Siemens Winder App

s
SIMOREG DC-MASTER
Application
Center Winder
6RA70 Series
Microprocessor-Based Converters from 6kW to 2500kW
for Variable-Speed DC Drives
Edition 06
Edition 06
1.4
05.2007
Operating modes and functions
The winder described can operate in several different modes using a variety of functions. Global settings
such as
control method
direction of winding
winder or unwinder
gear box stage
winding characteristic
are selected via the top level control system. Depending on the selection, the requisite parameter settings
are automatically made in the SIMOREG device. In the case of machines used to manufacture broad-web
products and therefore requiring a variety of control methods, it is possible to choose between several
different control modes simply by switching over control bits. There is no need to change any connector or
binector links. All you need to do is select the required settings for characteristics, controllers, parameters or
optimization runs.
If a hardware control is implemented, the required changes can be made using OR function blocks (for
details contact schematic 19).
The following modes of operation are implemented:
direct tension control with tensile force sensor

indirect tension control without tensile force sensor using torque control
dancer roll / compensating roll position control
v-constant control
The following functions are available in these modes:
inching, maneuvering (to lead the web)

stop tension
slip core control
setting of a variable web width
setting a variable material density
calculator for diameter with monotone or not monotone change of diameter
2 gear box stages
speed controller adaptation
tension controller adaptation
web break recognition
6-55
SIMOREG DC-MASTER
Siemens AG
Application Center Winder
05.2007
Edition 06
Closed-loop control of a winder
2.1
Criteria for selecting the control method
The following table lists selection criteria based on empirical values.

The maximum possible web velocity is dependent to a large degree on its relation to the web-lead or
maneuvering velocity (see also para. 1.2 Application guidelines).
Torque limiting control
Speed compensation control
Indirect tension
Direct tension
Dancer control
v-constant control
control
control
Diameter sensing Calculated from web Calculated from web Calculated from web
Calculated from
velocity setpoint and velocity setpoint and velocity setpoint and actual web velocity
winder speed
winder speed
winder speed
and winder speed
Up to approx. 10:1
Up to approx.15:1
Up to approx. 15:1
Diameter ratio
Good compensation Good compensation Good compensation
Dmax/Dcore
of acceleration
of acceleration
of acceleration
Up to approx. 15:1
torque and friction
torque and friction
torque and friction
required
required
required
Actual tension
No
Yes
No
No
sensing
Up to approx. 6:1
Up to approx. 20:1
Tension ratio
Good compensation Good compensation
Variable only with
Fmax/Fmin
of acceleration
of acceleration
variable dancer
torque and friction
torque and friction
weight
required
required
Torque
Up to approx. 30:1
Up to approx. 40:1
ratio
Dependent on
Mmax/Mmin
quality of actual
tension signal
Web velocity
Up to 300m/min
Up to 1000m/min
Up to 1000m/min
with good
with good
with good
Up to 1000m/min
compensation
compensation
compensation
Clamping point
Required
Required
Required
Not required
Web tacho
Not required
Not required
Not required
Required
Use preferably
Sheet metal,
Paper,
Rubber, cabling,
Sorting roller
for
textiles, paper,
thin foils
wire,
cabling
foil, textiles
(generally for
extensible
materials)
Control method
Siemens AG
SIMOREG DC-MASTER
7-55
Application Center winder
Edition 06
2.2
05.2007
Torque limiting control
The basis for this operating principle is the addition (winder) or subtraction (unwinder) of a fixed value =
override setpoint (5-10%) to/from the speed setpoint of the speed controller with active tension control and
web inserted. Through its connection to the web, the winder reaches one of its torque limits (pos. limit with
winder, negative limit with unwinder). The torque limit is obtained from a feedforward control value derived
from the tension setpoint, taking into account diameter, friction, moment of inertia and acceleration.
The ramp generator for the speed setpoint merely serves to produce the dv/dt signal (ramp-up and rampdown time should be set to 0).
2.2.1
Indirect tension control

Main drive
(injection of web velocity)
Winder
Web velocity setpoint
Converter
|nact|
i
Diameter set value
Core diameter
Calculator
for
diameter
I-controller
D
Monotony yes/no
Set diameter
Hold diameter
Web break
Ramp-function
generator
setpoint limiting
Winding from
top/bottom
Ramp-function
generator
n-controller
Velocity / speed
calculator
Setpoint
processing
Torque limitation
nact
dv/dt
Inching setpoint
kp-Adaption
Maneuver
D
Zsetp
Main
Zsetp
Stop
Override
setpoint
nrated
Tension setpoint
formation
D
Winding hardness
Web width
Material density
D
i
Variable
moment
of inertia
Constant
moment
of inertia
|nact|
Characteristic
of firction
dv/dt
i
+/Unwinder/winder
6RA70
Indirect tension control
8-55
SIMOREG DC-MASTER
Siemens AG
05.2007
Edition 06
Description of mode of operation:

Input of current diameter using "Set diameter". This can be done only when the drive is switched off.
The maneuvering setpoint stretches the web between the winder and main drive (clamping point). Applying
the "Tension control ON external" signal allows activation of the tension control (a minimum torque must also
be reached) and the override setpoint is switched in. At the same time, the speed controller input is switched
from maneuvering over to operating setpoint (winder), or to 0 (unwinder). The drive torque is adjusted to the
torque limit specified by the tension control (derived from tension setpoint). A winding hardness
characteristic (tension decreases in proportion to increase in diameter) can be activated as the tension
setpoint for the winder.
The machine can now be started.
With every change in velocity, the product of moment of inertia x acceleration is added to the tension
feedforward control.
The current diameter is calculated continuously from the quotient of web velocity/winder speed. The tension
feedforward control value is multiplied by the varying diameter, thus ensuring that the web tension remains
constant.
A reduced tension (=stop tension) can be injected at standstill. This is calculated as a percentage of the
current operating setpoint tension.
If the web breaks, the winder accelerates initially by its override setpoint, the unwinder decelerates to its
override setpoint (this is negative so the unwinder rotates in the opposite direction). The web break is
sensed, on the one hand, by the delayed evaluation of a minimum torque and, on the other, by a comparison
of the torque setpoint and actual values. These are identical if the tension control is active because the drive
is operating at its torque limit. When the web breaks, the actual torque decreases when the override speed is
reached and this setpoint/actual value difference is evaluated after a delay (to allow for temporary
deviations) by a limit monitor. The web velocity setpoint is canceled by the speed controller, both the winder
and unwinder rotate at their override setpoint in the winding direction. OFF3 is applied after a
parameterizable time period.
The "Web break" signal can also be specified from an external source (e.g. via light barriers).
To ensure that the specified torque produces a material tension as close as possible to the desired value,
the acceleration and friction torques must be compensated accurately!
Siemens AG
SIMOREG DC-MASTER
9-55
Edition 06
2.2.2
05.2007
Direct tension control

Main drive
Tensile force sensor

Winder
Tension feedback value
Converter
|nact|
i
Diameter set value
Core diameter
Calculator
for
diameter
I-controller
D
Monotony yes/no
Set diameter
Hold diameter
Web break
Ramp-function
generator
setpoint limiting
Winding from
top/bottom
Ramp-function
generator
Torque limitation
n-controller
nact
dv/dt
Velocity / speed
calculator
Setpoint
processing
Inching setpoint
kp-Adaption
Maneuver
D
nrated
Override
setpoint
Tension
controller
Unwinder/winder
Zsetp Main
Tension setpoint
formation
Zsetp Stop
Winding hardness
Web width
Material density
D
i
Variable
moment
of inertia
Constant
moment
of inertia
|nact|
Characteristic
of firction
dv/dt
i
+/Unwinder/winder
6RA70
Direct tension control
10-55
SIMOREG DC-MASTER
Siemens AG
05.2007
Edition 06

The maneuvering setpoint stretches the web between the winder and main drive (clamping point). If the
tension exceeds a minimum value within a prespecified period, the tension control is automatically activated,
the override setpoint switched in and the tension controller enabled along a ramp (if "Tension controller ON
external" signal is applied). At the same time, the speed controller input is switched from maneuvering over
to operating setpoint. The drive torque is adjusted to the torque limit specified by the tension control (derived
from tension setpoint). A winding hardness characteristic (tension decreases in proportion to increase in
diameter) can be activated as the tension setpoint for the winder.
The tension controller compares the actual tension with the tension setpoint and adds a corresponding
compensation signal to the tension feedforward control value.
With every change in velocity, the product of moment of inertia x acceleration is added to the tension
feedforward control value.
The current diameter is calculated continuously from the quotient of web velocity/winder speed. The sum of
tension feedforward control value + tension controller output is multiplied by the varying diameter, thus
ensuring that the web tension remains constant.
If the web breaks, the winder accelerates by its override setpoint, the unwinder decelerates to its override
setpoint (this is negative so the unwinder rotates in the opposite direction). The web break is sensed, on the
one hand, by the delayed evaluation of a minimum tension and, on the other, by a comparison of the torque
setpoint and actual values. When the web breaks, the actual torque decreases when the override speed is
reached and this setpoint/actual value difference is evaluated after a delay (to allow for temporary
deviations) by a limit monitor. The web velocity setpoint is canceled by the speed controller, both the winder
and unwinder rotate at their override setpoint in the winding direction. OFF3 is applied after a
parameterizable time period.
The "Web break" signal can also be specified from an external source (e.g. via light barriers).
Siemens AG
SIMOREG DC-MASTER
11-55
Edition 06
05.2007
2.3
Speed compensation control
2.3.1
Dancer control
In this case, a compensation value (magnitude of override 2-10%) is added to the speed controller setpoint.
The drive torque limits are always open.
Every time the velocity changes, the product of moment of inertia x acceleration is added as a
supplementary torque setpoint to the speed controller output.
The ramp generator for the speed setpoint merely serves to produce the dv/dt signal (ramp-up and rampdown time should be set to 0).
Main drive
Winder
Dancer
Actual position
M
P
U
Zsetp Main
Tension setpoint
formation
Zsetp Stop
Winding
hardness
|nact|
to external tension controller

(dancer weight control)
Converter
i
Diameter set value
Core diameter
Calculator
for
diameter
I-controller
D
Monotony yes/no
Set diameter
Hold diameter
Web break
Ramp-function
generator
setpoint limiting
Winding from
top/bottom
Ramp-function
generator
Torque limitation
n-controller
nact
dv/dt
Velocity / speed
calculator
Setpoint
processing
Inching setpoint
kp-Adaption
Maneuver
Dancer position
controller
nrated
Position setpoint
Unwinder/winder
Web width
Material density
D
i
Variable
moment
of inertia
Constant
moment
of inertia
|nact|
Characteristic
of firction
dv/dt
i
+/-
Unwinder/winder
6RA70
Dancer control
12-55
SIMOREG DC-MASTER
Siemens AG
05.2007
Edition 06

The maneuvering setpoint stretches the web between the winder and main drive (clamping point), thereby
moving the dancer out of its end position. This activates the position control and enables the position
controller along a ramp (if "Tension controller ON external" signal is applied); the position controller output
forms the supplementary speed setpoint. The dancer moves to its center position (when position setpoint =
0). At the same time, the speed controller input is switched from the maneuvering over to the operating
setpoint.
The current diameter is calculated continuously from the quotient of web velocity/winder speed.
The tension in the web is determined solely by the dancer weight. If a tension control function is required, the
dancer must be provided with a control device (e.g. pressure cylinder). The tension setpoint is converted to a
pressure setpoint in the 6RA70 and made available at an analog output. A winding hardness characteristic
(tension decreases in proportion to increase in diameter) can be activated as the tension setpoint for the
winder.
If the web breaks, the dancer moves to its end positions. The dancer position control is disabled and the
OFF3 process initiated. It is useful to delay OFF3 on the winder to allow any loose winding material to be
reeled up.
NOTE
It may be necessary to activate the D-action component in the actual-value channel for the position
controller. This helps to dampen the dancer roller and prevents build-up of oscillation between the dancer
and winder.
Siemens AG
SIMOREG DC-MASTER
13-55
Edition 06
2.3.2
05.2007
v-constant control (winder)
The three control methods described above each require a clamping point on the machine, e.g. in the form
of a pair of contacting rollers through which the web is fed and from which the winder receives the web
velocity setpoint. If there is no clamping point on the machine, the winder must be regulated to a constant
peripheral speed. This necessitates sensing the web velocity using a web tacho so that the diameter can be
calculated from v/n.
Since the winder is acting quasi as a "main drive" in this instance, the ramp generator must be used to ramp
the speed setpoint.
Winder
(v-constant)
Web tacho
Unwinder
M
Zsetp Main
Tension setpoint
formation
Zsetp Stop
Converter
Web velocity
Winding
hardness
|nact|
i
Diameter set value
Core diameter
Calculator
for
diameter
I-controller
D
Monotony yes/no
Set diameter
Hold diameter
Web break
Ramp-function
generator
setpoint limiting
Winding from
top/bottom
Ramp-function
generator
nact
dv/dt
Setpoint
processing
Torque limitation
n-controller
Velocity / speed
calculator
Inching setpoint
kp-Adaption
Maneuver
Dancer position
controller
nrated
Position setpoint
Unwinder/winder
Web width
Material density
D
i
Variable
moment
of inertia
Constant
moment
of inertia
|nact|
Characteristic
of firction
dv/dt
i
+/-
Unwinder/winder
6RA70
v-constant control
14-55
SIMOREG DC-MASTER
Siemens AG
05.2007
Edition 06

