Solution Products Pre-Information
Center Winder Training
Application Software
General
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 1
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 2
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions

A Center Winder, also known as an Axial Winder, is a
machine in which the rotational force is applied to the
center or (axial) point of which material is wound.
Tension Force
Velocit
y

The objective is to regulate surface Tension of the roll.
The Speed and Torque of the core must change as a
function of Roll Diameter.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 3
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
 Common Terms
– CORE: The object the material is to be wound around. The
minimum core diameter is the smallest diameter the Winder can
start or the smallest diameter an Unwind can reach.
– MAX ROLL DIA: The maximum roll diameter the machine is
designed for.
– BUILD-UP/ Winding ratio: The ratio of Max Roll Diameter to
Core diameter. If the max. roll diameter is 1000mm and the core
diameter is 100mm the Build-Up/ Winding ratio is 10 to 1.
– FULL ROLL: In a Winding application this is the finished or
completed roll diameter. In Unwind applications this is the
starting roll diameter to be unwound.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 4
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
 Common Terms
– CORE SPEED MATCH: The function of trimming the speed of
winder when in Speed Mode. This is typically used for
continuous process lines with automatic roll change function.
– WEB: The product (material) which is to be wound by the
machine. This is also known as the “strip” in the Metals.
– EXTENSIBLE: This is related to the properties of the web. A web
which is elastic is considered extensible. Example: Plastic food
wrap
– NON-EXTENSIBLE: This is related to the properties of the web.
A web which is rigid in length and width or one which cannot be
stretched is considered non-extensible. Example: Paper
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 5
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
 Common Terms
– TENSION: The force applied to the web. This is used to control
the web. Units of tension are [ N ] for Newtons or [ lb ] for
pounds.
– TAPER TENSION: The reduction of the reference tension as a
function of diameter. As diameter is increased the tension is
decreased.
– STALL TENSION: The meaning of “stall” is the mechanical
section is at or near zero speed. When Stall Tension is activated
the reference tension is reduced to a preset percentage of the
tension set-point.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 6
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
 Common Terms
– SPEED CONTROL: The drive is regulating speed of the machine
and the tension of the web is controlled by trimming the speed
based on tension feedback.
– TORQUE CONTROL: The drive is regulating torque of the
machine and the tension of the web is controlled by the Torque
reference. If tension feedback is used the torque reference is
trimmed with the tension feedback.
– Moment Of Inertia (WK2): Used for calculating torque required
to change the speed of a machine. The formula includes the
weight and dimensions to be accelerated. Additional
components, change in speed and change in time or (n/t), are
required for the calculation of torque required.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 7
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Common Terms and Definitions
 Common Terms
– DIAMETER CALCULATOR: The formula or process by which the
diameter of a center winder are calculated. The Center Winder
application is using the line velocity and actual roll rpm to
calculate the roll diameter.
– ROLL CHANGE: A function for continuous process lines in which
the finishing roll is automatically replaced by a new roll without
stopping the production process. Typically two (2) Center
Winders are used.
– TORQUE MEMORY: Process of storing the active actual torque
of the machine. Used in Roll Change.
– TORQUE BOOST: A multiplier to the Torque Memory, used for
aiding the cutting of the Web when a Roll Change is performed.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 8
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics

Basic Winder Macro Includes
 Dancer Control
 Indirect Tension Control
 Direct Tension Control




With Correction signal used as Speed Correction (Speed Trim)
With Correction signal used as Torque correction (Torque Trim)
Selectable Winder and Unwinder modes
Common Control Functions Include
 Diameter calculation
 Tension torque reference
 Calculation of moment of inertia
 Acceleration/deceleration torque compensation
 Loss Compensation
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 9
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
Formulas for the Winder
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 10
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
B
F
F= Tension Force
M=Torque
V= Material Speed
n= Rotational Speed
W= Angular Speed
B= Material Width
D= Diameter
JR= Moment of Inertia
JR1= Moment of Inertia of roller
JR2= Moment of Inertia of roll
JR3= Moment of Inertia of gearbox
JM = Moment of Inertia of Motor
JC = Total moment of Intertia (on motor side)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 11
Dia Min
Core Dia
JR1 + JR2
NR, WR, MR
Gear Box
JM,
NM, WM, MM
Motor
Printed 7-Dec-98
Dia Act (D)
Solution Products Pre-Information
v
[m/min]
Strip speed
D
[mm]
Coil diameter
Dmin
[mm]
Mandrel diameter
C
[1/sec]
Omega Coiler shaft
M
[1/sec]
Omega Motor Shaft
nC
[rpm]
Speed Coiler
nM
[rpm]
Speed Motor Shaft
Z
Gearratio
t
[mm]
Strip thickness
B
[mm]
Strip width
J
[kgm²]
Total inertia
Jfixed [kgm²]
Basic inertia
MB
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
[kg/dm³]
Mass density
[Nm]
Acceleration / Deceleration torque
SLIDE 12
Printed 7-Dec-98
Solution Products Pre-Information
General Formulas:
v=
D
*
2 C
2*v
=>  =
D
C
1
v=
D
*2**n
2
C
v
=> n =
C *D
2
Rated to the motor shaft wZth Z =
M =
Z*2*v
D
Z*v
n =
M *D
C
M
=> v =
M * D
Z*2
3
DZameter change (+ = TensZon reel, - = Pay off reel)
dD
2*h*
= 2*h*n =
dt 
C
*D
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
4
SLIDE 13
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
V
F
1. Power required for winding
F max*V max
Pmax =
KW
2. Relationship between Tension component and motor Torque
M = FxD/2
Nm : Winding Torque on the machine side
Mm= FxD/2Z
Nm : Winding Torque on the Motor side
3. Maximum and minimum Torques (ignoring the Inertia requirements)
With respect to Tension component
F max* D max
M max
*Z
=
M min
=
[Nm]
F min* D min
*Z
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
[Nm]
SLIDE 14
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
4. Maximum and minimum Motor Speeds
N min
N max
=
=
V min* Z *
D max* PI
V max* Z *
D min* PI
Formulas for the Winder
rpm
rpm
Relationship between Diameter "D" ,
Velocity "V" and rpm N
d [mm]
v [m/min]
n [rpm]
V
F
time
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 15
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
5. Intertia components
Formulas for the Winder
Torque available from motor is used to produce the Tension component
as well as to overcome the Inertia requirements
Fact * Dact
dw
Jc
Loss_ component
*Z
dt
F (n) Loss Loss * N ACT
Total _ Motor _ Torque( M m )
Loss_ component
V
F
Total inertia of System =( Inertia of Roll+ Inertia of roller+ Inertia of gear)reflected to motor side
+motor inertia
Jc Jm
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
( JR1
Z2
JR2 JR3 )
SLIDE 16
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
V
Inertia of shaft (roller)
Intertia _ of _ roller ShaftWt .*
F
ShaftOuterDia 2 ShaftInnerDia 2
2
Shaft Outer Dia
Inertia of roll ( material wound or unwound on the core)
Dia _ Act 2 D min 2
2
Dia _ Act 2 D min 2
MaterialWt . B * density * PI *(
)
32
2
Dia _ Act 4 D min 4
Inertia _ of _ roll B * density * PI *
32
Intertia _ of _ roll
MaterialWt .*
Shaft Inner Dia
Inertia (J mec. + J coil) = f (diamter)
Inertia of Gearbox
J [kgm²]
v [m/min]
d [mm]
Usually provided by the customer/mech supplier
Inertia of Motor
Motor Catalogues provide the motor Inertia.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 17
Printed 7-Dec-98
time
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
V
F
Total Torque to be developed by Motor Mm=
D
F
*
Mm =
+ MM1+MM2+MM3+Loss component
2Z
Mm = F *
Mm =
F*
D
2Z
+(J
D
f(Nm )
2Z
M
(JR1
Z2
dt
m
)
*
f(N
)
JR2 JR3 ) dw m
JR1 JR3 *
1
B * density *PI
1
Z
dV
4
4
J
)
*(D
D
*
*
min ) *
M
Z2
32
Z 2 30 *D dt
Fixed part
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Variable part
SLIDE 18
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Formulas for the Winder
Acceleration torque T (acc.) = f (diamter)
T (acc.) [Nm]
v [m/min]
d [mm]
Total torque T total = f (diamter)
T total [Nm]
v [m/min]
d [mm]
time
time
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 19
Printed 7-Dec-98
Solution Products Pre-Information
Relationship of Power and material
Fmax *V
max
Pmax
Fact *V
act
Pact
Fact
Funit _ tension * B * h
Funit _ tension * B * h *V
act
Pact
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 20
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
Control Configurations for Winders and Rewinders
 Indirect Tension Control
No Tension Feedback instrument is needed
 Direct Closed loop Tension control with Tension Feedback
Material Tension is measured directly from
a tension transducer.
