Spect Convert Titel - Siemens · Traversing drive functions of the Converting Toolbox are easily...

May 2006

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spectrumInnovative Solutions for the Converting Industry

CONVERTING

New Control and DriveConcept for LabelStamping Machines

Torque Motors SolveSpace Problems

New Control and DriveConcept for LabelStamping Machines

Torque Motors SolveSpace Problems

Shorter engineering with open standards:

Converting from a Toolbox

Shorter engineering with open standards:

Converting from a Toolbox

2 EDITORIAL

TRENDS3 China Boom

Automation technology in China

4 Converting from a ToolboxShorter engineering with openstandards

CASE STUDY6 Faster to Goal with

Motion ControlNew control and drive concept forlabel stamping machines

8 A New Twist to Roll ConvertingWebsSlitters with distributed control anddrive technology

10 Winders Suited for theFutureTorque motors solve space problems

12 Bundled ExpertiseHigh-level partnership between Siemens and Fabio Perini

13 Better Packing TogetherA growing partnership in lamination

14 Smooth SpeedPrecise control of film stretchinglines with torque motors

Dear readers,

Although the end products in the convertingsector are very different, the manufacturingprocess involves very similar process stages which we at Siemens have analyzed in depth.Based on our new Simotion and Sinamics sys-tem platform, we have developed tailor-madesolutions for dedicated applications in the con-verting industry (Converting Toolbox).One trend in the converting industry is webhandling control with angular synchronism insteadof speed ratio. Simotion is perfect for this: Bothcontrol modes can be implemented and com-bined according to technological requirements.Special functions such as center winding, rotaryknife, angular synchronism and flying saw can be combined and programmed in a modular mannerusing the web handling functions, as demon-strated by the article about a label cutting machine from Rotoflex (page 6). As a result,engineering expenditure and hardware costs canbe reduced. Our Converting Toolbox contains a complete set of the previous mentioned modules including the automatic splice, whichenables automatic roll change at full speed.These applications are fully open source and maybe modified as required.Another highlight of this issue is the use of torquemotors presented in the article on the retrofit-ting of the winder stands in a film stretching line(page 14). As the gearbox and mechanical trans-mission elements are eliminated, more robust,low-maintenance and high-performance driveunits can be used to transport the web in aconverting line.I hope you enjoy reading this issue and we lookforward to assisting you with your future con-verting projects.

2 CONTENTS EDITORIAL

spectrum converting 2006

spectrum convertingPublisherSiemens Aktiengesellschaft, Automation & Drives Division (A&D),Nuremberg

Group Executive ManagementHelmut Gierse, Hannes Apitzsch,Dr. Peter Drexel, Anton S. Huber

Editorial Responsibility in Accordance with the German Press LawPeter Miodek

Responsible for technical contentWulf [email protected]

Publishing housePublicis KommunikationsAgentur GmbH, Corporate PublishingP.O. Box 3240, 91050 ErlangenPhone +49 (0) 9131/91 92-5 21Telefax +49 (0) 9131/91 92-5 94Coordination: Sabine ZingelmannArtwork and layout: Juergen Streitenberger

DTPDoess, Nuremberg

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© 2006 by Siemens Aktiengesellschaft

Berlin and Munich.

All rights reserved

by the publisher.

“spectrum converting” is

printed on 100% recycled

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004900 RZ597 0406Circulation: 1000

Alexandre BonayHead of Business DevelopmentConverting Solutions


In the last five years, Siemens Automa-tion and Drives has achieved two-figuregrowth rates in China and has gained the

market leadership in the field of automationand drive technology. In addition to the morethan 2,600 employees, seven companies and44 regional offices presently located inChina, short-term plants include expandingthe sales and services network to 60 officesin total. These activities are complementedby a strong local presence and local exper-tise that allow Siemens to grow with the market and adapt to new requirements.

Different strategies for conquering the market

The Chinese market for automation tech-nology continues to grow. Siemens benefitsfrom this by entering strategic partner-

ships with local system integrators sincethese companies are always on the lookoutfor the latest technologies. With TotallyIntegrated Automation, Siemens providesan excellent automation platform for betterproduction visibility, a crucial factor forinternational competitiveness. After all,many of the plants in China are producingnot only for domestic but also for globalmarkets.

To improve access to the Chinese mar-ket, local partners are just as importantas global strategic partnerships and thedevelopment of in-house know-how. Thisincludes an extensive offer of services forcustomers. On a nationwide hotline net-work, service staff provide solutions toproblems within 2 hours. Training Centersin various cities pass on knowledge of new

technologies and products to customersand partners in China and complement the service portfolio. And a separate web-site for China has since become one ofthe favorite portals with chinese industrycircle.

