SIMOTION Line Tension Control V Unrestricted / Siemens AG All Rights Reserved.

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1 SIMOTION Line Tension Control V2.1.1 siemens.com/answers

2 Introduction The application SIMOTION Line Tension Control was developed with the objective to address many of the known tension control applications using just one application software. The source code of the application is open and can be configured or changed to the customers own requests. Using the SIMOTION control platform the application SIMOTION Line Tension Control allows tension control functionality to be implemented in a wide range of applications, e.g. foil making machines, printing machines, coating machines... Can be combined with other applications like: SIMOTION Axis Function Block SINAMICS DCC Load Sharing

3 Benefits when Shorter engineering and service time (same look & feel) Can be used in all programming languages Industry standards are used (PLC open) Supported by Centers World Wide Regularly updated on Intranet Open source code so that you can adapt the functions to your requirements User Manuals in English and German Easy learning using pre-programmed application examples Free of Charge

4 Contents of the User Manuals (English and German) PowerPoint presentation (English / German) Units / libraries (programming in ST or MCC) Change log

5 Scope of PULL HELD Tension controlled segment Dancer or Load cell location F Tension n>0 web n>0 n>0 Mode Representation Description PULL HELD M T - V+, F+ M P + n+ M f + M f + n+ n o + M P + M T + V+, F+ V: Machine velocity n>0 F: Tension in material line n: speed of drive Tension controlled segment F Tension web Dancer or Load cell location n 0 : velocity override for speed overcontrol Mf: Friction torque MP: Pre-control torque MT: Tension torque n o+

6 Scope of Process interface The interface to the process is based on the function block input parameter lineaxis. The following alternatives are implemented: lineaxis = TO#NIL: There is no master axis specified. The coupling is based on variables of the I/Ostructure sltcconfigtype. lineaxis = TO#driveAxis: The master axis is a speed controlled axis. The reference diameter of the axis has to be specified. lineaxis = TO#posAxis: The master axis is a linear positioning axis. lineaxis = TO#externalEncoderType: The master axis is a machine encoder.

7 Scope of Axis operating mode The tension controlled axis can be operated speed controlled or position controlled The coupling to the process is always based on a speed setpoint.

8 Scope of System of units data sltcconfig.eunitlineaxisvelocity sltcconfig.eunitlineaxisacceleration data sltcconfig.eunitltcaxisvelocity Values M_MIN, MM_MIN, M_S, MM_S, FT_MIN, INCH_MIN, FT_S, INCH_S, DEG_S_PRINT M_S2, MM_S2, FT_S2, INCH_S2, DEG_S2_PRINT Values M_MIN, MM_MIN, M_S, MM_S, FT_MIN, INCH_MIN, FT_S, INCH_S, DEG_S_PRINT, RPM, RPS, DEG_S, DEG_MIN Measured variable Unit Metric Anglo-American Length LU e.g.: m (meter) e.g.: ft (feet) Length (bigger unit) Lub m (meter) ft (feet) Velocity LU / TU e.g.: m / min e.g.: ft / min Acceleration LU / s² e.g.: m / s² e.g.: ft / s² Speed rptu or / TU e.g.: rpm e.g.: rpm Inertia J = mlub² kgm² lbft² Torque M = mlub²/s² Nm= kgm² / s² lbf ft = lbft² / s² Force, Tension Z = mlub/s² N = kg m /s² lbf = lb ft / s²

9 Scope of Control modes The LTC Function Block covers the most common control modes and is an open source code which allows individual adjustments or modifications to the customer s own puposes. Control modes (FBLTC): Indirect tension control with torque limiting Indirect tension control with speed setpoint correction Tension control with torque limiting Tension Control with speed setpoint-correction Dancer position control with speed setpoint-correction (Dancer position control with torque limiting) Draw-control

