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SINAMICS DCC
Winder V3.2
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Introduction
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...

The winder application can be used on the following devices:
SINAMICS S120, S150, G130, G150
SINAMICS DCM
SINAMICS Integrated in SIMOTION D4xx-2

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Shorter engineering and service times (same look & feel)
Industry standards are used
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

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PowerPoint presentation (English / German)

Programming in CFC

User Manuals (English / German)

Feedback sheets (English / German)

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Scope of Functionality


Tension
Coil
Tension
Coil
Nip
Center Winder or tandem center
winder
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
dancers or load cells for tension control are
optional
Roll hardness controlled by web tension
and optional by nip pressure

Turret winder
two or more centerwinds on a rotating axis
Roll change on the fly
A flying knife will slice the material and
automatically hold it while it starts to wrap
a new coil
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Scope of Functionality
Min Diameter D
Min
Max. Diameter
D
Max
Web Width w
Gear, Gear ratio i
Moment of Inertia J
gear
Material Velocity V
External Moment of
Inertia J
Core
Motor Moment of Inertia
J
Motor
D
act
Actual Diamter
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Scope of Functionality
V
+
, F
+
Winder from above
V+, F+
Winder from below
V+, F+
Unwinder from below
V+, F+
Unwinder from above
n+
n
o
+
M
f
+
M
P
+
M
T
+
n-
n
o
-
M
f
-
M
P
-
M
T
-
n-
n
o+
M
f
-
M
P
-
M
T
+
n+
n
o-
M
f
+
M
P
+
M
T
-
Mf: Friction Torque
MP: Torque Precontrol
MT: Tension
n: winder speed
no: speed override
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Scope of Functionality
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

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Scope of Functionality Indirect Tension Control
No tension feedback required
Web speed is set via nip
Tension Torque pre-controlled via torque setpoint
Good Inertia and friction torque compensation required
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
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Scope of Functionality Indirect Tension Control
Maneuver
Vset
overcontrol
M
Fset
1
Power unit
Speed
controller
Current
controller
Friction
moment
dn/dt
Dact
nact
Diameter
calculation
Kp-
adaptation
J
Tension taper curve
J og set point
Vconst
n+
M+
F
Dact
Inertia curve
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Scope of Functionality - Tension control with torque limiting
Tension measuring device required
Web speed is set via nip
Tension Torque pre-controlled via torque set point
Nip required, tension capsule is very damageable
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

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Scope of Functionality - Tension control with torque limiting
Maneuver
Vset
overcontrol
Fact
M
Fset
1
Power unit
Speed
controller
Current
controller
Friction curve
dn/dt
Dact
nact
Diameter
calculation
Fact
Kp-
adaptation
J
Kp-
adaptation
Dact
Tension taper curve
J og set point
Vconst
n+
M+ F
Tension
controller
Dact
Inertia curve
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Scope of Functionality - Dancer position control with speed setpoint-correction
Dancer position measuring device required (e.g. potentiometer,
encoder)
Web speed is set via nip
Web tension is controlled via additional speed setpoint
Nip required, dancer influences the web path
Diameter ratio up to app. 15:1
Tension ration controlled via dancer
Winder torque ratio up to app. 40:1, depending on the dancer
system
Web speed up to app. 2000 m/min
Material: rubber, cable, textile, film and paper
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Scope of Functionality - Dancer position control with speed setpoint-correction
Maneuver
vset
Sact
M
Sset
Power unit
Speed
controller
Current
controller
Friction moment
Dact
nact
Diameter
calculation
Sist
Kp-
adaptation
J
Kp- adaptation
Dact
Tension taper curve
P
U
Fset
1
Dact
J og set point
+
-
Vconst
M+
n+
F
Position
controller
dn/dt
Dact
Inertia curve
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Scope of Functionality constant v-control
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

