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1、Center Winder TrainingApplication SoftwareGeneral,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.,The objective is to regulate surface Tension of th
2、e roll.The Speed and Torque of the core must change as a function of Roll Diameter.,Winder BasicsCommon Terms and Definitions,Common TermsCORE: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
3、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 finis
4、hed or completed roll diameter.In Unwind applications this is the starting roll diameter to be unwound.,Winder BasicsCommon Terms and Definitions,Common TermsCORE SPEED MATCH:The function of trimming the speed of winder when in Speed Mode.This is typically used for continuous process lines with auto
5、matic 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 wrapNON-EXTENSIBLE:This is related to the
6、 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 BasicsCommon Terms and Definitions,Common TermsTENSION:The force applied to the web.This is used to control the web.Units of tension are N for Newtons or
7、 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
8、preset percentage of the tension set-point.,Winder BasicsCommon Terms and Definitions,Common TermsSPEED 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 m
9、achine 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
10、 be accelerated.Additional components,change in speed and change in time or(n/t),are required for the calculation of torque required.,Winder BasicsCommon Terms and Definitions,Common TermsDIAMETER CALCULATOR:The formula or process by which the diameter of a center winder are calculated.The Center Wi
11、nder 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.TORQU
12、E 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 BasicsCommon Terms and Definitions,Basic Winder Macro IncludesDancer ControlIndirect T
13、ension 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 modesCommon Control Functions IncludeDiameter calculationTension torque referenceCalculation of moment of inert
14、iaAcceleration/deceleration torque compensationLoss Compensation,Winder Basics,Winder BasicsFormulas for the Winder,Formulas for the Winder,F=Tension ForceM=TorqueV=Material Speedn=Rotational SpeedW=Angular SpeedB=Material WidthD=DiameterJR=Moment of InertiaJR1=Moment of Inertia of rollerJR2=Moment
15、of Inertia of rollJR3=Moment of Inertia of gearboxJM=Moment of Inertia of MotorJC=Total moment of Intertia(on motor side),Winder BasicsFormulas for the Winder,V,1.Power required for winding,Pmax=KW,2.Relationship between Tension component and motor TorqueM=FxD/2 Nm:Winding Torque on the machine side
16、Mm=FxD/2Z Nm:Winding Torque on the Motor side,3.Maximum and minimum Torques(ignoring the Inertia requirements)With respect to Tension component,Winder BasicsFormulas for the Winder,4.Maximum and minimum Motor Speeds,Winder BasicsFormulas for the Winder,5.Intertia components,Torque available from mot
17、or is used to produce the Tension componentas 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,Winder BasicsFormulas for the Winder,Inertia of shaft(roller),Inertia of roll(material wound or
18、unwound on the core),Inertia of GearboxUsually provided by the customer/mech supplier,Inertia of MotorMotor Catalogues provide the motor Inertia.,Winder BasicsFormulas for the Winder,Total Torque to be developed by Motor Mm=Mm=+MM1+MM2+MM3+Loss component,Mm=,Mm=,Fixed part,Variable part,Winder Basic
19、sFormulas for the Winder,Winder BasicsFormulas for the Winder,Relationship of Power and material,Control Configurations for Winders and Rewinders,Indirect Tension ControlNo Tension Feedback instrument is needed Direct Closed loop Tension control with Tension FeedbackMaterial Tension is measured dire
20、ctly 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 feebbackDrive remains in speed control Winder is use
21、d as Speed masterMaterial Tension is controlled by back tension provided by other equipmentWinder is controlled in speed control with Diameter Calculation to maintain uniform peripheral speed,Winder BasicsConfigurations,Basic Winder Macro IncludesDancer ControlIndirect Tension Control Direct Tension
22、 Control With Correction signal used as Speed Correction(Speed Trim)With Correction signal used as Torque correction(Torque Trim)Selectable Winder and Unwinder modesCommon Control Functions IncludeDiameter calculationTension torque referenceCalculation of moment of inertiaAcceleration/deceleration t
23、orque compensationLoss Compensation,Winder BasicsConfigurations,Indirect and Direct Tension Control,Tensiometer,Winder BasicsConfigurations,Tension to TQ cal,a)No Feedback system for Actual Tensionb)Feedback for Actual Tension is used,Winder BasicsConfigurations,P,I,D,TORQUE REFERENCE,SELECTOR,+,+,M
24、IN,MAX,0,1,2,3,4,5,TORQ REF1,TORQ REF SEL,TORQ REF2,EXTERNAL TORQUE REFERENCE,SPEED CONTROLLER OUTPUT,6,Macc=J*2/D*Z*dv/dt,LossTorq=K+N*K1,V,N,DIA CALCULATOR+INTEGRATOR,Gear Box,M,Linear Speed Reference,Web Density,Web Width,MIN DIA,MAX DIA,Count UP EN,Count DN EN,Winder/Rewinder,Dia Preset,t,Extern
25、al/Internal Dia Calc,External DIA,STATIC FRICTION,LINEAR FRICTION,X,C+I*C1,I,+,-,M,F,Tension Reference,DIA,Tension Ref,Taper Tension Generator,Torque Ref to DTC,Winder BasicsConfigurations-Indirect Ten,Is recommendable to use Indirect tension control in Direct coupled winders(no gearbox)In mech conf
