Converting Applications Made Easy Rotary Knife Flying Saw ... Center Wind Zone Tension Control Web Server / Diagnostics ... Modes of Diameter Calculation

Converting Applications Made Easy Presented by Jeff Reese

Manufacturing in America │ March 14-15, 2018

Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.

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What is Converting??

The Siemens Converting Toolbox

Web Handling with SIMOTION, SINAMICS and SIMATIC


Converting is Web Handling & Web Processing

Webs include paper, film, foil, nonwovens, and other thin flexible continuous materials.


Roll to Roll Web Processing

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

Roll-to-roll

Web Processes


Roll to Sheet Web Processing

Converting processes that start and end as a sheeted product are called roll-to-sheet.

Roll-to-sheet

Handling Cutting


Coating & Laminating Slitter Rewind

Converting Machines / Applications

Sheeter / Rotary Knife Tissue / Towel Lines

Label / Die Cut Core Winder


Converting Applications and Process Requirements

Unwind Process Rewind

Unwind

Automatic

splice

Tension

control

Knife /

Perforator

Register

control Rewind

Automatic

splice

Tension

control

Position Based

Web Control


Yesterdays Converting Solutions

Then


Today’s Converting Solutions

Flexible automation from a single source

Level of P

erf

orm

ance

The Converting Toolbox

Standardized automation packages

with tested know-how for

SIMOTION, SINAMICS and SIMATIC

MOTION CONTROLLER

DRIVE SYSTEM

PLC

← SINAMICS S120

← SIMOTION

← SIMATIC S7 PLC




Level of P

erf

orm

ance





Supported product

Detailed documentation

Wide range of functions

Applications and libraries

Open source software

Some with demo examples, & HMI

screens

MOTION CONTROLLER

DRIVE SYSTEM

PLC

← SINAMICS S120

← SIMOTION

← SIMATIC S7 PLC




Level of P

erf

orm

ance





MOTION CONTROLLER

DRIVE SYSTEM

PLC

← SINAMICS S120

← SIMOTION

← SIMATIC S7 PLC

Engineering time saving

Time-tested, reliable functions

Global Toolbox support

Available without charge

Every control platform


Application Overview

Traversing

Axis

Integrated

Register Control

Load

Sharing

Web

Accumulator

Rotary

Knife

Flying

Saw

Winder Splice

Control

Tension

Control

Converting

Library

Project generator1 Diagnostic

Pages

SIMOTION SIMATIC SINAMICS

1; TIA + MAC in progress


PLC-Based Solutions

SIMATIC Converting Module

SIMATIC HMI

SIMATIC PLC

Synchronous

Motors

Asynchronous

Motors

SINAMICS

S120 with

safety

integrated

Architecture


PLC-Based Solutions

SIMATIC Converting Module

Converting

Library

Center Wind Zone Tension

Control

Web Server /

Diagnostics

Flying Saw Electronic

Gearing

T

Features

• PLC ease of use and flexibility

• Open source code; structured text

• Centralized control


Drive-Based Solutions

SINAMICS (DCC) Converting Module

SIMATIC HMI

SIMATIC PLC

SINAMICS

S120 with

safety

integrated

Synchronous

Motors

Asynchronous

Motors

SINAMICS S120

Control Unit

Architecture


Drive-Based Solutions

SINAMICS (DCC) Converting Module

Features

• Drive-based performance

• Drive-based Graphical programming editor (DCC)

Converting

Library


Control

Web Server /

Diagnostics

Harmonic

Compensation

Unwind Flying

Splice Traversing Axis

Control

Rotary Knife Flying Saw Load Sharing

Electronic

Gearing


Motion-Based Solutions

SIMOTION Converting Module

SIMATIC HMI

SIMATIC PLC

Synchronous

Motors

Asynchronous

Motors

SIMOTION D

Motion controller

Architecture

SINAMICS

S120 with

safety

integrated


Motion-Based Solutions

SIMOTION Converting Module

Features

• Highest level of performance

• Include HMI application

• Can be demonstrated via SIMOTION demo

• Open source code

Converting

Library


Control

Web Server /

Diagnostics

Unwind Flying

Splice Traversing Axis

Control

Rotary Knife Flying Saw

Accumulator

Control

Electronic

Gearing

Project

Generator Register

Control


Winder Solutions

Control Mode Overview

CONTROL MODE

V Constant

Indirect tension control via torque adaption

Direct tension control via torque adaption

Direct tension control via speed adaption

Dancer position control via speed adaption

Dancer position control via torque adaption

Mode change during active loop control

SINAMICS

DCC SIMOTION

SIMATIC S7-

300/400

SIMATIC S7-

1200/1500

SIMATIC S7-

1500T


Winder Solutions

Modes of Diameter Calculation

CALCULATION MODE

External sensor

Web thickness and turns count

Archimedean spiral (slip core)

v/n (line speed / spindle rpm)