The machine can be started when the web is tensioned.
Web-break sensing is not operative in v-constant control mode. If the web breaks, the web tacho signal
switches to 0. The calculated diameter would then integrate in direction Dmin, resulting in a corresponding
increase in the winder speed. To prevent this from happening, the "monotone" setting of the diameter
calculator must be activated, i.e. the diameter can only increase for the winder and thus remains constant if
the web breaks.
NOTE
When the v-constant control method is used, the web velocity must be measured using a web tacho. This
also necessitates use of supplementary board SBP pulse encoder evaluation (second actual tacho
value).
2.4
Control function blocks
2.4.1
Stop tension control
The stop tension is injected as a function of the external control and the internal n=0 message. It can be
parameterized as a percentage of the set operating tension. If a constant stop tension is required, parameter
U151.01 must be connected to K0001.
2.4.2
Slip core control
The coil hardness influences, in conjunction with the diameter, the tension setpoint according to an
adjustable characteristic. The setpoints can be taken either from an internal characteristic block or externally
from the bus. Depending on the application, 5 additional characteristics are available. It is meaningful to
work without the slip core control if an unwinder is used. Switching between different characteristics is
implemented via external control.
2.4.3
Variable web width
The selection of different web widths is automatically taken into account for the calculation of the moment of
inertia and therefore also for the resulting feedforward control torque. In this case, the maximum web width
must always be assumed to be 100%. If a fixed web width is required, parameter U150.03 must be
connected to K0001.
2.4.4
Variable material density
The selection of different material densities is automatically taken into account for the calculation of the
moment of inertia and therefore also for the resulting feedforward control torque. In this case, the maximum
material density must always be assumed to be 100%. If a variable material density input is not required,
parameter U525.04 must be connected to K0001.
2.4.5
Calculator for the diameter
The diameter calculator calculates the current diameter from the web velocity setpoint (or actual web velocity
with V-constant control method) and the winder speed. This calculation is only performed if there is a
frictional connection to the continuous material, the tension controller is turned on and the system is in the
run state. Since the diameter can only decrease on an unwinder, and increase on a winder, calculation in the
opposite direction is disabled ("monotone" setting for diameter change).
If the user wishes to alter this behavior, he can enable the diameter calculator to work in both directions by
changing parameter P421 from 1 to 0.
2.4.6
Gearbox stage
The selection of gear stage 2 is automatically taken into account in the calculation of the moment of inertia
and the resulting feedforward control torque. The lower gear ratio must always be assumed to be 100%.
Siemens AG
SIMOREG DC-MASTER
15-55
Edition 06
2.4.7
05.2007
Speed controller adaptation
The proportional gain and reset time of the speed controller can be adapted as a function of moment of
inertia. An optimization process is used to determine the values at minimum and maximum winding
diameters and linear interpolation performed between them.
2.4.8
Tension controller adaptation
The proportional gain of the tension controller can be adapted as a function of moment of inertia.
2.4.9
Web break recognition
If the tension control is turned on, the web break recognition is enabled.
Direct tension control:
Triggering results if selectable torque variance is exceeded and torque drops

below minimum tension.
Indirect tension control: Triggering results if selectable torque variance is exceeded and torque drops
below selectable minimum.
Compensating roll:
Triggering results if instantaneous value exceeds selectable position value.
If web tear recognition is triggered, speed setpoint is set 0 and the calculation for the diameter is disabled.
The unwinder turns backwards, the winder forward, both using their bias. If a compensating (dancer) roll
control is used, the position controller reaches its limit due to the missing instantaneous value. The bias
results from the set intervention. After a selectable time , "Off 3 is triggered.
2.5
Acceleration compensation calculation
In order to ensure a constant tension torque during acceleration and deceleration, the armature current
should be pre controlled using the required torque. The moment of inertia is never a constant value due to
the steady change of the diameter of the winder.
Fixed inertia JF (adjustable using P407)

Variable moment of inertia JV (is calculated using building block 116, and is influenced by web width
(K3008) and material density K3009)
Chapter 4 contains instructions on how to calculate the two torques using available system data.
2.5.1
Determination of fixed value inertia
The fixed moment of inertia is the sum of the following moment of inertia
moment of inertia of motors

moment of inertia of gear corresponding to the shaft of the motor
moment of inertia of winder core corresponding to the motor shaft
additional moments of inertia such as couplers
Formula:
JF = JMotor + JGear +
JCore
i2
For motor or gear values please refer to the datasheet or type plate. The inertia of the winder core has to be
calculated. (Contact formula for the calculation of moment of inertia for solid cylinder or hollow cylinder.). If
the winder's core mass is relatively small, or the gear ratio rather large, the moment of inertia can be
considered irrelevant as it is in this application.
If the moment of inertia of the winder core is not negligible, the user can adapt the calculation accordingly
(taking into account Jcore with i2).
16-55
SIMOREG DC-MASTER
Siemens AG
05.2007
Edition 06
Moment of inertia solid cylinder
J=
b D4
[kgm]
32
Moment of inertia hollow cylinder

J=
b D4 D4Core
[kgm]
32
Calculation of percentage accelerating torque MbF using the fixed moment of inertia JF and the
acceleration time tb. The equation outputs a moment of inertia corresponding to the rated current in %.
Precondition: D = Dcore, tb = th and Jcore is ignored
Determining the value for parameter P407
MbF =
JF nN i
v
[%]
2,865 DCore PN tb
Determining the value for parameter P407
P407 =
2.5.2
MbF th
100%
P542
Determination of the variable moment of inertia
The following equation outputs a value for the maximum variable moment of inertia using the maximum
diameter, density and maximum width.
Jv max =
max b max D max 4 DCore 4

32 i
[kgm]
Calculation of percentage accelerating torque corresponding to the related current in %

Requirements: D = Dmax, tb = th and JF = 0
MbV =
b max max D max 4 DCore 4 nN v
[%]
29,18 i D max PN
tb
Determining the value for Parameter U529:

U529 =
2.5.3
b
D
Dmax
DCore
i
JF
JV
MbF
MbV
MN
nN
PN
tb
th
v
MbV th
100%
P542
Formulas and dimensions
web width [m]

diameter [m]
maximum diameter [m]
diameter of winder - core [m]
gear ratio
constant moment of inertia ( motor, Gear, winder - core) corresponding to shaft of motor [kgm]
variable moment of inertia result of windup material corresponding to shaft of motor [kgm]
maximum accelerating torque corresponding to JF [% of MN]
maximum accelerating torque corresponding to Jvmax [% of MN]
rated motor torque [Nm]
rated motor speed [rpm]
rated motor power [kW]
time of acceleration [s]
ramp up time of web velocity; range 0 Vmax [s]
speed difference [m/min]
specific weight (density) [kg/dm]
Siemens AG
SIMOREG DC-MASTER
17-55
Edition 06
05.2007
Interfaces
3.1
Received data from top level control
Data are exchanged via the communication board 1 (CBP2), PPO type 5.
The functionality implemented in this application can be guaranteed only if the interface settings are made
exactly as described in the table below.
Word
Connector
1
2
Binector
Label
Note
K3001
Control word 1
Control Word 1 according to user manual
K3002
system speed setpoint
K3003
Tension setpoint
K3004
Control word 2
Control Word 2 according to user manual
K3005
Control word 3
Control word 3 for coilers / winders
Set diameter
1.....Set
B3500
B3501
Stop diameter
1.....Stop
B3502
Wind/Coil from top/bottom
0.....top / 1.....bottom
B3503
Winder/Unwinder
0.....Winder / 1.....Unwinder
B3504
v-constant control
If 1, the state of B3506 is not relevant
B3505
Dancer roll control
If 1, the state of B3506 is not relevant
B3506
Dir./Indir. Tension Control
0.....direct / 1.....indirect
B3507
Gear box stage 1/2
0.....Stage1 / 1.....Stage 2
B3508
Switch characteristic for

coil hardness
B3509

coil hardness
The selected characteristic is the result of

the combination of these three binectors
(see truth table of the multiplexer)
B3510

coil hardness
B3511
Stop tension control
1.....On
B3512
Tension control ON ext.
1.....On
B3513
web break ext.
1.....On
B3514
Reserved
B3515
Reserved
K3006
Diameter set value
K3007
Ext. characteristic coil hardness
K3008
Web width
If different materials are produced
K3009
Density
If different materials are produced
10
K3010
Reserved
NOTE
It is not permissible to enable B3504 (v-constant control) and B3505 (dancer roll control) at the same
time. If they are enabled simultaneously, OFF3 will be triggered immediately!
18-55
SIMOREG DC-MASTER
Siemens AG
05.2007
3.1.1
Edition 06
Transmit data to top level control
Data exchange is done via the communication board 1 (CBP2), PPO-Type 5.

Word
Parameter
1
2
Bit
Label
Note
U734.01
status word 1
Status word 1 according to user manual.
U734.02
Actual speed value
K0179
U734.03
Instantaneous tension value
K9240
U734.04
status word 2
Status word 2 according to user manual.
U734.05
status word 3
Status word for winder/coiler status K9113
Tension control is ON
1.....ON
Tension control limit reached
1.....limit reached
Web break
1.....Web break
speed limit succeeded
1.....n>>
Operating mode ambiguous
1.....ambiguous
Reserved
Reserved
Reserved
Reserved
Reserved
10
Reserved
11
Reserved
12
Reserved
13
Reserved
14
Reserved
15
Reserved
U734.06
Current diameter
K9304
U734.07
Actual torque value (motor-related)
K0149
U734.08
Actual current value (motor-related)
K0107
U734.09
Output of tension control
K9249
10
U734.10
Web velocity
K0039
(when an optional SBP board is used for v-constant
control)
3.1.2
Analog input
Maneuver setpoint:
analog input main setpoint X174: 4-5

value range: -10V.....+10V
tension / position feedback value1: analog input 1 X174: 6-7
value range: tension feedback value: 0..........+10V
position feedback value: -10V.....+10V
(both end positions can be sensed with a +/- supply)
3.1.3
Analog output
Tension setpoint for compensating weight if compensating roll control is enabled :
3.1.4
analog output 1
X175: 14-15
Pulse generator input
Input for digital pulse - generator corresponding to User Manual.
Siemens AG
SIMOREG DC-MASTER
19-55
Edition 06
05.2007
Commissioning notes
4.1
Speed feedback adjustment
The following parameters have to be set:

U518
minimum diameter of winder shaft in mm
U519
gear ratio
If two gear box stages are used, the gear box with the smaller gear ratio has to be used
for example: i1=4, i2=5..... U519=4
i=
nMotor
nwinder
U520
rated speed
The motor speed in r.p.m. which occurs for the core diameter, maximum web speed setpoint and
for the gear transmission ratio set at U519 must be set.
U522
standardization of system speed in m/s at maximum setpoint
U523
standardization of diameter in mm. 100% = maximum diameter
4.2
Compensation of friction torque
In general, the friction depends on the speed of the winder. Gear warming can result in negative influence.
After a few hours of operation there is the possibility a post optimization has to be performed.
Procedure:
Operate winder only with speed control, binector B3512 (tension control ON ext.) has to be 0
Disable acceleration compensation f.e. by preventing the dv/dt Signal ( set P542 to 0,01 ).
Take measurements at minimum diameter of winder; set minimal diameter; there may be no connection
to material web.
Start drive via internal ramp function generator, and increase the speed in steps (f.e 10% steps)
Read the actual torque on connector K0142 at every step and enter in U283.01 to .10 (characteristic
block no. 106).
Stop drive
Select "Dancer control" and set binector B3501 (retain diameter) to 1.
Start drive for winder and increase speed in 10 % steps. After each increase check connector K0160
(output of speed controller). The value should be in the range of +/-3%.
NOTICE
Setting the friction compensation too high can cause the winder to break away and produce backlash in
the web while it is unwinding under indirect tension control.
20-55
SIMOREG DC-MASTER
Siemens AG
05.2007
4.3
Edition 06
Compensation of acceleration torque
Unless the acceleration torque is negligible in relation to the remaining torque, acceleration compensation
should be set on the winder with indirect and direct tension control. Acceleration compensation is not
generally required in dancer control mode, and is not generally activated in v-constant mode.
General procedure:
No connection to material web, gear box stage 1 selected (changeover to gear box stage 2 is
automatically taken in to account.
Set ramp up time and ramp down time according to the application
P542 (dv/dt evaluation) is preset to 30s, i.e. the dv/dt value is 100% with a ramp-up or ramp-down time
of 30s. P542 should always be set to the same value as the actual ramp-up and ramp-down time so that
the dv/dt signal (K0191) always corresponds to max. 100%. P542 can, if necessary, be set to another
value for the purpose of finely adjusting the acceleration compensation function.
Select operating state "indirect tension control" and set the bias P405 to 0 % and binector B3501 (hold
diameter value) to 1.
4.3.1
Take measurements at minimum coil diameter; set minimal diameter