Siemens aims to be number one or atleast number two in all fields of business infive years. With best products and systemsas well as extensive solution and engineer-ing know-how, Siemens wants to be a reliable, strong partner for importersfrom around the world and recommend itself to Chinese customers as a valuablebusiness partner in the broad field of con-verting industry. �

More information:www.ad.siemens.com.cn

Automation technology in China

China BoomToday, China is the third largest market worldwide for Siemens. The companyis planning investments of about one billion euros in China within the nextfew years, and as far as the outlook for the future is concerned, the Chinesemarket for automation technology is seen very optimistically.

3TRENDSSiemens in China


4Converting

TRENDS

Shorter engineering with open standards

Converting froma ToolboxThe “Converting Toolbox” simplifies applications for web processingand gives machine designers greater flexibility. With open func-tions such as winders, splice controls, cross cutters, flying saw, and traversing control, speed setpoint cascade and more, individual applications can be generated in the shortest possible time.

T he “Converting Toolbox” offers precise drive functions in a sin-gle package – suited for all converting applications and com-pletely scalable. The individual functions take the form of func-

tion blocks and can be used directly in the user program. Sampleapplications demonstrate how the necessary technological functioncan be efficiently and effectively implemented with a single functionmodule such as a rotary knife with print mark correction or a dancercontrolled winder with individual winding hardness characteristics.These sample applications are ready to use after only minor modifica-tions and are already equipped with some basic HMI functionality. Themachine function can therefore be remotely tested and optimizedwithin a very short time. The relevant code of the sample application,essentially the FB call with the interface to the operating interface, isthen simply transferred to your project via copy & paste.

Platform of choice

The Simotion motion control system is ideally suited as a system plat-form for the Converting Toolbox. Applications can be operated directlyon an intelligent drive – very compactly and without the need for anadditional PLC. In addition, controller-based topologies and PC-con-trolled automation are available with Simotion. With the current Mas-terdrives products, all converting Toolbox function components can beused on all Simotion hardware platforms as well.

Standardized and open

Engineering, programming, commissioning and documentation isgreatly reduced through the use of these standardized solutions. Acompany using standard solutions such as the Converting Toolbox canconsiderably reduce the time to market and improve its market posi-tion. In more than 80 percent of all cases, the required functionalityof a converting line can be covered by one or more of the ConvertingToolbox components. Usually only simple parameterization of thefunction suffices to automate a winder, print mark corrected rotaryknife. And these function blocks do more than their name implies. The“rotary knife,” for example, can be used equally well for rotational per-foration, punching and embossing.

In rare cases, the functionality of a component will need to be mod-ified, extended or changed. Here, since the source code is completelyopen, the Converting Toolbox functions provide a wide and solid basiswith which even special functions can be implemented very efficientlyand smoothly.

Because Siemens automation systems are open, machine designerand operator independence is ensured from the in-house diagnosisright through to modifications, extensions and adaptations. The ownerof a machine that has been automated using the Converting Toolboxalso enjoys the integrated diagnostics, maintenance and service func-tions typical of Totally Integrated Automation. Tele-maintenancethrough networks, and thus worldwide support, are also basic prop-erties of this converting solution. In addition, the rapid global Siemensservice team response ensures continuous high-level availability andproductivity and minimizes spare parts stocks. �

5

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WinderThe winder application cov-ers all of the usual closed-loop control types. Freelyselect from the followingparameterizable modes:

closed-loop dancer roll control with speed cor-rection, closed-loop tension control withtorque limiting, closed-loop tension controlwith speed correction and open-loop torquecontrol (indirect closed-loop tension control).

Splice controlThe splice control applica-tion includes all modulesneeded to implement anautomatic roll change at fullweb speed. Separate hard-

ware is not necessary. If required, a closed-loop register control can be superimposed.The rotary motion of the roll changing mech-anisms can be optionally controlled from theapplication itself.

Flying sawDepending on the tool used,this software applicationcan be used to implementprocedures such as drillingand embossing. Highlights

include synchronizing at a precise position,cutting at print marks, cutting to length andimmediate cutting, as well as generating agap.

Rotary knifeThe rotary knife applicationcovers all essential func-tions. One highlight is thecapability to change polyno-mial cams on-the-fly. In

addition, the cut length management func-tion allows formats to be changed and trig-gered by a print mark. Print mark correction ispossible with an adjustable correction speed.

Traversing driveTraversing drive functions ofthe Converting Toolbox areeasily integrated into exist-ing winder applications. Allrelevant data needed for tra-

versing is entered via an appropriate interfacealready provided on board. All traversing armdata can be changed in operation. Motionalgorithms and synchronous commands arecalculated in the application. Further, homing,jogging and free positioning can be enteredindependently of one another using axis com-mands.

