................................................................. 465.2 Comparison of the control concepts ................................................... 47

6 Winder checklist .............................................................................................. 486.1 Checklist for realization of a winder application ................................. 48

7 Short collection of formulas ........................................................................... 507.1 Calculations relevant for winder ......................................................... 507.2 Calculations relevant for splicing ........................................................ 537.3 Selecting the winding ratio (winding range) ....................................... 567.4 Power and torque ............................................................................... 567.5 Defining the signs ............................................................................... 577.6 Selecting the motor ............................................................................ 587.7 Dimensioning the gear unit................................................................. 587.8 Selecting the drive converter .............................................................. 58

Integrating the core functions .................................................................................. 598 Control and status words of the winder ........................................................ 60

8.1 Control word ....................................................................................... 608.2 Status word ........................................................................................ 628.3 Winder interface to the automation system ........................................ 63

9 Control and status word of the splice ........................................................... 659.1 Control word ....................................................................................... 659.2 Status word ........................................................................................ 659.3 Splice interface to the automation system ......................................... 66

Program description .................................................................................................. 6710 Function charts ................................................................................................ 68

10.1 Function charts of the winder application ........................................... 6811 Parameter description ..................................................................................... 94

11.1 Parameters of the winder application ................................................. 9411.2 Parameter for splice control ............................................................. 192

12 Faults and alarms .......................................................................................... 20112.1 Faults ................................................................................................ 20112.2 Alarms .............................................................................................. 202

13 Commissioning the function ........................................................................ 20313.1 Commissioning the application ........................................................ 203

Prerequisites .................................................................................... 203Preconditions for splice control ........................................................ 206Normalization ................................................................................... 210Interface adjustment ......................................................................... 210Velocity calibration ........................................................................... 221Setting the friction characteristic ...................................................... 221Inertia compensation: Constant moment of inertia .......................... 222Inertia compensation: Variable moment of inertia ............................ 222Winder with direct tension control and tension transducer - checking

the tension pre-control ...................................................... 222

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Commission the tension controller for direct tension control ........... 223Appendix ................................................................................................................... 22414 General information on the application ....................................................... 225

14.1 Scope of supply ................................................................................ 22514.2 References ....................................................................................... 22614.3 Contact ............................................................................................. 22714.4 History .............................................................................................. 22714.4.1 Changes of the documentation ........................................................ 22714.4.2 Change history of the application ..................................................... 228

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1 Basic information

1.1 Prerequisites


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1 Basic information

1.1 Prerequisites

The standard application is intended for all users of SINAMICS that wish to simplyand quickly implement winder functionality.

1.1.1 Technical environment

This standard application can only be used, unchanged in conjunction with:

SINAMICS S2and G from firmware version V4.5 HF1 with DCB library

TPdcblib_SINAMICS_4_5.3.0[5.0]

SINAMICS DCM from firmware version V1.3.x withTPdcblib_SINAMICS_4_4.3.0[9.0]

STARTER/Scout from Version 4.3.1.0 with CFC version 7.0 or higher

You can contact the specified contact partners for changes necessary for older

versions.

1.2 Winder solution design and structure

1.2.1 General design

Generally, a winder solution comprises a winder drive, a material web and possiblysensors. The function of a winder is to wind or unwind a material web with a

defined tension. When winding, the diameter changes. Depending on whether itinvolves a winder or an unwinder, the material is either wound or unwound. Thedrive system calculates the actual diameter using several system variables andcontrols the motor speed so that this maintains the tension of the material web at aconstant value. In order to achieve this, the actual material web velocity and thespeed of the winder axis must be known. If higher demands are placed on theperformance and the tension accuracy of the system, then a sensor must beincluded in the winder solution. This can either be a dancer roll or a tensiontransducer.

The dancer rollis a position-based measuring system through which the materialweb is routed. A cylinder with a deflection roll presses, with an adjustable force,against the material web. If tension is established in the material web then this acts

against the pressure from the dancer roll. If the dancer roll is at its center position,then the material web tension is the same as the selected dancer roll force. Inorder to control the tension of the material web (control), the control must ensure

2For SINAMICS S120 several instances of the winder application can be executed on a CU320-

2. The blocks available in the DCC charts and @Parameter occupy memory space in the driveunit. In DCC-SINAMICS with the CU320-2 module on SINAMICS S120, S150, G130, G150, amaximum of 1500 blocks and 1500 @ parameters can be configured. Without making anychanges, as a result of the number of blocks (500 with splice, 418 without splice) andparameters the winder application can have a maximum of 3 winder axes running on aSINAMICS S120 drive unit. The necessary computation time depends on the winder applicationfunctions used and this must be taken into consideration when designing the system. Dataregarding the computation time requirement of the individual execution groups is provided in

Chapter2.2 Characteristics and features of the "winder" application.

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that the dancer roll remains in its center position. If the tension in the systemchanges, then the dancer roll position also changes. This, in turn, is coupled to thecontrol through a position sensing system. The system responds if such a deviation

is detected and e.g. the drive speed is changed.

The tension transducerdirectly measures the tension in the system and signalsthis to the control. If the tension changes, then this can either be compensated bychanging the speed or by changing the motor torque.

The web tachometermeasures the web speed directly in front of the winder. Aweb tachometer is particularly needed for the constant v control

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1.2.2 Winding techniques

A differentiation is made between 2 winding techniques

Center winder

Figure 1-1

Speed

master

Vset

Fact

Load cell

Center winder

n+

With a center winder, the roll is driven by a central shaft. The diameter range is animportant factor when designing this type of winder. The reason for this is that at aconstant web velocity and constant tension, the speed is inversely proportional tothe diameter. This means that the maximum drive speed that is required is definedby the minimum roll diameter - whereby the maximum required torque is defined by

the maximum diameter.

The center winder is more complicated and from a control perspective, moredifficult to handle than the surface winder; however, it is still more widelyestablished of the two winder types.

This application was exclusively generated for central winder applications and thisdocumentation is only applicable for this winding technique. An extensive range ofclosed-loop control types, a wide range of functions and open-control methods are

available for this central winder application.

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Surface winder

Figure 1-2

n-controlledM-

controlled

Surface winder

For a surface winder, the roll is driven through one or several rolls that are incontact with the roll being wound. The drive speed and power depends on the

diameter of the roll being wound. From a mechanical design perspective, thiswinder technique is more complicated than that of a center winder.

The surface winder is mainly used when winding if there are no specialrequirements placed on the surface of the material being wound or unwound.

The surface winder is not considered in this particular application; however, inprinciple, it can be operated just like the central winder with constant diameter.

Note In order to set a constant diameter and maintain this, the "diameter computer"execution group is always required; the "integrating diameter computer"execution group is not required. Handling execution groups is described inChapter13.1 Commissioning the application.

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1.2.3 Control techniques

4 control techniques are mainly used for winders:

Indirect tension control

Figure 1-3

The indirect tension control is very frequently used if a user does not want to useexpensive sensor systems as there are no higher-level control loops available. Thistechnique must be able to operate without any tension feedback signal. Thistherefore places thehighest requirements on the torque setpoint conditioning andthe torque accuracy

3of the drive.

The indirect tension control is based on the physical interrelationship betweentorque and the tension of the material web. The motor torque is changed as afunction of the diameter of the roll being wound so that a setpoint (reference)

tension is obtained.

3Data on this is provided in the Catalog in the Chapter, System Description.

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Dancer roll position control

Figure 1-5

A dancer roll is used for the dancer roll position control - a position-controlledmeasuring system. The position of the dancer roll is determined using a suitableposition encoder, which is then compared with the position setpoint (referencevalue). The tension is only determined using the dancer roll. If the tension changes,then the position of the dancer roll also changes. By changing the winder speed,the dancer roll position control corrects this position offset. Although brief speedfluctuations have an effect on the position of the dancer roll, they hardly have anyeffect on the tension in the system. However, this only applies as long as thedancer roll does not reach its limits.

The dancer roll position control has the advantage that brief fluctuations in thetension can be absorbed due to the material web storage function of the dancer

roll. However, an intervention has to be made in the material web routing as aresult of the mechanical arrangement.

The limits of the dancer roll position control are predominantly defined by themechanical implementation of the dancer roll and its dynamic characteristics.

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Constant v control

Figure 1-6

Maneuver

Vset

VactM

Power unitspeed

controller

Current

controller

Friction moment

Dactnact

Diameter

calculation

Kp-adaption

J

Jog set point

M+n+

dn/dt

Dact

Inertia curve

Vact

With constant v control, the web speed is determined by the web tachometer andused for the diameter calculation. The web speed setpoint is directly provided tothe winder control. In constant v control the winder is running in speed controlledmode. The web tension is realized with the nip or uncontrolled in this control mode.

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1.2.4 Diameter calculation technique

For tension operation of the winder4, the diameter actual value, required to pre-

control the speed and the torque, can be calculated from the actual web velocityand the actual speed of the winder drive.

The division technique:

=

]min

1[

]min[

][

act

set

act

n

mV

mD

and the integration technique:

=ta

act

set

act

n

VmD

ta

0

0][

are available for this purpose.

The division technique continually supplies the value of the actual diameter;however, at very low winder speeds, due to the high noise signal when comparedto the useful signal of the speed actual value (this naturally also depends on thequality of the encoder system being used) it can only provide inadequate results.This is the reason that when a parameterized threshold for speed and web velocityare fallen below, the diameter value is held (frozen) which means that the value is

no longer updated.This problem is resolved with the integration technique. This is done by integratingthe speed actual value and the web velocity within a specific interval, and a newdiameter value is only calculated at the end of the integration interval. This meansthat interference signals, which are characterized by a symmetrical noise signal,are filtered-out.

This means that both techniques are based on evaluating the speed actual value.As a consequence, the diameter value can slightly deviate from the actualdiameter. This is due to closed-loop control operations of the tension or dancer rollcontroller - also as a result of elastic material. For the latter, the winder always runssomewhat faster or slower than the web itself as a result of stretching. This slightdifference between the calculated diameter and the actual diameter is however not

a problem for the majority of applications.These types of deviations can be eliminated when using a diameter sensor - whichis then used instead of the calculation. Further, it is also possible to calculate thediameter by knowing the material thickness and counting the number of layers.

4

Using a diameter sensor or layer counting, the diameter actual value can be transferredcontinuously. If continuous transfer is active, the plausibility check is deactivated.

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1.2.5 Overview of the features of the winding techniques

Functions

Various winding functions, e.g. direct tension control using speedcorrection or torque limiting, indirect tension control and constant v controlare possible

Bumpless changeover from the speed controller (the tension controller actson the torque limits) or speed correction technique (the tension controlleracts on the speed setpoint) - either of these techniques can be selected

The tension controller and speed controller gain are adapted as a functionof the diameter and the moment of inertia

Winding hardness control is possible

Acceleration pre-control (inertia compensation) as a function of themoment of inertia of the roll

Diameter calculation either using the division or integration technique,measurement using a diameter sensor or by counting the number of layers

of material (number of winder revolutions)

Optional use as main speed master with smoothing time

Tension transducer or dancer roll as measuring systems

Splice control 5

1.2.6 Solution using the standard "winder" application

The standard "winder" application presented here helps to implement the functionsshown and a functioning winder can be quickly developed.

The standard application includes, as a core function, a DCC chart. The functionsmentioned above are implemented in this DCC chart and can be simplyparameterized.

5The splice control can only be used on SINAMICS S units where the position controller

function module is activated. In order to save memory space and to make it easy for the user to

integrate this function into his system, for this example, there is a version with splice and aversion without the splice otherwise, the functionality is identical.

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1.2.7 Advantages of the standard application winder

When using the standard "winder" application users have the following advantages:

Programs can be quickly generated

Comprehensive winder functionality can be implemented easily and quickly usingthe standard "winder" application.

Possibility of adaptation

Using application-specific parameters, users can select their own sources forsetpoints and actual values. This means that the core function provided can besimply and quickly implemented taking into account the users own particularrequirements.

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1.3 Structure of a splice solution

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NOTE The splice control can only be used on SINAMICS S units where the position

controller function module is activated. In order to save memory space and tomake it easy for the user to integrate this function into his system, in the driveproject of this example there is a version with splice and a version without thesplice - otherwise the functionality is identical.