Tension control may be super-imposed over the Indirect Tension
control or used to control the drive in speed mode
 Direct Closed loop Tension Control with Dancer rolls
 Dancer Position feedback is used as a closed loop feebback
Drive remains in speed control
 Winder is used as Speed master
Material Tension is controlled by back tension provided by other equipment
Winder is controlled in speed control with Diameter Calculation to maintain
uniform peripheral speed
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 21
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations

Basic Winder Macro Includes
 Dancer Control
 Indirect Tension Control
 Direct Tension Control




With Correction signal used as Speed Correction (Speed Trim)
With Correction signal used as Torque correction (Torque Trim)
Selectable Winder and Unwinder modes
Common Control Functions Include
 Diameter calculation
 Tension torque reference
 Calculation of moment of inertia
 Acceleration/deceleration torque compensation
 Loss Compensation
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 22
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
Indirect and Direct Tension Control
Tensiometer
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 23
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
a) No Feedback system for Actual Tension
b) Feedback for Actual Tension is used
Configurations
Winder- Application
Software
Tension
Reference
Tension Controller
PI
Flux Code
Tension
to TQ cal
Torque Correction
Line Speed
Reference
Tension
Reference
Tension Controller
PI
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 24
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Linear Speed Reference
Gear Box
Web Width
M
Web Density
External DIA
Tension Reference
Configurations- Indirect Ten
Gear Box
Gear
Box
M
DIDIAA CALCULATOR+ INTEGRATOR
V
PI
Macc= J*2/D*Z*dv/dt
TORQUE REFERENCE
SELECTOR
SELECTOR
N
26.01
26.01
TORQ
TORQ REF
REF SEL
SEL
00
EXTERNAL TORQUE REFERENCE
MIN
Loss Torque= K+ N* K1
TORQ
TORQ REF1
REF1
33
44
22 11
55 66
2.08
2.08
MAX
MAX
D
RAMPING
RAMPING
SPEED CONTROLLER OUTPUT
2.09
2.09
TORQ
TORQ REF2
REF2
TORQ REF B
++
++
25.04
25.04
25.05
25.05
25.06
25.06
DIA CALCULATOR+ INTEGRATOR
t
Dia Preset
V
TORQ RAMP
UP TIME
TORQ
RAMP UP
TIME
TORQ RAMP
RAMP DN
DN TIME
TIME
TORQ
PI
Macc= J*2/D*Z*dv/dt
TORQUE REFERENCE
SELECTOR
N
TORQ REF SEL
0
EXTERNAL TORQUE REFERENCE
External /Internal Dia Calc
2
Winder/ Rewinder
Count UP EN
Count DN EN
MIN
LossTorq= K+ N* K1
TORQ REF1
MIN DIA
MAX DIA
MAX
LINEAR FRICTION
X
D
STATIC FRICTION
I C+I *C1
SPEED CONTROLLER OUTPUT
+
TORQ REF2
+
PI
Tension Ref
Taper Tension Generator
F
M
DIA
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 25
+
Printed 7-Dec-98
1
3
4
5 6
Torque
Ref
to DTC
Solution Products Pre-Information
Winder Basics
Configurations
Indirect Tension Control
The torque is calculated according to the formulas discussed before.
No feedback instrument is used for actual measurement of tension
Diameter needs to be computed accurately to control the correct tension
Friction& Windage are very crucial components to maintain accuracy of
tension.
Is recommendable to use Indirect tension control in
Direct coupled winders (no gearbox)
In mech configurations where the mechanical losses are low. (No worm gears, and no appreciable
difference between gearbox losses in warm or cold conditions
Where the Inertia component TQ to Tension component TQ ratio is small.
In process applications where the Tension range required is relatively small (less than 10:1)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 26
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
 Tension Control - Open Loop Torque
– The drive is torque regulated. The parent speed reference is
required from the process line controller for over speed control.
– The torque reference is calculated by the application based on
tension setpoint and machine parameters.
– The PI controller is NOT active in this mode and therefore there
is not any trim of the torque reference.
– The Tension control is made by calculating the torque
requirements. Careful dimensioning of the system with the
process parameters is recommended.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 27
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
 Indirect Tension Control- Open Loop Torque
– Recommendation for Use:
 Transducer - Actual tension feedback is not available
 Web dimensions are constant with limited variations in width
and density.
 Accurate system and material Inertia data is available.
 Process tension range is small.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 28
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
Direct Tension Control
The torque is calculated according to the formulas discussed before.
A feedback device is used for actual measurement of tension. This is used as
a superimposed control loop to correct the Torque reference.
Diameter needs to be computed accurately to control the correct tension
Friction& Windage are not very crucial as inaccuracies may be corrected by
the presence of the feedback loop.
Is recommendable to use Direct tension control in
Processes requiring high tension accuracy.
In mech configurations where the mechanical losses are high .
In processes where the tension range is very high (e.g 20:1)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 29
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
Direct tension Control
with speed Trim
Direct tension Control
Direct tension Control
with Torque Trim
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 30
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with speed Trim
 Tension Control - Closed Loop Speed Trim
– The drive is speed regulated. The parent speed reference
comes from the process line controller.
– Speed Trim is used to control the actual tension of the web. The
Tension Controller trim is added as a speed correction.
– Tension Controller is a PI controller receiving setpoint reference
from an operator control and receiving a feedback of actual
tension from the process.
– Diameter is calculated by using the line speed and the rotational
speed feedback from the drive.
– Inertia compensation may be added to improve the dynamics of
the control.(Losses in the form of friction and windage are
automatically compensated by the closed loop system)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 31
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with speed Trim
nRef
F-Controller
n-Controller
FRef
x
-
Speed Trim
Tq Speed Ctl out
+
-
Fact
F(D, V)
nact
Controller
adaptation
D
Gain
Gain
Web type (material thickness/ material width)
D
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Macc
Block Diagram of the Direct tension Control with speed Trim
SLIDE 32
Printed 7-Dec-98
Used TQ reft
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with speed Trim
 Direct Tension Control - Closed Loop Speed
Trim
– Recommendation for Use:
 If the material range is wide and extensive.
 If a large range of Web Widths are possible/required.
 Accurate Inertia data is not available.