More information:www.siemens.com/convertingE-mail: [email protected]

netic forces. Depending on the cutting for-mat, magnetic plates of varying lengthwrap around the magnetic cylinder. Thissubsequently produces a gap on the diecutting cylinder which would normallycause gaps in the cutting pattern. To com-pensate for this, the label material travelsin the opposite direction at the correct po-sition during each rotation of the magnet-ic cylinder.

The reverse motion is controlled usingan output cam. The individually drivendancers, located before and after the diestation, decouple the reverse motion of theproduct material from the continuous forward motion of the line determined bythe two winders. The winders also regulatethe material tension. The exact cutting positions are recorded with sensors usingprint marks on the label material and trans-ferred to the controller to immediately


6Converting

CASE STUDY

The switch to a new motion control system and matching drives has made labelinspection and finishing machines of a Canadian OEM more precise than everbefore, offering additional capabilities for extensions and future innovations.The standardized, open function modules ensure accelerated engineering. Theintensive support right from the start also convinced the new OEM.

For the past two years, Rotoflex Inter-national Inc. (Ontario/Canada) hasused electronic servo drives on its

Vericut (variable repeat die cutting) ma-chines to stamp printed web with flexibledie. These machines use magnetic cylin-ders which operate in reverse path move-ment. Recognizing the limitations of thecurrent technology, the manufacturersought a more modular, expandable andhigher performance solution to achievemore precise results in the finished prod-ucts. Drive-based Simotion D motion con-

trol systems and the matching Sinamicsdrives proved to be an ideal solution. Notonly flexibility and performance, but alsofast implementation have convincedRotoflex management to equip future ma-chine generations with the Simotion con-troller.

System change closes performancegaps

The core operation of the Vericut consists ofa turning magnetic cylinder on which aflexible die plate is placed and held by mag-

New control and drive concept for label stamping machines

Faster to Goal with Motion Control

Roto

flex

When it comes to die cuttinglabels, Rotoflex providescustom die cutting solutionsthat are the first choice of theworld's leading convertingcompanies


7

correct any deviations. The servo drive ofthe magnetic cylinder acts as the masterfor the complete line. This solution meets machine manufacturer demands for achiev-ing the required cutting accuracy of ± 0.1 millimeters (0.004 inch) and a produc-tion speed of more than 90 meters/minute(300 feet/minute).

The Canadian company can implementthe solution immediately with a high-per-formance control and drive system. Themost important component here is theSimotion D445 motion control system,which integrates the motion control, thetechnology and the PLC functionality in thecompact construction of the Sinamics S120drive family, and which permits cycle timesin the millisecond range without requiring

the usual interfaces. The converters of themodular Sinamics S120 series, which driveservo motors of the 1PH7 and 1FT6 series,are connected using the digital interface ofthe system. The first Vericut machineequipped with the new technology includesseven servo-controlled axes. A Simatic Mul-ti Panel MP270 Touch is used for operatorcontrol and monitoring of all processes.

More efficiency and flexibility with Simotion D

Conversion to Simotion D445 was primari-ly prompted by the fact that the previoussystem was limited in the number of axesand expandability. Additional axes wouldhave required an additional controller. Incontrast, a maximum of 64 drives can beconnected to the new Simotion motion con-

troller, giving manufacturers the neededflexibility for future extensions. This allowsVericut to be quickly and economically ex-panded with additional modules (even af-ter shipment) to fulfill specific customerrequirements. It is also possible to pre-con-figure these modules in standard controllersoftware to cover all requirements. Thisconcept helps to greatly simplify not onlythe engineering, but also commissioningand software maintenance.

The relative positions of the magneticcylinder and the web material changes inaccordance with the contact angle of thedie-cutting plate, and must thus be recal-culated for each new die plate. The Simo-tion controller allows this relationship to becalculated very precisely using a simple


All processes can be monitored using aSimatic Multi Panel MP270 Touch

Roto

flex

Bild

nac

hw

eis

1. Material moves forward as it iscutting the material

2. When the cylinderposition is at the gap,the material reversesdirection. The cylindercontinues in the samedirection

3. When the cylinderposition reaches the end of the gap, thematerial travels in theforward direction, re-synchronising thecutting to the nextrepeat of labels

output cam comprising of a linear and anexact sinusoidal component, rather thanthe previous system's individual interpola-tion points. This reduces the time for theonline calculation to a fraction of a mil-lisecond, with practically no waiting timefor the operator between job changes. Theproduction downtime after die platechanges is further reduced, increasingavailability and productivity of the line. Inaddition, thanks to the smoother, more har-monic motion control, the new control anddrive solution provides significantlysmoother running and a ± 0.1 millimetercutting accuracy of the Vericut. This, inturn, gives the manufacturer an additionaladvantage, since the machine not only cutsthe labels more precisely, but also at high-er speeds.

The use of standardized modules devel-oped by Siemens for a wide range of “con-verting” tasks also simplifies integration.The modules provide all of the requiredfunctionality for a specific task, for exam-ple, the used “winder” mode, various con-trol modes such as dancer position control,tension control with torque limitation andspeed correction or the torque control (in-direct tension control). The modules arealso easy to parameterize and no longer re-quire complex programming by the user.Another significant difference to the previ-ous solution is that the modules are com-pletely open. This allows the manufacturerto make changes and to customize the func-tionality to meet their specific needs. In thepast, even small changes to one of the mod-ules required program changes by the con-troller manufacturer.

Implemented in record time – together

Because Rotoflex wanted to present itsmodified machine at a trade show, the con-version to the new control and drive con-cept needed to be completed in just overfour weeks. Thanks to the intense cooper-ation between the Rotoflex and Siemens application specialists from Canada andGermany, the project was successfully com-pleted within the tight timeline. �

Leading manufacturers worldwide areincreasingly using slitters fromGoebel to process special papers, foils,

packaging materials and the like. The com-pany from Darmstadt has been developingand manufacturing these machines to cus-tomer-specific designs, and tailored to therespective product portfolio of the user.The automation technology used in manyGoebel systems has been “Made bySiemens” for many years. And for good rea-

son: The company’s export share, whichaccounts for approximately 80 percent of itsbusiness, is focused largely on Asian coun-tries, where the brand is highly valuedthanks to the reliability of its componentsas well as the rapid availability of spareparts and service around the globe.

High-level performance at low cost

While updating the automation design con-cept of the Goebel “xtraslit” universal

machine, developed to process paper andplastic films, Goebel was interested in find-ing a solution that would unite these twocriteria. The slitter is designed to longitu-dinally cut a wide roll of the base material,measuring up to 3.5 meters, into 2 to 10narrower lengths, and to rewind them com-

Slitters with distributed control and drive technology

A New Twist to RollConverting WebsGoebel Schneid- und Wickelsysteme GmbH of Darmstadt, Germany introduced a new automationdesign concept for its universal paper and foil slitters. With its modular and distributed design, itdiffers from previous models, largely as a result of the highly compact drives of the Sinamicsproduct range. The PC-based control system, another new feature, offers exceptional performancefor this class of systems, while helping to keep costs low.

Goe

bel

The first PC-based automatic Goebel‘xtraslit’ slitter-rewinder offers high-levelperformance and functionality at reducedcosts


8Converting

CASE STUDY

Peripherals without switch cabinets

“Distributed is the way to go.” This seemsto be the motto of the Darmstadt-basedcompany when it comes to the selection ofthe new Simatic ET 200pro peripheral sys-tem. The compact dimensions of the mod-ular connection system, used for the firsttime on the Goebel xtraslit universalmachine, are fully convincing, as is its IP67protection rating. It can be installed directlyon the machine without a switch cabinet.Communication with the PLC is currentlystill performed via Profibus. But, with thefuture in mind, Goebel deliberatelyselected ET 200pro for this task, becausethe system, similar to the Sinamics range ofproducts, is already configured for theplanned Profinet standard.

“The new, distributed approach hasproven to be very efficient and cost-effec-

tive, both here in-house and in everydayuse at the facilities of our customers,” con-cludes Harald Loos. “It offers increasedfunctionality and benefits without addedcosts, enabling us to automate othermachine types according to this model.” �

the use of the Drive-CLiQ digital systeminterface from the Sinamics product range.The unit connects all drive componentstogether and automates the drive parame-terization by replacing “electronic ratingplates” with the CU320 control units. Thisalso has clear benefits in the event of ahardware failure, because defective mod-ules can then simply be replaced withoutthe need for drive specialist assistance.Unlike with conventional resolver cables,Drive-CLiQ cables enable hot plugging andunplugging, thereby reducing downtimeduration even more. Drive-CLiQ cables,which are pre-assembled by the manufac-turer and fitted with plugs on each end,also reduce time and potential errorsources. Goebel procures these cables in afew standard lengths in order to simplifyspare parts stocks. Cable simplification isfurther supported by the fact that the same

cable can be used to connect to various feed-back sensors (resolver, absolute value, incre-mental). Given the company’s high marketshare in countries with a less stable powersupply, it is particularly important for Harald Loos that the Sinamics convertersbased on IGBT technology be completelyreliable in critical networks. There is con-tinuous energy compensation between thebraking and driving axes via the shared DCintermediate voltage circuit, thereby help-ing to optimize the user's operating costs.