1.3.1 General structure

A solution with a flying splice generally comprises 2 winders, sensors and amechanical system to change the rolls. Generally, the roll changer comprises a

rotating turret, knife and a splice roll. The objective of a flying splice is to splice thematerial web from the old roll with the material web from the new roll while thewinder is operating at its full velocity. The new roll is pressed onto the old materialweb using a splice roll and the old roll is cut using the knife. After this has beencompleted, the winding functionality is switched over to the new roll.

Fig. 1-7 Structure of a splice solution

New

Old Knife

Rotating turret

Splice roll

Splice position

For one winder axis, the winder application with DCC can be run on a CU320;several winder axes per CU are possible with the CU320-2 (this will be availablefrom firmware version 4.3 SP1). In order to use the splice function, this means thattwo CU320 modules or one CU320-2 and an additional SIMATIC PLC are required.This application is intended for use with the CU320-2 firmware version from V4.3SP1. The specified contact partners can be contacted if changes are required forolder versions.

The splice control is sub-divided between SINAMICS and the SIMATIC PLC.Depending on the winder position, the splice roll and the knife must be controlled

via cams.

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The closed-loop position control function module must be activated for the splicefunctionality. If the splice functionality is not required, then the closed-loop positioncontrol function module is not required and the associated execution group can be

sent to "do not calculate".

1.3.2 Functions

In order to be able to control the splice output cams, the following sub-functions partially in the DCC, partially in the script (splice point calculation) have beenimplemented.

Modulo correction

There is no possibility of defining modulo correction using the closed-loop positioncontrol function module. Parameter p2506 is used to specify how many Length

Units (LU) one revolution is (on the load side); this is taken as the modulo lengthand the application corrects the position actual value if an overflow (r2521 > p2506)or underflow (r2521 < 0) is detected. The modulo correction is realized via p2512(activate correction value) and p2513 (correction value) in the position controller.The correction value is p2506.

The position actual value r2521 can lie outside the modulo limits, because thecorrection is only effective in the next clock cycle and the overflow detectionrequires one overflow. A corrected position actual value (r23401) is also availablein the application, which is always located between the limits; this value can betransferred.

When switching-on, if the position actual value lies outside the modulo range forseveral modulo cycles, then the correction is made over several cycles.

Splice modulo

The cams required for the splice control must frequently be available for severalwinder revolutions; this is to allow an optimum splice operation. The user canparameterize how many revolutions the splice modulo contains.

For simplified output cam tracking and parameterization, the splice modulo value iscorrected by a measured value so that the splice position (if it is located under thesensor) always lies in the splice module at 0 + n * p2506. Splice outputs, the cams

also refer to the splice modulo.

Splice modulo is only active if the splice outputs are enabled.

It must be ensured that the splice modulo is sufficiently long so that it can containthe splice output cams.

Probe control

For unwinders, the new roll must be synchronized with the material web. Thisreferencing can be performed at standstill or while in motion, once or several times.Referencing is not required for winders. At least one valid measured value is

required to enable the output cams.

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Splice point calculation

For an optimum splice, it is important that the output cam points for the knife andsplice roll control are precisely set. One option for simple parameterization is

realized using a runnable script. The splice point calculation is based on thefollowing parameters:

Table 1-1 Parameters to determine the splice output cams

Parameter Unit Description

SRT [ms] Response time of the splice roll, for deadtime compensation

KRT [ms] Response time of the knife, for deadtime compensation

STP [mm] The splice roll is pressed onto the roll earlier by this distance

TOP [Degr] After the splice, the splice roll remains in the splice position

DSK [mm] Distance between the splice roll and the knife (minimum overlap)

OVLP [mm] Material overlap between the old and new roll

TOK [Degr] After the splice, the knife remains into the splice positionOTS [Degr] Offset between the sensor (for splice position identification) and the splice

point (where the splice roll is pressed)

Diameter [mm] Roll diameter for the splice (new roll) Used to convert parameters(from [mm] and [ms] to [LU])converted parameters havean_LUsuffix.

LineSpeed [m/min] Line velocity for the splice

Modulo [LU] LU per revolution

Table 1-2 Results of the splice point calculation

Parameter Unit Description

SPLP [LU] Splice point The results can be interpreted as

degrees, if the number of LUs perrevolution is appropriately set.CUT [LU] Cutting point

STON [LU] Position for splice roll on

STOFF [LU] Position for splice roll off

KTON [LU] Position for knife on

KTOFF [LU] Position for knife off

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Fig. 1-8 Splice parameters (before the splice)

Sensor

Old

New

Splice rollKnife

DSK

STP

OTS

Splice

position

Fig. 1-9 Splice parameters (after the splice)

Sensor

Old

New

Splice rollKnife

DSK

OVLP

OTS

Splice

position

The precise calculation is described in Chapter7 Short collection of formulas.Theinterrelationship between the parameters can be explaining using the followingdiagram. All of the parameters shown have already been converted to LU.

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Fig.1-10

Output cam control and splice sequence

The splice position is referenced using a probe. To do this, the basic functionavailable in the drive is used. Referencing can be activated just once or severaltimes. The application activates the probe if the enable signal has been explicitlyissued. The probe input is connected to the sensor for the splice position detection

or if this is not available with a pushbutton/digital signal for manual adjustment.

A valid measured value and the explicit splice enable signal must be available inorder to enable the splice outputs. The probe is automatically deactivated if thesplice outputs are activated. The enable signal from the SIMATIC PLC must be

withdrawn, in order to avoid reactivation after the splice.

The outputSplice ready signals that the splice sequence has been completed. Thissignal is reset when the splice enable is withdrawn; this means that the splice

sequence has been completely deactivated.The probe can be deactivated at any time if the enable signal is withdrawn. Anexisting valid measured value remains.

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Fig. 1-11 Splice sequence with several measurements

1

0

1

0

1

0

1

0

1

0

p23200

Enable

measured

value memory

p23201

Enable splice

p23202

Measured

value valid

r23501

Activate probe

r23503

Splice

completed

1

0

a)

1

0

r23502

Valid value

available

p23002

Singlemeasurement

r23506

Splice outputs

enabled

1

0

b) c)

d)

e)

f)

g)

a.) Probe is activated with the enable signal

b.) Probe acquires a measured value (the enable signal can be withdrawn at anytime), the application reactivates the probe with a rising edge

c.) Probe acquires a new measured value, the application reactivates the probewith a rising edge

d.) The splice is enabled, which means that the probe is deactivated

e.) Enable signal for the probe control is withdrawn

f.) The splice sequence has been completed (cam outputs of the application weredeactivated by the splice modulo) and the corresponding feedback signals set

g.) The splice enable signal is withdrawn

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26DCC Winder

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Fig. 1-12 Splice sequence with one measurement

1

0

1

0

1

0

1

0

1

0

p23200

Enable meas.