10 Scope of Indirect Tension Control No tension feedback required Web speed is set via nip Tension Torque pre-controlled via torque setpoint Good Inertia and friction torque compensation required Tension ratio app. 6:1 Web speed up to app. 600 m/min Material: foil, textile, paper

11 Scope of Indirect Tension Control Master axis Web axis velocity setpoint F tension [N] machine acceleration machine velocity diameter velocity override Speed setpoint web axis speed setpoint actual speed value power unit supplementory torque + torque limit speed current Web axis tension setpoint tension ramp up (RFG) tension setpoint after RFG torque precontrol torquelimits torque pre-control torque limits

12 Scope of Indirect Tension Control with speed correction No tension feedback required Web speed is set via nip Torque pre-controlled via torque setpoint Good Inertia and friction torque compensation required Tension ratio app. 6:1 Web speed up to app. 600 m/min Material: foil, textile, paper

13 Scope of Indirect Tension Control with speed correction Web axis velocity setpoint Master axis F tension [N] machine acceleration tension setpoint Setpoint conditioning RFG tension setpoint after RFG machine velocity tension diameter + velocity adaption Speed setpoint web axis speed setpoint actual speed value speed power unit supplementory torque + torque limit current Web axis actual tension value tension calculation actual torque torque precontrol torque pre-control

14 Scope of Tension control with torque limiting Tension measuring device required Web speed is set via nip Tension Torque pre-controlled via torque set point Nip necessary, load measuring cell is sensitive for overload Good Inertia and friction torque compensation required Tension ratio app. 20:1 Web velocity up to app m/min Tension control via torque limitation Material: paper, thin film

15 Scope of Tension control with torque limiting velocity setpoint Master axis F tension [N] Web axis machine velocity velocity override speed actual value power unit machine acceleration diameter Speed setpoint web axis speed setpoint speed supplementory torque + torque limits current Web axis actual web tension tension setpoint tension setpoint ramp function (RFG) tension tension setpoint after RFG output + torque precontrol torque limits torque precontrol torque limits

16 Scope of Tension control with speed correction Tension measuring device required Web speed is set via nip Tension Torque pre-controlled via torque set point Nip necessary, load measuring cell is sensitive for overload Good Inertia and friction torque compensation required Tension ratio app. 20:1 Web velocity up to app m/min Material: paper, thin film

17 Scope of Tension control with speed correction velocity setpoint Master axis F tension [N] Web axis machine acceleration machine velocity actual speed value power unit tension setpoint actual tension value Sollwertaufbereitung (Hochlaufgeber) tension setpoint after RFG tension diameter + velocity adaption Speed setpoint web axis speed setpoint speed supplementory torque + torque limit current Web axis torque precontrol torque pre-control

18 Scope of Dancer position control with speed setpoint-correction Dancer position measuring device required (e.g. potentiometer, encoder) Web speed is set via nip Web tension is controlled via additional speed setpoint Dancer influences the web path Tension ratio controlled via dancer Web speed up to app m/min Material: rubber, cable, textile, film and paper

19 Scope of Dancer position control with speed setpoint-correction velocity setpoint master axis Dancer counterforce F tension [N] Web axis + - machine acceleration position setpoint setpoint RFG machine velocity position setpoint after RFG position actual value diameter Position + correction value Speed setpoint web axis speed setpoint actual speed value speed power unit auxiliary torque + torque limit current Web axis tension setpoint setpoint RFG Optional torque pre-control torque pre-control

20 Scope of Draw control No tension feedback required Web speed is set via the drive itself The web tension is a result of the speed difference Material: film and paper

21 Scope of Draw control velocity setpoint Master axis F tension Sectional drive machine acceleration machine velocity drawfactor x + speed setpoint sectional drive speed setpoint speed actual value power unit supplementory torque + torque limits diameter speed Sectional drive current torque precontrol sectional drive torque precontrol

22 Scope of Torque pre-control The torque for the process is calculated from three components: Acceleration / Deceleration torque During acceleration or deceleration of the material an additional torque component is switched on the drive for more dynamic reaction and to prevent tension fluctuations. The acceleration compensation is based on the total torque of inertia. Friction compensation Compensation of mechanical losses for precise adjustments of the web tension. Tension pre-control Adjustment of the tension, especially in the control mode Indirect Tension Control. Using the torque pre-control, the technology data block is mandatory.