pletely automatically: fast, precisely and ascost-effectively as possible. In order to takeadvantage of the maximum performancepotential, the machine manufacturer, afterthorough preliminary tests, opted for thefirst time ever to use strictly a PC-basedcontrol system from a Simatic Box PC anda soft PLC WinAC with RTX 2005 real-timeexpansion, and to substitute several indi-vidual controllers. The decision was an easyone for Goebel, as they had been using theSimatic WinCC SCADA system with addi-tional tools programmed in C++, includingsome with very complex mathematicalmodels, for many years to achieve opti-mized station and blade adjustment (alsooptionally available for Goebel xtraslitmachines). This meant that a PC wasrequired on the machine. Along with theadditional tools, it was also possible totransfer the individual control algorithmsfor motion control to the new concept viaSimatic.

Distributed and modular drivetechnology

A key benefit of the new Sinamics S120drive system for the manufacturer as well asfor the user is its very compact booksizeformat. With its single and double axis mod-ules, which feature a uniform width, theentire drive assembly of the new machinerequires less than half of the switch cabinetspace used by the previous generation.“This has made it possible to install thedrives very close to the function, i.e. directlyon the wind-off, on the cutting stations, andon the winders in distributed switch cabi-nets, and to design our systems modularly,”says Harald Loos (Dipl.-Ing.), head of elec-trical design at Goebel. The modules pro-duced in this way can simply be configuredin accordance with the customer's require-ments, thereby standardizing engineeringand considerably reducing the timeinvolved. Moreover, the machines areinstalled and tested by Goebel prior to deliv-ery without dismantling them afterwards ,which in turn can cut the time needed forcommissioning at the customer's site byhalf, all depending on the machine size.The distributed assembly saves the user thetime needed to perform certain prepara-tory tasks such as the construction of foun-dations, underfloor ducting or cable trays –along with associated costs.

The time saved in installation and com-missioning is in large part attributable to


Goe

bel

Goebel implemented itsown C++ routines in theSimatic WinCC SCADAsystem to handle highlycomplex mathematicalcalculations


9

To replace the large fault-proneacceleration motors and complexelectromechanical brakes, Novelisturned to its system partnerUnitechnik, located in Wiehl,Germany, to have an existing paperweb winder retrofitted at its plant inLüdenscheid, Germany. 1FW3 torquemotors form the centerpiece of thetechnical solution. The motors notonly provide the necessary driveengineering capabilities, but also takeup considerably less space.

W ith 13,000 employees at 38 loca-tions, the Canadian Novelis groupis the world’s largest manufac-

turer of aluminum rolled products for theprocessing industry. The company’s prod-uct range includes beverage cans, sheetmetals for the automotive industry, roofand facade elements, lithograph plates,packaging foil, etc.

Based in Göttingen, Germany, NovelisDeutschland GmbH has a total of five pro-duction locations. The plant located in Lü-denscheid/Westfalia is the main location forthe finishing division, and is home to thefoil rolling mill. The mill specializes in alu-minum foil and produces top quality foilsfor flexible packaging applications. Theplant also produces plain and coated bandsfor pipe and cable applications, as well asmetalized paper for bottle labels.

Precise unwinding without processinterruption

The bottle labeling material is applied withthe help of a Monomatic polytype roll-fed

machine. Previously, the Tension in the webon the unwinder was generated by an elec-tro-magnetic brake. This, however, requiredextensive maintenance and was also sus-ceptible to faults. For a number of years, thecompany had been looking for an integrat-ed drive solution that would equally accom-modate the acceleration and braking oper-ations while allowing the existing machin-ery to remain in use. The main challengewas the space problem – the existing brakeswere extremely compact, and conventionaldrives with gears simply did not fit.

Some time ago, Unitechnik, a long-standing partner of the Lüdenscheid plantwith respect to automation and plant mod-ernization projects, introduced the idea oftorque motors. “As with so many other thingsin life, it came about purely by chance. Wecame into contact with torque motors aspart of a completely different project andthereby had the idea that they could be thesolution they had been looking for,” saysChristian Neuhaus, project engineer atUnitechnik.

Torque motors solve space problems

WindersSuitedfor theFuture

Nov

elis


10Converting

CASE STUDY

plains. Unitechnik carried out all of theelectrical modifications. The most impor-tant factor needing to be taken into consid-eration was the fact that the entire planthad been converted from analog to digitaldrive technology several years ago. Themain controller is a SPS Simatic S5-135.

The winder was fitted with a customizedSimatic S7-300 controller, while the torquemotors were actuated by Simovert Master-drives MC inverters. Christian Neuhauscomments: “What we had expected to be amajor problem at the beginning of the proj-ect – namely the supply of cooling waterwhile the winder is turning – actually provedto be quite simple. The rotary feedthroughsthat were utilized are extremely reliable.”After the necessary technical preparations,the modernized winder was taken into op-eration at the end of June 2005. Since then,the plant has been running for 24 hours aday without any problems. Barwich seesthe provision of the required functionalityalong with the increased productivity of theplant as the primary benefits. Although theplant does not run any faster than before,downtimes have been cut dramatically. “We

can definitely recommend torque motorsfor plant modernization,” as the plant man-ager confirms. �

Direct is better

Because of the significant potential for op-timization provided by direct drive sys-tems, linear motors and torque motors arerapidly gaining in importance. Simply stat-ed, a torque motor can be viewed as a “lin-ear motor bent into a circle.” Also referredto as a “direct drive,” the motor generateshigh torque values at comparatively lowspeeds. There is no need for the complexmechanical transmission components char-acteristic of conventional drives. In torquemotor solutions, searching for a toothedbelt and gears are not required. As a result,production machinery can often be made tooperate faster, definitely more precisely, re-liably as well as more economically in termsof the bottom line.

Siemens torque motors are available intwo designs – as complete motors for pro-duction machinery such as those used inthe winder at Novelis, and as frameless mo-tors which are particularly popular in ma-chine tool production. The permanently ex-cited complete synchronous motors of the1FW3 series offer a torque range of 100 –

20000 Nm. This ensures utilization with abroad range of applications. The SimovertMasterdrives MC and Simodrive 611 uni-versal converter families enable optimumperformance.

To ensure effective and optimum cool-ing, the 1FW3 torque motors are water-cooled. This results in minimal tempera-

ture influence at the interfaces with the ma-chine construction.

Optimized winding application

Realizing an application that involved a tur-ret winder with two torque motors provedto be a special challenge for the engineers.The signal and power data had to be trans-mitted to the rotating inverters on thetorque motors via slip rings using the tur-ret. The winder application itself posed afurther challenge. A high torque was need-ed at very low speeds. But the solution alsohad to cover a wide speed range. A motorwith a rated speed of 250 rpm can normal-ly be operated at up to 500 rpm with fieldcontrol. In this particular case, that was notenough. Unitechnik therefore suggestedtesting to see whether a field control of 1:3would be possible to enable a speed of upto 800 rpm to be achieved.

Once the experts at the main Siemensplant for torque motors in Bad Neustadt/Saale had come up with a positive result,there were no more obstacles in retrofittingthe winder. The dimensions of the motorswere based on the critical parameters of

web tension and maximum winding size.The result was the development of two 1FW3203 motors with a rated torque of 750Nmand a maximum torque of 1390Nm.

“Once the dimensions of the motors hadbeen finalized, we made the necessary me-chanical modifications here at our plant,”as Novelis plant manager Jens Barwich ex-


The modernization of the winder reduced downtimes significantly

Nov

elis

The two 1FW3 203 motors have a rated torque of 750 Nm and a maximum torque of 1390 Nm

Nov

elis


11


12Converting

CASE STUDY

Due to the very rapid development inthe production machinery sector,machinery manufacturers are forcedto engage in constant research toimprove the efficiency of their equip-ment. Fabio Perini SpA designed its“Time Line 7“ processing line withhighly innovative features: flexibility,simplified product change procedure,even several times per shift, as well as products of excellent quality with a very low discard rate – all with highperformance.

Fabio Perini SpA, a member of themultinational Körber Group, wasfounded in Lucca, Italy in 1966. To-

day, the company is a worldwide leader inthe production of tissue converting ma-chinery for use as toilet paper, kitchen tow-els, industrial wipers and communal tow-els. 80 percent of the production is export-ed primarily to Europe, but also to the USand various Asian countries.

Integrated platforms for a uniqueproduct portfolio

For markets where integrated platforms arein high demand, Siemens is one of the fewproducers in the world that covers the en-

tire range of solutions for machine au-tomation, including control systems, PLC,drives, motors and axis control. This alsoprompted Fabio Perini to choose Siemensas the supplier of the drives and an inte-grated control platform for the processingsystem. The line is equipped with the newgeneration Sinamics S120 servo drives andthe Simotion D drive-based motion controlsystem.

The compact asynchronous 1PH7 mo-tors are particularly well-suited for winders,calanders, web applications, and drawingapplications. Together with the 1FK7 brush-less motors, they are connected via DriveCliQ to the Sinamics S120 system. This in-terface ensures transparent access to themotor data, enabling the reading even ofthe serial numbers of the connected mo-tors, and ensuring extremely rapid startupand calibration of the parameters.

