Subject to change without prior notice

Order No.: E20001-Y360-P620-X-7600

Dispostelle 06372
SCH/28126 GD.MC.20.TEXT.59.0.01 MP
09101.0
Printed in Germany
Siemens AG 2010
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 31 80
91050 ERLANGEN
GERMANY
The information provided in this brochure contains merely
general descriptions or characteristics of performance
which in actual case of use do not always apply as described
or which may change as a result of further development
of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract.

All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use by
third parties for their own purposes could violate the rights
of the owners.
www.siemens.com/textile
Integrated and modular solutions for textile machines provide
highest productivity across the entire production process.
Answers for industry.
How do you achieve highest
reliability and cost effectiveness,
even in the smallest fiber?
Solutions for textile machines
for highest reliability and cost effectiveness
Whether textile machines for natural or man-made fibers are concerned,
or for their refining: The industry is facing new challenges every day. Short-lived
trends, fierce competition and enormous cost pressure are all making demands.

The integrated and modular automation and drives solutions from Siemens can
help you stay ahead. For we provide the flexibility you need in times of short-
lived trends.

Our innovative products and systems, along with plant-wide applications and
solutions for the entire textile production process, ensure high productivity and
efficiency right down to the smallest fiber.
siemens.com/textile
Perfect textile finishing
solutions in record time
Finishing Toolbox: Solutions for finishing
continuous material webs
Solutions for Textiles
2
Tailor-made solutions for textile
finishing with minimum effort:
the Finishing Toolbox
The textile industry is increasingly facing the challenges posed by rising production rates,
maximum availability, high flexibility, optimum product quality and minimum lifecycle costs.
In parallel industry specific technologies are placing ever increasing demands on the automa-
tion. Therefore, concepts with which you as a machine builder in the textile industry can con-
tinuously optimize the productivity of your solutions are in demand.
3
Totally convincing: the comprehensive portfolio from
Siemens.
As a system supplier, we address the complete range of
machines for finishing continuous material webs, with
our portfolio for automation and drives technology. As a
machine builder, you can depend on the latest state-of-
the-art technology, customized functions and outstanding
quality with our products, systems and services. For
instance, our mechatronically optimized machine con-
cepts ensure a high degree of flexibility, increase the cycle
rates, shorten changeover times and reduce maintenance
costs. Advantages that pay-off day in, day out.
Typical applications for our solutions:
Classic textile finishing: washing, bleaching, merceriz-
ing, dyeing, drying
Textile printing
Calendering
Heat-setting
Thermo bonding
Coating and laminating of non-woven materials and
technical textiles
Adhesive application
Powder coating
Impregnating viscose, glass and carbon fibres
and many more
Outstanding: the SINAMICS DCC Finishing Toolbox
The Finishing Toolbox a standard library of SINAMICS
DCC application blocks that can run on the SINAMICS
S120 motion control drive system and that have been spe-
cially created for you. This means that you can profit from
fully functional solutions and tested know-how perfectly
documented and tested in advance.
The Finishing Toolbox significantly simplifies material web
finishing applications - allowing for more margins when it
comes to pricing and deadlines. It includes open, para-
meterizable blocks, which optionally can be combined
with the SINAMICS S120 Safety Integrated functions.
With these pre-configured functions and applications you
can realize perfectly tailor-made solutions in the shortest
time.
SINAMICS DCC
Finishing Toolbox
4
Getting there faster with the
Finishing Toolbox applications
SINAMICS DCC Electronic Gearbox
The SINAMICS DCC Electronic Gearbox
application is used to realize angular syn-
chronous gearing with freely selectable
ratio between several axes. It can be used
universally for continuous material webs.
With the SINAMICS DCC Electronic Gear-
box application, two or more axes can be
operated with precise angular synchro-
nism without requiring a mechanical
coupling.
SINAMICS DCC Separate Chain
The SINAMICS DCC Separate Chain appli-
cation was specifically created for the
control of transport chain drives in
stenter frames. In this application two
chains guide the material web in angular
synchronism through the machine to
achieve precise alignment of the material
web at thread level.
This application is suitable for continuous
material fabric and non-woven material
webs as well as for fibres and yarn.
General properties:
A real or virtual master can be used
Gear ratio can be input as a rational
number
Integrated runtime correction
This application is based on the SINAMICS
DCC Electronic Gearbox, and enables
angular synchronous gearing between
two endlessly rotating rotary axes with a
fixed ratio of 1. During synchronous
operation a relative offset between the
synchronous axes can be set.
Graphic programming with SINAMICS Drive Control
Chart (SINAMICS DCC) in the SINAMICS S120 drive
system allows the drive functionality to be adapted to
specific machine configurations and technology-specific
features to be added. With its Finishing Toolbox,
Siemens offers a library with tried-and-tested blocks
specifically for applications in the textile industry with
which individual automation solutions can be quickly
and reliably created.
SINAMICS DCC and the Finishing Toolbox offer you the
following advantages:
Quick and reliable implementation of automation and
drive solutions using pre-configured and tested
parameterizable blocks
Adaptation to individual requirements as blocks can
be freely combined to supplement or modify your own
application-specific blocks
Blocks with machine builder specific know-how can be
protected
5
SINAMICS DCC Line Tension Control
The SINAMICS DCC Line Tension Control
application was developed to create a
flexible, parameterizable solution for
tension or dancer roll based control tasks
with SINAMICS S120 as a higher-level
controller. It is suitable for web-type
materials in the textile industry.