 If a “tight” control is not needed.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 33
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with Torque Trim
 Tension Control - Closed Loop Torque Trim
– The drive is torque regulated. The parent speed reference is
required from the process line controller for over speed control.
– The torque reference is calculated by the application based on
tension setpoint and machine parameters entered at the keypad.
– Torque Trim is used to control the actual tension of the web. The
Tension Controller trim is added as a torque correction.
– Tension Controller is a PI controller receiving setpoint reference
from an operator control and receiving a feedback of actual
tension from the process.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 34
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with Torque Trim
nRef
F-Controller
n-Controller
FRef
x
-
Tq Speed Ctl out
+
-
Fact
F(D, V)
nact
Controller
adaptation
D
Gain
Gain
Web type (material thickness/ material width)
D
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Macc
Block Diagram of the Direct tension Control with speed Trim
SLIDE 35
Printed 7-Dec-98
Used TQ reft
Solution Products Pre-Information
Winder Basics
Configurations- Direct Tension Control with Torque Trim
 Direct Tension Control - Closed Loop Torque
Trim
– Recommendation for Use:
 Greater dynamic response.
 Web dimensions are basically constant with minimal
variations in width and density.
 Accurate system and material Inertia data is available.
 Transducer feedback is required.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 36
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Dancer Control
Dancer Control
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 37
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Dancer
Mechanical Configurations

Fixed back tension systems
Variable back tension systems

Dancer
Position
Feedback
to ACS600
0 volts
Fixed Back Tension
Force
+10 volts
Response polarity as with a Transducer
Dancer
Position
Feedback
to ACS600
0 volts
Servo
(I/P)
Force
+10 volts
Response polarity as with a Transducer
Variable Tension System
Fixed Tension System
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Loading
Cylinder
SLIDE 38
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
 Dancer Control
– The drive is speed regulated. The parent speed reference
comes from the process line controller.
– Speed Trim is used to Control Dancer Position. The Dancer
Controller trim is added as a speed correction.
– The Dancer Controller is a PI controller receiving a set-point
reference which is a constant from the keypad and receiving a
feedback of Dancer position from the process.
Dancer
Position
Feedback
to ACS600
0 volts
Loading
Cylinder
Servo
(I/P)
Force
+10 volts
Response polarity as with a Transducer
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 39
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations
Block Diagram of Dancer Control - Speed Control and
speed correction- Fixed Tension system
nRef
P-Controller
n-Controller
PRef
x
-
Tq Speed Ctl out
+
-
Pact
F(D, V)
nact
Controller
adaptation
Macc
D
Gain
Gain
Web type (material thickness/ material width)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
D
SLIDE 40
Printed 7-Dec-98
Used TQ reft
Solution Products Pre-Information
Winder Basics
Configurations- Dancer - Fixed Tension
How is Tension regulated ?
Tension of the Winder is regulated indirectly by regulating the
the position of the Dancer and adjusting the “restraining forces”
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 41
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Configurations- Dancer- variable Tension
Block Diagram of Dancer Control - Speed Control and
speed correction- Variable Tension system
nRef
P-Controller
PRef
n-Controller
x
-
Tq Speed Ctl out
+
-
Normally Fixed as Parameter
Pact
F(D, V)
Tension Setpoint
nact
Macc
Controller
adaptation
Loading
Cylinder
Web type (material
thickness/ material width)
Gain
Gain
Servo
(I/P)
D
Force
D
Stall and Taper
Reference
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 42
Printed 7-Dec-98
Used TQ reft
Solution Products- Pre-Information
Winder Basics
Dimensioning
Dimensioning the Winder
Understanding the Load Requirements
Selecting the correct Motor
Recommending the optimal gearbox and speeds
to mechanical supplier
Mike Vallier and Narendra Gupta/ 98-12-01
File : Solutions_Winder.ppt
Solution Products Pre-Information
Winder Basics
 Analyzing the Load Requirements
Dimensioning- Load Requirement
How the customer specifies his load (typically)
30KW, 800rpm/1500rpm ,150% overload
General Interpretation
a) Constant Torque application , Constant Power above base speed
b) Requirement is to deliver at base speed
Torque
9550 *Pw
( Nm)
Nbase
Torque
P
KW
P
HP
N
rpm
N
rpm
5252 *Pw
(lb
Nbase
ft )
c) Generally the required torque below base speed is same
d) Specified overload of 150% is required at all speed points
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 45
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
Graphical Interpretation of the specified Load
30KW, 800 rpm/ 1500 rpm 150% overload
600
Torque [Nm]
500
Constant TQ
400
300
TQ requirement proportional to
200
1
Nact
100
0
0
200
400
600
800
1000
1200
Speed [rpm ]
max load
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
cont load
SLIDE 46
Printed 7-Dec-98
1400
1600
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
To optimize the Winder it is important to know other information
Process Parameters
Tension ranges- Stall tension and Taper Tensions range
Diameter Ratios for specified materials
Peripheral speed - Crawl / thread speed, Max speed,
Operating speeds
Acceleration and deceleration rates
Gear Ratios
Material Specific Wt and density
E.g.
Tension range : Material type 1
Material type 2
: 5 KN, material thickness =3mm
: 1 KN ,material thickness =0.5mm
Diameter Ratio : Min 600 mm
Max :1500 mm
Line speed max = 300 mpm, Minimum speed = 60 mpm
Operating speed= 250 mpm
Acceleration rates= 20 sec to full speed / fast stop =10sec from full speed
material width = 800 mm, density= 1100 kg/m3
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 47
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
Calculating the Min and max values
Power
30
KW
Motor Base Speed
700
rpm
Motor Max Speed
1500
rpm
Tmax
6000
N
max rpm
1592
rpm
min rpm
637
rpm
Max motor torque
Max torque to process
409
4093
Nm
Nm
Vmax * Z
D min * PI
Nmax (rpm)
D min (m)
Vmax (m / min)
Z = Gear Ratio(
Nmin (rpm)
Nmotor
)
Nmech
Vmax * Z
D max * PI
D max (m) = Maximum dia
Fmax (N)
Ps * 60,000
Vmax
Torque
Ps (KW)
P
KW
Vmax (m / min)
N
rpm
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
9550 *Pw
( Nm)
Nbase
SLIDE 48
Vmax (m / min)
Z = Gear Ratio(
Printed 7-Dec-98
Nmotor
)
Nmech
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
Calculating the minimum speed point
The minimum rotational speed point is calculated by using the minimum
linear operating speed at the maximum diameter.
N (rpm)
Vmin operating speed * Z
min
D max * PI
D max (m) = Maximum dia
The minimum linear operation speed is the speed at which the
winder may run continuously for a extended period of time.
Vmax (m / min)
Nmotor
This does not have any effect on dimensioning when a separately Z = Gear Ratio(
N
ventilated motor is used.
mech
800
700
Line stops before
max dia is reached !!
600
Torque [Nm]
Nmin in this
example = 125 rpm
500
400
300
200
100
0
0
200
400
M2BA 315 SMA8
max load
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
600
800
1000
1200
1400
1600
Speed [rpm ]
cont loadabilit y
SLIDE 49
cont load
Printed 7-Dec-98
)
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
If the minimum operating speed was about 200rpm the selected motor
could have been reduced by 1 frame size !!
Motor selected = M2BA 280 SMB 6
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 50
Printed 7-Dec-98
Solution Products Pre-Information
Calculating the Torque at different speed points
Winder Basics
Dimensioning- Load Requirement
Out diam. [m]
1.50
Speed [m/min]
300
In diam. [m]
0.60
Tension [kN]
5.0
Width [m]
0.80
Acc. time [s]
20.0
Density [kg/m^3]
7800
Fast stop [s]
10.0
Strip den. [kg/m^3]
1100
Em. stop [s]
10.0
Gear (nmot/mach.)
10.00
Coupling [kgm^2]
5
Motor [kgm^2]
1
Recoiler (R) /
Uncoiler (U)
R
Calculation based on Tset =Tmax conditions
Coile r
Em. stop R e sult
Diameter
Motor Speed
J
[m]
[rpm]
[kgm^2]
[Nm]
[Nm]
0.60
1592
2
15
0.69
1384
2
0.78
1224
2
0.87
1098
0.96
Acc. Torq. J Tension torque Tot. acc. torq.
Fast stop
at base
[Nm]
[Nm]
speed [Nm]
150
165
-31
-45
Basespeed [rpm]
637
14
173
186
-28
-37
Max.speed [rpm]
1592
13
195
208
-26
-32
Tmax(nmax) [Nm]
165
2
13
218
230
-26
-29
Ttens.(nmax) [Nm]
150
995
2
13
240
253
-26
-28
Tmax(nbase) [Nm]
395
1.05
909
3
13
263
276
-26
-28
Tten(nbase) [Nm]
375
1.14
838
3
14
285
299
-28
-29
Tens. power [kW]
25
1.23
776
4
15
308
323
-30
-31
Max.power [kW]
28
1.32
723
4
16
330
346
-33
-33
Overload(%)
1.41
1.50
677
637
5
6
18
20
353
375
371
395
-37
-41
-37
-41
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 51
Printed 7-Dec-98
95%
Solution Products Pre-Information
Calculating the Torque at different speed points
Winder Basics
Dimensioning- Load Requirement
Out diam. [m]
1.50
Speed [m/min]
300
In diam. [m]
0.60
Tension [kN]
1.0
Width [m]
0.80
Acc. time [s]
20.0
Fast stop [s]
10.0
Em. stop [s]
10.0
Density [kg/m^3]
Calculation based on Tset =Tmin
conditions
7800
Strip den. [kg/m^3]
1100
Gear (nmot/mach.)
10.00
Coupling [kgm^2]
5
Motor [kgm^2]
1
Recoiler (R) /
Uncoiler (U)
R
Coile r
Em. stop R e sult
Diameter
Motor Speed
J
Fast stop
at base
[m]
[rpm]
[kgm^2]
[Nm]
[Nm]
0.60
1592
2
15
30
[Nm]
[Nm]
speed [Nm]
45
-31
-45
Basespeed [rpm]
637
0.69
1384
2
14
35
48
-28
-37
Max.speed [rpm]
1592
0.78
1224
2
13
39
52
-26
-32
Tmax(nmax) [Nm]
45
0.87
1098
0.96
995
2
13
44
56
-26
-29
Ttens.(nmax) [Nm]
30
2
13
48
61
-26
-28
Tmax(nbase) [Nm]
95
1.05
909
3
13
53
66
-26
-28
Tten(nbase) [Nm]
75
1.14
838
3
14
57
71
-28
-29
Tens. power [kW]
5
1.23
776
4
15
62
77
-30
-31
Max.power [kW]
8
1.32
723
4
16
66
82
-33
-33
Overload(%)
1.41
1.50
677
637
5
6
18
20
71
75
89
95
-37
-41
-37
-41
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Acc. Torq. J Tension torque Tot. acc. torq.
SLIDE 52
Printed 7-Dec-98
26%
Solution Products Pre-Information
Calculating the Torque at different speed points
Power
Motor Base Speed
30
KW
700
rpm
Motor Max Speed
1500
rpm
T max
6000
N
max rpm
1592
rpm
min rpm
637
rpm
409
4093
Nm
Nm
Max motor torque
Max torque to process
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Winder Basics
Dimensioning- Load Requirement
Calculating based on Tset =Tmax conditions
SLIDE 53
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Calculating the Torque at different speed points
Power
Motor Base Speed
30
KW
700
rpm
Motor Max Speed
1500
rpm
T max
6000
N
max rpm
1592
rpm
min rpm
637
rpm
409
4093
Nm
Nm
Max motor torque
Max torque to process
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Dimensioning- Load Requirement
Calculating based on Tset= Tmax conditions
SLIDE 54
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Calculating the Torque at different speed points
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Dimensioning- Load Requirement
Calculation based on Tset =Tmin
conditions
SLIDE 55
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Calculating the Torque at different speed points
Dimensioning- Load Requirement
Calculation based on Tset =Tmin
conditions
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 56
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Load Requirement
Results:

The max and minimum required load torques for the process
demand are
30 Nm to 395 Nm depending on the tension set-point
and the acceleration/deceleration phases.


Overload requirements can be accurately identified.
All the speeds (base and maximum speeds are accurately determined)
 The maximum and minimum load torque has to be supplied by the
same drive+motor set. Minimum resolutions and accuracy of control
will start to be important considerations
 Overload and minimum operating speeds affect the motor selection
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 57
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Selecting the Motor
Rule 1 : The motor should not be over-dimensioned. Over- Dimensioned
motors will increase the inverter size which in turn effects the current
resolution of the drive.
Wide tension ranges will not be attainable
The ability of the inverter to maintain the requested motor torque is stated as
a % of the nominal torque of the motor. Increasing the motor torque way beyond
the load requirements reduces the accuracy of tension/torque control
Rule 2 : Motor overload characteristics are proportional to I/N2. Load torque
requirements are proportional to 1/N.
Therefore the overload requirements may often lead to the next frame size of the
motor. Check the overload requirements carefully such a case. Generally Winders
overloads are needed during the fastest stop or acceleration and can be calculated!
Reducing (Convincing the customer)the acceleration/deceleration rates by a small percentage
may be a better solution then over-dimensioning the motor to fulfil this requirement.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 58
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Selecting the Motor
Motor Load torque and the maximum loadibility of the motor
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 59
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning- Selecting the Motor
Rule 3 : Check the minimum rotational speed of the motor. This criteria leads to a
bigger motor in self ventilated motors.
Minimum rotational speed for the motor is at minimum operational speed and
at the maximum diameter.
The problem with the motor loadibility curve is only when the maximum tension is
requested and the maximum designed diameter is used.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 60
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Selecting the motor+Gearbox
Using the same process example
Required Process Tension
5
kN
Max Process speed
300
m/min
Min Diameter
0.6
m
Max Diameter
1.5
m
Max Process rpm (mandrel)
159
rpm
Min process rpm (mandrel)
64
rpm
Calculated Power required
25
KW (based on no overloads)
Speed ratio=
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
2.484375
SLIDE 61
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Selecting the motor+Gearbox
We are free to choose the gearbox !!!
We know the power requirement - say 30KW, 150% overload
We know the speed ratio = 2.48
this implies that the motor runs into field weakening
up to about 2.5 times.
Choose the motor based on
Easiest availability
Best torque curve fitting
<Best motor is the one whose base speed can
be as close to our process base speed>
Choose the gearbox based on the speeds
=
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 62
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Selecting the motor+Gearbox
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 63
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning
Using the Application Checklist Form
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 64
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning
Application Checklist Form for Selecting Winder Applications
GENERAL
Customer Name:_____________________
Application:_________________________
Date:______________________
Machine Section:____________
APPLICATION REQUIREMENTS
(Che ck all that apply)
Unwind:
W inder:
Tension:
Dancer:
Torque:
MOTOR DATA
Size:
Supply Voltage:
Supply Frequency:
Synchronous Speed:
KW
VAC
Hz
rpm
Nominal Speed:
Encoder:
Encoder Resolution:
Encoder Supply:
rpm
Yes______ No______
ppr
12Vdc______ 24Vdc______
(Che ck one )
OVERLOAD
Overload:
% for ______ second(s)
-
every ______ minute(s)
MECHANICAL DATA
Unwind/W inder:
Single Position:______ Turret:______
Unwind/W inder:
Over______ Under______
Number of Cores:
Min. Core O.D. _____ mm
Total Gear Ratio:
:1
(Che ck both if r e quir e d)
Core # 2 O.D. ______ mm
Core # 3 O.D. ______ mm
Min W eb W idth:
Max W eb W idth:
mm
mm
Min. W eb Thickness:
Max. W eb Thickness:
mm
mm
Full Roll Diameter:
Max. Roll W eight:
mm
kg
Core Shaft Material:
Core Shaft Inner Dia.:
Core Shaft Outer Dia.:
mm
mm
MACHINE SPECIFICATIONS
Line Speed Reference:
Current______
Voltage______
Signal Range:
(0)4-20mA______
0-10Vdc______
Isolated:
Line Speed Min:
Min Accel Time:
Min. Fast Stop Time:
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
m/min
secs
secs
Communicated______
Yes______ No______
Line Speed Max:
Min Decel Time:
SLIDE 65
m/min
secs
Printed 7-Dec-98
Solution Products Pre-Information
Winder Basics
Dimensioning
DANCER SPECIFICATIONS
Dancer Supply Source:
Dancer Feedback:
Signal Range:
Existing______ Drive______
Current______
(0)4-20mA______
Max Dancer Travel:
Dancer Supply:
Vdc
Voltage______
None______
______ to ______Vdc
Isolated:
Yes______ No______
mm
TENSION SPECIFICATIONS
Tension Reference:
Signal Range:
Current______
(0)4-20mA______
Voltage______
0-10Vdc______
Communicated______
Isolated:
Yes______ No______
Tension Feedback:
Signal Range:
Current______
(0)4-20mA______
Voltage______
0-10Vdc______
None______
Isolated:
Yes______ No______
Min Tension:
Max Tension:
N
N
Stall Tension:
Max Taper:
Max Tension Variation @ Steady State:
Max Ttension Variation During Accel/Decel:
kg
kg
N
%
Loadcell Type:
COMMUNICATIONS
(Che ck one )
Modbus:
Modbus +:
Device Net:
CS31:
Profibus:
Advant
:
None:
COMMENTS:
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 66
Printed 7-Dec-98
Solution Products Pre-Information
Center Winder Training
Application Software
Implementation
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 67
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Integration of the Winder Application
Standard and Multidrive
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 68
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
Winder Application consists of the macros :
Winder Ten
Winder Dan
Unwinder Ten
Unwinder Dan
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 69
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Dancer Control
– The drive is speed regulated. The parent speed reference
comes from the process line controller.
– Speed Trim is used to Control Dancer Position. The Dancer
Controller output is added as a speed correction.
– The Dancer Controller is a PI controller receiving a setpoint
reference which is a constant from the keypad and receiving a
feedback of Dancer position from the process.
– Recommendation for Use:
• To create Isolation of sections.
• Typical Unwind Applications.
Dancer
Position
Feedback
to ACS600
Loading
Cylinder
0 volts
Servo
(I/P)
Force
+10 volts
Response polarity as with a Transducer
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 70
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Tension Control - Closed Loop Speed Trim
– The drive is speed regulated. The parent speed reference
comes from the process line controller.
– Speed Trim is used to control the actual tension of the web. The
Tension Controller output is added as a speed correction.
– Tension Controller is a PI controller receiving setpoint reference
from an operator control and receiving a feedback of actual
tension from the process.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 71
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Tension Control - Closed Loop Speed Trim
– Recommendation for Use:
•
•
•
•
If the material range is wide and extensive.
If a large range of Web Widths are possible/required.
Accurate Inertia data is not available.
Transducer feedback is required.
Transducer;
Actual
Tension
Feedback
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 72
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Tension Control - Closed Loop Torque Trim
– The drive is torque regulated. The parent speed reference is
required from the process line controller for over speed control.
– The torque reference is calculated by the application based on
tension setpoint and machine parameters entered at the keypad.
– Torque Trim is used to control the actual tension of the web. The
Tension Controller output is added as a torque correction.
– Tension Controller is a PI controller receiving setpoint reference
from an operator control and receiving a feedback of actual
tension from the process.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 73
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Tension Control - Closed Loop Torque Trim
– Recommendation for Use:
• Greater dynamic response.
• Web dimensions are basically constant with minimal
variations in width and density.
• Accurate system and material Inertia data is available.
• Transducer feedback is required.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 74
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Tension Control - Open Loop Torque
– The drive is torque regulated. The parent speed reference is
required from the process line controller for over speed control.
– The torque reference is calculated by the application based on
tension setpoint and machine parameters.
– The PI controller is NOT active in this mode and therefor there is
not any trim of the torque reference.
– Recommendation for Use:
• Transducer - Actual tension feedback is not available
• Web dimensions are constant with limited variations in width
and density.
• Accurate system and material Inertia data is available.
• Stall tension is not required.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 75
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
 Dancer Controller
Motor
RPM
DTC
Diameter
Calculator
Line Speed
div
add
Dancer
Feedback
Dancer
Setpoint
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
PI
SLIDE 76
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Dancer Controller
– Activation of the Dancer Controller is selected via parameter.
– Parameter selectable Dancer Position Feedback.
– Automatic Centering of the Dancer. The Dancer position of
regulation is defaulted to the center of it’s maximum travel. This
may be adjusted with the Center Offset parameter.
62:7 Dancer FDBK Input
AI 1
AI 2
AI 3
XT AI1 0V
XT AI2 0V
XTAI2 -10V
62:5 Dancer Ctl Enable
NOT SEL
ENABLE
DI 2
DI 3
DI 4
DI 5
DI 6
XT DI1
FIELDBUS
Running
&
Reference
Feedback
62:10 Max Dancer Travel
2
div
add
62:11 Center Offset
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
PI
Regulator Release
SLIDE 77
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Dancer Controller
– P-Gain Min and P-Gain Max: P-Gain of controllers are adjusted
as a function of diameter. As diameter increases the P-Gain of
the Controller is increased linearly to P-Gain Max for improved
regulation as diameter is changed.
– Two selectable web configurations. Each parameter for WEB 1
and WEB 2 are (infinitely) adjustable.
• Two (2) sets of PI gains for Dancer controllers.
Stall Mode Enable
62:13 Web Selection
62:1 P-Gain 1 Min
62:14 P-Gain 2 Min
62:2 P-Gain 1 Max
62:15 P-Gain 2 Max
62:3 Integ Time 1
62:16 Integ Time 2
PI
K
K
X
Diameter
I
62:4 Range Adjust
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 78
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Dancer Controller
Parameters
– Dancer Setpoint: Used in applications where Stall Tension and/or
Tension Taper functions are required. In these modes a servo
(I/P) must be used to adjust the tension applied to the web. An
analogue output is used to control the servo.
– Taper Tension: Reduction of tension reference as a function of
diameter.
