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Answers for industry.
Web Handling Drive Control Concepts
Then
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Web Handling Drive Control Concepts
Now
PLC
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Drive
Motion
Evaluation Criteria
Usability
Functionality
Performance
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Evaluation
Usability
Functionality
Performance
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Usability – Engineering System
Single Point Communications
Single point communications with routing to each
system device for both centralized and distributed
control
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Usability – Engineering System
Common Engineering Environment
A common engineering tool with a common database
unifying programs and all system components.
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
IEC 61131 Programming Languages
Ladder diagram (LAD
Function block diagram (FBD)
Structured text (ST)
Statement list (STL)
Sequential function chart (SFC)
Continuous Function Chart (CFC)
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Usability – Programming Languages & Environment
(CFC) Continuous function chart or a graphical editor is the ideal
language for process engineering, visualization and documentation
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Usability – Diagnostics & Commissioning Tools
Diagnostic and Troubleshooting tools
Integrated online monitoring capability
Time and frequency based trace tools
Drive axis commissioning control panel.
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Usability – Maintenance & Engineering
Program Storage
Program storage on removable media, permits
easy swapping of hardware without the
requirement of program downloading.
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Usability – Maintenance & Engineering
Integrated Applications
Center Wind
Splice
Accumulator
Zone Tension
Flying Saw
Elec. Gearing
Load Sharing
Rotary Knife
Smoothing
Registration
Integrated Applications reduce engineering time, and simplify
commissioning and maintenance.
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Evaluation
Usability
Functionality
Performance
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Functionality - Control Concepts & Related Technology
PLC
Tension
Wind
Splice (time)
Ramp
Setpoint
Load Share
Smoothing
Position
Gear
Cam
Saw
Cut
Accumulator
Speed
Torque
Drive
Speed
Torque
Position
Motion
Speed
Torque
Position
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Registration
Functionality - PLC Based Architecture (Centralized)
PLC
HMI
Network
Drive Section #1
Machine & Web Control
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Drive Section #2
Functionality - Drive Based Architecture (Distributed)
Machine Control
PLC
HMI
Network
Web Control
Drive Section #1
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Web Control
Drive Section #2
Functionality - Motion Control Architecture (Centralized)
Machine Control
PLC
HMI
Network
Web Control
Drive Section #1
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Drive Section #2
Evaluation Criteria
Usability
Functionality
Performance
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Performance
The performance of any machine or system will be directly related to the control
system's Process Throughput Time.
Process throughput time is the time that it takes to receive the feedback (from the
motors and tension sensors), process all of the control loops and send the
respective commands to the drives.
Setpoints
(master)
Tension
controller
Speed
controller
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Current
controller
Converter
Performance
Three components contribute to the process throughput time;
CONTROLLER
Setpoints
(master)
Tension
controller
1
DRIVE
Current
controller
Speed
controller
Converter
Network
2
250us
3
Controller scan time or process cycle
Communication network type (sync or async) and cycle time
Drive loop cycle time
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Network Performance – Asynchronous clock cycles
Process Throughput =
(Tension control cycle *2) + (Network cycle *2) + (Drive Cycle Time * 2)
Because of the signal timing uncertainty in
asynchronous networked systems, process
throughput must be calculated as worst
case
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Network Performance – Synchronous clock cycles
Process Throughput = (Tension control cycle *2) + Drive Cycle Time
Note:
Calculation assumes that the data is read in one cycle, processed and transmitted next
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synchronous cycle.
Performance – Networked Components
Each system component will have different ranges of system cycle
or scan time performance.
Device
Common Cycle Times
Notes:
PLC
~5 – 100 ms
Drive - (program)
~1 – 8 ms
Depending on Program size and
processor power
Configurable program cycle time
Drive - (loops)
~62.5 – 250 us
Normally fixed
Motion Control
~0.25 - 8 ms
Network
~0.25 – 8 ms
Configurable program or background
task cycle times
Normally configurable
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PLC Control Architecture - Performance
Process Throughput = (Tension control cycle *2) + (Network cycle *2) + (Drive Cycle Time * 2)
= (12ms * 2) + (2ms*2) + (250us*2) = 28.5ms
PLC
Machine control
Setpoints
(master)
Tension
controller
Speed
controller
DRIVE #1
Current
controller
Converter
Asynchronous Network
2ms
Motor #1
250us
Tension
controller
Web Control
Speed
controller
DRIVE #2
Current
controller
Converter
Motor #2
12ms
250us
Tension
controller
Speed
controller
DRIVE #3
Current
controller
Converter
Motor #3
250us
To Drive n ...