Prohibit influence of variable moment of inertia. fe. by setting the web width to 0% using K3008.
Vary the speed of the winder between 10% and 90% and observe K0160 (output of speed controller)
during acceleration and deceleration. The deviation from the final value then equals the acceleration or
deceleration torque.
Set evaluation of the const. moment of inertia in P407 to the value calculated in the paragraph above.
The output of the tension/dancer controller (K9249) can be monitored in direct tension control or dancer
control mode to check the setting. This should remain within a range of +/-3%.
4.3.2
Constant moment of inertia
Variable moment of inertia
Set the following parameters:

U526 = U528 = Maximum possible diameter in mm
P404 = Core diameter as % of maximum diameter
U527 = Core diameter in mm
If possible insert a rather fully loaded coil with a large material width and density.
Set values of actual diameter, density of material and web width
Vary the speed of the winder between approx. 10% and a speed at which the maximum peripheral
speed of the winder roller is not exceeded and monitor connector K0160 (speed controller output) while
the drive is accelerating and decelerating. The deviation from the final value then equals the acceleration
or deceleration torque.
Set evaluation of the var. moment of inertia in U529 such that the value calculated in the paragraph
above is output at K9121 (sum of const. and var. moments of inertia).
The output of the tension/dancer controller (K9249) can again be monitored in direct tension control or
dancer control mode to check the setting. This should remain within a range of +/-3%.
NOTE
If the web width and / or the density is always constant, Parameter U150.03 and / or U525.04 (density)
have to be set to K0001 (100%)
Siemens AG
SIMOREG DC-MASTER
21-55
Edition 06
4.4
05.2007
Optimization of speed controller
Raise torque limits, for example by setting the signal Compensating roll position control ON . (P605 is set
to 150%)
Set the adaptation of kp 2 using P559 and Tn 2 using P560. The value can be calculated using the following
formula
P559 = P560 =
D max 4 DCore 4
D max 4
U529 100 [%]
Requirement: Density and width of material have to be 100%, U529 calculated according to 4.3.2
The thresholds 1 (P556, P557) must always equal to 0.
4.4.1
Run system with fully loaded winder

Perform optimization for speed controller according to the user manual (P051=26).
Use value of P225 (kp) and P226 (Tn) to set P550 / P551 (equals lower values of kp-and Tn adaptation)
4.4.2
Optimization at minimal diameter
Optimization at maximum diameter
Run system with empty winder

Perform optimization for speed controller according to the user manual (P051=26).
The set values in P225 and P226 equal the upper values of kp and Tn adaptation
4.5
Hints for setting parameters
P406:
Gear stage 2.
The value is calculated as follows: i1/i2.
f.e. i1=4, i2=5 P406 = 4/5 = 80%
U198:
Tension control: Value for required tension or torque for web break observation 5%.
Position control: Set observation value for compensating roll, f.e. 90%90%.
U282.01-.10: Characteristic of friction.

U283.01-.10: Only positive values allowed.
U285.01-.10: Characteristic for slip coil control
U286.01-.10: Only positive values allowed.
U288.01-.10: Characteristic (Building block 108).
U289.01-.10: Using this block, you can delinearize the influence of the potentiometer for maneuvering
(a characteristic is set which equals approximately y=f (x))
U450:
Delay web break recognition.

Is used to disable false triggering on short, sudden tension or torque drops.
U453:
Time, during which the minimum tension (set using U198) has to be surpassed to activate the
tension control.
U456:
Time for reverse winding if web break occurs.
22-55
SIMOREG DC-MASTER
Siemens AG
05.2007
U539.01:
Edition 06
Integration time - calculator for diameter
The following formula is used for calculation:
U539.01 =
D max
Dsleeve
v max
dmin
0.95
Siemens AG
SIMOREG DC-MASTER
(D max
Dsleeve ) * v max * U537

* 0,95 [s]
D max * dmin * 0,42
Maximum roller diameter [m]

Minimum (core) diameter [m]
Maximum system speed [m/min]
Minimum thickness of the material [mm]
Factor for incorporating 5 % safety margin
23-55
Edition 06
05.2007
Appendix
5.1
List of freely assignable function blocks used
Block type
Blocknumber
Binector/connector converter
13
Average value during n cycles
16
Adders/subtractors
20,21,22,23,24,25
Sign inverters
35,36
Switchable sign inverters
40,41
Dividers
42,45,46
Multipliers
50,51,52,53,290.....297
High resolution multipliers/dividers
55,56
Absolute value generators with filter
60,61
limiters
65
Limit-value monitors without filters
73,74
Maximum selection
80
Tracking-/storrage element
82
Analog signal selector switches
90.....99
Integrators
101
Characteristic blocks
106,107,108, 280
Simple ramp-function generator
113
Technology controller
114
Velocity/speed controller
115
116
Multiplexer
86,87
AND elements
121.....132
OR elements
150.....167
Inverters
180.....193
NAND elements
200
RS-flipflop
215
Timers
240.....246
Binary signal selector switch
250.....253
PI-controller
260
24-55
SIMOREG DC-MASTER
Siemens AG
05.2007
5.2
Edition 06
List of settable fixed values used
Parameter
Function
Sheet
P401
Inching setpoint
1.1
P402
Adjustment of setpoint actual value difference of torque for web break recognition
17.1
P403
Fine tuning of web (system) speed
8.4
P404
Diameter of core in % of Dmax
8.6
P405
Bias for speed controller in conjunction with direct and ind. tension cont.
14a.1
P406
i gear stage 2
11.1
P407
Constant moment of inertia
11.2
P408
Scaling of torque setpoint
16.1
P409
Influence tension-/position controller
15.5
P410
Stop tension
12.4
P411
Position setpoint (always 0 except in the case of dancer control!)
15.1
P421
Change of diameter monotone 0.....no 1.....yes
8.2
U099.01
Dancer end position sensing
17.1
U099.02
Maximum torque in n control mode
16.5
U099.03
Minimum tension setpoint
12.1
U198
Minimun tension or minimum torque
17.1
U201
Maximum permissible torque deviation for web break detection
17.5
5.3
Detailed schematics
See following sheets 1.....20
NOTE
For easier identification, the winder-specific changes to binector and connector links, and parameter
changes, are displayed on a light gray background. These values deviate from the factory setting.
Siemens AG
SIMOREG DC-MASTER
25-55
26-55
SIMOREG DC-MASTER
P436 (0)
K0401
K
K
K
K
K
K
K
P438.F(208)
K3002
system - speed setpoint
K0401
Select
setpoint
P435 (0)
B
B
B
B
B
B
B
B
Select injection
of inching
setpoint
Inching, bit 1
from control word 1
Inching, bit 0
from control word 1
Inching Setpoint
P401.F (2,00)
Inching setpoint
.01
.02
.03
.04
.05
.06
.07
.08
.01
.02
.03
.04
.05
.06
.07
.08
0
1
0
1
&
0
1
&
0
1
&
0
1
&
0
1
&
0
1
&
0
1
&
&
P437.01
P437.02
P437.03
P437.04
P437.05
P437.06
P437.07
P437.08
=1
0%
ON command
from ON/OFF1
(from sheet
"Crawling setpoint")
&
to sheet "Ramp-function generator"
Bypass ramp-function generator
K0207
K0202
Sheet 1
On command
from INCH
(to control word 1)
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
ON from CW1
.01
.02
.03
Maneuversetpoint
&
P444.B (0)
B
&
P440 (0)
B9350
B
B
B
B
B
B
B
-200%
x1
23
y1
X-Values
y10
.01
.02
.03
.04
.05
.06
.07
.08
x10
+200%
10
Y values
U289.01 to .10 (0)
B9350
120
Select
injection of
crawling setpoint
Switch-on/shutdown
from terminal 37
(from Sheet "Binary inputs 1")
P654.B (1)
B3100
Selection
for shutdown
108
U287.01 (0)
K0011
ON from CW1
(alternatively B0012)
Selection for
switch-on/shutdown
Tension Control OFF 13.8
U320 (1)
B3100
B9454
B
K9231
D Q
<1>
1
R
D Q
1
....
P443.F(207)
K
P441 (0)
K9231
K
K
K
K
K
K
K
.01
.02
.03
.04
.05
.06
.07
.08
Select
crawling setpoint
<1>
Level/edge
P445
0
1
0
1
&
P442.08
0
1
&
0
1
&
0
1
&
0
1
&
0
1
&
0
1
&
&
P442.01
P442.02
P442.03
P442.04
P442.05
P442.06
P442.07
<1> Flip-Flops are reset when P445=0
Maneuver
Sheet 2
K0206
K0201
ON command from
CRAWL
(to control word 1)
to sheet "Ramp-function generator"
to sheet
"Ramp-function
generator"
Switch-on command
from ON/OFF1
(to control word 1)
05.2007
Edition 06
27-55
28-55
SIMOREG DC-MASTER
P323.F (1)
K
P645.F (0)
K
.01 <1>
.02 <1>
.03 <1>
.04 <1>
K0198
.01
.02
.03
.04
K0197
K0196
Minimum
<1> When P643.0x=9, the limit

selected via P642.0x acts
with inverted sign as a
negative limit
P643 (9)
K
K
K
K
r029
K
K
K
K
P642 (2)
P321.F (100,00)
(-300,00...300,00 %)
Additional setpoint
P322.F (1)
K
P644.F(206)
1.8
K0207
Main setpoint
P320.F (100,00)
(-300,00...300,00 %)
Setpoint processing
K0195
K0194
P635.F(194)
K
-1
0%
11
10
01
00
Enable negative direction of rotation from control word 1
Enable positive direction of rotation from control word 1
U607.B(9382)
B
U608.F (15,00%)
Normalization
Sheet 3
to ramp-function generator
input
no direction of rotation
enabled
B0210
K0193
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
P646.B (1)
B
P641.B (0)
B
Select bypass
ramp-function
generator
P640.B (0)
B
&
Run
B0104
ON delay
P319.F (0,05)
(0,00...10,00 s)
Enable changeover of starting integrator
Bypass ramp-function generator from

sheets "Fixed setpoint", "Inching
setpoint", "Crawling setpoint"
Enable ramp-function generator from

control word 1 (with "0"-Signal: y=0)
P639 (167)
.01
K
.02
K
B0161
Shutdown
K0190
(RFG
output)
Enable setpoint from

control word 1
Operating state
- -, I or II
Ramp-function
generator input
0% 0
from starting integrator control

(see P302)
RFG setting 3
Setpoint
r028
Ramp-down time
P312.F
P308.F
Set ramp-function
generator
Setting value
r315.1
n-act -
n-act +
r315.3
P318.F
P302.F
Set RFG Starting
on
integrator
shutdown
r315.2
y=0
dv/dt
B0209
B0208
B0207
r027
2.8
P633 (9)
K
K
K
K
Maximum
Minimum
.01 <1>
.02 <1>
.03 <1>
.04 <1>
.01
.02
.03
.04
P301.F
negative
setpoint limit
K0182
B0206
K0170
K0183
K0181
Sheet 4
Highest negative
setpoint limit
Limitation after
RFG has responded
Speed setpoint
Lowest positive
setpoint limit
Ramp-function generator enable

Ramp-function generator start
Setpoint enable & /OFF1
Set ramp-function generator
Track ramp-function generator
Ramp-down
Ramp-up
positive
setpoint limit
P300.F
0:
1:
2:
3:
4:
5:
7:
15:
15
Display of RFG status on r316
<1> When P633.0x = 9, the positive limit

selected via P632.0x acts with inverted
sign as negative limit
RFG active to status word 2
ramp-down
ramp-up
K0190
P632 (1)
K
K
K
K
P303 - P306
P311 - P314
P307 - P310
Effective
parameters
FS
P634
.01
190
K
.02
K0201 0
Ramp-function
generator setting
2
3
0
0
0
1
1
0
... RFG setting 1 [s]
K0191
Time difference [s]