Stall Tension Enable
62:9 Max Taper/%Taper
KEYPAD
AI 1
AI 2
AI 3
XT AI1
62:6 Dancer Setpoint
XT AI2
FIELDBUS
AI 1
AI 2
AI 3
XT AI1
XT AI2
FIELDBUS
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
ACS600
% Taper
Analogue
R
e
f
Output
Loading
Cylinder
Diameter
Servo
(I/P)
Force
mul
62:18 Stall Setpnt
(%)
SLIDE 79
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Dancer Controller
– Stall Tension: If selected, is automatically activated when the line
speed falls below a parameter set value. At this time the Tension
reference is reduced to a parameter set percentage of setpoint
tension. Stall PI gains are available for separate PI controller
adjustment when in stall tension.
Stall Mode Enable
62:17 Stall Enable
1) DISABLE
2) NORMAL GAIN
3) STALL GAIN
Line Speed Ref
62:19 Stall Speed
If = 3 then
&
62:20 Stall P-Gain
If NOT = 1 then
A1
B1
A1 < B1
&
62:20 Stall Integ
Stall Tension Enable
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 80
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
Dancer / Tension Trim - Speed Control
nRef
P-Controller
n-Controller
PRef
x
-
Tq Speed Ctl out
+
-
Pact
F(D, V)
nact
Controller
adaptation
Macc
D
Gain
Gain
Web type (material thickness/ material width)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
D
SLIDE 81
Printed 7-Dec-98
Used TQ reft
Solution Products Pre-Information
Winder Application
 Tension Controller
Parameters
Motor
RPM
DTC
Diameter
Calculator
Torque Ref.
Line Speed
div
Tension
Feedback
add
Spd Ref.
mul
Torque Control
Tension
Setpoint
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
PI
SLIDE 82
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Tension Controller
Parameters
– Activation of the Tension Controller is selected via parameter.
– Parameter selectable Tension Setpoint.
– The actual Tension Reference is a calculation including selection
of Tension Setpoint, Stall Tension, and Taper Tension based on roll
diameter.
– Taper Tension: Reduction of tension reference as a function of
diameter.
– Parameter selectable Tension Feedback (Transducer). Actual
Feedback signals must be connected via Analogue Inputs.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 83
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Tension Controller
63:5 Tension Ctl Enable
NOT SEL
ENABLE
DI 2
DI 3
DI 4
DI 5
DI 6
XT DI1
FIELDBUS
63:6 Tension Setpoint
AI 1
AI 2
AI 3
XT AI1
XT AI2
FIELDBUS
Parameters
Running
&
63:9 Max Taper/%Taper
KEYPAD
AI 1
AI 2
AI 3
XT AI1
XT AI2
FIELDBUS
63:7 Tension FDBK Input
AI 1
AI 2
AI 3
XT AI1
XT AI2
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Stall Tension Enable
PI
Regulator Release
Reference
Feedback
% Taper
R
e
f
Diameter
mul
63:21 Stall Setpnt (%)
SLIDE 84
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Tension Controller
– P-Gain Min and P-Gain Max: P-Gain of controllers are adjusted
as a function of diameter. As diameter increases the P-Gain of
the Controller is increased linearly to P-Gain Max for improved
regulation as diameter is changed.
– Two selectable web configurations. Each parameter for WEB 1
and WEB 2 are (infinitely) adjustable.
• Two (2) sets of PI gains for Dancer controllers.
Stall Mode Enable
63:16 Web Selection
63:1 P-Gain 1 Min
63:17 P-Gain 2 Min
63:2 P-Gain 1 Max
63:18 P-Gain 2 Max
63:3 Integ Time 1
63:19 Integ Time 2
PI
K
K
mul
Diameter
I
63:4 Range Adjust
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 85
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Tension Controller
– Stall Tension: If selected, is automatically activated when the line
speed falls below a parameter set value. At this time the Tension
reference is reduced to a parameter set percentage of setpoint
tension. Stall PI gains are available for separate PI controller
adjustment when in stall tension.
Stall Mode Enable
63:20 Stall Enable
1) DISABLE
2) NORMAL GAIN
3) STALL GAIN
Line Speed Ref
63:22 Stall Speed
If = 3 then
&
63:23 Stall P-Gain
If NOT = 1 then
A1
B1
A1 < B1
&
63:24 Stall Integ
Stall Tension Enable
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 86
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Tension Controller - Torque
– Tension Control Mode selection.
• (Speed Trim, Torque Trim, or Torque No-Trim)
– The selections for Tension Control Mode are
(Torque Ctrl or Speed Ctrl). An additional parameter
selection is required to select the operation of Torque Ctrl.
– Torque Control can be activated in Open Loop when Speed
Control is the selected control mode. This is for special
applications which require Tension trim in Speed ctrl and an
additional Torque only mode,
(Special load share applications).
– When in speed control the normal selection of the Torque Trim
Sel parameter is [Tentorq Trim].
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 87
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Tension Controller - Torque
63:11 Tension Ctrl Mode
Torque Ctrl
Speed Ctrl
63:12 Torque Trim Sel
TenTorq Trim
Torque NoTrim
DI1 (NoTrim)
D
I2 (NoTrim)
DI4 (NoTrim)
X
DI1 (NoTrim)
XDI2 (NoTrim)
FBA (NoTrim)
Over / Under Sel
Pull / HoldBack
Algorithm for determining
Torque Reference Selection:
When in Speed Control the selections
[TenTorq Trim] & [Torque NoTrim] do not
operate. In this mode torque can only
be commanded with DI or FBA. The
Torque mode is without trim.
When in Torque Control the [Torque
Trim Sel] determines if the Tension
feedback trims the torque or if the
torque is not trimmed. If an input is
selected the operation is Torque Trim
when the input is 0 and Torque NO trim
when the input is 1.
Torque Reference
Selector
TORQ REF SEL
0
MIN
MAX
+
+
The selections of Over / Under and
Pull / Holdback determine the selection
in Torque Control for the Torque
Reference Selector [ Min or Max ]
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 88
Printed 7-Dec-98
3
4
2 1
5 6
Torque
Ref to
DTC
Solution Products Pre-Information
Winder Application
Parameters
 Tension Controller - Torque
– Frictional Losses: Static Friction for constant losses of the
machine and Linear Friction for frictional loss change as a
function of roll diameter.
Tension Reg Output
63:10 Maximum Tension
63:4 Range %
Roll Diameter
Inertia Compensation
mul
+
Torque Reference
Selector
63:14 Linear Friction
TORQ REF SEL
Diameter
Tension Reference
Gear Ratio
Roll Diameter
*/
63:13 Static Friction
0
+
Torq Ref 1
MIN
3
4
2 1
+
5 6
MAX
Torq Ref 2
+
+
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 89
Printed 7-Dec-98
Torque
Ref to
DTC
Solution Products Pre-Information
Winder Application
Tension Trim - Torque Control
Winder- Application
Software
Diameter
Calculation
Tension
Reference
Tension
to TQ cal
Tension Controller
PI
Line Speed
Reference
Tension
Reference
Tension Controller
PI
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Parameters
Flux Code
Torque Correction
Speed
Reference
Flux
Accelerate
Torque
SLIDE 90
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Inertia Compensation - WK²
– The calculation for Torque required due to speed change per time
change (n/t).
– Parameters for Motor and Gearing inertia.
– Parameters for calculation constant system inertia.
– Can be deactivated in Speed control mode.
– Two selectable web configurations. Each parameter for WEB 1
and WEB 2 are (infinitely) adjustable. Selection of Web 2 is done
in the Dancer or Tension parameters.
• Two (2) Web width parameters
• Two (2) Web density parameters
– Recommendation for Use:
• Required for all torque control modes and recommend for
improved performance in speed control modes.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 91
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Diameter Calculation
Parameters
– The calculation of the diameter is a function of line speed and
winding roll rpm.