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Scope of Functionality constant v-control
Maneuver
Vset
Vact
M
Power unit
speed
controller
Current
controller
Friction moment
Dact
nact
Diameter
calculation
Kp-adaption
J
J og set point
M+
n+
dn/dt
Dact
Inertia curve
Vact
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Scope of Functionality Diameter calculation
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

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Scope of Functionality Taper characteristic
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


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Scope of Functionality Controller adaption
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

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Scope of Functionality Torque pre-control
Optional compensation of the acceleration/ deceleration torque,
resulting of the moment of inertia to improve the dynamic reaction
of the drive
Inertia compensation reduces tension fluctuation based on speed
changes
Inertia compensation is required if indirect tension control is used
and recommended in tension control mode via load cell
Inertia compensation is set up during commissioning
Inertia compensation is calculated based on the diameter, the
web width, the gear ratio und the material density

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Scope of Functionality tension operation
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

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Scope of Functionality Maneuvering input
The maneuvering input can e.g. be connected with an analog input
to influence the internal speed setpoint.

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Scope of Functionality Jog
J og operation is only enabled when tension operation is disabled
J og speed setpoint either via fixed setpoint or via connectable
input
During jog operation, the maneuvering mode is disabled
separate ramp function generator

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Velocity master, synchronize and stop web setpoint
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

- WI1111 -
Function diagram
8 7 6 5 4 3 2 1
Wickler DCC V3 1 en.VSD DO: SERVO, VECTOR, DC CTRL
SINAMICS 12.06.12 V03.01.00 Setpoint Computer Part 2 (Speed setpoint calculation; Master; Stop)
<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 Stopis 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.
1
0
0 %
(0)
BI: Synchronize/stop web setpoint
[ 0 =synchr.; 1 =stop]
p21621
Ramp-up time, web
velocity catch up [ms]
p21622 (5000ms)
BO: Web velocity synchronized
r21626
BO: Web velocity stopped
r21627
1
stop after splice active
stop after web length
braking active
[WI1020.4]
[WI1020.4]
p21000[3]
SetpointComputer
[WI1010.2]
[WI1010.2]
<2>
RUT
ST ST ST ST ST ST ST ST
RDT
Tup_eff Tdn_eff
Web velocity ramp function
generator
x
y
t
y
dy/dt
y
1
&
1
winder
as speed master
1
1
ramp
stop speed master
fast stop
speed master
1 0
Ramp-down time, web
velocity, fast stop [ms]
p21624 (2500ms)
Ramp-down time, web
velocity, stop [ms]
p21623 (5000ms)
1
0
100 %
CI: Velocity setpoint
material web
(setpoint/actual value
nip position)
(0)
p21515
<1>
x
y
1
0
1
0
Smoothing time ramp
function generator
web velocity [ms]
p21625 (200ms)
lower limit velocity master [%]
p21629 (-2.0 -200%)
upper limit velocity master [%]
p21628 (2.0 200%)
100%
0%
r21630
CO: velocity
setpoint RFG
velocity
master [%]
Stopp amAntrieb aktiv [WI1030.7]
r21512
CO: Motor speed, actual value [rpm]
r21547
CO: Multiplier setpoint channel [1/m]
Normierung
Bahngeschwindigkeit
RFG followup
when external stop
r21517
CO: Material web velocity,
actual [m/min]
[WI110x.3]
[WI110x.3]
[WI110x.7]
[WI1010.2]
[WI1010.2]
[WI110x.1]
[WI1010.2]
[WI1110.3]
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Scope of Functionality web length and braking distance
calculation of the actual web length by integration of the material
web velocity
stop the winder when reaching a set web length setpoint

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Scope of Functionality Splice control
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

New
Old
Knife
Rotating turret
Splice roll
Splice position
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Scope of Functionality Execution groups
The required components of the application are enabled via
execution groups:

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Scope of Functionality Execution groups
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.
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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)
Actual web velocity
(0)
p21515
Normalization,
speed [rpm] (r2700)
p21511
speed act. value
motor encoder (r63)
p21510
Diameter computer
r21517
Web velocity actual value [m/min]
r21512
actual motor speed [rpm]
<>0
=0
Setting value
fixed diameter [m]
p21522 (0.1)
Setting value
diameter normalized
to maximumdiameter
(0)
p21523
r21524
Setting value,
diameter effective [m]
Maximum
diameter
p21534 (2 m)
Minimumdiameter
p21535 (0.1m)

=
motor speed
gear factor web velocity
Diameter
r21545
Calculated diameter, absolute [m]
r21547
Multiplier, setpoint channel[1/m]
set diameter
hold diameter
winding frombottom
[WI1030.7]
[WI1010.4]
[WI1030.7]
Diameter is limited to
the maximum
diameter
Diameter is limited to
the minimum
diameter
[WI1020.4]
[WI1020.4]
Normalization web velocity
Speed normalization
gear factor
- WI1101 -
Function diagram
8 7 6 5 4 3 2 1
Wickler_DCC_V3_en.VSD DO: SERVO, VECTOR, DC_CTRL
SINAMICS 29.11.10 V03.00.00 Diameter computer integrating method (p21538=1, p21540=0, p21541=0)
1
0
r21548
Diameter value saved
(retentively) [m]
Saved diameter value valid
r21549
saved diameter value
as setting value
[WI1010.5]
Diameter setting value
Non-volatile (retentive)
memory for the diameter
value
Balancing time web velocity
integrating method p21536 (0 ms)
Smoothing time diameter integrating
method [ms] p21537 (100.000)
(0)
BI: smoothing diameter out-
put integrating method
[1=OFF; 0=ON]
p21539
Wound roll revolutions per
integration interval
p21525 (1)
t (integration interval)
r21546
Calculated diameter, relative [%]
Dmax
p21000[0]
integratingDiaComp
p21000[1]
Diameter Computer
minimum
diameter
maximum
diameter
motor speed
material web velocity actual diameter
gear factor M
x
y
Gear factor, load revolutions
p21520 (1)
Gear factor, motor revolutions
p21521 (1)
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Example Configuration
Example Configuration:

SINAMICS CU310 DP/PN
SINAMICS S120 PM340 AC/AC
TM31 (analog input)
Breaking resistor (optional)
e.g. 1PH8 motor


Standards:
SINAMICS DCC Winder

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
Winder
e.g. 1PH8
S
I
N
A
M
I
C
S

C
U
3
1
0

D
P

PROFIBUS
HMI
PM340
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Example Configuration
SIMATIC S7
Machine control
PROFIBUS
HMI
Web handling
TM31
SINAMICS CU310 DP DCC
SINAMICS S120 AC/AC
1PH8
Winder
Dancer system
(or load cell)
Nip
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Example Configuration
Example Configuration:

SINAMICS CU320 (1 Winder / CU)
SINAMICS S120 DC/AC
TB30 or TM31
e.g. 1PH8 motor

Standards:
SINAMICS DCC Winder
SINAMICS DCC
Load Sharing
(Tandem Winder)
Benefits:
Modular solution based on standard products
High hardware integration (no external traversing controller required)
No programming necessary
No PLC required for simple applications
S
I
N
A
M
I
C
S

C
U
3
2
0

PROFINET / PROFIBUS
SIMATIC S7
(Machine control)
M
o
t
o
r

m
o
d
u
l
e

Winder
(Master)
e.g. 1PH8
Slave
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Example Configuration
HMI
Web handling
TM31
SINAMICS CU320 / DCC
SINAMICS S120 DC/AC
1PH8
Winder
Dancer system
(or load cell)
Nip
PROFINET / PROFIBUS
1PH8
SIMATIC S7
Machine control
C
U
3
2
0

I
n
f
e
e
d

M
o
t
o
r

M
o
d
u
l
e
s

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