ʃv ʃn (integral line speed / spindle rpm)

s / α (web length / spindle angle change)

SINAMICS

DCC SIMOTION

SIMATIC S7-

300/400

SIMATIC S7-

1200/1500

SIMATIC S7-

1500T

Active calculation mode change

Compensation of dancer motion


Winder Solutions

Auxiliary Functions

Diagnostic pages for web browser

CALCULATION MODE

Torque pre control

Controller loop adaption (tension /speed)

Taper tension

Web break detection

Stop at web position

Stop at diameter

SINAMICS

DCC SIMOTION

SIMATIC S7-

300/400

SIMATIC S7-

1200/1500

SIMATIC S7-

1500T

Project wizard for commissioning


Zone Tension Control Solutions

Control Mode Overview

CONTROL MODE

Draw control

Indirect tension control via torque adaption

Direct tension control via torque adaption

Direct tension control via speed adaption

Dancer position control via speed adaption

Dancer position control via torque adaption

Mode change during active loop control

SINAMICS

DCC SIMOTION

SIMATIC S7-

300/400

SIMATIC S7-

1200/1500

SIMATIC S7-

1500T


Zone Tension Control Solutions

Auxiliary Functions

CALCULATION MODE

Torque pre control

Controller loop adaption (tension /speed)

Web break detection

SINAMICS

DCC SIMOTION

SIMATIC S7-

300/400

SIMATIC S7-

1200/1500

SIMATIC S7-

1500T

Project wizard for commissioning

Diagnostic pages for web browser


Performance Review - Diameter Calculation Methods

Comparing the Calculation Methods

In analyzing diameter calculator methods, two factors are considered:

Constant speed operation vs. acceleration profile

Update frequency of the diameter calculator logic

Evaluation of actual results.

The following analysis will look at three

calculation modes under different conditions.

http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjB_4CmpvbNAhWBE5oKHc1wCPAQjRwIBw&url=http://www.freeiconspng.com/free-images/analysis-icon-11469&bvm=bv.127178174,d.bGs&psig=AFQjCNEtUSWfRf8975bqLJNquUrO0OdGHg&ust=1468700506999740



RED - V/n diameter

GREEN - INTEGRAL diameter

BLUE - POSITION diameter

Constant web speed: 100 m/min



RED - V/n diameter



Acceleration profile: 50 m/min > 300 m/min > 10 m/min

Update (sampling) time: 6 ms



RED - V/n diameter



Acceleration profile: 50 m/min > 300 m/min > 10 m/min

Update (sampling) time: 1 ms


The Converting Toolbox Libraries (Available blocks)

General tools

Cycle time determination

Ramp-function generator (with or without jerk limiting)

Characteristic block (20 or 180 interpolation points)

Linear interpolation between two interpolation points

Interpolation of a point table

Limit value monitoring

Braking distance and time calculation

Drive functions

Recording a friction characteristic, e.g. for the winding block

Diameter Calculator (with multiple modes)

Activating interfaces

Closed-loop control related functions

PT1 element

Derivative action element/integrator

DT1 filter

Dead zone and dead band filter

Limiter with feedback signal

Limit value monitoring

PID controller

Sliding average value generator

Setpoint control


The Converting Toolbox (Integrated Web Server)

Functionality

Download a programs

Perform Firmware updates

Status overview of specific variables

Evaluate of alarms and faults

Monitoring and change parameters

Archive machine documentation

Create Custom Web Pages


The Converting Toolbox (Integrated Web Server)


Automation Architectures - Solution / Machine Type

Application Example Machine Type

1-6 Axes 6-50 Axes 50-200 Axes

Simatic Module

•Slitter Rewind

•Doctor Machine

•Slitter Rewind

•Coating Line

Sinamics Module

•Slitter Rewind

•Narrow Web (offline)

•Filament Winder

•Load Share

•Slitter Rewind

•Coating Line

•Coating & Laminating

Line

•Film Line

Simotion Module

•Rotary Knife

•Core Cutter

•Die Cutter

•Paper Sheeter

•Offset Press

•Narrow Web Press

•Diaper Machine

•Tissue / Towel Line

•Flexo Press

Network Options

PROFIBUS PROFINET

Web Control

Motion Control

Web Control

Web Control

Motion Control

Module


The Converting Toolbox on Flash Drive

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Seminar Slides

After MiA, seminar slides will be available at:

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Questions?

Jeff Reese

Siemens Industry, Inc.

5300 Triangle Parkway

Norcross, GA 30092

Phone: +1 (336) 521-1624

E-mail: [email protected]

Website: www.usa.siemens.com/converting

mailto:[email protected]

http://www.usa.siemens.com/converting

Documents

Converting Applications Made Easy Rotary Knife Flying Saw ... Center Wind Zone Tension Control Web Server / Diagnostics ... Modes of Diameter Calculation