P542.F
RFG status
r316
P317.F
RFG
tracking
r315.4
Upper transition
rounding
P314.F
P310.F
P306.F
Lower transition
rounding
P313.F
P309.F
P305.F
Rounding
Parameter selection
Ramp-up/down
time
P304.F
K0192
B0211
P303.F
Ramp-up time
P311.F
P307.F
This changeover to RFG settings 2 and 3

has priority over the input of RFG setting 3
by the starting integrator control
RFG-setting 2
.01
.02
Ramp-function generator
start from control word 1
P638.B (0)
B
P637.B (0)
B
P636 (1)
K
K
Ramp-function generator
05.2007
Edition 06
29-55
U516 (0)
K0170
Current diameter 8a.7
4.8
K9304
30-55
SIMOREG DC-MASTER
U240 (0)
K9257
5.8
K
U241 (0)
B9550
.01
.02
1
min.Diameter
(10,0...6553,5mm)
U518.F (6500,0)
(-32,768...32,767 m/s)
n022
velocity set point
Normalization
U523 (1638)
(10...60000mm)
Normalization
U522 (16,38)
(0,01...327,67m/s)
U517 (0)
Speed calcualtion
v set
K9210
i 11.3
90
U145 (1)
K9210
K9214
.01
.02
.01 x1
.02 x2
x1 *100%
x2
45
K9145
U140 (0)
K9145
nset
U141 (0)
B9389
RESET
(Q=0)
SET
(Q=1)
U520.F (1450)
Rated speed
n rated
winding from top / bottom 18.5
POWER ON
<1>
U415 (0)
B9362
B0121
U519.F (1,00)
Gear ratio
Web break 17a.3

n<
vset i
nset = ----------------- 100%
D nrated
Velocity / speed - calculator
115
y = -x
-1
B9551
215
B9550
speed set point

n023
speed set point
K9140
40
Sheet 5
K9257
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
P555.F (0)
K
x
y
I comp. n contr.
P630 (162)
K
0%
n contr. Kp(act)
r219
Adap.point 2
P554.F (0)
K9437
P563.F(-100,00)
(-199,99...0,00%)
P562.F(100,00)
(0,00...199,99%)
-1
K0176
dn(droop)
P557.F (0,00)
(0,00 ... 100,00 %)
Adap.point 1
P226.F (0,650)
(0,010 ... 10,000)
n contr. Tn2
P551.F (0,650)
(0,010 ... 10,000)
n contr. Tn1
Adaptation of the integration time
Speed controller P gain

to Sheet Speed controller 2
n contr. droop Kp (act)

r217
P561.F (0,00)
(0,00 ... 100,00 %)
Variable moment of inertia 11.6
P559.F (0,00)
(0,00 ... 100,00 %)
Adap.point 2
Enable droop from

control word 2
Adap.point 1
P558.F (0,00)
(0,00 ... 100,00 %)
P227.F (0,0)
(0,0 ... 10,0)
n contr. droop Kp2
P552.F (0,0)
(0,0 ... 10,0)
n contr. droop Kp1
P556.F (0,00)
(0,00 ... 100,00 %)
Adap.point 1
(3.0)
P225.F (3,0)
(0.10 ... 200,00)
200.00)
(0,10
n contr. Kp2
P550.F (3,00)
(0,10 ... 200,00)
n contr. Kp1
Droop (with adaptation)
Variable
P553.F (0)
moment
K9437
of inertia 11.6
Adaptation of the P gain
Speed controller (1)
P560.F (0,00)
(0,00 ... 100,00 %)
Adap.point 2
Sheet 6
Speed controller integration time

to Sheet Speed controller 2
n contr. Tn(act)
r218
05.2007
Edition 06
31-55
32-55
SIMOREG DC-MASTER
P115
P202.F (0)
(0 ... 3)
quality
0%
r025
K0177
0%
n(act)
Fast stop
P629 (177)
K
P627 (178)
K
P200.F (0)
(0 ... 10000 ms)
Smooth. n(act)
P228.F (0)
(0 ... 10000 ms)
Smooth. n(set)
P203.F (1)
(1 ... 140 Hz)
Resonant frequency
P204.F (0)
(0 ... 3)
quality
P206.F (0) P205.F (0)

(0 ... 100ms) (0 ... 1000ms)
T1
Tv
P626.F(167)
K
K0166
K0167
n(set,limit)
P625.F(170)
K9140
n(act,filter)
P083.F
P201.F (1)
(1 ... 140 Hz)
Resonant frequency
135,05
* P115
P628 (179)
K
n(act)
P609 (0)
K
Internal
actual EMF
value
K0040
Actual value from

pulse encoder
K0013
Main actual value
1
-1
Reverse polarity of actual speed value on field

reversal and applied negative field direction
from Sheet "Field reversal with SIMOREG
6RA70 single-quadrant device"
Speed controller (2)
r026
P621 (176)
K9451
K0178
-1
P624 (0)
K
K0168
K0169
n(act, smooth)
K0179
P623 (179)
K
Contr. dev.
P620 (165)
K
r219
r023
r218
Kp
P698.B (0)
B
Absolute actual speed value
K0166
Switchover P222.F
speed
A
B<A
&
Enable speed controller from

control word 2 and sequencing control
Stop I component when G-limitation,

current limitation, torque limitation, speed
limiting controller reached
Stop I-comp. n contr.

P696.B (0)
B
Set I-comp. n contr.

P695.B (0)
B
Set.val.I-comp.n contr.
P631 (0)
K
K0165
dn
Speed controller P gain

from Sheet Speed controller 1
Supplementary
speed setpoint
14a.6
Speed controller integration time

from Sheet Speed controller 1
n(set, smooth) P622 (174)

K
K0174
Switchover to
P controller
Tn
B0205
Fast stop
K0148
Sheet 6a
M(set,n contr.)
P component
I component
Speed controller
setpoint/act. val. deviation
1
Friction and
moment of
inertia
compensation P223.F (1)
0%
P502 (0)
K
K0160
K0161
K0162
K0164
P229.F
Master/slave drive from control word 2:

Make I component follow on slave drive
so that M(set, n contr.) = M(set, limit) and set
speed setpoint = actual speed value (K0179)
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
K0164
K0168
dv/dt * P542
vom Hochlaufgeber
-P530
-100%
P520
P521
0%
100%
P530
P543.F
K0191
P541.F
P540.F
K0152
K0150
Dancer or v-constant control 14.4
P619 (191)
K9215
(0...10000ms)
P546.F (0)
K0172
P697.B (1)
B9385
0%
K0173
ATTENTION! Do N O T activate, contact sheet 11 for further information
Compensation of moment of inertia (dv/dt - Addition)
K0179
Compensation of friction
K0171
Sheet 7
05.2007
Edition 06
33-55
34-55
SIMOREG DC-MASTER
.01
U391 (0)
B9390
.01
.02
B0421
Monotone yes / no
P421.F (1)
Un./Winder 18.5
|nact| 6a.3
U172 (0)
K0166
U242 (0)
System speed.
setpoint after rampg. 4.5
K0170
K0039
Actual value 20.7
from web tacho
U243 (0)
v-constant control 18.5
B9391
U160 (0)
K9211
-1
-1
U161 (1)
K9211
91
191
.01
.02
.03
K9455
U331 (1)
B0421
B
B9461
16
60
Smooth.
0...10000ms
U162 (100)
.01
.02
.03
U330 (1)
B0421
B
18.5 B9390
B9461
average
of
n Cycles
Anzahl der
Abtastzyklen
U173.01 (10)
Calculator for diameter (1)
&
&
B9361
131
B9360
130
U152 (0)
K0403
K9160
K0001
x1 * x2
100%
x1 * x2
100%
increasing monotone
decreasing monotone
K
K9304
U120 (0)
K9167
.01
.02
.03
K9152
K9153
U155 (1)
K0404
K9120
y
x
X<B
y1
v
n
K9167
55
K9155
Sheet 8
K9410
280
B9151
B9150
y=
x4 / x3
x10
+200%
10
U282.11 to .20 (0)

X values
23
y10
Y values
U283.11 to .20 (0)
65
B+
X>B+
x4 (32Bit)
<1>
Diameter limits
x4=
x1 * x2
-200%
x1
B+
.01 x1
.02 x2
.02 x3
Stalls at X< -0.2% to Y=-5%

and at X>+0.2% to Y=+5%
at -0.2%<X<+0.2%, Y=0
U281.02 (0)
K9120
20
-1
FS
.01
0
.02
K0001 9165
.03
K0404 9166
U175
K9155
K9153
K0404
K9152
Core
diameter
P404.F (10,00)
Core diameter 8.5
53
.01 x1
.02 x2
52
.01 x1
.02 x2
Current 8a.7
diameter
100,00 %
U153 (0)
K9455
K9214
i 11.3
K0403
K9160
Adaption of
system speed.
P403.F (100,00)
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
.01
U533 (0)
K
Diameter set value 9.8 K9213
Set diameter 9.8
U532 (0)
B
B9382
K9300
.01
U536 (1)
K
PI-controller
.01 Setzwert fr I-Anteil

.11 Setzwert fr PI-Regler-Ausgang
U537.01
(0,2)
.01
U538 (1)
K9304
1 = Stop I-component in negative dir. <7>
0 = Disable PI - controller <1>

1 = Stop I - component <5>
1 = Stop output <3>
1 = Stop positve I - component <6>
T1
260
8a.7
.01 1 = Set I - component <4>

.11 1 = Set value PI - controller output <2>
Set PI - controller
.01
.11
.21
.31
.41
Enable PI - controller
U530 (0)
K9410
U531 (0)
B0001
Hold diameter 9.8 B9381
Tension feedb < GW 17a.8 B9483
decreasing monotone 8.4 B9360
increasing monotone 8.4 B9361
8.8
8.8
.01
Smooth
U535.01 (50 ms)
U534 (1)
K
Calculator for Diameter (2)
0
0
Tn
U539.01
(3,000 s)
K9303
K9302
K9301
.01
U543.01
(100,0)
U542 (1)
K
* -1
G(s) =
negative limit
K9307
B9650
Regler an Ausgangsbegrenzung
Current diameterl
Sheet 8a
Priority:
1. Disable PI - controller
2. Set Output
3. Stop Output
4. Set I - component
5. Stop I -component
6. Stop I- component in pos. direction
7. Stop I- component in neg. direction
B9670
Controller has reached
negative limit
K9304
PI - controller output
B9660

negative limit
K9305
positive limit
K9306
1
1 + sTn
--------- * Kp * --------1 + sT1
sTn
Transfer function:
<5> Stop I - component:

P -component active
Stop I - component
Output = P-component + I-component
<6> Stop I - component in positive direction:
P-component active
If controller input (X) positive,
then I - component is stopped
Output = P-componentl + I-component
<7> Stop I - component in negative direction
P-component active
If controller input (X) is negative,
then the I - component is stopped
Output = P- component + I - component
U545.01
(100,0)
Stop I - component in
neg. direction and set to
negative limit
(K9307)
Stop the I - component

in positvie direction,
and limit it to positive
(K9305)
I-component
P-component
U540.01 (0) U541.01 (1)

0 = Set
0 = set
P-component I-component
zero
U544 (9306)
zero
.01
K0404
Core diameter 8.5
0 0
Kp
05.2007
Edition 06
35-55
B0001
Power On Imp.
U440 (0)
B0001
B
U443 (0)
B9050
B
Stop / Set diameter
36-55
SIMOREG DC-MASTER
1 = Reset
Impulsgenerator
On / Off delay.
T
T
delayed Off
Delayed ON
U441 (5,000)
(0,000...60,000s) U442 (0)
1 = Reset
Impulsgenerator
U445 (3)
On / Off delay.
T
T
delayed Off
Delayed ON
U444 (3,000)
(0,000...60,000s)
240
Current
diameter
241
U380 (0)
Tensioncontrol ON ext. 18.7
B9396
B9581
B9580
8a.7
B9583
B9582
U223 (0)
B9580
B
B
U222 (0)
K9304
.01
.02
.03
1 y=x
freeze y
&
Prioritt:
1. RESET
2. TRACK
3. STORE
82
n<
B9354
Power On Imp.
124
Web break 17a.3
B9380
150
U247 (0)
B9582
U352 (0)
B9354
B9050
B
B9380
B0121
B9386
U351 (0)
K9195
K9195
U246 (0)
K3006
ext. Diameter setvalue
Mode Power On
U224 (0)
.01
.02
.03
U324 (1)
B9387
B9454
B0105
Set diameter ext. 18.5

Tensioncontrol OFF 13.8
Operation
B9450
.01
.02
.03
180
U350 (0)
B9450
Stop diameter ext. 18.5 B9388
Operation B0105
.01
.02
.01
.02
.03
.01
.02
.03
K9213
93
B9382
152
B9381
151
Sheet 9
Diameter
set value
Set diameter
Stop diameter
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
U525 (1)
K9304
K
K
Density of material K3009
Current diameter. 8a.7
.01
.02
.03
.04

