Converting Applications Made Easy Presented by Jeff Reese Manufacturing in America March 14-15, 2018

Transcription

1 Converting Applications Made Easy Presented by Jeff Reese Manufacturing in America March 14-15, 2018

2 Before we start A Penny for Your Thoughts At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!

3 What is Converting?? The Siemens Converting Toolbox Web Handling with SIMOTION, SINAMICS and SIMATIC

4 Converting is Web Handling & Web Processing Webs include paper, film, foil, nonwovens, and other thin flexible continuous materials.

5 Roll to Roll Web Processing Converting processes that start and end with a wound roll of material are called roll-to-roll (R2R). Roll-to-roll Web Processes

6 Roll to Sheet Web Processing Converting processes that start and end as a sheeted product are called roll-to-sheet. Roll-to-sheet Handling Cutting

7 Converting Machines / Applications Slitter Rewind Coating & Laminating Sheeter / Rotary Knife Tissue / Towel Lines Label / Die Cut Core Winder

8 Converting Applications and Process Requirements Unwind Process Rewind Unwind Register control Rewind Knife / Perforator Tension control Position Based Web Control Tension control Automatic splice Automatic splice

9 Yesterdays Converting Solutions Then

10 Level of Performance Today s Converting Solutions Flexible automation from a single source MOTION CONTROLLER The Converting Toolbox SIMOTION DRIVE SYSTEM SINAMICS S120 PLC SIMATIC S7 PLC Standardized automation packages with tested know-how for SIMOTION, SINAMICS and SIMATIC

11 Level of Performance Today s Converting Solutions Flexible automation from a single source MOTION CONTROLLER The Converting Toolbox DRIVE SYSTEM SIMOTION SINAMICS S120 Supported product Detailed documentation Wide range of functions Applications and libraries Open source software Some with demo examples, & HMI screens PLC SIMATIC S7 PLC Standardized automation packages with tested know-how for SIMOTION, SINAMICS and SIMATIC

12 Level of Performance Today s Converting Solutions Flexible automation from a single source MOTION CONTROLLER The Converting Toolbox DRIVE SYSTEM SIMOTION Engineering time saving Time-tested, reliable functions Global Toolbox support Available without charge Every control platform SINAMICS S120 PLC SIMATIC S7 PLC Standardized automation packages with tested know-how for SIMOTION, SINAMICS and SIMATIC

13 Application Overview SIMOTION SIMATIC SINAMICS Winder Splice Control Tension Control Web Accumulator Rotary Knife Flying Saw Traversing Axis Integrated Register Control Load Sharing Diagnostic Pages Project generator 1 Converting Library 1; TIA + MAC in progress

14 PLC-Based Solutions SIMATIC Converting Module SIMATIC PLC Architecture SIMATIC HMI SINAMICS S120 with safety integrated Synchronous Motors Asynchronous Motors

15 PLC-Based Solutions SIMATIC Converting Module Features PLC ease of use and flexibility Open source code; structured text Centralized control Converting Library Center Wind Zone Tension Control Flying Saw Electronic Gearing Web Server / Diagnostics T

16 Drive-Based Solutions SINAMICS (DCC) Converting Module SIMATIC PLC Architecture SIMATIC HMI SINAMICS S120 Control Unit SINAMICS S120 with safety integrated Synchronous Motors Asynchronous Motors

17 Drive-Based Solutions SINAMICS (DCC) Converting Module Features Drive-based performance Drive-based Graphical programming editor (DCC) Converting Library Center Wind Zone Tension Control Web Server / Diagnostics Harmonic Compensation Electronic Gearing Unwind Flying Splice Traversing Axis Control Rotary Knife Flying Saw Load Sharing

18 Motion-Based Solutions SIMOTION Converting Module SIMATIC PLC Architecture SIMATIC HMI SIMOTION D Motion controller SINAMICS S120 with safety integrated Synchronous Motors Asynchronous Motors

19 Motion-Based Solutions SIMOTION Converting Module Features Highest level of performance Include HMI application Can be demonstrated via SIMOTION demo Open source code Converting Library Center Wind Zone Tension Control Web Server / Diagnostics Accumulator Control Electronic Gearing Unwind Flying Splice Traversing Axis Control Rotary Knife Flying Saw Project Generator Register Control

20 Winder Solutions Control Mode Overview CONTROL MODE SINAMICS DCC SIMOTION SIMATIC S7-300/400 SIMATIC S7-1200/1500 SIMATIC S7-1500T V Constant Indirect tension control via torque adaption Direct tension control via torque adaption Direct tension control via speed adaption Dancer position control via speed adaption Dancer position control via torque adaption Mode change during active loop control