Simotion D is integrated in the drivestructure and manages all motion controlfunctions such as position control, calcula-tion of the motion profiles, gear ratios andcam profiles. Even higher-level automationmanaged by PLC and control systems is ac-cessible via Profibus, which is on board asstandard equipment on both Sinamics andSimotion.

Completing the project within the es-tablished time line required the coordinat-ed effort of experts from Fabio Perini SpA

High-level partnership between Siemens and Fabio Perini

Bundled Expertise

and from the Siemens Motion Control andSolutions & Applications groups. Theirclose collaboration enabled them to devel-op and complete the new line with the newplatforms and to establish a program forthe training, service and preparation activ-ities of the managers for commissioningthe machinery. In general, with its selec-tion, Fabio Perini SpA recognizes the im-portance of having an integrated platformfrom a single supplier to ensure integra-tion, optimization and service. �


With the support of Siemens, the PeriniTimeline system produces embossed andprinted toilette paper and kitchen towelsin a single process step

Fabi

o Pe

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Fabi

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13Converting

CASE STUDY

Nordmeccanica SpA, active in the ma-chine manufacturing sector for lam-ination and bonding of plastic film,

produces everything from simplest ver-sions to machines for bonding up to fivedifferent materials. Their clients operatelargely in the flexible packaging market, anindustry closely connected with the foodand pharmaceutical sector.

The machines are equipped with auto-matic changing systems for processing sol-vent-based, water-based and solvent-freeadhesives, and configurable for in-registercold-seal application on preprinted reels,with a flexible modular construction to en-able custom assembly to client demands.

High-performance lamination withefficient drive technology

The Triplex machine, one of Nordmeccani-ca’s best performing machines, is equippedwith a dual-zone drying system. Consider-ing the type of product handled, the systemfor control of the processed material ishighly accurate.

The drives belong to the Masterdrivesline: as a Vector Control version for drivingthe compact asynchronous 1 PH7 motors,and a Motion Control version for control ofbrushless 1FK7 motors. The lines can con-trol as many as 80 axes. The decision to ap-ply a decentralized technology of the drivespermits fast management and modularitywhile respecting the philosophy of TotallyIntegrated Automation, as Profibus is thebasic architecture, permitting creation of atransparent network of accessibility to dataat all levels. The same fieldbus also con-nects all decentralized peripherals of theSimatic ET 200S series, the PLC of theSimatic S7-300 family, as well as panels forremote viewing and the drives.

One major advantage is having a singlesupplier whose products are totally inte-grated. This has helped the company to op-

timize the use of standard products, ratherthan developing special products. Remoteservice is also possible and is now com-pletely standardized at Nordmeccanica –even for machinery installed abroad.

Improved adjustment with modular drives

The most recent project includes a newSinamics S120 drive platform. Thanks tothe Drive CLiQ serial interface and im-proved adjustment performance via a cen-tral control unit, the system is defined by ahigh level of hardware component integra-tion.

The Simplex machine, the first mutualproject developed with Sinamics S120, is amodular unit that features a speed controlCPU with 3 Sinamics functions for wind-ing, unwinding and coating and a MultiPanel MP270 display. Medium-term plansinclude expanding Sinamics S120 applica-tions to the various machine productionlines. �


The Multi Panel display Simatic MP 270 is the centralelement of Nordmeccanica’s

operating console

The Simplex machine features a Sinamcis speedcontrol CPU for winding,unwinding and coating

A growing partnership in lamination

Better Packing TogetherThe Italian company Nordmeccanica, one of the world leaders in the sector of bonding machines, collaborated with Siemens to improve its innovative lamination machines.

Nor

dmec

can

ica

Nor

dmec

can

ica

flows onto a cooling roller where a layerwith a thickness of about 1 millimeter isformed. A film thickness of between 3 and30 micrometers is produced by stretchingon the longitudinal and transverse stretch-ing machines. The subsequent surface treat-ment by high voltage discharging or heat-ing prepares the film for further coatingprocesses such as printing. In film widthsof 3 to 10 meters, the material is then woundonto rolls of 1.5 meters diameter and up to10 tons in weight on a winder. The wholeline stretches over a length of up to 150meters.

Integrated automation throughout the plant

It goes without saying that such an exten-sive system needs safe and easy to use au-tomation. Brückner relies on the compre-hensive standard of Totally Integrated Au-tomation (TIA) from Siemens. The SimaticS7-414 programmable logic controller (PLC)takes over the jobs of the main control, afailsafe Simatic S7-315F provides the safe-ty technology. ET 200M and ET 200S con-nect the periphery to the control. Since theSimovert Masterdrives MC and VC convert-ers offer excellent possibilities for the ten-sion control of winder applications, Brück-ner has used them to construct the maindrives for the plant’s rollers. Converters of

the Micromaster type are used for auxiliarydrives such as pumps and fans. All devicescommunicate via Profibus DP.