U529 (1,00)
(0,10...100,00)
Normalization of
max. diameter
U528 (10000)
(10...60000mm)
Normalization of
Core diameter
U527 (10000)
(10...60000mm)
Normalization of diameter
U526 (10000)
(10...60000mm)
D4 - DCore4
JV = ------------------ * K
Dmax4
116
K9258
Sheet 10
05.2007
Edition 06
37-55
38-55
SIMOREG DC-MASTER
|nact| 6a.3
K0166
U281.01(0)
292
.03 x1
.04 x2
290
.03 x1
.04 x2
.01
.02
x1 * x2
100%
x1 * x2
100%
y1
x
x10
+200%
10
U282.01 to .10 (0)

X values
23
y10
Y values
U283.01 to .10 (0)
-200%
x1
Characteristic of firction
U151 (0)
K0191
K9214
dv/dt 4.6
i 11.3
U150 (0)
K3008
U248 (0)
K0001
K0406
K9258
K0406
K0001
U249 (0)
B9394
Web width
Var. moment of inertia 10.7
P406.F (100;00)
Gear stage 2
100,00 %
Gear stage 1/2 18.7
293
.05 x1
.06 x2
x1 * x2
100%
x1 * x2
100%
.01
.02
.03
291
.05 x1
.06 x2
U122 (0)
K9156
K9229
U151 (0)
K9121
K9432
U150 (0)
K9214
K9214
K9229
106
K9432
K9430
K9214
94
Compensation of aceleration and friction
i
K9431
22
K9122
K9433
8a.7
Current
diameter
.01 x1
.02 x2
.03 x3
297
unw. / winder 18.5
<1>
.01
.02
U135 (0)
K9122
U250 (0)
K9122
K9135
56
K9156
U121 (0)
K9437
K0407
K
U251 (0)
B9390
y=
x4 / x3
P407.F (0,00)
fixed moment
of inertia
K9437
K0407
x4 (32Bit)
x1 * x2
100%
x4=
x1 * x2
.05 x1
.06 x2
Summ of pre
control moments
U156 (1)
K9433
K9304
K
U153 (0)
K9431
K9430
.01
.02
.03
y = -x
-1
21
35
K9135
K9215
95
K9121
Sheet 11
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
FS
.01
0
.02
0
.03
1
1 = Enable simple
ramp generator
0 = Set ramp gnerator
to zero
Stop simple ramp

generator
113
<1>
TH
y=0
TR
0s
y=x
U099.03 (5.0)
Min. tension
K9503
ext. Tension s.point
U220 (0)
K3005
K9503
K
.01
.02
.03
x1
x2
x3
MAX
<2> from electronic system powersupply monitor
y
K9193
80
Stop tension value

P410.F (0,00)
Priority:
1. S (SET)
2. R (RESET)
B9191
23
y10
K0410
y1
K0410
.01 x1
.02 x2
Stop Tension 18.7

n<
U151 (0)
K9193
K9230
x1 * x2
100%
U329 (1)
B9395
B0121
B
51
K9151
.01
.02
.03
U152 (0)
K9450
K9236
K0001
K3007
U311 (0)
K9230
K
K
K
K
K
U310 (0)
B3308
B3309
B3310
.03 x1
.04 x2
.01
.02
.03
.04
.05
.06
.07
.08
.01
.02
.03
&
B9359
129
X0
X1
X2
X3
X4
X5
X6
X7
U258 (0)
K9193
K9151
U259 (0)
B9359
U254 (0)
K9434
K
U255 (0)
B9392
x1 * x2
100%
dancer. roll pos. ctrl. 18.5
K0001
ext. slip core control
Switchover
characteristic of
slip core control
100,00 %
x10
+200%
10
U285.01 to .10 (0)

X values
-200%
x1
B9190
Y values
U286.01 to .10 (0)
0 = Ramp generator
first run
K9236
107
U284.01(0)
K9304
8a.7
Current diameterl
ramp - down time

U303 (5,00)
POWER ON <2>
freeze y
0s
ramp - up time
U302 (5,00)
<1> If U301.01 = 9191 is active only once after beeing enabled (Flanke log. "0" auf "1")
9.4
U301
B9582
B
B
12.7
Tension setpoint
U300 (0)
K9219
Override
ramp gnerator
Setpoint processing
.01
.02
.01
.02
294
K9434
B3 B2 B1
86
0
1
0
1
0
1
0
1
K9450
0
0
1
1
0
0
1
1
X0
X1
X2
X3
X4
X5
X6
X7
Sheet 12
Tensionsetpoint
K9219
99
K9217
97
Tension control after

influence of slip core control
0
0
0
0
1
1
1
1
B3 B2 B1
05.2007
Edition 06
39-55
40-55
SIMOREG DC-MASTER
B9452
182
P750 (0)
K9434
-1
-1
.01
.02
.03
U452 (0)
B9452
B
P751 (0)
U323 (1)
B9588
Tensioncontrol ON ext. 18.7 B9396
OFF3
B0110
U382 (0)
B9483
Tension setpoint after

slip core control
12.7
tension feedback value

< limit or.
actual position 17a.8
> limit
Tensioncontrol enable
&
244
B9588
U455 (0)
B9353
B
Smooth.
(0...10000ms)
P752 (0)
B9353
123
r006
y [V] =
x
* P753
100%
Normalization
-200,00...+199,99V
P753 (10,00)
K0026
Tensioncontrol ON
1 = Reset
Offset
-10,00...+10,00V
P754 (0,00)
D
A
X175
U384 (0)
B9353
1 = Reset
B9589
On / Off delay.
T
T
Impulsgenerator
delayed Off
15
14
U457 (1)
Impulsegnerator
On / Off delay
T
T
Delayed Off
U456 (10,000)
(0,000...60,000s)
Delayed ON
0
Delayed ON
U454 (0)
U453 (5,000)
(0,000...60,000s)
Tensioncontrol OFF
B9454
184
Sheet 13
Tension setpoint
for external Tensioncontrol
B9590
Tensioncontrol del. OFF
B9591
245
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
Dancer control 18.5
v-constant control 18.5
.01
.02
.03
.01
.02
.03
U400 (1)
B9391
B9392
B
U355 (0)
B9391
B9392
B
U393 (0)
B9391
Switchinglogic for the control methods
&
v-constant or
Dancer control ON
B9385
155
B9470
200
v-constant control
B9463
193
U392 (0)
B9470
B9462
192
P659 OFF3
Operating mode ambiguous
Sheet 14
05.2007
Edition 06
41-55
Bias for speed

controller in
conjunction with
tensioncontrol
P405.F (5,00)
K0405
42-55
SIMOREG DC-MASTER
y = -x
-1
U385 (0)
Unwinder/Winder 18.5
B9390
U136 (0)
K405
U388 (0)
Dancerrollcontrol 18.5
B9392
36
Dir./ ind.
tensioncontrol 18.5
U386 (0)
B9393
y
K9136
B9455
185
B9458
188
B9456
186
U353 (0)
B9392
B9456
B
U312 (0)
K
14a.1 K0405
K9136
K
Output of Tension/
position controller 15.8 K9254
K
K
K
U310 (0)
B9484
B9485
Dancerrollcontrol 18.5 B9392
U326 (1)
B9454
Zugregelung EIN 13.4
B9353
Unwinder/Winder 18.5
B9390
U325 (1)
B9458
Tensioncontrol ON 13.4 B9353
B9455
Switchinglogic for the control methods (2)
.01
.02
.03
.04
.05
.06
.07
.08
.04
.05
.06
.01
.02
.03
.01
.02
.03
.01
.02
.03
&
&
X0
X1
X2
X3
X4
X5
X6
X7
B3 B2 B1
0
0
0
0
1
1
1
1
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
Supplementary speed setpoint
K9451
87
.01
.02
.03
.01
.02
.03
U354 (0)
B9392
B9459
B
U327 (1)
B9353
B9383
B9384
B3 B2 B1
U473 (0)
B9392
B9356
B
U472 (0)
B9392
B9355
B
Web break 17a.5
B9356
126
Tensioncontrol ON 13.4
B9355
125
B9383
153
X0
X1
X2
X3
X4
X5
X6
X7
.01
.02
.03
.01
.02
.03
B9485
253
B9484
252
&
B9384
154
B9357
127
Sheet 14a
Enable Tension/
pos. controller
Edition 06
05.2007
Siemens AG
Siemens AG
SIMOREG DC-MASTER
U486 (0)
K
n016
.01
.02
.03
.04
U485.F (0,00)
P411.F (0,00)
n017
.01
.02
.03
.04
Position setpoint
Tension setpoint
U484 (0)
K0411
12.8 K9217
K
K
K0411
U480 (0)
15b.7 K0230
K
K
K
Kp-factors
0,10...30,00
U492.F U493.F
(1,00)
(1,00)
U489 (0)
K9437
11.6
Var. moment of inertia
X2
K9240
1
0
K9241
U502.F (0)
<1>
K9244
Kp-factor
U483.F(0)
14a.8
Smooth.
U481.F(0,00s)
1000
n018
U505 (0)
K
U506 (0)
B
U500 (0)
B9357
0%
K9245
K9246
K9242
Hold I -component
Set I - component
Kp
Tn
1000 1
K0409
U494.F
(3,000)
K9248
K9247
U503.F (1) U504.F (1)

0 = Set
0 = Set
p-component I-component
zero
zero
U509 (9252)
K
U510.F
(50,0)
Hold I - component
K9249
U507 (1)
K9221
15a.5
U508.F
(50,0)
U142 (0)
K0409
U143 (0)
B9390
U495.F(0)
Tension/Position-Controller
U488.F
(3,00)
U499.F
(-100,00)
U497.F(0,0)
Influence Tension/
Un-/Winder 18.5
position contr.
P409.F (100,00)
Enable Tension / pos. controller
D-Component
U482.F(0,000)
U498.F
(100,00)
U496 (0)
B
Statik addition for
controoler
114
0 = D-component influences only the feddbackvalue channel

1 = Normal PID-Regler: D-componentl is active for control deviation
K9243
0%
0% 1
0
Setpoint
U490.F U491.F
(0,00) (100,00)
0,00...200,00%
Threshold
X1
Smooth. [s]
U487.F(0,00)
Y1
Y2
Tension- or Dancer - roll pos. contrl.(1)
-1
* -1
n019
K9251
negative limit
K9253
K9254
Output of Tension/
position controller
K9250
positive limit
K9252
K9141
41
Sheet 15
B9499
output limit
U511 (1)
K9141
U512.F
(100,0)
I-component
P-component
y = -x
05.2007
Edition 06
43-55
Enable
Tension/pos. controller 14a.8
U390 (0)
B9357
100,00 %
Tension-/position controller (2)
B9460
190
K0001
U267 (0)
U266 (0)
B
B9460
U264 (0)
K0001
.01
.02
Set value
Set integrator
Stop
integrator
y
x
Tn
Integrationtime (Tn)
(10...65000ms)
U265 (3000)
y
K9221
101
Tension - / position
controller limit
Sheet 15a
Edition 06
05.2007
44-55
SIMOREG DC-MASTER
Siemens AG
Siemens AG
SIMOREG DC-MASTER
Current diameter
Instentaneous value of moment
U145 (1)
K0149
K9304
.03 x1
.04 x2
Tension-/position controller (3)
x1 *100%
x2
42
K9142
14a.5
P456 (0)
B9383
B
.03
.01
.02
P457 (0)
K
K
K
.01
.02
P458 (0)
B
B
.03
.01
.02
.01
.02
Connector selector switch
P455 (0)
K9142
K0015
Tension/pos.current value
Dancer control or
dir. tension control
K0231
K0230
Sheet 15b
05.2007
Edition 06
45-55
P408.F (100,00)
Normalization of
moment setpoint
K0408
Output
Tension/Pos. Contrl. 13.8
Tension setpoint 12.7
U153 (0)
K9435
K0408
U123 (0)
K9254
K9217
K
.03 x1
.04 x2
.01
.02
.03
K9123
x1 * x2
100%
.05 x1
.06 x2
x1 * x2
100%
.01
.02
.03
K9435
U124 (0)
K9436
K9215
K
295
B9453
U321 (1)
B9453
OFF3 B0110
Tensioncontrol ON 13.4 B9353
183
K9436
Summ of precontrol moments 11.8
296
U152 (0)
K9123
Current 8a.7 K9304
diameter
23
U383 (0)
B9385
Dancer or v-constant control 14.4
Determination of moment setpoint if tensioncontrol is active
.01
.02
.03
24
&
K9124
U099.02 (100)
Torque limit in
n control mode
K0408
B9351
121
U252 (0)
K0408
K9124
U253 (0)
B9351
.01
.02
0
K9216
96
P605.01
Moment feedback value
if tension control is active
Sheet 16
Edition 06
05.2007
46-55
SIMOREG DC-MASTER
Siemens AG
Siemens AG
SIMOREG DC-MASTER
U099 (90,00)
Dancer roll
endposition
K0402
.01
.02
U150 (0)
K9161
K0402
-1
-1
.01
.02
.03
.01 x1
.02 x2
U164 (1)
U244 (0)
K9186
K9501
U125 (0)
Moment setpoint 16.7
K9216
K
K9150
Adjustment of
momentsetpoint - actual value diff.
P402.F (100,00)
U163 (0)
instentaneous value K0142
of moment
U198 (5,00)
Minimum
tension or
torque
K9186
K9501
U245 (0)
B9392
Web break recognition (1)
x1 * x2
100%
K9212
25
K9125
16.7
50
K9150
U146 (1)
K9125
K9216
0...10000ms
U165 (0)
92
.01 x1
.02 x2
K9161
61
U256 (0)
K9150
|Tension, position or
K9241
torque actual values| 15.3
U257 (0)
Dancer control or
B9383
dir. tension control 14a.5
x1 *100%
x2
.01
.02
46
K9146
U201 (20,00)
Maximal allowed
moment deviation
K9187
K9218
98
FS
U200
.01
K9146 0
.02
K9187 9187
74
U197
FS
.01
0
K9218
.02
K9212 9186
73
U202
U199
U199
U199
U202
U202
U202/2
U202
U199
U199/2
Hysteresis
0,00...199,99
U202 (0,00)
Hysteresis
0,00...199,99
U199 (0,00)
A=B
A<B
<1>
|A|<B
A=B
A<B
<1>
|A|<B
Sheet 17
B9174
B9173
B9172
B9171
B9170
B9169
05.2007
Edition 06
47-55
.01
.02
.03
.01
.02
.03
U332 (1)
B9386
v-konstant-Regelung B9463
B
U446 (0)
B9590
B
U356 (0)
B9586
Web break ext. 18.7 B9397
B
Tensioncontroll OFF dellayed 13.8
U381 (0)
B9482
181
48-55
SIMOREG DC-MASTER
&
.01
.02
U470 (0)
ind. Tensioncontrol 18.5
B9393
B
B9173
Moment setpoint - 17.8
actual value diff. > limit
Web break recognition (2)
U322 (1)
B9483
B9451
B9584
B9362
132
Web break
B9386
156
1 = Reset
Impulsgenerator
.01
.02
.03
B9482
250
&
242
U328 (1)
B9362
B9591
B
B9585
B9584
.01
.02
.03
U389 (0)
B9362
B9459
189
&
B9358
128
U387 (0)
B9169
Web break
Actual tension and/or