Value memory

p23201

Enable splice

p23202

Measured

value valid

r23501Activate meas.

probe

r23503

Splice

completed

1

0

a)

1

0

r23502

Valid value

p23002

Singlemeasurement

r23506

Splice outputs

enabled

1

0

b)

c)

d)

e)

f)

a.) Probe is activated with the enable signal

b.) Probe acquires a measured value (the enable signal can be withdrawn at any

time), the probe is not reactivated

c.) Enable signal for the measuring probe is withdrawn

d.) The splice is enabled

e.) Splice sequence has been completed (cam outputs of the application were

deactivated by the splice modulo) and the corresponding feedback signal set

f.) Splice enable signal is withdrawn

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OVLP = DSK

End If

'Show inputsstrMsg = "Input parameter:" & vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Response time of the splice roll: " & SRT & " ms" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Response time of the knife: " & KRT & " ms" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Applying the splice roll: " & STP & " mm" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Lifting the splice roll: " & TOP & " Degrees" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Overlap of the material: " & OVLP & " mm" &

vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Distance between the splice roll and knife: " & DSK& " mm" & vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Lifting the knife: " & TOK & " Degrees" &


strMsg = strMsg & Chr(149) & "Offset, sensor splice point: " & OTS & " Degrees" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Roll diameter: " & Diameter & " mm" & vbNewLine& vbNewLine

strMsg = strMsg & Chr(149) & "Line velocity: " & LineSpeed & " m/min" &vbNewLine

MsgBox strMsg

'Convert parameters to degrees/1000

ModLength = Parameters(2506, 0)

LengthToDeg = ModLength / (Diameter * 3.14159265)

TimeToDeg = LengthToDeg * LineSpeed / 60

SRTd = SRT * TimeToDeg

KRTd = KRT * TimeToDeg

STPd = STP * LengthToDeg

TOPd = TOP * ModLength / 360

OVLPd = OVLP * LengthToDeg

DSKd = DSK * LengthToDeg

TOKd = TOK * ModLength / 360

OTSd = OTS * ModLength / 360

'Calculate SPLP and outputCam position

Delay1 = KRTd + DSKd - OVLPd

Delay2 = SRTd + STPd

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If Delay1 > Delay2 Then

SPLP = Delay1

ElseSPLP = Delay2

End If

SPLP = CLng(((SPLP-(SPLP Mod ModLength))/ModLength + 1) * ModLength +OTSd)

STON = CLng(SPLP - STPd - SRTd)

STOFF = CLng(SPLP + TOPd)

CUTPOS = CLng(SPLP + OVLPd - DSKd)

KTON = CLng(CUTPOS - KRTd)

KTOFF = CLng(CUTPOS + TOKd)

'Show outputs

strMsg = "Output parameters:" & vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Splice point: " & SPLP & "Degrees" & vbNewLine &vbNewLine

strMsg = strMsg & Chr(149) & "Position for the splice roll ON: " & STON &"Degrees" & vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Position for the splice roll OFF: " & STOFF &"Degrees" & vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Cutting position: " & CUTPOS & "Degrees" &vbNewLine & vbNewLine

strMsg = strMsg & Chr(149) & "Position for knife ON: " & KTON & "Degrees" &


strMsg = strMsg & Chr(149) & "Position for knife OFF: " & KTOFF & "Degrees" &vbNewLine & vbNewLine

MsgBox strMsg

'Write parameters

Parent.Parent.Units("Winder").Symbols("p23003") = KTON 'Knife on position

KTON (deg*1000)

Parent.Parent.Units("Winder").Symbols("p23004") = KTOFF 'Knife off positionKTOFF (deg*1000)

Parent.Parent.Units(" Winder").Symbols("p23005") = STON 'Roll on positionSTON (deg*1000)

Parent.Parent.Units(" Winder").Symbols("p23006") = STOFF 'Roll off positionSTOFF (deg*1000)

Else

MsgBox "Script run has been interrupted!", 4112, "Note"

End If

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2 Functions of the winder application

2.1 Tasks that can be implemented using this application


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2.1 Tasks that can be implemented using this application

This application is used to control rotating equipment and machines to wind orunwind a material web (film, paper, wire, foil, etc.)

The "winder" application conditions the signals that are required to control thewinder axis. These signals include speed and torque.

The "winder" application comprises drive control blocks (DCBs) that generatesetpoints from the system variables. These system variables include, for instance,material velocity and acceleration, the selected control mode, possibly the dancerroll actual position and tension actual value for the winder axis. Depending on thecontrol mode these are speed setpoints, torque limits and torque setpoints. Theapplication handles all of the essential open-loop winder control functions - such asdiameter calculation, moment of inertia calculation or sets the sign as a function of

the winding direction. Further, it is also possible to control splicing.

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2.2 Characteristics and features of the "winder" application

32DCC Winder

3.2.0, Entry-ID: 38043750

2.2 Characteristics and features of the "winder"

applicationThe following characteristics and features were taken into account in the standard

application and these can actually be used:

Diameter computer

The actual diameter is obtained from the ratio between the web setpoint velocityand the actual speed. The diameter value is required, among other things, toconvert the web velocity into the corresponding motor speed.

There is optional the division method:

]rpm[n

]min

m[V

]m[Dact

set

act =

or the integrating method:

=

ta

0

act

ta

0

set

act

n

V

]m[D

available, whereas the integrating method delivers smoother diameter actual

values and therefore it is more suitable for low speed values.

In operation (e.g. depending on the actual velocity) it is always possible to changeover between the calculation using the division technique and the integrationtechnique. For example, at very low speeds where the division technique cannotprovide any satisfactory calculation results, this allows the integration technique tobe started. At high speeds, where the calculation interval is significantly increased(automatically) in order to obtain satisfactory results, it is possible to again changeback to the division technique.

Further, is also possible to connect a diameter sensor and to use this instead of

calculating the diameter.

It is also possible to calculate the diameter using the material thickness by countingthe number of layers of material.

For dancer control, it is possible to reduce the influence of the dancer movement to

the diameter computer by different adjustment values.

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Winding hardness characteristic

A winding hardness characteristic is required if the tension, with which the material

is being wound, is to be decreased as the diameter of the roll being woundincreases. The winding hardness control is only effective while winding and it onlymakes sense to use it here. The winding hardness characteristic depends on theactual diameter. There are 4 different characteristics that are available to calculatea winding hardness characteristic:

Maximum tension decrease at infinity

Maximum tension decrease at the maximum diameter

Linear tension decrease

Free characteristic

Controller adaptation

The gain of the tension controller can be adapted as a function of the diameter.This permits a higher controller gain to be used at large diameters

The speed controller gain in the drive can be adapted as a function of themoment of inertia of the roll being wound. This is also necessary for a full rollso that this can be moved with a fast response time

Inertia compensation (acceleration pre-control)

While the material is being accelerated and decelerated, a compensating torquecan be entered into the drive. This compensating torque comprises a variable and

a constant moment of inertia. This compensating torque is used to dynamicallyrespond to velocity changes.

The inertia compensation avoids tension dips or tension increases due to velocitychanges. This pre-control is especially required for indirect tension control - but

also for tension control using a tension transducer.

The inertia compensation (acceleration pre-control) is adjusted and set-up whenthe winder system is being commissioned.

Friction compensation

The frictional losses are compensated using a parameterizable polygoncharacteristic with 10 points along the characteristic. These points must bedetermined when commissioning the system. For SINAMICS these points along

the characteristic can be automatically traced and recorded. (also see Chapter13.1Commissioning the application).

Tension operation

Tension operation can only be selected in the operation (run) mode and not if aweb break signal is present. The machine must always be stationary whenchanging over from web to tension operation and vice versa.

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Web break detection

The web break detection is active when the tension control is switched-in. Theweb-detection function is configured differently depending on the control type.

Direct tension control with tension transducer and torque limiting

A web break is detected when a selectable minimum tension is fallen below or ifthe speed controller intervenes (when the drive no longer operates at the torquelimit).

In the case of a web break, the speed controller intervenes and controls thecircumferential velocity of the drive to the specified web velocity setpoint plus theselected overcontrol value.

Direct tension control with tension transducer and speed correction

A web break is detected when a selectable minimum torque is fallen below.In the case of a web break, the speed controller intervenes and controls () thecircumferential velocity of the drive to the specified web velocity setpoint plus theoutput limit of the tension controller.

Direct tension control with dancer roll and speed correction

A web break is detected when a selectable dancer roll end position is exceeded.

When the web breaks, the dancer roll drops to its lower limit. The position controllergoes to its limit. The speed controller controls () the circumferential velocity of thedrive to the specified web velocity setpoint plus the output limit of the positioncontroller.

Indirect tension control

A web break is detected when a selectable minimum torque is fallen below or if thespeed controller intervenes (when the drive no longer operates at the torque limit).

When the web breaks, the speed controller intervenes and controls () thecircumferential velocity of the drive to the specified web velocity setpoint plus the

selected overcontrol value.

Constant v control

Web breaks can not be detected in case of constant v control,an external webbreak detection device must be used.

After a web break has been detected, The diameter computer is held,

Tension operation is disabled, and

The tension controller is inhibited (the enable signal is withdrawn)

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36DCC Winder

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Fast stop

SINAMICS drive converters have three shutdown modes as standard.

In the OFF 1mode, the motor is braked down to zero speed (standstill)along the down-ramp of the ramp-function generator and the pulses arethen inhibited.

For the OFF 2mode, the drive converter is immediately shut down. Themotor coasts down and the mechanical brake is activated.

For the OFF 3mode, the motor is braked along a fast stop ramp that canbe parameterized and then the pulses are inhibited.

NOTICE If the OFF3 mode is used in conjunction with closed-loop tension controlvia the torque limits, then for SINAMICS S and G, parameter p1551 shouldbe interconnected to r899.5. This means that after OFF3 has been selected,the full torque that has been enabled - is available for braking!

In the OFF1 mode it is absolutely necessary that the tension mode isdeselected.

For SINAMICS DCM, it is absolutely necessary for OFF1 and OFF3 that thetension mode is deselected.

CAUTION In normal operation, the winder operates in synchronism with the webvelocity. This means that the standard switch-off modes result in a loss ofcoordination, which can result in a web break or the formation of materialloops.

For the winder application, there is also the possibility of braking the winderalong a web velocity-referred ramp; this is described under thesynchronizing and stopping function.

Generally, it is necessary to stop the winder, coordinated with the drives that areconnected through the material web. In this case, it is sufficient to brake the drivethat specifies the web velocity actual value for the winder, i.e. the drive of the so-called nip position. The winder can then be braked in a coordinated fashion (e.g. intension control) and can then be deactivated when the machine comes to a

standstill.

CAUTION Is constant v control used, a coordinated stop can only be realized using rcontrol word for the winder

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Execution groups

Several execution groups are available when operating the application:

Integrating diameter computer: the additional calculations necessary forthe integration technique are executed in this execution group; theexecution group is, when required, activated in addition to the executiongroup "diameter computer"; if only the division technique is required, thenthe execution group can be set to "do not calculate",

Diameter computer:The diameter is calculated and the actual values

necessary for this are sensed in this execution group. This execution groupis always required,

Winding hardness computer: In this execution group, using aparameterizable characteristic, the decrease of the tension setpoint iscalculated as a function of the actual diameter; this execution group is onlyrequired for winders using the tension control technique with tensiontransducer and only when it is necessary to reduce the winding hardness;

it can be set to "do not calculate" for the other configurations.

Tension - dancer roll controller: This execution group is required for allcontrol techniques with the exception of the indirect tension control,

Setpoint computer:The speed and torque setpoints are calculated in thisexecution group; this execution group is always required,

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38DCC Winder

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Control unit: The control of internal functions is calculated in thisexecution group; this execution group is always required,

Web break detection: The web break monitoring function is calculated inthis execution group. If monitoring is not required - or this is externally

realized - the execution group can be set to "do not calculate"

Splice control: the splice control is calculated in this execution group; if asplice control is not required, then the execution group can be set to "donot calculate",

6

Length calculator: the web length traveled is calculated in this executiongroup; the braking distance for the web length braking and part of thediameter calculation using a layer counter are also calculated,

6The splice control can only be used on SINAMICS S units with activated position controller

function module. In order to save memory space and to make it easier for users to integrate the

function, for this example, there is a version with splice and a version without the splice -otherwise the functionality is identical.

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Notes regarding the computation time requirement

Different utilization levels of the Control Unit computational performance areobtained depending on the drive unit configuration and depending on the execution

groups of the winder application that have been activated.

Note The computation time utilization of the Control unit should be observed -especially for short sampling times (monitoring parameter r9976). If necessary,the application modules should be processed in a slower sampling time.

Notes for use with SINAMICS S120

The following computation times are required when the standard sampling timesare set in conjunction with a CU320-2 and firmware version 4.5:

Execution group Standardsampling

time

ms

Computationtime

requirement

%

Own selection

Integrating diameter computer 4 1,0

Diameter computer 4 2,6

Tension-dancer roll controller 4 2,6

Setpoint calculator 4 6,6

Winding hardness characteristic 4 1,5

Controller 4 3,9

Web break detection 4 1,4

Splice control 1 12,7

Length computer 4 1,6

The blocks and @parameters in the DCC charts take up memory space in thedrive unit. In DCC-SINAMICS with the CU320-2 module on SINAMICS S120,S150, G130, G150, a maximum of 1500 blocks and 1500 @-parameters can beconfigured. Without making any changes, due to the number of blocks (500 withsplice, 418 without splice) and parameters the winder application can have amaximum of 3 winder axes on one SINAMICS S120 drive unit.

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40DCC Winder

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Example configurations

Basic winder with indirect closed-loop tension control:

Execution group Sampling timems

Computationtime requirement

%

Integrating diameter computer Do not calculate 0


Tension-dancer roll controller Do not calculate 0


Winding hardness characteristic Do not calculate 0

Control unit 4 3,9

Web break detection Do not calculate 0

Splice control Do not calculate 0

Length computer Do not calculate 0

Total: 13,1

Sophisticated winder with dancer roll control and splice:

Execution group Sampling time

ms

Computationtime requirement

%

Integrating diameter computer 4 1,0


Tension-dancer roll controller 4 2,6


Winding hardness characteristic 4 1,5

Control unit 4 3,9

Web break detection 4 1,4

Splice control 1 12,7

Length computer 4 1,6

Total: 33,9

Note The required computation time can be scaled by adapting the sampling times.

For example, by changing the sampling time from 4ms to 8ms the computationtime required can be halved.

The basic utilization of the drive system can be calculated using the Sizer tool.The necessary computation time of the winder application must then beadditionally available.

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3 Automation solution

3.1 Hardware and software components required


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3 Automation solution

3.1 Hardware and software components required

Hardware components

CU320-27control module for SINAMICS S

8and G from firmware version V4.5

HF1 with DCB library TPdcblib_SINAMICS_4_5.3.0[5.0]

SINAMICS DCM from firmware version V1.3.x with

TPdcblib_SINAMICS_4_4.3.0[9.0]

Standard software components

STARTER commissioning tool or Scout from Version 4.3.1.0 with installed DCC forSINAMICS (SINAMICS S and G from DCC library versionTPdcblib_SINAMICS_4_5.3.0[5.0], SINAMICS DCM from DCC-library version

TPdcblib_SINAMICS_4_4.3.0[9.0])

File examples and projects

All of the files that are used for the application are listed below.

Table 3-1

Component Note

SINAMICS_DCC_Winder_chart_exports_V3_2_0.zip This zipped file contains the XMLexport of the DCC charts.

SINAMICS_DCC_Winder_Script_exports_V3_2_0.zip This zipped file contains the XMLexport of the script files forcommissioning support.

38043750_DCC_Winder_en_V3_2_0.pdf This document.

7Further, it is possible to use the application on a SINAMICS S120 drive system with CU320.

The specified partners can be contacted regarding adaptations required for older versions.

8For SINAMICS S120, several instances of the winder application can be executed on a

CU320-2. The blocks available in the DCC charts and @parameter occupy memory space inthe drive unit. In DCC-SINAMICS with the CU320-2 module on SINAMICS S120, S150, G130,G150, a maximum of 1500 blocks and 1500 @parameters can be configured. Without makingany changes, as a result of the number of blocks (500 with splice, 418 without splice) andparameters the winder application can have a maximum of 3 winder axes running on aSINAMICS S120 drive unit. The necessary computation time depends on the winder applicationfunctions used and this must be taken into consideration when designing the system. Dataregarding the computation time requirement of the individual execution groups is provided in

Chapter2.2 Characteristics and features of the "winder" application.

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4 Installing the hardware and software

4.1 For your safety


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4.1 For your safety

4.1.1 Safety information and instructions

Pictograms, signal words and text

Every piece of safety information & instruction in this document is designated bytext graphics comprising pictogram and signal word, and supplemented byexplanatory text. A clear classification according to the degree of the potentialhazard is provided as a result of the combination of pictogram and signal word.Safety information/instructions are provided in front of the information regarding

activities to be executed.

Classification

There are three different stagesregarding safety information/instructions.Theseare designated by the same pictogram. They differ by the signal word.

!DANGER

DANGER indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury.

!WARNING

WARNING indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.

NOTICE NOTICEused without the safety alert symbol indicates a potential situation which,if not avoided, may result in an undesirable result or state.

4.1.2 Responsibilities of the operator

Correct operation and use

The correct use of the application components exclusively relates to the test set-ups that were adapted to the power/performance of the application components. Inorder that the application functions perfectly, the required standard SINAMICScomponents as well as also the necessary hardware and software components

must be installed.

The company/person operating the system may only make changes to theapplication components after having received written authorization from thesuppliers.

Misuse

The following are considered to be misuse:

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4.1 For your safety

44DCC Winder

3.2.0, Entry-ID: 38043750

Any application deviating from the use specified above - or applications that gobeyond the specified use.