Precise roller control

The use of 1FW3 torque motors on thewinders since the summer of 2003 is revo-lutionary. Fluctuating speed during trans-port of the sensitive material through theline is the biggest problem because tearsmay occur. “When you’re producing a thinfilm which tears easily and transporting itthrough a long line, the accuracy and dy-namic of the speed control plays an impor-tant role,” Günter Oedl, Head of ElectricalDesign at Brückner explains. The rollerstherefore have to be controlled as accu-rately as possible. Since the mechanicaldrive chain with the motor, gear and belt al-ways remains a disturbing element, a drivetechnique which completely does away withmechanical elements, like the torque mo-tors, is the answer. Brückner preferred the1FW3 torque motors from Siemens for tworeasons: firstly because of their wide pow-er range, secondly because Siemens pro-vides both the motors and the converterswhich minimizes interfacing problems.The mechanical engineering company usesup to ten motors in the power range from 5to 10 kilowatts with a torque of 400 New-

CASE STUDY

Precise control of film stretching lines with torque motors

Smooth SpeedTo further improve the speed constancy at the film winder,the Brückner company in Siegsdorf has equipped this part of their film stretching plants with 1FW3 torque motors. Encouraged by the positive experience the designers nowwant to convert the other plant sections to the modern technology.

H igh quality plastic films are some ofthe most frequently used packagingmaterials – and the tendency is ris-

ing. In addition they have a lot of other tech-nical applications such as capacitor films,audio or video tapes. Longitudinally andtransversely (biaxially) stretched films ex-hibit product properties which are far supe-rior to other film types: tear and punctureresistance, high impermeability to gases andsteam, an attractive glossy or transparentappearance and good printing properties.

Stretching in two directions

Brückner Maschinenbau in Siegsdorf, Ger-many built the first complete sequentialplant for biaxially stretched films in 1965and is today the world market leader in thisfield. The product range of the Brücknergroup includes flat film lines, extrusiontechnology and turnkey factory projects inaddition to sequential and simultaneousfilm stretching lines. In the company’s owntechnology center with laboratory installa-tions, the customers can test whether andunder what conditions their planned raw materials can be stretched and what proper-ties the films have afterwards. This gives cus-tomers the necessary investment security.

The casting process stands at the begin-ning of every film stretching line: afterpreparation and plastification, the plastic


14

tonmeters each. The synchronization is provided by thesetpoint cascade Simolink.

Using torque motors not only keeps the speed moreconstant – about ten times better than conventional drives –but also reduces the number of parts and maintenance required. Brückner was able to reduce the customer’s needfor spares stocks as a result. And the water cooling of themotors also produces less air turbulence than conven-tional drives, which places less stress on tear sensitivefilm. Torque motors are well known for their quiet opera-tion which, according to Günter Oedl, means that “plantfaults are easier to detect.” The designer mentions other ad-vantage: “The high-speed constancy and the direct forcetransmission have enabled us to implement an observerfunction in the drive controller which allows us to deter-mine the tension. This eliminated the need for an addi-tional measuring roller.”

Following the positive experience with a plant whichwent into operation in June 2003, the owners have also con-verted the haul-off units to torque motors. Since the newtechnology has proven very effective, the owners are high-ly encouraged to stay on this course: other plant sectionswill be converted to torque motors in the future. �


15

More information:www.siemens.com/driveswww.siemens.com/torquemotorsE-mail: [email protected]

When an exist-ing machine

does not meet re-quirements or aproven machine isto be developedfurther, Mechatron-ic Support offershelp: A machineanalysis first pro-vides information of the developmentpotential of a givenmachine concept.

Together with Simulation and Virtual Prototyping, theanalysis results can be exactly quantified. The customer cantherefore look for the best machine solution as early as thedevelopment phase.

This is the ideal basis for a simulated machine model(changes can still be made to the design at this construc-tion stage). The virtual prototype created on the computeralready has all the characteristics of the real machine – nowthere’s nothing stopping series production. �

Mechatronic Support

More information:www.siemens.com/motioncontrol/mechatronic

Torque motors1FW3 on thewinders control the speed preciselyand prevent thefilm from tearing

The film roll weighsup to 10 tons whenit is fully wound up

Phot

os: B

rück

ner

The torque motor technology convinced Brückner: the winderstands have also been fullyconverted to direct drives

converting

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