actual torque < limit or
actual position > limit 17.8
B9352
122
Tensioncontroll OFF del. 13.8
Mode
U448 (0)
On / Off delay.
T
T
Delayed Off
Delayed ON
U447 (5,000)
(0,000...60,000s)
B9451
.01
.02
.03
U458 (0)
B9358
B
U449 (0)
B9352
B
187
.01
.02
.01
.02
T
O
Mode
1 = Reset
Impulsgenerator
Mode
U460 (3)
On / Off delay.
T
T
Delayed Off
O
T
Delayed ON
O
T
1 = Reset
U459 (1,00)
(0,00...600,00s)
Impulsgenerator
On / Off delay.
T
T
Delayed Off
Delayed ON
.01
.02
.03
U451 (0)
U471 (0)
B9392
B9169
B9457
U450 (2,000)
(0,000...60,000s)
B9457
Dancerroll control 18.5

17.8
246
B9593
B9592
B0587
B9586
Sheet 17a
OFF 3
P658
B9483
251
Web break int.
243
Edition 06
05.2007
Siemens AG
Setting Controlword 3
Siemens AG
SIMOREG DC-MASTER
.01
.02
.03
.01
.02
.03
.01
.02
.03
.01
.02
.03
.01
.02
.03
.01
.02
.03
U359 (0)
B
B3502
B
U360 (0)
B
B3503
B
U361 (0)
B
B3504
B
U362 (0)
B
B3505
B
U363 (0)
B
B3506
B
.01
.02
.03
U358 (0)
B
B3501
B
U357 (0)
B
B3500
B
B9393
Dir./ ind. tensioncontrol
163
B9392
Dancerrollcontrol
162
v-constant control
B9391
161
B9390
Unwinder/Winder
160
B9389
Winding from
top / bottom
159
B9388
Hold diameter ext.
158
B9387
Set diameter ext.
157
U367 (0)
B
B3513
B
U366 (0)
B
B3512
B
U365 (0)
B
B3511
B
U364 (0)
B
B3507
B
.01
.02
.03
.01
.02
.03
.01
.02
.03
.01
.02
.03
B9397
Web break ext.
167
B9396
Tension Control ON ext.
166
B9395
Stop tension
165
B9394
Gearstage 1/2
164
Sheet 18
05.2007
Edition 06
49-55
Tensioncontrol ON 13.4
Tension controller operates in limit 15.8
Web break 17a.3
speed limit succeeded
Operating mode ambiguous 14.6
Statusword 3
U113 (0)
B9353
B9499
B9386
B0120
B9462
B
B
B
B
B
B
B
B
B
B
B
.01
.02
.03
.04
.05
.06
.07
.08
.09
.10
.11
.12
.13
.14
.15
.16
15
14
13
12
10
Bitfield 4
Binector- / Connektorchanger 1
11
5
4
n013
13
K9113
Statusword 3
Sheet 19
Edition 06
05.2007
50-55
SIMOREG DC-MASTER
Siemens AG
Siemens AG
SIMOREG DC-MASTER
Control track
Zero pulse
Track B
Track A
Power supply
Pulse encoder
75
74
73
72
71
70
69
68
X401
67
66
65
64
63
62
61
60
X400
CTRL - = M
CTRL +
Zero pulse -
Zero pulse +
Track B -
Track B +
Track A -
Track A +
Fine pulse 2
+5/15V
B7003
B7002
B7001
Fine pulse 2
B7000
Control track
Pulse encoder evaluation
Number of lines
100...20000
U792 (1024)
<2>
Coarse pulse 2 <2>
Coarse pulse 1
Encoder type
Voltage level
U793=0: A/B track
U790.01: A/B, CTRL track
U793=1: Forward/reverse tracks U790.02: Zero pulse
<2>
Coarse pulse 2 <2>
Coarse pulse 1
Ground coarse/fine
- Vss
+ Vss
Supply voltage
U791 = 0: 5V
U791 = 1: 15V
SBP pulse encoder evaluation

(optional for web tacho, required only in v constant control mode)
<1>
Position acquisition
n024.02
n795
<1> 0=Enable position counter (KK0038)

1=Reset (KK0038:=0)
<2> The signals "coarse pulse 2" and "fine pulse 2"
are only routed to binectors B7002 and B7003
in the SIMOREG DC Master.
They have no other function.
&
&
Reset
position counter
U796
Speed measurement
Reference speed
50.0...6500.0
U794 (500,0)
KK0036
B0056
B0055
K0038
K0039
Sheet 20
Position
value range:
8000 0000H to 7FFF FFFFH
Overflow
Underflow
Speed actual value in rpm
Speed actual value
05.2007
Edition 06
51-55
Edition 06
5.4
05.2007
Parameter list
Download file "achswickler.winder.dnl" is stored in the "Applications_d" folder on the SIMOREG DCMASTER CD-ROM (Order No.: 6RX1700-0AD64).
The file "achswickler.winder.dnl" has been created with "DriveMonitor" and can only be loaded with this
application. This should not be done until the basic commissioning process (motor data settings, optimization
runs) is finished. Parameters modified during basic commissioning are not altered by the contents of the
download file.
NOTE
After "achswickler.winder.dnl" has been downloaded, parameter U969 must be set to 4. This ensures
that unconnected function blocks are deselected and any connected function blocks are selected
(activated) if they are not selected already.
Deselecting any function blocks that are not needed reduces the load on the processor
(see visualization parameter n009).
52-55
SIMOREG DC-MASTER
Siemens AG
Edition 06
SIMEA
Siemens Industrial Manufacturing,
Engineering and Applications
P.O. Box 83, A-1211 Vienna
05.2007
Siemens AG, 2000-2007

Subject to change without notice
SIMOREG DC-MASTER
Printed in EU (Austria)
SINAMICS DCC
Winder V3.2
Siemens AG 2012. All Rights Reserved.
Converting Toolbox
Introduction
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
The application SINAMICS DCC Winder was developed with the

objective to address many of the known winder applications using
one application software.
If required, the application can be configured and/or also changed.
Using the application SINAMICS DCC Winder allows winders and
un-winders to be implemented in a wide range of applications, e.g.
foil making machines, printing machines, coating machines...
Example
Configuration
Tools
The winder application can be used on the following devices:

SINAMICS S120, S150, G130, G150
SINAMICS DCM
SINAMICS Integrated in SIMOTION D4xx-2
Industry Sector
Converting Toolbox
Benefits when using the Application
Introduction
Shorter engineering and service times (same look & feel)
Benefits when
using the
Application
Industry standards are used
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools
Supported by the various PM Application Centers

Continuously updated in the Intranet
Essentially open source code so that you can adapt the functions
to your requirements
User Manuals in English and German
Free of Charge

Industry Sector
Converting Toolbox
Contents of the Application
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
PowerPoint presentation (English / German)

Programming in CFC
User Manuals (English / German)
Feedback sheets (English / German)
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality
Introduction
Center Winder or tandem center

winder
Coil
Benefits when
using the
Application
Contents of the
Application
winds material around a core or mandrel

the coil is driven by a motor
the motor can be operated in torque or
speed controlled mode
Tension
dancers or load cells for tension control are

optional
Scope of
Functionality
Roll hardness controlled by web tension

and optional by nip pressure
Function Block
Overview
Example
Configuration
Turret winder
Coil
Tools
two or more centerwinds on a rotating axis

Roll change on the fly
Tension
Nip
A flying knife will slice the material and

automatically hold it while it starts to wrap
a new coil
Industry Sector
Converting Toolbox
Introduction
Min Diameter DMin
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools
Dact Actual Diamter
Material Velocity V
External Moment of
Inertia JCore
Web Width w
Motor Moment of Inertia
JMotor
Max. Diameter
DMax
Gear, Gear ratio i
Moment of Inertia Jgear

Industry Sector
Converting Toolbox
Mf-
Introduction
V+ , F+
Benefits when
using the
Application
Mf+
n+
MP+
V+ , F+
MT-
MT+
Contents of the
Application
Example
Configuration
Tools
n o-
n o+
Scope of
Functionality
Function Block
Overview
MP-
n-
Winder from below
Winder from above
Mf+
MfMP-
MP+
n-
MT+
V+ , F+
no+
Unwinder from below

Mf: Friction Torque
MP: Torque Precontrol
MT: Tension
n: winder speed
no: speed override
n+
V+ , F+
MTno-
Unwinder from above

Industry Sector
Converting Toolbox
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
The Winder Function Block covers the common control modes and
is an open function for adjustments or build in your own Know-how!
Control modes:
indirect tension control
dancer roll control with speed correction
tension control with speed correction
tension control with torque limiting
constant v-control
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Indirect Tension Control
Introduction
No tension feedback required
Benefits when
using the
Application
Web speed is set via nip
Contents of the
Application
Good Inertia and friction torque compensation required
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tension Torque pre-controlled via torque setpoint

Diameter ratio app. 10:1
Tension ratio app. 6:1
Winder torque ration app. 40:1
Web speed up to app. 600 m/min
Material: foil, textile, paper
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Indirect Tension Control
Introduction
Benefits when
using the
Application
Contents of the
Application
n+
M
Speed
controller
Vset
Current
controller
Power unit
Jog set point
Scope of
Functionality
Function Block
Overview
M+
Vconst
overcontrol
Maneuver
J
Kpadaptation
Diameter
calculation
nact
Dact
Example
Configuration
Tools
Fset
Tension taper curve

dn/dt
Friction
moment
Dact
Inertia curve

Industry Sector
Converting Toolbox
Scope of Functionality - Tension control with torque limiting
Introduction
Tension measuring device required
Benefits when
using the
Application
Contents of the
Application
Nip required, tension capsule is very damageable
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools
Tension Torque pre-controlled via torque set point

Good Inertia and friction torque compensation required
Diameter ratio app. 15:1
Tension ratio app. 20:1
Winder torque app. 100:1
Web velocity up to app. 2000 m/min
Tension control via torque limitation
Material: paper, thin film

Industry Sector
Converting Toolbox
Scope of Functionality - Tension control with torque limiting
Introduction
Benefits when
using the
Application
Contents of the
Application
M+
Vconst
n+
Fact
M
Speed
controller
Vset
Current
controller
Power unit
Jog set point
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools
overcontrol
Maneuver
Fset
Dact
Diameter
calculation
nact
Kpadaptation
Tension taper curve
Tension
controller
Fact
Friction curve
Dact
dn/dt
Kpadaptation
Dact
Inertia curve