Non-observance of the safety information and instructions.

If faults that could have a negative impact on the safety are not immediatelyresolved/removed.

Any changes/modifications to equipment/devices that are used to ensureperfect function and operation, unrestricted use as well as active or passivesafety.

If recommended hardware and software components are not used.

If the application components are not in a perfect technical condition, are notoperated conscious of safety and hazards and not taking into account all of theinstructions provided in the documentation.

The manufacturer assumes no liability for incorrect use (misuse).

Responsible for monitoring

The company or person operating the system is responsible in continuallymonitoring the overall technical status of the application components (defects anddamage that can be externally identified as well as changes in the operatingbehavior & characteristics).

The company/person operating the system is responsible in ensuring that theapplication is only operated in a perfect state. He must check the state of theapplication components before they are used and must ensure that any defect isremoved before commissioning.

Qualification of personnel

The operating company/person may only deploy trained, authorized and reliable

personnel. In so doing, all safety regulations must be carefully observed.Personnel must receive special instructions regarding the hazards/dangers thatcan occur.

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5 Selecting the control concept

5.1 Control concepts

46DCC Winder

3.2.0, Entry-ID: 38043750

winding hardness characteristic. The output signal of the winding hardnesscharacteristic can be used as required.

When a dancer roll is used as actual value transmitter, this has the advantage thatthe dancer roll (when the stroke is selected long enough) simultaneously serves as

storage element for the material web. This means that it already is a ' tensioncontroller'. Although dancer roll controls are quite complex, they offer unbeatablecontrol characteristics.

The material web storage function has a damping effect on

Rolls of material that are not completely round (out-of-true)

Jumps between layers - e.g. when winding cables

Roll changes

5.1.3 Direct tension control with tension transducer via the torque limits

A tension transducer directly senses the material tension. Its output signal isproportional to the tension and is fed to the tension controller as actual valuesignal. This means that in this case the tension controller is effective and directlycontrols the tension of the material web. As for indirect tension control, the speedcontroller operates in the drive in the overcontrolled condition. The drive is at oneof the two torque limits and is controlled through these torque limits. The correctionvalue from the tension controller acts on these torque limits. Supplementary torquesetpoints from the acceleration pre-control, the winding hardness characteristic andthe friction characteristic are additionally switched to the torque limits.

For this technique, it is not necessary to intervene in the material web as is thecase for a dancer roll system. However, contrary to a dancer roll, this system does

not have a material storage function.

5.1.4 Direct tension control with tension transducer and speed correction

Also for this control type, a tension transducer is used to sense the tension that isthen fed to the tension controller as actual value. In this case, the tension controlleroutput acts as velocity correction value on the speed controller. Acceleratingtorque, frictional torque and tension are pre-controlled. Contrary to the dancer roll

control, the control with tension transducer has no material storage function.

5.1.5 Constant v control

The previously described control methods depend on a nip position, where the webspeed is kept constant.

If no nip position exists, a tension control cannot be realized.

Constant v control means, that the web tension cannot be controlled by the winderdrive. The web speed must be determined by a web tachometer. The web speedactual value from this tachometer is used to calculate the actual diameter. Thewinder is controlled to run with constant web speed. Accelerating torque, frictionaltorque and tension are pre-controlled.

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5 Selecting the control concept

5.2 Comparison of the control concepts


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5.2 Comparison of the control concepts

The most important criteria when selecting a suitable control concept are

summarized in the following table:control

conceptIndirect

tension controlDirect tensioncontrol with

dancer roll andspeed

correction

Direct tensioncontrol with

tensiontransducer via

the torquelimits

Direct tensioncontrol with

tensiontransducer and

speedcorrection

constant vcontrol

Informationregarding thetension actualvalue sensing

Tension actualvalue sensing is

not required

Intervenes inthe materialweb routing,

ability to storematerial

Sensitive tooverload, doesnot intervene inthe web routing

Sensitive tooverload, doesnot intervene inthe web routing

no tensionactual value

sensing

Winding ratio

coreD

Dmax

Up to approx.

10:1, goodcompensation

ofdt

dvand

friction required

From

experience, upto approx. 15:1

From

experience, upto approx. 15:1,

precisedt

dv

compensationrequired

From

experience, upto approx. 15:1,

precisedt

dv

compensationrequired

up to approx.

15:1

Tension range

min

max

Z

Z

Up to approx.6:1 for good

compensationof the friction

anddt

dv

Can only bechanged if the

dancer rollsupport can be

set

Up to approx.20:1 for precise

dt

dv

compensation

Up to approx.20:1 for precise

dt

dv

compensation

not relevant

Winding ratiotension range

min

maxmax

Z

Z

D

D

core

Generally up to40:1

Dependsheavily on thetype of dancer

roll support - upto approx. 40:1

Up to 100:1,essentially

depends on thetension actualvalue signal

Up to 100:1,essentially

depends on thetension actualvalue signal

not relevant

Web velocity Up to 600m/min for goodcompensation

Up to over 2000m/min

Up to 2000m/min forprecise

dt

dv

compensation

Over 2000m/min

depending frommechanicalconstruction

Controlconcept,preferablyused for

Sheet steel,textiles, paper

Rubber, cable,wire, textiles,foils, paper

Paper, thin foils Elasticexpandable

material

sorter

Nip positionrequired

Yes Yes Yes Yes No

web

tachometerrequired

No No No No Yes

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6 Winder checklist

6.1 Checklist for realization of a winder application


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This checklist should be used to list customer requirements in order to investigate

the feasibility of the winder application. The fields with white background must

be completed; the fields with gray background can be calculated using the

appropriate formulas from the collection.

This checklist is provided in the Attachments to this documentation - and is alsoavailable as form that should then be completed. This can then be easily e-mailedto the Application Center. This checklist only serves to estimate whether theapplication is suitable for the actual winder requirements. It is not used to selectand dimension drive components!