To set the required material tension
and/or to ensure correct material trans-
port through the machine, the standard
SINAMICS DCC Line Tension Control
application includes various closed and
open-loop control modes:
Tension control using torque limiting
Tension control using speed adaptation
Dancer roll position control using speed
adaptation
SINAMICS DCC Setpoint Cascade
The SINAMICS DCC Setpoint Cascade
application allows a velocity cascade to
be calculated in the drive. This is de-
signed for larger production lines invol-
ving a minimum of eight drives.
The setpoint cascade application com-
prises of system ramp-function generator
and setpoint cascade function blocks. The
system ramp-function generator operates
as a central ramp-function generator for
the complete production line and is cou-
pled to the higher-level controller.
Open-loop control mode:
Indirect tension control (tension
pre-control) using a torque limit
Draw control (ratio between speeds)
Additional functions:
Torque pre-control (tension, friction,
acceleration)
Line operation, without closed-loop
control
Typically the components involved in the
closed-loop control are part of a larger
system/machine, which may include
several tension zones and also winders.
Communication to the PLC can be
realized via PROFIBUS or PROFINET. To
control the overall cascade a separate
setpoint cascade is used for each drive.
Function overview:
Group setpoint
Supplementary setpoint for catching up
or closed-loop dancer roll control
Individual operation
SINAMICS DCC Harmonic Wave
Compensation
The SINAMICS DCC Harmonic Wave
Compensation application can be used to
counteract harmonics. The advantages:
relieves the speed controller and reduces
speed ripple.
Application features:
Can be flexibly adapted for a particular
machine
Independent compensation of up to
three sinusoidal, periodic torque
harmonics
6
SINAMICS DCC Winder:
Solution for winder applications
The SINAMICS DCC Winder application is
directly implemented in the drive and
addresses a wide range of winder appli-
cations with one single application soft-
ware package. As a result of its openness,
the application can be configured or if
necessary modified as required. The
application allows a winder or unwinder
to be implemented for the widest range
of applications also in textile machines.
Machine builders can optimally incorpo-
rate their existing know-how and profit
from the fact that the look & feel is simi-
lar to that of a function chart.
SINAMICS DCC Load Sharing Control
Coupled axes are used in a large number
of machines. The coupling can either be
rigid (direct) or flexible (through the
material web itself). In such cases the
load must be distributed between the
coupled drives.
The SINAMICS DCC Load Sharing appli-
cation offers the following features:
The following winder functions are
available:
Closed-loop control mode: closed-loop
dancer roll position control with speed
correction, closed-loop tension control
with torque limiting, closed-loop ten-
sion control with speed correction and
open-loop torque control (indirect
closed-loop tension control)
Integrated diameter calculation using
the ratio between the material web
velocity and winder speed
Optional: tension reduction for winders
(winding hardness characteristic)
Torque pre-control (tension, moment of
inertia compensation, friction)
Torque de-coupling
Overcontrol and torque limiting
Droop and compensation
Advantages of a correctly adjusted
load distribution:
Energy efficiency
Less heat is generated
7
Complete portfolio from a single source
As your partner, we can offer you all of the
components that you need to realize first-
class solutions for finishing continuous
material webs:
SIMATIC S7-300: This modular controller
is the optimum solution for applications in
central and distributed topologies. In addi-
tion to standard automation functions,
safety technology and motion control can
also be integrated.
SIMATIC HMI: The globally-leading,
complete and seamless range of products
and systems for all tasks involving opera-
tor control and monitoring.
SINAMICS S120: This modular drive
system is the first choice for high-perfor-
mance motion control applications in
industrial machine building and plant
construction.
Value-added for machine and plant
Powerful and high-performance motors
for motion control applications:
From our extensive motor portfolio, you
can select the optimum motor that is pre-
cisely matched to the SINAMICS S120 drive
system for your application. Especially our
1LE1 induction motors, MOTOX geared
motors and 1FK7 servomotors have admi-
rably proven themselves in textile machine
applications.
In addition to their outstanding properties
and their perfect interaction, our compo-
nents set themselves apart through the
consequential use of well-proven commu-
nication standards such as PROFIBUS and
PROFINET.
Whether talking about productivity, flexibility, costs, safety or shorter times to
market: our comprehensive portfolio can play a decisive role for you in setting new
standards with your solutions and so helping you to sustainably improve your
competitiveness. Our portfolio precisely addresses the issues that allow you
to fulfill the continuously increasing challenges in your industry.
MOTOX geared motors
SIMATIC HMI
SIMATIC S7-300
SINAMICS S120
1FK7 servomotors
1LE1 induction motors
SINAMICS S120 with
Safety Integrated
functions
SIMATIC HMI
SIMATIC
S7-300
SINAMICS DCC
Finishing Toolbox
Servomotors
PROFIBUS/PROFINET with PROFIsafe
Induction motors
Additional information:
www.siemens.com/textile
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 3180
91050 ERLANGEN
GERMANY
Subject to change without prior notice 09/11
Order No.: E20001-A1500-P620-X-7600
Dispo 06372
SCH/34634 B2TX.52.1.04 WS 09112.0
Printed in Germany
Siemens AG 2011
The information provided in this brochure contains merely
general descriptions or characteristics of performance which
in case of actual use do not always apply as described or which
may change as a result of further development of the products.
An obligation to provide the respective characteristics shall only
exist if expressly agreed in the terms of contract.

All product designations may be trademarks or product names
of Siemens AG or supplier companies whose use by third
parties for their own purposes could violate the rights of the
owners.
siemens.com/textile
Reference, Marzoli S.p.A.
Automation for the leader in innovation
Strategic partnership for developing textile machines in-line with the market
Everything but hand-knitted: Marzoli the textile machine specialist securing its power of innovation
by entering a long-term partnership with Siemens automation technology.
Marzoli based in Brescia, Italy has been manufactur-
ing textile machines since 1851. Its strength lies in its
portfolio of machines and systems that covers the
complete spinning production process. The companys
port folio extends from machines for processing cotton,
man-made and composite fibers from bale breakers to
carding lines, drawframes, flyers and the manufacturing
of yarn using a ring-spinning process.
Strategic partnership creates security
Its many years of experience, in-depth industry know-
how, high level of technological competence and flexible
manufacturing system allow Marzoli to respond to market
demands with a high degree of innovation. To secure this
position Marzoli has been working closely with Siemens
for many years in the field of automation and drive tech-
nology. Their complete portfolio of machines has been
equipped with SIMOTION and SINAMICS to achieve the
highest degree of homogeneity in the different machine
series.
Efficient drive technology
The modular, scalable structure of the SINAMICS S120
family of drives and the enormous flexibility of SIMOTION
controllers significantly simplify and rationalize the
development of various machine types. For instance,
machines can essentially inherit the hardware and soft-
ware engineering that has been implemented in other
machines.
The multi-axis technology of the SINAMICS S120 family
allows the control cabinet design to be optimized: the
space required is minimized, cabling and electro-
mechanical components are reduced.
Rugged and durable
The configuration of motor modules connected to a
common DC bus and fed by an Active Line Module
guarantees a high degree of reliability and ruggedness,
even if the quality of the line supply is poor. This feature
is of special significance for flyers and spinning frames.
Until now voltage dips or power failures could cause all of
the yarns to break resulting in significant production
downtimes.
The SINAMICS drive modules with Cold Plate technology
dissipate the power loss using an external heat sink via
the thermal interface at the rear of the unit. This techno-
logy avoids the risk of the power unit overheating, which
can occur in environments heavily laden with fluff.
The information provided in this brochure contains merely
general descriptions or characteristics of performance which
in case of actual use do not always apply as described or
which may change as a result of further development of the
products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract.
All product designations may be trademarks or product names
of Siemens AG or supplier companies whose use by third
parties for their own purposes could violate the rights of the
owners.
Subject to change without prior notice
Order No.: E20001-A1510-P620-X-7600
DISPO 06372
SCH/36072 B2TX.52.1.06 SB 09111.0
Printed in Germany
Siemens AG 2011
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 31 80
91050 ERLANGEN
GERMANY
Recipe for success: Flexibility through standardization
Integration makes the difference
The principle of integration employed by the multi-axis
system SINAMICS S120 allows all of the drive param eters
to be saved on one compct flash card, therefore signifi-
cantly simplifying the commissioning of serial machines.
The system also proves itself in operation: The Control
Unit recognizes if a module is defective and the spare
part is automatically integrated without having to
recommission the drive. Using the standard STARTER
software tool, it is also possible to engineer all of the
converters and servo drives of the SINAMICS family. The
diagnostic tools available in STARTER allow the dynamic
behavior of the drive components to be analyzed in
detail.
As a result of the extensive options for setting the control
parameters in the drive the Marzoli application engineers
can implement in creased levels of machine performance
without overstressing the mechanical system. The
mechanical transmission elements are specially protected
as the torques of the individual motors in the coupled
drive train can be flexibly distributed. The fact that the
components are fully integrated via a fieldbus allows a
whole series of internal drive parameters to be displayed
at the operator interface where they can be easily moni-
tored.
Consequentially, maintenance technicians can simply call
up useful information for monitoring the condition of the
machine. Using the operator interface (MP 277) and
communication with the Marzoli supervisory system via
Ethernet, operators can simply adapt the process parame-
ters to the particular yarn.
Energy-saving is a must
A large family of reliable motors power the Marzoli
machines, starting with 1FK7 servomotors for dynamic
axes up to 1LG and 1LE induction motors for higher
power ranges.
Marzoli has made a fundamental decision to use IE2
motors with increased efficiency according to the latest
European energy-saving standard for all of their
machines. The use of induction motors with increased
efficiency in conjunction with the SINAMICS Active Line
Module infeed units (with active front-end technology)
clearly demonstrates that Marzoli is convinced that energy-
saving and innovation go hand in hand. According to the
companys philosophy of standardization, SINAMICS S120
Motor Modules are used for all of the machine types.
With a few components and a minimum stock of spare
parts it is possible to cover the complete range of drives
installed in the system. In conjunction with the global
presence of Siemens, it is ensured that maintenance costs
and system down times can be reduced across the board.
More than just a supplier relationship
In its partnership with Siemens, Marzoli has found a sin-
gle supplier for the complete automation of its machines
and systems one single partner for the quality, the inte-
gration and the after sales support provided through the
global Siemens service centers.
In close cooperation, the common objectives are pursued
in an open spirit of partnership which in turn gu ar antees
a continuous improvement process. Starting with the
technical optimization of the solutions, which are used
for the complete range of machines, up to the joint logis-
tical control of supplied machines, both partners work
hand in hand to create optimum solutions to address the
current challenges of the spinning frame industry.
A trusting partnership bonds Marzoli and Siemens.
In their cooperation, their individual core competen-
cies are optimally applied, which in turn secures the
ongoing technological development of Marzoli
machines and systems.
siemens.com/textile
RWTH Aachen University, Institute for Textile Technology
Flexible harness control
on a loom
Development of a test stand to optimize
the heddle/harness system
The Institute for Textile Technology of the renowned
RWTH Aachen is a recognized partner to the textile
machinery construction sector. At RWTH, a harness test
stand was developed in order to analyze and optimize the
interaction of the heddle/ harness system for the weav-
ing process. The special challenge: Harness motion was
to be able to be flexibly varied. For the electrical equip-
ment to move the harnesses, RWTH Aachen completely
used Siemens components. Siemens not only supplied the
automation, but also supported RWTH when designing the
drives, commissioning the test stand and the mechatronic
optimization.
Technological task
The heddle/harness system is used to form the shed in
the weaving process. A vertical play between the heddles
and the carrier rail of the harness is absolutely necessary
and is used among other things to thread the yarn, rectify
yarn breaks and compensate for tolerances in the high-
speed weaving process. However, this play must be pre-
cisely dimensioned. Otherwise, this will result in rougher
yarn, diminished weaving quality, negative effects on
machine operation and increased energy usage. In order
to improve the heddle/harness system, the interaction
of the heddle play had to be analyzed. To achieve this,
the Institute for Textile Technology of RWTH developed
a measuring system, which acquires the relative motion
of the heddles in the harness frame during high-speed
operation. In parallel to this, a test stand was designed
which allows the influencing parameters to be varied and
simultaneously utilized in actual operation. This test stand
was developed in close cooperation with
Siemens.
Test stand to vary parameters
To start, a requirement profile for the test
stand was developed and sub-divided
into mandatory, reference and can crite-
ria. The must criteria included the follow-
ing: the static and dynamic relationships
at the machine were to be emulated as
close as possible to those in practice at
realistic machine speeds of up to 1000
rpm and different motion profiles had to
be emulated (with/without rest phase).
After evaluating different methods, the
components for the measuring system
shown in Fig. 1 were selected. In addi-
tion, the noise was determined according
to the envelope technique. The complete
sensor system can be used in industrial
weaving machines and can therefore be
used in weaving mills. The team then
drafted various test stand concepts and
mirrored the requirements that had been
drawn-up against these. The concept in-
volving an industrial weaving machine
with modified shedding formation device
was finally selected, which guaranteed
the best possible reference to practice.
The weaving machine equipped with
single-motor drives to move the harness
is shown in Fig. 2. This design allowed
the harness motion profile to be widely
varied: e.g. a sinusoidal motion and mo-
tion with a rest phase (see Fig. 3).
Using this test stand and the measuring
system, it was possible to analyze how
the various parameters, e.g. machine
speed, motion profile, warp tension level
and harness type affect the relative mo-
tion of the heddles in the harness frame,
the noise generated as well as the wear
and the weave quality.
Drive equipment to move the
harnesses
The automation configuration for the test
stand is shown in Fig. 4. It comprises four
servo motors and the drive system to
control the motors. The test stand is op-
erated using the SIMOTION Scout

engi-
neering system. An operator panel is not
required. All of the drive components are
connected through DRIVE-CLiQ

, the uni-
form, digital interface system.
Highest dynamic performance required
In order to achieve the specified machine
speeds of 1000 rpm, the harnesses must
be accelerated at an extremely high rate.
This is the reason that RWTH used 1FK7
HD (High-Dynamic) permanent-magnet
synchronous motors to move the har-
nesses. These motors set themselves
apart as they have a very low intrinsic
moment of inertia and 300% overload ca-
pability. Further, two motors are coupled
to one shaft for each harness (see Fig. 2).
With the same total torque, the motors
have a lower moment of inertia than a
correspondingly larger single motor for
each harness. A motor follows the torque
of the coupled motor. The torques can
be generated in absolute time synchro-
nism as a result of the connection
through the digital DRIVE-CLiQ interface
system.
The test stand requires a total of four mo-
tors. These are controlled from two dou-
ble motor modules from the SINAMICS
S120 drive system. These motors are con-
nected to a common DC link fed from a
Base Line Module. The motors can ex-
change energy through the DC bus. As a
consequence, the energy that is released
when a motor brakes can be used by an-
other motor to accelerate.
Motion control using cams connected
in series
SIMOTION D from Siemens is used to con-
trol the drive to implement the motion
profile that is required. The module is di-
rectly integrated into the drive line-up.
SIMOTION also executes the PLC func-
tions, which means that a separate, pro-
grammable logic controller is not re-
quired. What is especially worth
mentioning is the fact that SIMOTION
provides a wide range of motion control
and technology functions, including a
cam function. For the test stand, the mo-
tion of the harnesses is derived from a
virtual master axis - and implemented in
a user-friendly fashion using two elec-
tronic cams connected in series
(see Fig. 5).
Fig. 1: Measuring components at the heddle play test stand Fig. 2: Motors mounted on the test stand
High-speed camera
Lighting
Harness stroke sensor
Warp
tension sensor
Sound
measurement
To start, the relationship between the
machine angle of the loom and the har-
ness position (height in millimeter) is de-
fined. The associated angular position of
the eccentric (in degrees) is then mapped
at the gear unit output. Contrary to their
mechanical peers, electronic cams can be
quickly replaced and their cam shape can
be configured as required. As a conse-
quence, harness motion can be specified
intuitively in a user-friendly fashion and
the motion function of the harnesses can
be varied over wide ranges. This is abso-
lutely necessary in order to investigate
the influencing parameters; however,
this is either not possible or only possible
with some restrictions at a conventional
series loom.
Test support using user-friendly
diagnostic options
The SIMOTION Scout engineering system
combines the functions to parameterize,
program, diagnose and document the au-
tomation under one user interface. As a
consequence, Scout is not only used to
dimension the drives, for commissioning
and to enter different motion profiles,
but is also used to operate the test stand.
During the various investigations, the
trace function turned out to be especially
useful. Using this trace function, internal
and external parameters for example
setpoint and actual speed and torque val-
ues - can be recorded in real time, ar-
chived and exported to other programs.
Interaction between technology and
automation know-how
As a partner to the textile machine
sector, Siemens also gets deeply involved
when it comes to innovative topics at
an early stage. Within the scope of this
project, drive and automation solutions
from Siemens were convincing from
many perspectives:
It was clearly shown: The product port-
folio from Siemens fulfills the require-
ments of the textile sector - in a com-
prehensive and efficient fashion.
The automation task was able to be
completely realized using standard
components. When compared to cus-
tomized solutions, they offer advantag-
es due to the fact that spare parts are
available worldwide and cost efficiency
as existing platforms can be used..
Fig. 5: Electronic cams connected in series to implement harness motion
Fig. 4: Automation configuration for harness motion
Fig. 3: Examples of possible motion functions of the harnesses at the test stand
Machine
angle
Harness position Eccentric
position
Cam 1 Cam 2
DRIVE-CLiQ
SIMOTION
SCOUT Engineering
HMI
Configuring
Control
Parameterization
Programming
Commissioning,
diagnostics
Communication
Configuration
Drive
Commissioning
Harness 2 Harness 1
SINAMICS S120
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Machine angle ()
Sinusoidal motion profile
Motion profile with rest phase
0 90 180 270 360 450 540 630 720
Subject to change without prior notice
Order No.: E20001-A1150-P620-X-7600
Dispo 06372
Sch/34628 GD.MC.PM.B2TX.52.1.05
SB 08111.0
Printed in Germany
Siemens AG 2011
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 3180
91050 ERLANGEN
GERMANY
The information provided in this brochure contains merely
general descriptions or performance characteristics which in
case of actual use do not always apply as described or which
may change as a result of further development of the prod-
ucts. An obligation to provide the respective characteristics
shall only exist if expressly agreed in the terms of contract.

All product designations could be trademarks or product
names of Siemens AG or other companies, which, if used by
third parties, could infringe the rights of their owners.
Drive generation
change
Textile
www.siemens.com/textile
Totally Integrated Automation in impregnation
systems for technical fibers with SINAMICS
For years now, Benninger Zell has been
depending on Totally Integrated Auto-
mation for its impregnation systems for
tire cord and other technical fibers. The
global market leader has now complet-
ed the change to the latest generation
of drives the SINAMICS S120. The
machine manufacturer as well as the
end-users both profit to the same
extent. At the beginning, various
manufacturers of transport belts
became involved with the mining
industry in the US and China as well as
with the manufacturer of cord fibers
for the tire industry. The conveyor belts
used in mining are used to transport
earth, ores and coal often along
stretches of several hundred kilome-
ters. The width of new transport belt
conveying systems has been increased
from 1.6 up to 3.2 m; this places high
demands on the drive system and the
design of the belts. The core of the
textile fiber must bear the majority of
the forces that occur.
The advantage of textile-based
conveyor belts:
if they break, they can be more simply
spliced than steel-armored versions.
This has led to a certain end-user
preference and in turn, to a whole
series of orders that Benninger Zell has
in-house.
Stability to the power of three
An absolute must for the consistently
high quality of the impregnation and
the success recipe for this company
belonging to the Swiss Benninger AG
is the absolute constant tensions,
temperatures and times during impreg-
nation. This secures the optimum ad-
hesion of the rubber or plastic coatings
that are subsequently applied to the
material even under extreme loads
and continuous bending cycles. For
years, Benninger Zell achieved this
demanded stability especially in the
continuously running center section of
its systems using control and drive
technology from Siemens.
A redundant PC system enters the set-
points, which communicates with the
SIMATIC S7-400 system control via
Ethernet. Several tension units with
driven roll pairs are connected to the
SIMATIC PLC control via Profibus. These
roll pairs are precisely coordinated with
one another, therefore guaranteeing
that the continuous material web is
precisely stretched or that is to say
constant tensions and bumpless
changeover between stretching and
tension. According to Benninger Zell,
the speed of the drives must be con-
trolled with an extremely high
precision and a synchronous operation
tolerance of 0.1% continuously main-
tained. As a consequence, the company
critically views any potential change to
a proven, running system.
Benninger Zell GmbH, Germany
The drive concept of the Benninger Zell system with SINAMICS converters
www.siemens.com/textile
New drive generation with advantages:
Having said that, Benninger Zell wants to
sustainably secure its leading position in
the market and of course innovation
represents the best way of achieving this.
This is the reason that the company has
now brought its drive solutions up to the
latest state-of-the-art technology. It is
called SINAMICS S120 and still has the
high closed-loop control quality of
MASTERDRIVES its predecessor. The
SINAMICS family is seamlessly integrated
into the well-proven SIMATIC STEP 7 sys-
tem platform; this means the maximum
degree of seamless integration in the
configuring/programming as well as the
communication and data management
between the control, HMI and drive lev-
els. And as a consequence, significantly
simplifies a lot of work from engineer-
ing up to (remote) diagnostics. Benninger
Zell has consequentially used the modul-
arity and scalability of the new SINAMICS
system and has developed a drive con-
cept that is also applicable for future sys-
tems as it is simple to transfer and adapt.
In this case, a SINAMICS CU320 Control
Unit is used for the motors for the un-
winder, process section and winder plant
areas respectively. The digital system in-
terface DRIVE-CLiQ connects the associat-
ed components with one another and
eliminates all of the signal transmission
problems that used to sporadically occur
for cable lengths of over 100 m. The ma-
chine manufacturer also sees an addit-
ional advantage in the fact that the inter-
action between the SINAMICS converter
and the standard Siemens induction
motors is intensively checked to ensure
that it functions perfectly in the field.
This is an additional detail that shortens
the time to market as well as the com-
missioning of a system. The drive line-up
of a typical impregnation system for
transport conveyor belts includes nine
single-motor drives (DC/AC) with power-
ratings of up to 30 kW for the material
web transport, six auxiliary drives
(DC/AC) as well as six fan drives (AC/AC).
Also part of the system are 18 smaller
MICROMASTER 440 units to power the
motors for the lateral guides controlled
via the SIMATIC ET 200.
Subject to change without prior notice
Order No.: E20001-A1130-P620-X-7600
Dispo 06372
SCH/10809304 B2TX.52.1.03 SB 04111.0
Printed in Germany
Siemens AG 2011
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 3180
91050 ERLANGEN
GERMANY
Saves space, costs and effort
The modular system design with its
autonomous control modules (Control
Units) and power units (Motor Modules)
in a compact booksize format saves space
in the control cabinet so that in the
future, smaller standard control cabinets
can be used which of course, are more
favorably priced. The common DC busbar
also means that disconnectors, fuses and
copper busbars can be eliminated, there-
fore significantly reducing the installation
and wiring costs. The parameter assign-
ment of the motor modules used in the
system (available for one or two
motors) is saved on the compact flash
memory card in the Control Unit. This
means that it is immediately available
when service is required. This keeps
downtimes short and the productivity
of these systems which basically run
around the clock at the highest level.
Not only this, but with the changeover to
the new generation, Benninger Zell has
again secured the long-term availability
of spare parts, which for system lifetimes
of up to 30 years is an advantage for
future customers that should certainly
not be underestimated. As a well known
brand, many users prefer Siemens as they
know they can offer spare parts and
support around the globe. The change-
over to the new drive standard in the
impregnation systems of Benninger Zell
went smoothly during their day-to-day
business without any problems of note.
Siemens drive specialists supported
Benningers inhouse team for two days
during the hot phase while the system
was being commissioned.
The information provided in this brochure contains merely
general descriptions or characteristics of performance
which in case of actual use do not always apply as described
or which may change as a result of further development
of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract. All product designations may be
trademarks or product names of Siemens AG or supplier
companies whose use by third parties for their own
purposes could violate the rights of the owners.
www.siemens.com/textile
Textile
The machine experts from Klagenfurt, Austria,
achieve perfectly harmonized motor speeds for
their coating machines using SINAMICS.
SINAMICS
J. Zimmer Maschinenbau GmbH with Siemens on the winners side
For 134 years, the name Zimmer
stands for high-tech textile ma-
chines. Today, this company has
approximately 340 employees in
its two factories: 140 of these
employees develop and produce
digital printing machines in the
Kufstein factory the other 200
are mainly engaged in rotary screen
printing and coating machines in
the Klagenfurt facility. The person-
nel in Klagenfurt have specialized
on magnoroll machines that are
based on a magnet-roll system used
in screen printing and coating
technology that the company has
developed. Product Manager Gert
Scheriau reported that recently,
customers have been increasingly
demanding that complete plants
and systems are supplied: As a
consequence, for three or four years
now, we have been more actively
engaged in plant and system
construction. This meant a transi -
tion for us at the beginning, be -
cause as a machine construction
facility, we produce as many parts
as possible in our own company
on one hand, to keep delivery times
short, and on the other hand, to be
able to guarantee quality through
our own production. We purchase
parts and components where it
doesnt make sense for us to manu -
facture them ourselves. This is the




reason that for our coating ma-
chines and dryers, we can assume
a vertical range of manufacture of
70%. In doing so, the modular
design is a main issue. Modules
for four different widths from
500 mm up to about 6,000 mm
form the grid basis for all the
systems that we can supply.