Industry Sector
Converting Toolbox
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
Dancer position measuring device required (e.g. potentiometer,

encoder)
Web tension is controlled via additional speed setpoint
Nip required, dancer influences the web path
Diameter ratio up to app. 15:1
Tension ration controlled via dancer
Example
Configuration
Winder torque ratio up to app. 40:1, depending on the dancer

system
Tools
Web speed up to app. 2000 m/min

Material: rubber, cable, textile, film and paper

Industry Sector
Converting Toolbox
Scope of Functionality - Dancer position control with speed setpoint-correction
Introduction
Vconst
Benefits when
using the
Application
Sact
n+
M+
Dact
Fset
Contents of the
Application
P
U
Tension taper curve
Speed
controller
vset
Scope of
Functionality
Maneuver
Current
controller
Power unit
Jog set point
Function Block
Overview
nact
Example
Configuration
Sset
Tools
Sist
Diameter
calculation
Kpadaptation
Dact
Friction moment
Position
controller
dn/dt
Dact
Dact
Kp- adaptation
Inertia curve

Industry Sector
Converting Toolbox
Scope of Functionality constant v-control
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Web velocity input via web tachometer

Web speed isnt set via nip
Tension cant be affected by winder
No nip required
Diameter ratio up to app. 15:1
Web velocity is depending on the mechanical construction
Especially for sorter
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality constant v-control
Introduction
Benefits when
using the
Application
n+
Contents of the
Application
Scope of
Functionality
Example
Configuration
Vact
speed
controller
Vset
Maneuver
Function Block
Overview
M+
Current
controller
Power unit
Jog set point
J
Vact
nact
Kp-adaption
Diameter
calculation
Dact
Friction moment
Tools
dn/dt
Dact
Inertia curve

Industry Sector
Converting Toolbox
Scope of Functionality Diameter calculation
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Diameter calculation based on ratio between web velocity and

winder rotational speed
The diameter is required to e.g. calculate the correct speed of the
winder axis from the machine speed
optional there is an integrating calculation methode, a division
method, the possibility to interconnect a diameter sensor or a
methode with layer counting available
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Taper characteristic
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Optional for rewinder, if the tension is reduced with increasing diameter

Taper characteristic depends on the actual diameter
Decrease can be absolute (N) or relative (% of tension setpoint)
four characteristics are implemented:
Hyperbolic characteristic with:
Max. tension reduction at infinite diameter
Max. tension reduction at specified diameter
Linear characteristic with tension reduction when maximum diameter is reached
Personal characteristic using 10 points along the characteristic
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Controller adaption
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Controller gain of the tension/position controller is adaptable

based on the actual diameter
higher gain at higher diameter
Controller gain of the speed controller is adaptable based on the
moment of inertia of the roll
higher controller performance with high load conditions
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Torque pre-control
Introduction
Benefits when
using the
Application
Optional compensation of the acceleration/ deceleration torque,

resulting of the moment of inertia to improve the dynamic reaction
of the drive
Contents of the
Application
Inertia compensation reduces tension fluctuation based on speed

changes
Scope of
Functionality
Inertia compensation is required if indirect tension control is used

and recommended in tension control mode via load cell
Function Block
Overview
Inertia compensation is set up during commissioning
Example
Configuration
Inertia compensation is calculated based on the diameter, the

web width, the gear ratio und the material density
Tools

Industry Sector
Converting Toolbox
Scope of Functionality tension operation
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Tension operation can only be enabled if the control is in

operation and web break detection is not signaling an error
It is recommended to only enable tension operation in machine
stand still
Tension or position setpoint will be enabled using adaptable ramp
functions
If tension operation is not active, the diameter computer and the
speed override are disabled
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Maneuvering input
Introduction
Benefits when
using the
Application
The maneuvering input can e.g. be connected with an analog input

to influence the internal speed setpoint.
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Jog
Introduction
Benefits when
using the
Application
Contents of the
Application
Jog operation is only enabled when tension operation is disabled

Jog speed setpoint either via fixed setpoint or via connectable
input
During jog operation, the maneuvering mode is disabled
separate ramp function generator
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox Scope of Functionality

Velocity master, synchronize and stop web setpoint
Introduction
Benefits when
using the
Application
winder can operate as velocity master for the whole machine

stop the winder on continuing web, e.g. after flying roll change
synchronize a stopped winder to the web, e.g. before splicing
BI: Synchronize/stop web setpoint
[ 0 = synchr.; 1 = stop]
p21000[3]
SetpointComputer
p21621
(0)
stop after splice active
Contents of the
Application
[WI1020.4]
stop after web length

braking active
[WI1020.4]
winder
as speed master
<1>
If winder is used as speed master, the internal setpoint for web

speed is used for the diameter calculation
<2>
tension operation is deactivated when Stop is selected,

if a fixed web velocity is set and this value is also used as
speed setpoint for the speed master, p22060 has to be set
to 1"
When the winder is set as speed master, r21626 shows the
reaching of the upper velocity limit, r21627 the reaching of the
lower velocity limit.
[WI1010.2]
Scope of
Functionality
ramp
stop speed master
fast stop
speed master
[WI1010.2]
[WI1010.2]
&
Ramp-down time, web

velocity, stop [ms]
p21623 (5000ms)
Function Block
Overview
Example
Configuration
Tools
Ramp-up time, web

velocity catch up [ms]
p21622 (5000ms)
CI: Velocity setpoint

p21515
material web
(setpoint/actual value
nip position)
100 %
0%
[WI1010.2]
Web velocity ramp function

generator
RDT
BO: Web velocity synchronized

<2>
r21626
BO: Web velocity stopped
r21627
r21517
CO: Motor speed, actual value [rpm]

[WI110x.3]
r21512
Smoothing time ramp

function generator
web velocity [ms]
p21625 (200ms)
y
RUT
(0)
<1>
[WI1010.2]
CO: Material web velocity,

actual [m/min]
[WI110x.1]
CO: Multiplier setpoint channel [1/m]

[WI110x.7]
Ramp-down time, web

velocity, fast stop [ms]
p21624 (2500ms)
r21547
Normierung
[WI110x.3]
Bahngeschwindigkeit
dy/dt
ST
ST
ST ST
ST
ST
ST
ST
[WI1030.7] Stopp am Antrieb aktiv

RFG follow up
when external stop
100%
upper limit velocity master [%]

p21628 (2.0 200%)
Tup_eff
Tdn_eff
y
x
CO: velocity
setpoint RFG
velocity
master [%]
r21630
[WI1110.3]
1
0%
lower limit velocity master [%]

p21629 (-2.0 -200%)
4
3
2
1
DO: SERVO, VECTOR, DC CTRL
Setpoint Computer Part 2 (Speed setpoint calculation; Master; Stop)
Siemens6 AG 2012. All

Rights Reserved.
8
7
Function diagram Industry Sector
- WI1111 Wickler DCC V3 1 en.VSD
12.06.12 V03.01.00
SINAMICS
Converting Toolbox
Scope of Functionality web length and braking distance
Introduction
Benefits when
using the
Application
calculation of the actual web length by integration of the material

web velocity
stop the winder when reaching a set web length setpoint
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Splice control
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
flying roll change with optional application splice control

(precondition is active position controller for position sensing)
cam outputs to control knife and splice roll
rewinding after splice for unwinder
Old
Knife
Splice roll
Function Block
Overview
Splice position
Example
Configuration
New
Tools
Rotating turret

Industry Sector
Converting Toolbox
Scope of Functionality Execution groups
Introduction
Benefits when
using the
Application
The required components of the application are enabled via

execution groups:
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools

Industry Sector
Converting Toolbox
Scope of Functionality Execution groups
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools
The execution groups Diameter computer, Setpoint calculator,

Control unit are always required, the execution group
TensionDancerContr not for indirect closed-loop tension control,
the execution groups Winding hardness calculator, Integrating
diameter computer and Web break detection - only if the
functions are actually required.
For drive systems with the CU320-2 Control Unit, sampling times
of 4ms are recommended; for standard settings, this corresponds
to the clock cycles of the execution group BEFORE speed
setpoint channel for servo - or BEFORE position controller
for servo and vector (This execution group is available
independent of the activated basic positioner function module).
Sampling times of 8ms or 16ms are recommended for the
SINAMICS DCM drive system.
Industry Sector
Converting Toolbox
Function Block Overview
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
The winder functionality is part of the

application SINAMICS DCC Winder.
The application is implemented in DCC.
The documentation is based on function
plans.
Normalization web velocity
[m/min] p21516 (30)
BI: smoothing diameter outp21539

put integrating method
[1=OFF; 0=ON]
Normalization web velocity

Web velocity actual value [m/min]
r21517
Actual web velocity p21515
p21000[0]
integratingDiaComp
(0)
p21000[1]
Diameter Computer
Calculated diameter, absolute [m]
Diameter computer
(0)
r21545
minimum
diameter
actual diameter
material web velocity
Calculated diameter, relative [%]

r21546
Dmax
Example
Configuration
Gear factor, load revolutions

p21520 (1)
Gear factor, motor revolutions
p21521 (1)
x
y
Multiplier, setpoint channel[1/m]

r21547
maximum
diameter
gear factor
motor speed
Wound roll revolutions per

integration interval
p21525 (1)
Normalization, p21511
speed [rpm]
(r2700)
Tools
gear factor
Speed normalization
r21512
actual motor speed [rpm]
speed act. value p21510

motor encoder
(r63)
Setting value
fixed diameter [m]
p21522 (0.1)
[WI1010.5]
saved diameter value
as setting value
<>0
p21523
(0)
t (integration interval)
Diameter
web velocity
motor speed
gear factor
Setting value,
diameter effective [m]
r21524
Diameter setting value
Diameter value saved

(retentively) [m]
r21548
=0
Setting value
diameter normalized
to maximum diameter
Maximum
diameter
p21534 (2 m)
Non-volatile (retentive)
memory for the diameter
value
Saved diameter value valid

r21549
Minimum diameter
p21535 (0.1m)
Balancing time web velocity
integrating method p21536 (0 ms)
Diameter is limited to
the maximum
[WI1020.4]
diameter
Diameter is limited to
the minimum
[WI1020.4]
diameter
Smoothing time diameter integrating

method [ms] p21537 (100.000)
[WI1030.7]
[WI1030.7]
[WI1010.4]
set diameter
hold diameter
winding from bottom
1
2
3
4
DO: SERVO, VECTOR, DC_CTRL
Diameter computer integrating method (p21538=1, p21540=0, p21541=0)
6
Wickler_DCC_V3_en.VSD
29.11.10 V03.00.00
7
Function diagram
SINAMICS
8
- WI1101 -

Industry Sector
Converting Toolbox
Example Configuration
Example Configuration:
Benefits when
using the
Application
Contents of the
Application
HMI
PROFIBUS
SINAMICS CU310 DP/PN

SINAMICS S120 PM340 AC/AC
TM31 (analog input)
Breaking resistor (optional)
e.g. 1PH8 motor
SINAMICS
CU310 DP
Introduction
PM340
Scope of
Functionality
Winder
e.g. 1PH8
Standards:
SINAMICS DCC Winder
Function Block
Overview
Example
Configuration
Tools
Benefits:
Cost effective and simple stand alone solution
Integrated I/O and Safety functions (STO)
Integrated TTL/HTL/SSI encoder interface
No PLC required for simple applications

Industry Sector
Converting Toolbox
Web handling
HMI
Machine control
PROFIBUS
SIMATIC S7
SINAMICS CU310 DP DCC

SINAMICS S120 AC/AC
TM31
1PH8
Nip
Dancer system
(or load cell)
Winder
Industry Sector
Converting Toolbox
SIMATIC S7
(Machine control)
Contents of the
Application
Scope of
Functionality
Standards:
SINAMICS DCC Winder
SINAMICS DCC
Load Sharing
(Tandem Winder)
Function Block
Overview
Example
Configuration
PROFINET / PROFIBUS
SINAMICS CU320 (1 Winder / CU)

SINAMICS S120 DC/AC
TB30 or TM31
e.g. 1PH8 motor
SINAMICS CU320
Benefits when
using the
Application
Winder
(Master)
e.g. 1PH8
Motor module
Example Configuration:
Introduction
Slave
Tools
Benefits:
Modular solution based on standard products
High hardware integration (no external traversing controller required)
No programming necessary
No PLC required for simple

applications
Industry Sector
Converting Toolbox
HMI
Machine control
PROFINET / PROFIBUS
SIMATIC S7
TM31
1PH8
Motor Modules
SINAMICS CU320 / DCC