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7 Short collection of formulas

0

50DCC Winder

3.2.0, Entry-ID: 38043750


7.1 Calculations relevant for winder

Dcore

D V

F

J2

n2n1

M

J1

Gear unit (i = n1 / n2)

bMb

(1) Winding ratio:

=mmmm

DDq

core

max

(2) Speed [rpm]:

[ ]rpmD

Vn

=

(3) Winding torque referred to the rotor shaft [Nm]:

= 1

mmNi2000

DFMw

(4) Winding power [kW]:

=

1

min/Nm

i2000

VFPw

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(5) Gear unit ratio, max. motor speed / max. sleeve/core speed:

==

min/m

min/mm

V1000

nD

n

ni

max

maxcore

2

1

(6) Moment of inertia, full/solid cylinder [kg m2]:

(7) Moment of inertia, hollow cylinder [kg m2]:

( ) ( )

=

=

3

44core412

4core

46 dm

mmkgmmDDb

1032DD

108

mJ

(8) Moment of inertia reduction through a gearbox:

221

i

JJ =

(9) Fixed moment of inertia [kg m2]

determined by the fixed parts and components of the winder (motor, gearbox and wound

roll/core) referred to the motor shaft

2

coregearmotorF

i

JJJJ ++=

(10) Variable moment of inertia [kg m

2

]

( )

=

3

44core

4

212v dm

mmkgmmDD

i1032

bJ

(11) Accelerating torque referred to the motor shaft [Nm] for accelerating time tb

( )vfb

b JJt

V

D3

i100M +

=

=

=3

44

12

2

6 dm

mmkgmmDb

1032D

108

mJ

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52DCC Winder

3.2.0, Entry-ID: 38043750

(12) Accelerating power [kW]

( )vfb

2

2

bb JJt

V

D9

vi10M

D30

ViP +

=

=

(13) Rated motor torque [Nm]

N

NN

n

P9549M

=

(14) Wound roll storage - capacity for flat materials [m]:

( )2core2Max DDd4000l

=

(15) Wound roll storage - capacity for round materials [m]:

( )2core2Max2R

DDD32000

bl

=

(16) Relative storage capability depending on the winding ratio:

q 2 3 4 5 6 7 8 9 10

2max q

11

l

l= 75 % 88.9% 93.8% 96% 97.2% 98% 98.4% 98.8% 99%

(17) Winding time [s]:

v

l60t =

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7.2 Calculations relevant for splicing


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(18) Conversion factor from mm to LU

*Diameter

revolutionperLUmmToLU =

(19) Conversion factor from degrees to LU

360

revolutionperLUdegToLU =

(20) Conversion factor from ms to LU

60

LineSpeed*mmToLUmsToLU =

(21) Delay time when activating the knife

mmToLU*OVLP-mmToLU*DSKmsToLU*KRTDelayKNIFE +=

(22) Delay time when activating the splice roll

mmToLU*STPmsToLU*SRTDelay LSPLICE_ROL +=

(23) Maximum delay in revolutions

1revolutionperLU

)Delay,MAX(DelayTRUNCDelayRev

PLICE_ROLLSKNIFE +

=

(24) Splice point calculation

degToLU*OTSrevolutionperLU*DelayRevSPLP +=

(25) Cutting point calculation

mmToLU*DSKmmToLU*OVLPSPLPCUT +=

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54DCC Winder

3.2.0, Entry-ID: 38043750

(26) Calculation output cam for knife control

msToLU*KRTCUTKTON =

degToLU*TOKCUTKTOFF +=

(27) Calculation output cam for splice roll control

msToLU*SRTmmToLU*STPSPLPSTON =

degtoLU*TOPSPLPSTOFF +=

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Formulas and dimensions used

b = material width [mm]

bmax = maximum material width of the wound roll [mm],

d = material thickness [mm]

D = actual diameter [mm]

Dcore = core or sleeve diameter [mm]

DMax = maximum diameter [mm]

DR = diameter of round materials [mm]

F = tension [N]

i = gear unit ratio (refer to (5))

J = moment of inertia [kgm2]

JF = fixed moment of inertia as a result of the unchanging parts of the winder

(motor, gear unit + winder core) referred to the motor shaft [kgm2]

l = material length [m]

lmax = maximum material length (for a core diameter 0 mm) [m]

Jgear = moment of inertia of the gear unit referred to the motor shaft [kgm2]

Jcore = moment of inertia of the winding core [kgm2]

Jmotor = moment of inertia of the motor [kgm2]

JV = variable moment of inertia as a result of the material being wound -

referred to the motor shaft [kgm2] (refer to (10))

m = weight [kg]

Mw = winding torque referred to the motor shaft [Nm]

Mb = accelerating torque referred to the motor shaft [Nm]

MbF% = percentage accelerating torque as a result of the fixed moment of inertia JFat the minimum diameter [% of MN] (refer to the formula (1.2))

MbV% = percentage accelerating torque as a result of the variable moment of inertia

JVat maximum diameter and maximum width [% of MN] (refer to the formula (1.5))

MN = rated motor torque [Nm] (refer to (13))

n = speed [rpm]

nmax = maximum motor speed [rpm] (no-load speed at maximum field weakening)

nN = rated motor speed at rated voltage and rated motor field current [rpm]

Pb = accelerating power [kW]

PM = required motor power [kW]

PN = rated motor power [kW]

Pw = winding power [kW]q = winding ratio (refer to (1) )

= specific weight [kg/dm3]

t = winding time [s]

tb = accelerating time [s]

th = time for the web velocity to ramp-up/accelerate from 0 to Vmax[s]

V = web velocity [m/min]

Vmax = maximum web velocity [m/min]

V = velocity difference [m/min]

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7.3 Selecting the winding ratio (winding range)

56DCC Winder

3.2.0, Entry-ID: 38043750

7.3 Selecting the winding ratio (winding range)

Winding operation is discussed in the following. The same essentially applies for

unwinding.

The winding ratio is given by the following quotient:

core

max

D

D

The quantity that can be actually wound as a % is, according to theformula (14):

4)D-(D core

2max

2

For a winding ratio of 6:1 then the winding length that can be used is already ~~ 97 %.

7.4 Power and torque

The power required for winding is constant over the complete winding range if, atthe selected web velocity, the selected tension when being wound is to be kept

constant (also refer to formula 4).

(3.1) Winding power Pw :

kW1060

VdbF=P

3

sW

b = operating width in mmd = operating thickness in mmV = web velocity in m/min

Fs = specific material tension in

N/(mm2material cross-section

surface)

The torque required increases linearly with the diameter of the roll being wound.

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