SIMOTION Winder

V2.2.1

© Siemens AG 2010. All Rights Reserved.

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Introduction

Introduction The application SIMOTION Winder was developed with the objective to
Benefits when address many of the known winder applications using one application
using the software.
Application

Contents of the
Application
If required, the application can be configured and/or also changed.
Scope of
Functionality Using the SIMOTION control platform the application “SIMOTION Winder”
Function Block allows winders and un-winders to be implemented in a wide range of
Overview applications, e.g. foil making machines, printing machines, coating
Example machines...
Configuration

Example Project
Can be combined with other applications like:
Tools
SIMOTION Line Axis / SIMOTION Axis Function Block
SIMOTION Splice Control
SIMOTION Traversing Drive
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Benefits when using the Application

Introduction ƒ Shorter engineering and service time (same look & feel)
Benefits when
using the
ƒ Can be used in all programming languages
Application
ƒ Industry standards are used (PLC open)
Contents of the
Application ƒ Supported by Application Centers World Wide
Scope of ƒ Regularly updated on Intranet
Functionality

Function Block ƒ Open source code so that you can adapt the functions to your
Overview requirements
Example ƒ User Manuals in English and German
Configuration

Example Project ƒ Easy learning using pre-programmed application examples

Tools ƒ Free of Charge

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Contents of the Application

Introduction ƒ PowerPoint presentation (English / German)

Benefits when
using the
Application ƒ Units / libraries (programming in ST or MCC)
Contents of the
Application ƒ User Manuals (English and German)
Scope of
Functionality
ƒ Example project for SIMOTION D demonstration case
Function Block
Overview

Example ƒ Feedback sheets (English / German)

Configuration

Example Project ƒ Change log (change history)

Tools

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Scope of Functionality

Introduction
Center Winder or Tandem center
Coil
Winder
Benefits when
using the
ƒ Winds material around a core or mandrel
Application ƒ The coil is driven by a motor
Contents of the Tension
ƒ The motor can be operated in torque or
Application speed controlled mode

Scope of
ƒ Speed and torque are diameter dependent
Functionality ƒ Dancers or load cells for tension control are
optional
Function Block
Overview

Example Turret winder

Configuration ƒ Two or more center winds on a rotating axis
Example Project ƒ Roll change on the fly
Coil
Tools

Tension Nip
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Scope of Functionality

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Process interfacing

Introduction The interfacing to the process is based on the value on the function block
Benefits when input parameter lineAxis. The following alternatives are implemented:
using the
Application
lineAxis = TO#NIL:
Contents of the
There is no master axis specified. The coupling is based on variables of the I/O-
Application
structure sWinderConfigType.
Scope of
Functionality
lineAxis = TO#driveAxis:
Function Block
The master axis is a speed controlled axis. The reference diameter of the axis has to
Overview
be specified. Optional position information has to be input externally via I/O-structure.
Example
Configuration
lineAxis = TO#posAxis:
Example Project
The master axis is a positioning axis. Position information is available.
Tools

lineAxis = TO#externalEncoderType:
The master axis is a machine encoder. Position information is available.

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Scope of Functionality – Winder operating mode

Introduction The winder axis can be operated

Benefits when speed controlled
using the
Application

Contents of the or
Application position controlled
Scope of
Functionality
The coupling to the process is always based on a speed setpoint.
Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – System of units

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Control modes

Introduction ƒ The Winder Function Block covers the common control modes and is an
Benefits when open function for adjustments or build in your own Know-how
using the
ƒ Control modes:
Application
ƒ Indirect tension control
Contents of the
Application ƒ Tension control with torque limiting
Scope of ƒ Dancer position control with speed setpoint-correction
Functionality
ƒ (Dancer position control with torque limiting)
Function Block
ƒ (Tension Control with speed setpoint-correction)
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Indirect Tension Control

Introduction ƒ No tension feedback required

Benefits when ƒ Web speed is set via nip
using the
Application ƒ Tension Torque pre-controlled via torque setpoint
Contents of the ƒ Good Inertia and friction torque compensation required
Application ƒ Diameter ratio app. 10:1
Scope of ƒ Tension ratio app. 6:1
Functionality
ƒ Winder torque ration app. 40:1
Function Block
Overview ƒ Web speed up to app. 600 m/min
Example ƒ Material: foil, textile, paper
Configuration

Example Project

Tools

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Scope of Functionality – Indirect Tension Control

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality - Tension control with torque limiting

Introduction ƒ Tension measuring device required

Benefits when ƒ Web speed is set via nip
using the
Application ƒ Tension Torque pre-controlled via torque set point
Contents of the ƒ Good Inertia and friction torque compensation required
Application ƒ Diameter ratio app. 15:1
Scope of ƒ Tension ratio app. 20:1
Functionality
ƒ Winder torque app. 100:1
Function Block
Overview ƒ Web velocity up to app. 2000 m/min
Example ƒ Tension control via torque limitation
Configuration ƒ Material: paper, thin film
Example Project

Tools

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Scope of Functionality - Tension control with torque limiting

Winding axis
Introduction
Master axis
FTension [N]
Benefits when
Setpoint velocity
using the
Application

Contents of the
Application

Scope of
Functionality
Auxiliary Torque limit
Function Block Diameter
Speed setpoint Speed setpoint torque

Overview calculation
Diameter
Winding axis
(overridden)
+
Speed/Position
Speed Control
controller loop
Example
Configuration
Winding drive
Tension actual
Example Project value
Tension
Setpoint controller
Tools Tension
preparation (Ramp
setpoint
generator)

Precontrol
Torque torque
Tension setpoint precontrol
RFG + Torque limits
Torque limiting

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Scope of Functionality - Dancer position control with speed setpoint-correction

Introduction ƒ Dancer position measuring device required (e.g. potentiometer, encoder)

Benefits when ƒ Web speed is set via nip
using the
Application ƒ Web tension is controlled via additional speed setpoint
Contents of the ƒ Dancer influences the web path
Application ƒ Diameter ratio up to app. 15:1
Scope of ƒ Tension ration controlled via dancer
Functionality
ƒ Winder torque ratio up to app. 40:1, depending on the dancer system
Function Block
Overview ƒ Web speed up to app. 2000 m/min
Example ƒ Material: rubber, cable, textile, film and paper
Configuration

Example Project

Tools

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Scope of Functionality - Dancer position control with speed setpoint-correction

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Diameter calculation

Introduction The diameter calculator is the most important element in a winder control.
Benefits when
The precise diameter is required e.g. for the conversion of the machine
speed into the winder speed as well as for the calculation of the required
using the
torque.
Application
The diameter is calculated based on the relation between material and
Contents of the winder speed or is measured by external device.
Application

Scope of The following types of diameter calculation are implemented:

Functionality ƒ External sensor
Function Block
ƒ Ratio between Web velocity and winder speed
Overview ƒ Integration of material thickness
ƒ Integration of web velocity and winder speed (length and angle)
Example
Configuration ƒ Measurement of the web position and winder angle (length and
angle)
Example Project

Tools

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Scope of Functionality – Diameter calculation

Introduction Mode DIAM_CALC:

Diameter calculation based on ratio between web velocity and winder rotational speed. The diameter
Benefits when calculated in this mode during acceleration and deceleration phases is not reliable.
using the
Application Mode DIAM_CALC_INTEGRAL:
Diameter calculation based on ratio between web length and winder angle. Web length and winder
Contents of the
angle are determined by velocity and speed integration (no position feedback required). The
Application integration length is parameterized by a multiplier of winder revolutions.
Scope of
Functionality Mode DIAM_CALC_POSITION:
Diameter calculation based on ratio between web length and winder angle. For this calculation a
Function Block direct position feedback is used. The measuring angle can be paramterized as multiples from winder
Overview revolutions.

Example
Mode DIAM_THICKNESS_ADDITION:
Configuration
Basis of the calculation is that the diameter change of every winder revolution is 2 * material
thickness. The winder angle will be determined by winder speed integration. For this calculation mode
Example Project
the material thickness must be very accurate as well as the winder angle.
Tools
Mode DIAM_CALC_EXT:
The diameter is determined by an external measuring device or by winder speed characteristic.

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Scope of Functionality – Diameter calculation

Introduction The further processing of the calculated diameter value comprises a

Benefits when plausibility check and interpolation.
using the
Application
The following methods are implemented:
Contents of the
Application ƒInterpolation with ramp-function generator based on the material thickness
Scope of ƒInterpolation with ramp-function generator (only position based diameter
Functionality calculation)
Function Block ƒInterpolation without ramp-function generator (only position based
Overview
diameter calculation)
Example
Configuration

Example Project

Tools

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Scope of Functionality – Diameter calculation

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Taper characteristic

Introduction Optional for rewinds, if the tension is reduced with increasing diameter
Benefits when ƒ Taper characteristic depends on the actual diameter
using the
Application ƒ The following characteristics are implemented:
Contents of the ƒ Hyperbolic characteristic, max. tension reduction at infinite diameter
Application ƒ Hyperbolic characteristic, max. tension reduction at specified diameter
Scope of ƒ Linear characteristic, max. tension reduction at specified diameter
Functionality
ƒ Breakpoint table with linear interpolation
Function Block
Overview
Taper

Example 100%
Configuration
NO_TAPER
LINEAR
Example Project HYPERBOLIC_1
HYPERBOLIC_2
TABLE
Tools
r32TensionTaper
Ratio

r32TensionTaper r32TensionTaper
DiameterStart DiameterMax
D

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Scope of Functionality – Controller adaption

Introduction ƒ Controller gain of the tension/position controller is adaptable based on the

Benefits when actual diameter
using the
Æ higher gain at higher diameter
Application

Contents of the
Application ƒ Controller gain of the speed controller is adaptable based on the moment
Scope of of inertia or the diameter of the roll
Functionality Æ higher controller performance with high load conditions
Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Torque pre-control

Introduction The torque for the winding process is calculated from three components:
Benefits when ƒAcceleration / Deceleration torque
using the
Application During acceleration or deceleration of the material an additional torque
component is switched on the drive for more dynamic reaction and to
Contents of the
Application
prevent tension fluctuations
Scope of The acceleration compensation is based on the diameter, the web width,
Functionality the gear ratio and the material density.
Function Block ƒFriction compensation
Overview
Compensation of mechanical losses for precise adjustments of the
Example tension
Configuration
ƒTension pre-control
Example Project
Adjustment of the tension, especially in the control mode indirect tension
Tools
control

Using the torque pre-control, the technology data block is mandatory.

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Scope of Functionality – tension operation

Introduction ƒ Tension operation can only be enabled if the control is in operation and
Benefits when web break detection is not signaling an error
using the
ƒ It is recommended to only enable tension operation in machine stand still
Application
ƒ Tension or position setpoint will be enabled using adaptable ramp
Contents of the
Application
functions
Scope of ƒ If tension operation is not active, the diameter computer and the speed
Functionality override are disabled
Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality –Technology controller

Introduction Technology controller based on the functionality of a PID-controller for

Benefits when usage e.g. as a dancer or tension controller
using the
ƒSetpoint ramp function generator with settable input
Application
ƒPID-controller
Contents of the
Application ƒRFG as controller output for smooth transitions
Scope of ƒKp-Adaption
Functionality
ƒOptional D-portion in the actual value channel
Function Block
Overview

Example
Configuration

Example Project

Tools

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Scope of Functionality – Residual length calculation

Introduction Residual length calculation – FCRLC (LConLib)

Benefits when ƒ The residual length of a roll can be calculated by entering the following
using the
parameters:
Application
ƒ Web thickness
Contents of the
Application ƒ Actual diameter
Scope of ƒ Target diameter
Functionality
ƒ Output either the length of the material on the roll or the length of the
Function Block material still to be wound
Overview

Example
Configuration

Example Project

Tools

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Function Block Overview

Introduction The Converting Library is available as:

Benefits when ƒLibrary export (SIMOTION Converting Library)
using the ƒSample project (SIMOTION Winder)
Application

Contents of the The Converting Library consists of 3 Units:

Application

Scope of Unit ToolConv:

Functionality
General Drive-related functionality (closed loop
Function Block control function blocks, System handling)
Overview

Example
Unit WI_Tools:
Configuration
Winder related function blocks (Diameter calculator,
Example Project
Technology controller, Taper characteristic etc.)
Tools

Unit WI_Template:
Winder function block

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Function Block Overview – FBWinder

FBWinder

Introduction BOOL enable busy BOOL

ANYOBJECT winderAxis active BOOL

Benefits when
ANYOBJECT lineAxis error BOOL
using the
eControlMode controlMode errorID DWORD
Application
enumtaskname taskmode kpAdaptionRatio WORD

Contents of the eDiamMode selectDiamMode diameter REAL

Application
eTaperCharMode tensionTaperMode diameterFactor REAL

Scope of eWinderFBMode fbMode velocity REAL

Functionality BOOL ctrlEnable additiveVelocity REAL

Function Block BOOL setDiamCalc controllerOutput REAL

Overview BOOL holdDiamCalc additiveTorque REAL

BOOL blockPIDCorrection additiveTorqueActive BOOL

Example
REAL tensionSetpoint torqueLimitNegative REAL
Configuration
REAL positionSetpoint torqueLimitNegativeActive BOOL

Example Project REAL diamExtVal torqueLimitPositive REAL

Tools REAL diamSetVal torqueLimitPositiveActive BOOL

REAL actValuePID webBreak BOOL

sWinderConfig sWinderConfig sWinderConfig

Type Type

REAL LatchDiamCalc REAL

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Example Configuration

Introduction Example Configuration: HMI

(stand alone / low Performance)
Benefits when Ethernet / PROFIBUS
using the •SIMOTION D410
Application •SINAMICS S120 AC/AC
PM340
•Breaking Resistor (optional)
Contents of the
•TM31 (optional)
Application
•Drive-Cliq Hub (optional)
Scope of •e.g. 1PH8 Motor
Functionality
SIMOTION D410
Function Block Standards:
Overview SIMOTION Winder
SIMOTION Line Axis or 1PH8
Example
SIMOTION Axis Function Block
Configuration

Example Project
Benefits:
Tools
ƒModular solution based on standard products
ƒHigher hardware integration (no external traversing controller required)
ƒFast and scalable control
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Example Configuration

Web handling
HMI
Machine control SIMOTION D410
SINAMICS S120 AC/AC
SIMATIC S7 PROFIBUS

TM31
Machine encoder (HTL/TTL/SSI)
or analog coupling

1PH8

Nip

Dancer system
(or load cell) Winder

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Example Configuration

Introduction Example Configuration:

(Machine control)
Benefits when PROFINET / PROFIBUS
using the •SIMOTION D4x5
Application •SINAMICS S120 DC/AC
Contents of the •Infeed (ALM / SLM / BLM)

SIMOTION D4x5
Application •TB30/TM31 (optional)
•1PH8 Motor
Scope of
Motor Modules
Functionality
Standards:
Function Block SIMOTION Winder
Overview SIMOTION Line Axis or
SIMOTION Axis Function Block Aux. axis /
Example Winder Material handling
Configuration 1PH8

Example Project
Benefits:
Tools
ƒTime saver during test and commissioning
ƒHigher hardware integration (no Winder PLC)
ƒModular solution based on standard products
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Example Configuration

HMI
Machine control

Web handling Ethernet / PROFIBUS

SIMOTION D4x5
SINAMICS S120 DC/AC

1PH8 TM31

1PH8
Nip

Dancer system Winder

(or load cell)

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Example Project

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Example Project

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Tools - Sizing

Introduction

Benefits when
using the
Application

Contents of the
Application

Scope of
Functionality

Function Block
Overview

Example
Configuration

Example Project

Tools

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Thank you for your attention!

Application Center
I DT MC PMA APC

Frauenauracher Str. 80
D-91056 Erlangen

E-Mail: applications.erlf.aud@siemens.com

© Siemens AG 2010. All Rights Reserved.