23 Scope of tension operation In Draw Control mode the web tension is set by the relative velocity difference of the respective transport rolls. The tension is not directly measured or controlled. Tension Control mode (indirect tension control, dancer position control, tension control with load cell feedback) can only be activated when the Function Block is in run mode and there is no web break indicated. Switching over from Draw Control to Tension Control and opposite should be preferably carried out at machine standstill. The engaging of setpoints during switching over will be done via adjustable ramp function generators. The deselection of Tension Control leads automatically into Draw Control mode. That means the axis will be operated without override or speed correction.

24 Scope of Technology The technology is based on the functionality of a PID- and is used in dancer- or web tension applications. Setpoint ramp function generator with settable input PID- RFG as output for smooth transitions Kp-Adaption Optional D-portion in the actual value channel

25 Function Block The application is available as a library, called LLTCLib. This library also uses the Converting Library LConLib. The llibrary includes 3 sources: Unit aversion: Library changelog Unit dtypes: User defined type definitions Unit fltc: FBLTC function block and additional sub functions

26 Function Block FBLTC FBLTC BOOL sltclineaxis MotionVectorType eltccontrol ModeType BOOL enable lineaxismotionvector controlmode ctrlenable busy active ctrlbusy error BOOL BOOL BOOL BOOL BOOL REAL blockpidcorrection tensionsetpoint errorid diameterfactor DWORD REAL REAL REAL positionsetpoint actvaluepid velocity additivevelocity REAL REAL REAL drawfactor Output additivetorque REAL REAL additivetorqueactive torquelimitnegative BOOL REAL torquelimitnegativeactive torquelimitpositive BOOL REAL torquelimitpositiveactive sltcdiag BOOL sltcdiagtype sltcconfigtype sltcconfig sltcconfigtype

27 Example Example : (stand alone / low Performance) SIMOTION D410-2 SINAMICS S120 AC/AC Breaking Resistor (optional) TM31 (optional) Drive-Cliq Hub (optional) e.g. 1PH8 Motor Standards: SIMOTION LTC SIMOTION Axis Function Block PROFINET SIMOTICS M 1PH8 SIMATIC HMI SIMOTION D410-2 SINAMICS S120 Blocksize AC/AC PM340 Motor Module Benefits: Modular solution based on standard products Fast and scalable Onboard I/O and onboard Machine Encoder Interface

28 Example Example : (Machine control) SIMOTION D4x5-2 SINAMICS S120 DC/AC Infeed (ALM / SLM / BLM) TB30/TM31 (optional) 1FK7 Motor Standards: SIMOTION Line Tension Control SIMOTION Axis Function Block PROFINET SIMATIC HMI SIMOTION D4x5-2 SIMOTICS S 1FK7 SINAMICS S120 Booksize Motor Modules SIMATIC S7-15xx (machine-plc optional) I/Os TM17 External encoder evaluation SMC30 Benefits: Time saving for engineering and commissioning High degree of hardware integration Fast and scaleable platform Modular solution based on standard products

29 Example Nip Machine encoder Dancer system (or load cell) Production process M M M DRIVE CLiQ PROFINET Machine encoder (External master axis) Feedback dancer position (Web tension) SINAMICS S120 (Drive control) SIMATIC S7 (Machine PLC and remote I/Os) SIMOTICS M (Main motors)

30 Converting module for Project Assisted configuration Generation of a machine project incl. control sequence SIMOTION Project

31 Thank you for your attention! Center DF FA PMA APC Frauenauracher Str. 80 D Erlangen siemens.com/answers