SINAMICS S120 DC/AC
Infeed
CU320
Web handling
1PH8
Nip
Dancer system
(or load cell)
Winder

Industry Sector
Converting Toolbox
Tools
Introduction
Benefits when
using the
Application
Contents of the
Application
Scope of
Functionality
Function Block
Overview
Example
Configuration
Tools

Industry Sector
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
1 Introduction
1 Introduction
The "Converting Library" is intended to provide S7-1200 users with help while
engineering and programming converting machinery.
The Converting Library provides standards that can be adapted depending on
the particular machine and application. These standards cover the typical basic
functions of a converting machine. These functions are available as an open
source.
The appropriate interfaces are provided to make adaptations depending on the
specific machine and application. These interfaces are described in detail in the
following documentation. Changes to standard functions that go beyond this
should only be made in exceptional cases as this is not in-line with the level of
standardization that we wish to achieve here.
1.1.1
Segment, Machine & Unit description

This library is intended to be used for moderate dynamics applications and will
help when engineering & programming converting machinery. This library
covers the typical basic functions of a converting machine. The appropriate
interfaces are provided to make adaptations depending on the specific machine
and application. The functions are available as open source.
1.1.2
Scope of Application
Applications where this library can be used:
Secondary Slitters
Web Inspection machines
Coil Rewinders
Wire drawing machines
Coating lines
Extrusion line winders
Printing machines (Mechanical Line Shaft)
Copyright
Siemens Ltd. 2013 All rights reserved
1.1 Area of Application
1.2 Objective
1.2.1
Task
The Library consist of simple function blocks which can be helpful for any
machine and also includes complete solutions to fulfill the demanding
requirements of winders, tension controlled sections and material transport.
This document will highlight the technical requirements of Winder application &
solution which is developed to cater it.
Application Handbook
Version 1.0.1
1 Introduction
1.2.2
Advantages
Copyright
The Library includes complete solution to fulfill the demanding

requirements of winders, tension controlled sections and material
transport.
Appropriate interfaces are provided to make adaptations depending on
the specific machine and application.
The library is open source code.
Reduction of engineering time
Possibility of making changes
Version 1.0 .1
2 Winder Solution Overview

2.1 General overview of Winders
Copyright
Generally, a winder solution comprises a winder drive, a material web and

possibly sensors. The function of a winder is to rewind or unwind a material web
with a defined tension. When winding, the diameter changes. Depending on
whether it involves a rewinder or unwinder, the material is wound or unwound.
The motion control system calculates the actual diameter using several system
variables and controls the motor speed so that the tension of the material web
is kept constant. To do this, the actual velocity of the material web and the
speed of the winder shaft must be known. If the system must fulfill higher
demands regarding the performance and tension accuracy, then an appropriate
range of sensors must be added to the winder solution. These can include a
dancer roll or a load cell.
The dancer roll is a position-controlled measuring system. The material web is
threaded through this dancer roll system. A cylinder with a deflection roll
presses, with an adjustable force against the material web. If tension is
established in the material web then this acts against the pressure from the
dancer roll. If the dancer roll is at its center position, then the material web
tension is the same as the selected dancer roll force. In order to control (closedloop) the tension in the material web, the motion control system must ensure
that the dancer roll remains at its center position. If the tension in the system
changes, then the position of the dancer roll also changes that is in turn
coupled with the motion control system via a position detection function. If such
a deviation is detected, then the system would respond, and e.g. change the
drive speed.
The tension measuring transducer directly measures the tension in the
system and transfers this signal to the motion control system. If the tension
changes then this can either be compensated by changing the speed or by
changing the motor torque.
10
Version 1.0.1
2.1.1
Winding Techniques
In general there are two types of winding techniques used in industry-
Copyright
Center Winder
With a center winder, the roll is driven by a central shaft. The diameter range is
an important factor when designing this winder type. The reason for this is that
for a constant web velocity and constant tension, the speed is inversely
proportional to the diameter. This means that the maximum required drive
speed is defined by the minimum roll diameter whereby the maximum
required torque is defined by the maximum diameter.
The center winder is more complicated and from control perspective more
difficult to handle than the surface winder; however it is still more widely
established of the two winder types.
Surface Winder
For a surface winder, the roll is driven through one or several rolls that are in
contact with the roll being wound. The drive speed and power depends on the
diameter of the roll being wound. From a mechanical design perspective, this
winder technique is more complicated than that of a center winder.
The contact winder (surface winder) is essentially used if there are no special
requirements placed on the surface quality of the material being wound.
Version 1.0 .1
11
2.1.2
Tension Control Techniques

The standard application library allows following control concepts to be
implemented:
Indirect Tension Control
Tension Control using Load-cell
Tension Control using Dancer
These control concepts will be briefly explained in the following.
Indirect Tension Control:
Copyright
The indirect tension control is very frequently used if a user does not want
to use expensive sensor systems as there are no higher-level control loops
available. This technique must be able to operate without any tension
feedback signal. This therefore places the highest requirements on the
torque setpoint conditioning and the torque accuracy of the drive.
The indirect tension control is based on the physical interrelationship
between torque and the tension of the material web. The motor torque is
changed as a function of the diameter of the roll being wound so that a
setpoint (reference) tension is obtained.
The technology controller is not used instead, the tension setpoint (reference
value) is multiplied by the diameter and the result is directly pre-controlled as
torque setpoint. This means that the motor current linearly increases with
increasing diameter and the tension is kept constant. In this case it is important
that the friction and accelerating torques are precisely compensated so that the
pre-controlled torque setpoint results in the best possible approximation to the
required material tension. For this control type it must be ensured that the
mechanical losses are kept as low as possible. This means that worm gears
may not be used, no open intermediate gear ratios - and if herringbone gearing
is used, then the shaft should rotate in the direction of the herringbones. It is
also important to ensure the lowest possible loss differences between
gearboxes in the warm and cold states.
12
Version 1.0.1
Copyright
Block diagram:
Tension Control using Load-cell

For the tension control, the tension acting in the system is measured using
a static measuring device and is compared with the tension setpoint
(tension reference value) as measured quantity. The tension control is used
if the precision of the open-loop torque control is no longer sufficient. This
can be the case if a high torque control range is demanded or if the winder
is subject to disturbances.
A load cell directly senses the material tension. Its output signal is proportional
to the tension and is fed to the technology controller as actual value signal. This
means that in this case the technology controller is effective and directly
controls the tension of the material web. Just the same as for indirect tension
control, the speed controller in the drive operates in saturation (at its end limits).
The drive is at one of the two torque limits and is controlled through these
torque limits. The correction value from the technology controller acts additively
on these torque limits. Supplementary torque setpoints e.g. from the
acceleration pre-control (inertia compensation) or the tension taper
characteristic are connected-up so they act additively to the torque limits.
For this technique, it is not necessary to intervene in the material web as is the
case for a dancer roll system. However, in this case there is not the advantage
of having a storage function for the material web.
Version 1.0 .1
13
Copyright
Tension Control using Load-cell : Torque Control

Tension controller output is added with Friction & Moment of inertia torque
which in turns act as torque limit.
14
Version 1.0.1
Copyright
Tension Control using Load-cell : Speed Control

Tension controller output is added as additional speed setpoint along with main
setpoint scaled with actual diameter of the roll.
Version 1.0 .1
15
Tension Control using Dancer
Copyright
A dancer roll is used for the dancer roll position control - a positioncontrolled measuring system. The position of the dancer roll is determined
using a suitable position encoder, which is then compared with the position
setpoint (reference value). The tension is only determined using the dancer
roll. If the tension changes, then the position of the dancer roll also
changes. By changing the winder speed, the dancer roll position control
corrects this position offset. Although brief speed fluctuations have an effect
on the position of the dancer roll, they hardly have any effect on the tension
in the system. However, this only applies as long as the dancer roll does
not reach its limits.
The dancer roll position control has the advantage that brief fluctuations in
the tension can be absorbed due to the material web storage function of the
dancer roll. However, an intervention has to be made in the material web
routing as a result of the mechanical arrangement.
The limits of the dancer roll position control are predominantly defined by
the mechanical implementation of the dancer roll and its dynamic
characteristics.
2.2 Functions of the Application Library

The application library is used to control rotating mechanical equipment to wind
or unwind a material web (film, paper, wire, foil, etc.)
The core function conditions the signals that are required to control the winder
shaft such as speed and torque.
The core function comprises a function block, which generates the setpoints to
control the winder shaft. These setpoints are the setpoint velocity and,
depending on the control mode torque limits, additive torque setpoints as well
as variables to control the controller gain adaptation function.
16
Version 1.0.1
The block handles all of the essential functions of the winder such as diameter
calculation, moment of inertia calculation, Tension Preparation, Gain Adaption
and Tension Taper Characteristic.
The winder block can be simply changed-over to various control modes by
appropriately parameterizing it. It is not necessary to make any changes to the
program in order to, for example, toggle between indirect and direct tension
control. However, it is possible to access the code of the winder function blocks
as this is not password protected.
2.2.1
Properties and features of the core Winder functions

The following properties and features were taken into account while developing
this library and can even be used in user programs that you generate yourself:
Copyright
Diameter calculator
4 different techniques are available to calculate the diameter of the roll being
wound:
The diameter is calculated using the ratio between the velocity of
the material web and the winder speed
The diameter is calculated by adding the material thickness
The diameter comes from extern (sensor)
The diameter is calculated from the ratio between the material
length and the revolutions of the winder (integration)
Tension taper characteristic
A tension taper characteristic is required if the tension, with which the material
is wound, is to be decreased as the diameter of the roll being wound increases.
5 different techniques are available to calculate the tension taper characteristic:
No characteristic
Linear characteristic the tension is linearly reduced as a
function of the actual diameter
Hyperbolic characteristic type 1 the tension decreases
according to a hyperbolic function/characteristic
Hyperbolic characteristic type 2 the tension decreases
according to a hyperbolic function/characteristic
Interpolated characteristic using a table of points 10 points can
be entered to define the characteristic
Tension preparation
Preparing the tension setpoint value for further usage
Functions implemented for tension control with dancer roll, tension control with
load cell, indirect tension control and taper characteristic
Version 1.0 .1
17
Controller Adaptation
The gain of the technology controller can be adapted as a function of the
diameter. This permits a higher controller gain at a bigger diameter
In case of S120 drives, the speed controller gain in the drive can be adapted as
a function of the moment of inertia or the actual diameter of the roll being
wound. This is necessary so that a full roll can also be rapidly accelerated or
decelerated.
Copyright
Inertia Compensation
While the material web is being accelerated and decelerated, an additive torque
can be switched to the drive in order to respond dynamically (quickly) to velocity
changes.
The inertia compensation avoids tension dips or tension increases due to the
velocity change. This pre-control is required, especially for indirect tension
control but also for tension control with a load cell.
The pre-control is made available to the user as an additive torque at the output
of the winder function block. Instructions for making the appropriate
interconnections are explained step-by-step in Section Integration of the core
function using as an example, a SINAMICS drive.
18
Version 1.0.1

Siemens Winder App

Загружено:

Сведения о документе

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Siemens Winder App

Загружено:

Авторское право:

Доступные форматы

s

Operating modes and functions

direct tension control with tensile force sensor

The following functions are available in these modes:

inching, maneuvering (to lead the web)

Closed-loop control of a winder

Criteria for selecting the control method

The following table lists selection criteria based on empirical values.

Torque limiting control

Indirect tension control

Web velocity setpoint

Description of mode of operation:

Direct tension control

Tensile force sensor

Web velocity setpoint

Tension feedback value

Description of mode of operation:

Speed compensation control

Web velocity setpoint

to external tension controller

Description of mode of operation:

v-constant control (winder)

Description of mode of operation:

Control function blocks

Stop tension control

Slip core control

Variable web width

Variable material density

Calculator for the diameter

Speed controller adaptation

Tension controller adaptation

Web break recognition

Triggering results if selectable torque variance is exceeded and torque drops

Acceleration compensation calculation

Fixed inertia JF (adjustable using P407)

Determination of fixed value inertia

moment of inertia of motors

Moment of inertia solid cylinder

Moment of inertia hollow cylinder

Determining the value for parameter P407

max b max D max 4 DCore 4

Calculation of percentage accelerating torque corresponding to the related current in %

b max max D max 4 DCore 4 nN v

Determining the value for Parameter U529:

web width [m]

Received data from top level control

Control Word 1 according to user manual

system speed setpoint

Control Word 2 according to user manual

Control word 3 for coilers / winders

Wind/Coil from top/bottom

If 1, the state of B3506 is not relevant

Dancer roll control

If 1, the state of B3506 is not relevant

Dir./Indir. Tension Control

Gear box stage 1/2

Switch characteristic for

Switch characteristic for

The selected characteristic is the result of

Switch characteristic for

Stop tension control

Tension control ON ext.

web break ext.

Diameter set value