– Starting Diameter Values:
• The starting diameter can be preset using digital inputs or
FieldBus. These inputs can be used to trigger a selection of
three (3) parameter preset diameters. The first being
Minimum core for a Winder or Maximum roll for an Unwind.
• The starting diameter can also be set by DI’s or FieldBus to
manually increase or decrease the diameter value (Digital
Operated Potentiometer).
• An ultrasonic sensor or mechanical measurement can also be
implemented through XT AI2 and triggered through DI or
FBus.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 92
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
t
Diameter Calculator
Line Speed Reference
Actual Core Speed
Diameter
V
t
Diameter Reset
Dancer / Tension Enable
N
Unwinder / Rewinder
Count UP Enable
Count DOWN Enable
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Min Core Dia
Max Roll Dia
Web Thickness
SLIDE 93
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Diameter Calculation
Parameters
– Running Diameter Memory: The actual calculated diameter is
stored in flash prom when power is lost to the drive. When power
is restored the diameter is preset to the stored value.
– Web Thickness is used in the diameter calculation algorithm only
as a maximum change limiter, to prevent unexpected speed
change if a calculation error occurs.
– Diameter calculation inhibit functions:
• Diameter calculation is stopped when the line speed is below
parameterized value.
• Diameter calculation decrease can be inhibited in Winders.
• Diameter calculation increase can be inhibited in Unwinds.
• Diameter calculation is stopped when torque mem is active.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 94
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Diameter Calculation

Parameters
The Diameter Calculator can be bypassed if an external device
such as an Ultrasonic sensor is preferred. The Diameter
calculator can be disabled with a parameter.
– There are available two (2) supervisory parameters for indication
of diameter reached. In winder applications the indication is the
preset diameter has been exceeded. In unwind applications the
indication is the actual diameter is less than the presets.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 95
Printed 7-Dec-98
Solution Products Pre-Information
Digitally operated potentiometer
REF select
11.4
Enable
DI4
FB_SPD_DEC
>
+20,000 units
DI3
FB_SPD_INC
DEC
>
INC
>
TON
POT Rate 1
POT rate 2
R
Emergency stop
&
-20,000 units
Run Enable
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 96
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Additional Features
 Active Flux Control
– The automatic reduction of motor flux dependant on
torque required. As the machine torque requirement
is reduced the motor flux is reduced to improve
current resolution.
100
90
80
70
Motor 60
Flux % 50
40
30
20
10
0
Required
Motor
Torque %
Flux
Torque
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Time
SLIDE 97
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Active Flux Control
Parameters
– Actual formula for Flux control
– Torque depends on flux vectors: T = c (s x r)
y
U3
U2
U4
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
U6
U5
s

U1
r
SLIDE 98
x
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Over / Under wind selection
– Over or Under Wind selection can be made with the Forward /
Reverse selection parameter. Over wind = Forward. To select
Under wind the the reverse mode must be activated with a DI or
FieldBus.
 Web Loss Detection
– Web Loss detection is calculated in the application. If web loss
detection is desired, a Relay Output can be assigned to this
function. The actions taken if a web loss occurs is dependant
upon external controls provided by the end user.
• Web Loss Delay Timer adjustable at the keypad.
• Dancer & Tension Control: Web Loss trip point is an adjustable.
• Torque Control:
Web Loss if speed actual is 10% greater than
speed reference.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 99
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
Single Position Winder
Under
Winding
Winding
Transducer;
Actual
Tension
Feedback
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Under
Winding
SLIDE 100
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
 Turret Winder Roll Change
– The following functions were intended for use in Turret Winder
applications in which automatic roll change is used.
– Core Speed Match: Used in pure speed control to trim the speed
of the core. Trimming the speed of the core is done to adjust the
web transfer to the new core during roll change. This may also
be used to adjust the speed of the core when the core diameter
varies in small percentages per the same standard core size.
61:1 Spd Mtch Ref Sel
No SpdMtch
AI 1
AI 2
61:4 Spd Match Rate
AI 3
XT AI1
XT AI2
FIELDBUS
61:2 Spd Match W/Trim
Scaling &
Digital
Operated
Pot Rate
Additive Spd Ref
mul
0
Line Speed Ref
61:3 Spd Match Range
DI3, DI4
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
FBus b4,5
SLIDE 101
Printed 7-Dec-98
23:4
Solution Products Pre-Information
Winder Application
Parameters
 Turret Winder Roll Change
– Torque Memory is used to memorize the actual torque of the
motor. The torque is memorized in order to maintain stable
tension regulation during a continuous process roll change. The
function is triggered through DI’s or FieldBus.
• Before indexing the finishing roll from the wind position a
Sample of the actual torque is stored in the application.
• As indexing begins the Torque Memory is enabled. The drive
changes to direct torque control independent of the normal
operating mode. The memorized torque is then used as the
torque reference.
• When the indexing is near the web transfer point the Boost
Torque function may be activated to increase the actual
tension of the web to aid in knife cut. The boost torque can
be triggered form DI, Field-Bus, or a time delay function.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 102
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Turret Winder Roll
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
Parameters
Change Continued
SLIDE 103
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameters
Turret Winder - 2 Position
Indexing
Transducer;
Actual
Tension
Feedback
Winding
Position
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 104
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Turret Winder - 2 Position
Parameters
Roll Change in Process, The Layon Roll moves to Position
Torque Sample Memorized
Activating Torque Memory
Indexing
Layon Roll
Transducer;
Actual
Tension
Feedback
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 105
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Turret Winder - 2 Position
Parameters
Roll Change in Process
Torque Sample Memorized
Torque Memory Active
Indexing
Activate Boost Torque
Transducer;
Actual
Tension
Feedback
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 106
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
Winder Application consists of the macros :
Selectable from Parameter 99.2
Winder Ten
Winder Dan
Unwinder Ten
Unwinder Dan
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 107
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
Selecting Dancer modes automatically uses Speed Control
Group 63 is hidden
62.5 = Enable or DIy high
when DIy goes low pure speed control is selected
If Tension modes are selected further configuration is required
To select Indirect Torque Control
63.5 = Enable or DIy
when DIy goes low pure speed control is selected
63.11 = Torque ctrl
63.12 = Torque no trim or DIx high
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 108
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
If Tension modes are selected further configuration is required