Performance
In Inc.
this2013
example,
web traveling at 600mpm will displace 2.85cm in one tension cycle.
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Drive Control Architecture - Performance
Process Throughput = (Tension control cycle *2) + (Drive Cycle Time )
= (2ms * 2) + (250us*2) = 4.5ms
PLC
DRIVE #1
Setpoints
(master)
Machine control
Network
Tension
controller
Speed
controller
Current
controller
Converter
Motor #1
250us
2ms
DRIVE #2
Tension
controller
Web Control
Speed
controller
Current
controller
Converter
Motor #2
2ms
Synchronous Drive
Peer to Peer
Network
250us
2ms
DRIVE #3
Tension
controller
Speed
controller
Current
controller
Converter
Motor #3
2ms
250us
2ms
To Drive n ...
Performance
In Inc.
this2013
example,
web traveling at 600mpm will displace 0.45cm in one tension cycle.
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Motion Control Architecture - Performance
Process Throughput = (Tension control cycle *2) + (Drive Cycle Time )
= (2ms * 2) + (250us*2) = 4.5ms
PLC
Machine control
MOTION CONTROLLER
Setpoints
(master)
Tension
controller
Speed
controller
DRIVE #1
Current
controller
Converter
Synchronous Network
2ms
2ms
Motor #1
250us
Tension
controller
Speed
controller
DRIVE #2
Current
controller
Converter
Motor #2
Web Control
2ms
250us
Tension
controller
Speed
controller
DRIVE #3
Current
controller
Converter
Motor #3
250us
To Drive n ...
Performance
In Inc.
this2013
example,
web traveling at 600mpm, will displace 0.45cm in one tension cycle.
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Architecture / Machine Reference
Example Machine Type
Application
1-6 Axes
Web Control
6-50 Axes
50-200 Axes
PLC
•Slitter Rewind
•Doctor Machine
•Slitter Rewind
•Coating Line
DRIVE
•Slitter Rewind
•Doctor Machine
•Filament Winder
•Load Sharing
•Slitter Rewind
•Flexo Press
•Coating/Lam. Line
•Coating /Lam. Line
•Film Line
•Rotary Knife
•Core Cutter
•Die Cutter
•Paper Sheeter
•Offset Press
•Gearless Flexo
•Narrow Web Press
•Diaper Machine
•Tissue/Towel Line
Web Control
Motion Control
Web Control
MOTION
Motion Control
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Technology Trends
Integrated Web Server
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Integrated Web Server
Integrated Web Servers are now common place in
most industrial controllers.
PC with Browser /
Application
An integrated web server has many benefits,
among them; the ability to obtain diagnostics
without use of proprietary tools.
Any web-capable PC / notebook / tablet with an
Internet browser is typically sufficient.
Custom web pages can be created.
Monitoring and Troubleshooting, without an
engineering system
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Internet
Industrial Ethernet
Integrated Web Server
Custom Web Pages
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Integrated Web Server
Functionality
 Download a programs
 Perform Firmware updates
 Status overview of specific variables
 Evaluate of alarms and faults
 Monitoring and change parameters
 Archive machine documentation
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Web Handling Drive Control Concepts
Then
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Web Handling Drive Control Concepts
Now
PLC
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Drive
Motion
Conclusions
Considering the optimum control architecture can be an interesting challenge. Each
of the detailed systems has its benefits and limitations.
PLC based solutions offer a medium level of performance with a high level of
usability.
Drive base solutions offer a higher level of performance through their distributed
control structure. They typically have high usability through optimum engineering
tools.
With the continuing demands on production speeds, product quality and considering
the general trend of motion based control, integrated drive and motion are not only
well suited but becoming common place in the industrial landscape. The concepts
and benefits of motion control based solutions can be extremely attractive for both
new converting lines and retrofits.
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Thank You
William Gilbert
Siemens Industry, Inc.
5300 Triangle Parkway
Norcross, GA 30092
Phone: +1 (770) 625-5658
Mobile: +1 (678) 314-4222
E-mail: william.gilbert@siemens.com
Website: www.usa.siemens.com/converting
Answers for Converting
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