Rotary printing machine
for non-woven materials
A rotary printing machine for non-
woven materials was recently
shipped from our Klagenfurt plant
to the Freudenberg Company based
in the US, a daughter company of
the large German company having
the same name. The machine with
a working width of 2,200 mm pro-
duces non-woven materials at a
rate of up to 50 meters per minute.
After the unwinding equipment, the
non-woven material passes through
the following stations: a splice table
to automatically establish a thermal
connection with the next roll, a
viewing table for the first optical
check, a metal detector to track
needles that may have remained
in the material after production on
the needle loom and a subsequent
buffer zone. This is then followed
by a cleaning machine before the
material passes through a material




the other hand, in plant construction
worldwide, it can be clearly seen that if
you work with Siemens, then you are cer-
tainly on the winners side. It is all about
service, availability, and subsequent
support. In the case of the large coating
system for Freudenberg, the partnership
with Siemens went far beyond the nor-
mal customer support on a partnership
basis: Siemens gave us a level of on-site
support that was quite exceptional. Our
electrical technicians and Siemens ex-
perts met at least once or twice a week.
The next project phase was discussed,
every participant was allocated his speci-
fic tasks and then the next week, the
results were combined and incorporated
in the program. This also meant that we
could use this contract to simultaneously
train our personnel.
Intelligent SINAMICS drive technology
Martin Hafner, Drive Technology Consult -
ant and Siemens expert on site, provided
the technical details: The drive system
itself is a SINAMICS S120 multi-axis
system that controls 14 drives. The con-
nection is realized through PROFIBUS.
The multi-axis system uses four coordi -
nat ed CU320 control units that control
several drives. These units are logically
structured: The first unit handles the un-
winder, the closed-loop dancer control
and the material buffer. The next unit
controls the four drives of the magnoroll.
What is especially important in this case
is that the rotary screens must move in
angular synchronism to the magnet roll.
The third unit controls the feeding
system, fan and upper or lower belt of
the mechanisms in the dryer and the
fourth is responsible for the two drives in
the J-Box and the winder. The intelligent
drive system controls the angular syn-
chronism, which ensures that the angle
of the rolls with respect to one another
and the peripheral velocities of the rolls,
which are in contact with the material
web, always remain the same. Further,
the drive controls the complete winding

and unwinding functions as well as
the closed-loop dancer roll control.
These types of functions can be easily
pro gramm ed in the drive using DCC
(Drive Control Chart). The PLC, a
SIMATIC S7/317 F, only outputs the
setpoint, the drives orientate themselves
to the magnet roll. All of the drives are
equipped with safety functions. In the
case of an emergency stop, the system
must come to a standstill within two
seconds. This emergency stop can either
be manually initiated or using integrated
repeater rolls and pressure sensors. This
sophisticated safety system was especial-
ly important for the US client. When as-
ked about installing the system in the US,
Scheriau, the Product Manager, respond-
ed by saying that commissioning will be
performed together with the personnel
who will later be the machine operators.
And added: If things do get a little diffi-
cult, then we can also contact Siemens
locally perfect support and cooperation
will certainly be available from there.
The information provided in this brochure contains merely
general descriptions or characteristics of performance
which in actual case of use do not always apply as described
or which may change as a result of further development
of the products. An obligation to provide the respective
characteristics shall only exist if expressly agreed in the
terms of contract.
All product designations may be trademarks or product
names of Siemens AG or supplier companies whose use
by third parties for their own purposes could violate the
rights of the owners.
guide device, which optimally positions
the material before the actual printing
process. The main machine in this plant
is our magnoroll printing machine,
explained Product Manager Scheriau.
There are two magnet systems inside
the printing cylinder that are used to
operate two rotary screens. This means
that two-color coatings can be realized
in just one operation this is a unique
feature that other manufacturers do not
have. The material then passes through
our drying system, which is at a temper -
ature between 160 and 180 degrees,
and in this particular case is over
36 meters long. This is where the
printing ink is dried and fixed.
From unwind to wind
Just like other non-woven products, this
type of felt is extremely sensitive to ex-
pansion when it is warm. This is the
reason that after drying, it is cooled
down in a controlled fashion in a cold-air
cooling duct. It then reaches the so-called
J-Box. If a bale is changed while the
finished product is being rolled, then the
material is first buffered in this box until
a new product has been fed and rolling
can continue with the edges correctly
aligned. Our scope of supply extends
from the unwind operation up to the
wind operation and therefore naturally
includes all control cabinets as well as
washing equipment for the printing
screens. From what has already been
stated, it is clear that all of the various
roll mechanisms of the plant must be
precisely controlled so that they perfectly
interact with one another, explained
Scheriau about the essential features
of the process.
Successful cooperation with Siemens
When all is said and done, customers
also have their say when selecting
suppliers. We are more than willing to
accept this as long as customers dont
start to specify no-name products. On

Subject to change without prior notice
Order No.: E20001-A970-P620-X-7600
Dispo 06372
SCH/10809304 GD.MC.20.TEXT.52.0.06 SB
10101.0
Printed in Germany
Siemens AG 2010
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 31 80
91050 Erlangen
GERMANY
www.siemens.com/textile
The advantages for Cordenka
Increased production capacity
through a higher degree of flexibility
and plant availability
Simplified maintenance
Integrated solution from Siemens
The control and drive technology were
designed in close cooperation with
Cor denka in the Summer of 2004. The
innovated machines had to fulfill four
criteria: Single-motor drives, line failure
buffering, simple operator control and
preparation for a central machine
visualization. The machine was
mechanically overhauled and the drive
technology modernized using single-
motor drives. The objective was to
increase the production capacity
through a higher degree of flexibility
and plant availability, improve the
quality and create a basis for future
technological developments in the
form of single-motor drives and
automated production operations.