To select Direct Tension control with Speed Trim
63.5 = Enable or selectable by DIy high
when DIy goes low pure speed control is selected
63.11 = Speed Ctrl
63.12 = Tension Torque Trim or DIx low
when DIx goes high system goes to pure torque
To select Direct tension control with Torque trim
63.5 = Enable or selectable by DIy high
when DIy goes low pure speed control is selected
63.11= Torque Ctrl
63.12 = Tension torque Trim or DIx low
when DIx goes high system goes to pure torque
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 109
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Configuration
If a Switch between Dancer mode Speed trim and pure speed1 control
is required
 Parameter 62.5 should be connected to one of the DIy inputs
62.5 = Enable or DIy high
when DIy goes low pure speed control is selected
e.g. : Needed after a web break to wind the material into the core
If a Switch between Torque mode and pure speed1 control
is required
 Parameter 62.5 should be connected to one of the DIy
inputs
62.5 = Enable or DIy high
when DIy goes low pure speed control is selected
e.g. : Needed after a web break to wind the material into the core
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 110
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
DDCS Interface
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 111
Printed 7-Dec-98
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
DATASET 3 WORD 3 : Speed match
DATASET 5 WoRD1 : Percent Draw Trim
DATASET 5 WORD 2 : Selectable Pointer
DATASET 5 WORD 3: Selectable Pointer
50 ms
50 ms
100 ms
100 ms
50 ms
SLIDE 112
100 ms
Fieldbus Adapters (External protocol to DDCS protocol)
ExternalPLC
PLC
External
Printed 7-Dec-98
DATASET 6 WORD 3: Selectable Pointer
DATASET 6 WORD 2 : Selectable Pointer
DATASET 6 WoRD1 : Percent Draw Trim
DATASET 4 WORD 3: Selectable Pointer
DATASET 4 WORD 2 : Selectable Pointer
DATASET 4 WoRD1 : Percent Draw Trim
DATASET 2 WORD 3: Selectable Pointer
DATASET 2 WORD 2 : Selectable Pointer
DATASET 2 WoRD1 : Selectable Pointer
DATASE 3 WORD2 : Taper Set-point
50 ms
DATASET 1 WORD3 : Application CW
50 ms
DATASET 3 WoRD1 : Dancer / Tension
DATASET 1 WORD 2 Speed Reference
10 ms
50 ms
DATASET 1 WoRD1 : Command Word
50 ms
Solution Products Pre-Information
Winder Application in ACx6xx
100 ms
Solution Products Pre-Information
Winder Application
Parameter Group 6
DATASET COMM
(if USED)
1 DATASET 1 WORD 1
50ms
Bit 0 Drive Enable (Drv Contactor – DCS)
Bit 1 E-STOP NOT
Bit 2 Reserved
Bit 3 Run Command
Bit 4 Direction
Bit 5 Constant Speed 1 Act
Bit 6 Constant Speed 2 Act
Bit 7 Fault Reset
Bit 8 Inching Speed Act
Bit 9 Payout Speed Act
Bit 10 Remote Command
Bit 11 Relay Output 1 Act
Bit 12 Relay Output 2 Act
Bit 13 Relay Output 3 Act
Bit 14 CH0 Comm Heartbeat
Bit 15 Reserved
2 DATASET 1 WORD 2
10ms
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
DDCS Interface - Inputs
DT1 WRD1
(Command Word)
(Profibus only)
(Return Signal from Master)
DT1 WRD2
SLIDE 113
Speed Reference
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Parameter Group 6
3 DATASET 1 WORD 3
50ms
Bit 0 Dancer / Tension Enable
Bit 1 Dancer / Tension Gain2 Sel
Bit 2 Tension Trim Off (Open Loop Torque)
DDCS
DT1 WRD3
Interface
- Inputs
Application
Command Word
In Tension Mode – Commands Open loop
Torque – No Tension Fdbk required
Zero’s the Integration Time of the PI-regulators.
Regulators act a P-regulator
Bit 3 Dancer / Tension Zero Integ Time
Bit 4 Core Speed Increase
Bit 5 Core Speed Decrease
Bit 6 Diameter Setpoint 1
Increase Core Speed Match
Decrease Core Speed Match
Bit 6 & Bit 7 both on will activate Diameter
Setpoint 3
Bit 7 Diameter Setpoint 2
Bit 8 Diameter Hold
Bit 9 Diameter Increase
Stop the Diameter Calculator form Changing
For adjusting starting diameter – Off when in
Dancer or Tension Mode
For adjusting starting diameter – Off when in
Dancer or Tension Mode
Sample the running Torque for Roll Change
Torque Memory circuit.
Enable Memorized (Sampled) Torque – the
drive will operate in Torque mode
Multiply the Memorized Torque by the Boost
Torque % to increase tension at Knife Cut
Bit 10 Diameter Decrease
Bit 11 Torque Sample
Bit 12 Torque Memory Enable
Bit 13 Boost Torque ON
Bit 14 Reserved
Bit 15 Reserved
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 114
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
DDCS Interface - Inputs
Parameter Group 6
4
5
6
7
DATASET 3 WORD 1
DATASET 3 WORD 2
DATASET 3 WORD 3
DATASET 5 WORD 1
50ms
50ms
50ms
50ms
DT3 WRD1
DT3 WRD2
DT3 WRD3
DT5 WRD1
Dancer / Tension Setpoint
Taper Setpoint
Speed Match Setpoint
Percent Draw Trim – for progressive Draw
from over-riding controller (x100)
8 DATASET 5 WORD 2
9 DATASET 5 WORD 3
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
100ms
100ms
DT5 WRD2
DT5 WRD3
SLIDE 115
Selectable – pointer
Selectable – pointer
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
DDCS Interface - Outputs
Dataset Comm Out
DATASET 2 WORD 1
DATASET 2 WORD 2
DATASET 2 WORD 3
DATASET 4 WORD 1
DATASET 4 WORD 2
DATASET 4 WORD 3
DATASET 6 WORD 1
DATASET 6 WORD 2
DATASET 6 WORD 3
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
No Parameter
Short Name
Description
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
Selectable – pointer
50ms
50ms
50ms
100ms
100ms
100ms
100ms
100ms
100ms
SLIDE 116
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
 Analogue Inputs
Additional Hardware
– Standard AI (Qty 1 : 0-10v) (Qty 2 : 0-20ma)
– Dancer Mode Requirements
 Speed Reference
 Draw Set-point
 Dancer Set-point
 Taper Set-point
 Dancer Feedback
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 117
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Additional Hardware
 Analogue Inputs
– Tension Mode Requirements
 Line Speed Reference
 Draw Setpoint
 Tension Setpoint
 Transducer Feedback
 Taper Setpoint
– If more than (1) input 0-10v
- NAIO-021 req.
• Potentiometers require 0-10v
– If all listed Tension Inputs selected
1
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
- NAIO-021 req.
NAIO-01 is not supported by the application software
SLIDE 118
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Additional Hardware
 Digital Inputs - Standard (6) 24vdc
 Maximum of 10DI and 5AI, 4AO and 5DO
 2 NDIO units and 1 NAIO-02 modules
– Normal DI Selections for Winder Applications
•
•
•
•
•
•
•
•
•
•
1) RUN
2) ENABLE
3) FAST STOP
4) REVERSE - (Over/Under Winding)
5) FAULT RESET
6) TENSION ENABLE / DANCER ENABLE
7) DIAMETER RESET 1
8) DIAMETER RESET 2
9) TORQUE MEMORY SAMPLE
- (Not available for Unwind)
10) TORQUE MEMORY ENABLE - (Not available for Unwind)
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 119
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Additional Hardware
 Digital Inputs - Standard (6) 24vdc
– Possible DI Selections for Winder Applications
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
1) RUN
2) ENABLE
3) FAST STOP
4) REVERSE (Over / Under)
5) RAMPED SPEED 1
6) RAMPED SPEED 2
7) INCHING SPEED
8) FAULT RESET
9) TENSION ENABLE / DANCER ENABLE
10) DIAMETER RESET 1
11) DIAMETER RESET 2
12) TORQUE MEMORY SAMPLE - (Not available for Unwind)
13) TORQUE MEMORY ENABLE - (Not available for Unwind)
14) TORQUE BOOST ENABLE (Not available for Unwind)
15) P-GAIN 2 SELECT
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 120
Printed 7-Dec-98
Solution Products Pre-Information
Winder Application
Additional Hardware
 Digital Inputs - Standard (6) 24vdc
– Most Winder Applications typically require at least
(1) NDIO module.
– Turret Winder Applications with roll change requirements
typically require (2) NDIO modules.
– Unwind Applications can typically be done with standard
DI - Depending on Customer requirements.
Narendra Gupta & Michael Vallier / 98-12-01
File : Solutions_Winder.ppt
SLIDE 121
Printed 7-Dec-98