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## Center Winder Training Application Software General

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**Center Winder Training**Application Software General**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 Velocity Winder Basics Common Terms and Definitions • 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.**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. 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 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. 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. 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. Winder Basics Common Terms and Definitions**Basic Winder Macro Includes**Dancer Control Indirect Tension Control Direct Tension Control With Correction signal used as Speed Correction (Speed Trim) With Correction signal used as Torque correction (Torque Trim) Selectable Winder and Unwinder modes Common Control Functions Include Diameter calculation Tension torque reference Calculation of moment of inertia Acceleration/deceleration torque compensation Loss Compensation Winder Basics**Winder Basics**Formulas for the Winder Formulas for the Winder**Winder Basics**Formulas for the Winder 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)**F**Winder Basics Formulas for the Winder V 1. Power required for winding 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**V**F Winder Basics Formulas for the Winder 4. Maximum and minimum Motor Speeds**V**F Winder Basics Formulas for the Winder 5. Intertia components Torque available from motor is used to produce the Tension component as well as to overcome the Inertia requirements Total inertia of System =( Inertia of Roll+ Inertia of roller+ Inertia of gear)reflected to motor side +motor inertia**V**F Inertia of shaft (roller) Shaft Outer Dia Shaft Inner Dia Inertia of roll ( material wound or unwound on the core) Winder Basics Formulas for the Winder Inertia of Gearbox Usually provided by the customer/mech supplier Inertia of Motor Motor Catalogues provide the motor Inertia.**V**F Mm= Winder Basics Formulas for the Winder Total Torque to be developed by Motor Mm= Mm= + MM1+MM2+MM3+Loss component Mm= Variable part Fixed part**Winder Basics**Formulas for the Winder**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**Basic Winder Macro Includes**Dancer Control Indirect Tension Control Direct Tension Control With Correction signal used as Speed Correction (Speed Trim) With Correction signal used as Torque correction (Torque Trim) Selectable Winder and Unwinder modes Common Control Functions Include Diameter calculation Tension torque reference Calculation of moment of inertia Acceleration/deceleration torque compensation Loss Compensation Winder Basics Configurations**Winder Basics**Configurations Indirect and Direct Tension Control Tensiometer**Winder- Application**Software Flux Code Tension Reference Tension Controller PI Torque Correction Line Speed Reference Tension Reference Tension Controller PI Winder Basics Configurations a) No Feedback system for Actual Tensionb) Feedback for Actual Tension is used Tension to TQ cal**Winder Basics**Configurations- Indirect Ten Linear Speed Reference Gear Box Tension Reference External DIA M Web Density Web Width DIA CALCULATOR+ INTEGRATOR Macc= J*2/D*Z*dv/dt TORQUE REFERENCE Dia Preset t SELECTOR V TORQ REF SEL N 0 EXTERNAL TORQUE REFERENCE 1 Torque Ref to DTC External /Internal Dia Calc 2 3 Winder/ Rewinder 4 MIN LossTorq= K+ N* K1 5 6 Count UP EN TORQ REF1 Count DN EN MIN DIA MAX D MAX DIA STATIC FRICTION + SPEED CONTROLLER OUTPUT - + TORQ REF2 LINEAR FRICTION + I C+I *C1 X P I Taper Tension Generator Tension Ref F M DIA**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)**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.**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.**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)**Winder Basics**Configurations Direct tension Control with speed Trim Direct tension Control Direct tension Control with Torque Trim**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)**Winder Basics**Configurations- Direct Tension Control with speed Trim nRef F-Controller n-Controller Tq Speed Ctl out + Used TQ reft FRef x Speed Trim - - Fact F(D, V) nact Controller adaptation Macc Web type (material thickness/ material width) Gain Gain D D Block Diagram of the Direct tension Control with speed Trim**Winder Basics**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.**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.**Winder Basics**Configurations- Direct Tension Control with Torque Trim nRef F-Controller n-Controller Tq Speed Ctl out + Used TQ reft FRef x - - Fact F(D, V) nact Controller adaptation Macc Web type (material thickness/ material width) Gain Gain D D Block Diagram of the Direct tension Control with speed Trim**Winder Basics**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.**Winder Basics**Configurations- Dancer Control Dancer Control**Loading Cylinder**Dancer Position Feedback to ACS600 Servo (I/P) Dancer Position Feedback to ACS600 Fixed Back Tension Force Force +10 volts 0 volts Response polarity as with a Transducer +10 volts 0 volts Response polarity as with a Transducer Winder Basics Configurations- Dancer • Mechanical Configurations • Fixed back tension systems • Variable back tension systems Variable Tension System Fixed Tension System**Dancer Control**The drive is speed regulated. The parent speed reference comes from the process line controller. Speed Trim is used to Control Dancer Position. The Dancer Controller trim is added as a speed correction. The Dancer Controller is a PI controller receiving a set-point reference which is a constant from the keypad and receiving a feedback of Dancer position from the process. Loading Cylinder Dancer Position Feedback to ACS600 Servo (I/P) Force +10 volts 0 volts Response polarity as with a Transducer Winder Basics Configurations**Winder Basics**Configurations Block Diagram of Dancer Control - Speed Control and speed correction- Fixed Tension system nRef P-Controller n-Controller Tq Speed Ctl out + Used TQ reft PRef x - - Pact F(D, V) nact Controller adaptation Macc Web type (material thickness/ material width) Gain Gain D D**Winder Basics**Configurations- Dancer - Fixed Tension How is Tension regulated ? Tension of the Winder is regulated indirectly by regulating the the position of the Dancer and adjusting the “restraining forces”**Winder Basics**Configurations- Dancer- variable Tension Block Diagram of Dancer Control - Speed Control and speed correction- Variable Tension system nRef P-Controller n-Controller Tq Speed Ctl out + Used TQ reft PRef x - - Normally Fixed as Parameter Pact Macc F(D, V) nact Tension Setpoint Controller adaptation Loading Cylinder Web type (material thickness/ material width) Servo (I/P) Gain Gain Force D D Stall and Taper Reference**Dimensioning the Winder**Winder Basics Dimensioning • Understanding the Load Requirements • Selecting the correct Motor • Recommending the optimal gearbox and speeds • to mechanical supplier**Winder Basics**Dimensioning- Load Requirement • Analyzing the Load Requirements 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 c) Generally the required torque below base speed is same d) Specified overload of 150% is required at all speed points**Winder Basics**Dimensioning- Load Requirement Graphical Interpretation of the specified Load 30KW, 800 rpm/ 1500 rpm 150% overload Constant TQ TQ requirement proportional to**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 : 5 KN, material thickness =3mm Material type 2 : 1 KN ,material thickness =0.5mm Diameter Ratio : Min 600 mm Max :1500 mm Line speed max = 300 mpm, Minimum speed = 60 mpm Operating speed= 250 mpm Acceleration rates= 20 sec to full speed / fast stop =10sec from full speed material width = 800 mm, density= 1100 kg/m3**Winder Basics**Dimensioning- Load Requirement Calculating the Min and max values**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. The minimum linear operation speed is the speed at which the winder may run continuously for a extended period of time. This does not have any effect on dimensioning when a separately ventilated motor is used. Nmin in this example = 125 rpm Line stops before max dia is reached !! M2BA 315 SMA8**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**Winder Basics**Dimensioning- Load Requirement Calculating the Torque at different speed points Calculation based on Tset =Tmax conditions