4: COMPENSATION TORQUE

The torque value as derived earlier is required to maintain the set tension in the sheet. In
addition to this value, there are two more components of the torque given by the motor. The total
torque required from the motor is given by
M* = Mz* + Mb* + Mf*
Where,
M* = Total torque required from the motor
Mz* = Tension torque required to maintain the required tension in the coil
Mb* = Acceleration compensation torque
Mf* = Friction compensation torque
The description of the compensation torque is given below,
a) Friction compensation torque
b) Acclration compensation torque
Friction compensation torque is required to compensate the frictional losses. Thus the Tension
torque is fully utilized to maintain the tension in the strip.
Acceleration compensation torque is given to compensate for the additional torque requirement
during acceleration so that the tension in the strip remains constant (= set value) during
acceleration. Acceleration compensation torque has two components. They are as follows
1) When the mill is under acceleration, the reels are also under acceleration. Thus some
torque is required to accelerate the reels so that there is no tension loss. Thus, when the
mill is under acceleration, the torque of the exit side motor should increase and the
torque of the entry side motor should decrease.
2) Even though the mill speed is constant, due to change in the diameter value, the reels
are always under acceleration. Thus some amount of torque is required for this
acceleration.
4.1 CALCULATION OF COMPENSATION TORQUE
a) Friction compensation torque
Friction compensation torque is constant. This figure is calculated during preliminary
checking of the reels. The graph of friction compensation torque Vs motor speed (rpm) is
given in annexure a.
b) Acceleration compensation torque:
Acceleration compensation torque depends upon the following parameters of the reel
1) Moment of inertia of the system
2) Gear ratio of the reel
3) Diameter of the coil
4) Strip width
5) Thickness of the strip
6) Density of the material
7) Mandrel diameter of the reel
8) Maximum line speed
9) Acceleration time (from zero to full speed)

To calculate the acceleration compensation torque, we first calculate three constants

k1, K2 and k3. We have the equations for these constants as

namely

k1 = Gd^2 * i / 2 * g
k2 = 3.1416 * Density / 16 * i * g
k3 = Dmin^4 * K2
Where,
Gd^2

= GD^2 value of the system in kg-m^2 [motor + break drum + gearbox + mandrel]
= (1394 kg-m^2)
i
= Gear ratio of the reel
(1.543)
g
= Acceleration due to gravity in m/sec^2 (9.81 m/sec^2)
Density = Density of the material in kg/m^3 [Steel in this case] (7850 kg/m^3)

Dmin

= Mandrel

diameter

of reel in m (0.508 m)

Substituting the above values in equation we get,

k1 = 1395 * 1.543 / 2 * 9.81
= 109.7 kg-m-sec^2
Substituting the above values in equation we get
k2 = 3.1416 * 7850 / 16 * 1.543 * 9.81
= 101.83 kg-sec^2 / m^4
Substituting the above values in equation we get
k3 = 0.508^4 * 101.83
= 6.78 kg-sec^2
To calculate the two acceleration compensations, we have following formulae,
1) To calculate acceleration compensation torque when line is under acceleration, we have the
formula,
Mb*1 = dl/dt [ k1/d + b(k2 * d^3 - k3/d)]
Where,
l = Maximum line speed in m/sec( 1.533 m/sec^2 )
t = Time required to accelerate from zero to full speed (10 sec)
d = Current diameter of the coil in m
b = Strip width of the coil in m
When the line is under acceleration, torque of the exit side reel should increase and the torque of
entry side reel should decrease. The reverse is true when the line is under deceleration. When
the line is under acceleration, total torque of the motor is given by,
For exit side reel
M* = Mz* + Mf* + Mb*1
And for entry side reel,
M* = Mz* + Mf* - Mb*1
The graph of acceleration compensation torque when the line is under acceleration Vs diameter
of the coil is given in annexure a. Some important values of acceleration compensation torque are
as follows,
Mb*1 at min coil diameter and max strip width = 330.83 kg-m
Mb*1 at max coil diameter and max strip width = 1345.2 kg-m

2) To calculate the acceleration compensation torque, when the line is running at constant speed,
we have the formulae,
Mb*2 = 2 * l^2 * t / 3.1416 * d^2 (k')
Where,
l = Line speed in m/sec
t = Thickness of the strip in m
d = Current diameter of the coil in m
k' = k1/d + b (k2 * d^3 - k3 / d)
Since the exit side reel is always under deceleration due to increase in diameter value, the torque
of the exit side reel should reduce. Whereas, since the entry side reel is always under
acceleration, the torque of entry side reel should increase. Thus the total torque of the motor is
given by,
For exit side reel,
M* = Mz* + Mf* + Mb*1 - Mb*2
And for entry side reel
M* = Mz* + Mf* -Mb*1 + Mb*2
In the above equations, Mz* and Mf* are continuously given to the motor if the tensions are
switched on. Mb*1 and Mb*2 components of torque given to the motor is zero when the line is at
standstill (since l = 0 and dl/dt = 0). Mb*1 component given to the motor is zero when the line is
running at a constant speed (since l > 0 and dl/dt = 0)