26、igurations where the mechanical losses are low.(No worm gears,and no appreciable difference between gearbox losses in warm or cold conditionsWhere 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
27、:1),Indirect Tension Control,The torque is calculated according to the formulas discussed before.No feedback instrument is used for actual measurement of tensionDiameter needs to be computed accurately to control the correct tensionFriction&Windage are very crucial components to maintain accuracy of
28、 tension.,Winder BasicsConfigurations,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.T
29、he 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 BasicsConfigurations,Indirect Tension Contr
30、ol-Open Loop TorqueRecommendation for Use:Transducer-Actual tension feedback is not availableWeb dimensions are constant with limited variations in width and density.Accurate system and material Inertia data is available.Process tension range is small.,Winder BasicsConfigurations,Is recommendable to
31、 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),Direct Tension Control,The torque is calculated according to the formulas discussed before.A feedback devic
32、e is used for actual measurement of tension.This is used asa superimposed control loop to correct the Torque reference.Diameter needs to be computed accurately to control the correct tensionFriction&Windage are not very crucial as inaccuracies may be corrected by the presence of the feedback loop.,W
33、inder BasicsConfigurations,Direct tension Control,Direct tension Controlwith speed Trim,Direct tension Controlwith Torque Trim,Winder BasicsConfigurations,Tension Control-Closed Loop Speed TrimThe drive is speed regulated.The parent speed reference comes from the process line controller.Speed Trim i
34、s 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
35、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,Win
36、der Basics,Configurations-Direct Tension Control with speed Trim,Tq Speed Ctl out,nRef,FRef,+,F-Controller,n-Controller,-,Fact,nact,Controlleradaptation,-,D,Gain,D,Gain,Web type(material thickness/material width),x,F(D,V),Macc,Used TQ reft,Speed Trim,Block Diagram of the Direct tension Control with
37、speed Trim,Direct Tension Control-Closed Loop Speed TrimRecommendation 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
38、 with speed Trim,Tension Control-Closed Loop Torque TrimThe 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 k
39、eypad.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,Config
40、urations-Direct Tension Control with Torque Trim,Winder Basics,Configurations-Direct Tension Control with Torque Trim,Tq Speed Ctl out,nRef,FRef,+,F-Controller,n-Controller,-,Fact,nact,Controlleradaptation,-,D,Gain,D,Gain,Web type(material thickness/material width),x,F(D,V),Macc,Used TQ reft,Block D
41、iagram of the Direct tension Control with speed Trim,Direct Tension Control-Closed Loop Torque TrimRecommendation 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 feed
42、back is required.,Winder Basics,Configurations-Direct Tension Control with Torque Trim,Dancer Control,Winder BasicsConfigurations-Dancer Control,Winder BasicsConfigurations-Dancer,Mechanical ConfigurationsFixed back tension systems Variable back tension systems,Fixed Tension System,Variable Tension
43、System,Dancer ControlThe 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 i
44、s a constant from the keypad and receiving a feedback of Dancer position from the process.,Winder BasicsConfigurations,Tq Speed Ctl out,nRef,PRef,+,P-Controller,n-Controller,-,Pact,nact,Controlleradaptation,-,D,Gain,D,Gain,Web type(material thickness/material width),Block Diagram of Dancer Control-S
45、peed Control and speed correction-Fixed Tension system,x,F(D,V),Macc,Used TQ reft,Winder BasicsConfigurations,How is Tension regulated?Tension of the Winder is regulated indirectly by regulating thethe position of the Dancer and adjusting the“restraining forces”,Winder BasicsConfigurations-Dancer-Fi
46、xed Tension,Block Diagram of Dancer Control-Speed Control and speed correction-Variable Tension system,Winder BasicsConfigurations-Dancer-variable Tension,Tq Speed Ctl out,nRef,PRef,+,P-Controller,n-Controller,-,Pact,nact,Controlleradaptation,-,D,Gain,D,Gain,Web type(material thickness/material widt
47、h),x,F(D,V),Macc,Used TQ reft,Normally Fixed as Parameter,Tension Setpoint,Stall and TaperReference,Loading Cylinder,Force,Servo(I/P),Winder BasicsConfigurations-Power directions,Material flow,Material flow,Material flow,Material flow,Unwinder,Winder,1,2,3,4,Understanding the Load Requirements,Dimen
48、sioning the Winder,Selecting the correct Motor,Recommending the optimal gearbox and speeds to mechanical supplier,Winder BasicsDimensioning,Analyzing the Load Requirements,How the customer specifies his load(typically)30KW,800rpm/1500rpm,150%overload General Interpretationa)Constant Torque applicati
49、on,Constant Power above base speedb)Requirement is to deliver at base speedc)Generally the required torque below base speed is samed)Specified overload of 150%is required at all speed points,Winder BasicsDimensioning-Load Requirement,Graphical Interpretation of the specified Load30KW,800 rpm/1500 rp
50、m 150%overload,Constant TQ,TQ requirement proportional to,Winder BasicsDimensioning-Load Requirement,To optimize the Winder it is important to know other information Process ParametersTension ranges-Stall tension and Taper Tensions rangeDiameter Ratios for specified materialsPeripheral speed-Crawl/t