Rayon is a material that is obtained from cellulose and is used to reinforce
high-performance tires. As a result of its advantageous characteristics, it is
the preferred reinforcing material for tires that have emergency running
properties.
Cordenka in Obernburg, one of the leading manufacturers of high strength
textile fibers, wanted to further expand its production capacity and mod-
ernize its machines to reflect the latest state-of-the-art technology.
To retrofit its spinning machines, which up until now used products from
various manufacturers, Cordenka used a complete electrical solution from
Siemens.
Textile
www.siemens.com/textile
Retrofit for a higher
production capacity
Cordenka GmbH, Germany
Using a complete solution from Siemens, spinning
machines for tire cord were brought up to speed to
reflect the latest state-of-the-art technology
Reliable in a tough environment
The machine spins tire cord-viscose
fibers from cellulose dissolved in a
sulfuric acid spinning bath and winds
them for further processing. The
aggressive ambient air has a high
concentration of hydrogen sulfide that
places high demands on the electrical
equipment. Special protective mea-
sures were applied to the converters,
contacts and metals to secure their
reliability and to increase their resis-
tance to corrosive gases.
Innovative technology cocktail
In the first four machines, our experts
replaced the central gearbox with line
shaft using a controlled MASTERDRIVES
VC Compact Plus and Active Front End
(AFE) infeed. The SIMATIC S7-300
control, the distributed ET200M I/O and
PROFIBUS completed the retrofit.
www.siemens.com/textile
Subject to change without prior notice
Order No.: E20001-A1140-P620-X-7600
Dispostelle 06372
SCH/29061 GD.MC.20.TEXT.52.0.03 SB 10101.0
Printed in Germany
Siemens AG 2010
Siemens AG
Industry Sector
Motion Control Systems
P.O. Box 3180
91050 ERLANGEN
GERMANY
The information in this brochure only provides a general
description and performance features. For a specific
application, this information will not always be applicable
in the form described here. This information can also
change due to ongoing product development. The required
performance features are only binding if they had been
expressly agreed upon in the form of a written contract. All
product designations could be trademarks or product names
of Siemens AG or other companies, which, if used by third
parties, could infringe the rights of their owners.
For the fifth machine, the new drive and
automation solution is an interaction
between the following components: the
SIMATIC S7-300 control with the OP17
operator stations and PROFIBUS DP as
well as the latest family of SINAMICS
S120 converters with coldplate technol-
ogy and Active Line Modules, which - op-
erating as infeed/regenerative feedback
units - ensure a higher degree of security
against failure.
The SINAMICS coldplate technology
directly dissipates the power loss and
therefore removes heat sources from the
control cabinet. Cordenka benefits from a
low temperature inside the cabinet - and
as a consequence from a longer service
life of the equipment in it.
Also included in the retrofit:
Maintenance-free SIEMOSYN synchro-
nous motors without encoder including
gearbox for the spinning pumps, godet
rolls, winding and traversing roll as well
as standard 1LA motors.
Future already integrated
A possible expansion to include a central
service station was also taken into
account in the concept. Siemens config-
ured the automation so that a central
machine visualization using an HMI
station - that will only be implemented in
a subsequent modernization step - is
already prepared.
Satisfied customer
Siemens received an order for the
complete management of the electrical
project - including the engineering,
commissioning and building the control
cabinet. Working very closely with
Cordenka, a complete solution was
drawn-up that was implemented by the
Siemens Application Center (APC) in
Erlangen. The complete modernization
project, including the development and
implementation of the integrated drive
and automation solution, was completed
on schedule.
Higher capacity, homogeneous quality
Extensive and careful planning facilitated
a straightforward changeover from
MASTERDRIVES VC to SINAMICS S120
Booksize drive units. The coldplate
technology proved itself to be a practical
supplement to the Siemens product
range.
An additional advantage of the retrofit:
By using individual drives for the various
functions, the number of mechanical
components - which are prone to wear
- was reduced, therefore increasing the
plant availability and simplifying mainte-
nance. The powerful drives increased the
production capacity by more than 10%,
improved the quality and increased the
overall flexibility of machine.
The new drives maintain the velocity
setpoints - generated using a setpoint
cascade - very precisely and reliably. As a
consequence, the quality of the end
product is more uniform and consistent.
In order to avoid material faults, the
Active Line Module infeed/regenerative
feedback units and kinetic buffering (KIP)
buffer brief line failures. Not only this,
they minimize line harmonics and EMC
load for the existing low-voltage supply.
As a result of the many advantages,
Cordenka is planning additional machines
based on innovative drive and automa-
tion technology from Siemens.
New: Equipment with motors for single
drives and operator station.
The control cabinet with converters is
located centrally on a platform.
Old: Equipment with central gearbox
and motor (cannot be seen) as well as
power distribution and operator station.