21 Winder Solutions Modes of Diameter Calculation CALCULATION MODE SINAMICS DCC SIMOTION SIMATIC S7-300/400 SIMATIC S7-1200/1500 SIMATIC S7-1500T External sensor Web thickness and turns count Archimedean spiral (slip core) v/n (line speed / spindle rpm) ʃv ʃn (integral line speed / spindle rpm) s / α (web length / spindle angle change) Compensation of dancer motion Active calculation mode change

22 Winder Solutions Auxiliary Functions CALCULATION MODE SINAMICS DCC SIMOTION SIMATIC S7-300/400 SIMATIC S7-1200/1500 SIMATIC S7-1500T Torque pre control Controller loop adaption (tension /speed) Taper tension Web break detection Stop at web position Stop at diameter Diagnostic pages for web browser Project wizard for commissioning

23 Zone Tension Control Solutions Control Mode Overview CONTROL MODE SINAMICS DCC SIMOTION SIMATIC S7-300/400 SIMATIC S7-1200/1500 SIMATIC S7-1500T Draw control Indirect tension control via torque adaption Direct tension control via torque adaption Direct tension control via speed adaption Dancer position control via speed adaption Dancer position control via torque adaption Mode change during active loop control

24 Zone Tension Control Solutions Auxiliary Functions CALCULATION MODE SINAMICS DCC SIMOTION SIMATIC S7-300/400 SIMATIC S7-1200/1500 SIMATIC S7-1500T Torque pre control Controller loop adaption (tension /speed) Web break detection Diagnostic pages for web browser Project wizard for commissioning

25 Performance Review - Diameter Calculation Methods Comparing the Calculation Methods In analyzing diameter calculator methods, two factors are considered: Constant speed operation vs. acceleration profile Update frequency of the diameter calculator logic Evaluation of actual results. The following analysis will look at three calculation modes under different conditions.

26 Performance Review - Diameter Calculation Methods Constant web speed: 100 m/min RED GREEN BLUE - V/n diameter - INTEGRAL diameter - POSITION diameter

27 Performance Review - Diameter Calculation Methods Acceleration profile: 50 m/min > 300 m/min > 10 m/min Update (sampling) time: 6 ms RED GREEN BLUE - V/n diameter - INTEGRAL diameter - POSITION diameter

28 Performance Review - Diameter Calculation Methods Acceleration profile: 50 m/min > 300 m/min > 10 m/min Update (sampling) time: 1 ms RED GREEN BLUE - V/n diameter - INTEGRAL diameter - POSITION diameter

29 The Converting Toolbox Libraries (Available blocks) General tools Cycle time determination Ramp-function generator (with or without jerk limiting) Characteristic block (20 or 180 interpolation points) Linear interpolation between two interpolation points Interpolation of a point table Limit value monitoring Braking distance and time calculation Drive functions Recording a friction characteristic, e.g. for the winding block Diameter Calculator (with multiple modes) Activating interfaces Closed-loop control related functions PT1 element Derivative action element/integrator DT1 filter Dead zone and dead band filter Limiter with feedback signal Limit value monitoring PID controller Sliding average value generator Setpoint control

30 The Converting Toolbox (Integrated Web Server) Functionality Download a programs Perform Firmware updates Status overview of specific variables Evaluate of alarms and faults Monitoring and change parameters Archive machine documentation Create Custom Web Pages

31 The Converting Toolbox (Integrated Web Server)

32 Automation Architectures - Solution / Machine Type Module Application Example Machine Type 1-6 Axes 6-50 Axes Axes Simatic Module Web Control Slitter Rewind Doctor Machine Slitter Rewind Coating Line Sinamics Module Web Control Motion Control Slitter Rewind Narrow Web (offline) Filament Winder Load Share Slitter Rewind Coating Line Coating & Laminating Line Film Line Simotion Module Web Control Motion Control Rotary Knife Core Cutter Die Cutter Paper Sheeter Offset Press Narrow Web Press Diaper Machine Tissue / Towel Line Flexo Press Network Options PROFIBUS PROFINET

33 The Converting Toolbox on Flash Drive Ask for yours It s free!

34 How did we do? Share your thoughts to win! Got 1 minute? Rate this seminar via MiA App for a chance to win Detroit Tigers tickets:

35 Seminar Slides After MiA, seminar slides will be available at:

36 Questions? Jeff Reese Siemens Industry, Inc Triangle Parkway Norcross, GA Phone: +1 (336) Website: