- aimcal · tension. wind. ramp. accumulator. setpoint. load share. ... motors and tension...

Answers for industry.© Siemens Industry, Inc. 2016 All rights reserved.

www.siemens.com/converting

Restricted © Siemens Industry, Inc. 2013 All rights reserved.

Web Handling Drive Control Concepts

Then



PLC Drive Motion

Now


Evaluation Criteria

Usability

Functionality

Performance


Evaluation

Usability

Functionality

Performance


Usability – Engineering System

Single Point Communications

Single point communications with routing to each system device for both centralized and distributed control


Usability – Engineering System

Common Engineering Environment

A common engineering tool with a common database unifying programs and all system components.


IEC 61131 Programming Languages

Usability – Programming Languages & Environment

Ladder diagram (LAD

Function block diagram (FBD)

Structured text (ST)

Statement list (STL)

Sequential function chart (SFC)

Continuous Function Chart (CFC)


Usability – Programming Languages & Environment

(CFC) Continuous function chart or a graphical editor is the ideal language for process engineering, visualization and documentation


Usability – Diagnostics & Commissioning Tools

Diagnostic and Troubleshooting tools

Integrated online monitoring capabilityTime and frequency based trace tools Drive axis commissioning control panel.


Usability – Maintenance & Engineering

Program StorageProgram storage on removable media, permits easy swapping of hardware without the requirement of program downloading.


Integrated Applications

Usability – Maintenance & Engineering

Integrated Applications reduce engineering time, and simplify commissioning and maintenance.

Center Wind Splice Accumulator Zone Tension Flying Saw

Elec. Gearing Load Sharing Rotary Knife Smoothing Registration


Evaluation

Usability

Functionality

Performance


Functionality - Control Concepts & Related Technology

PLCSplice (time)

Position

Torque

Position

Speed

Torque

Speed

Torque

SpeedDrive

Motion

RampTension Wind Accumulator

Setpoint Load Share Smoothing Position

Gear Cam Saw Cut Registration


Functionality - PLC Based Architecture (Centralized)

HMI

Drive Section #1 Drive Section #2Machine & Web Control

PLC

Network


Functionality - Drive Based Architecture (Distributed)

PLC

HMI

Drive Section #1 Drive Section #2

Network

Machine Control

Web Control Web Control


Functionality - Motion Control Architecture (Centralized)

Machine Control

Web Control

PLC

HMI

Network

Drive Section #1 Drive Section #2


Evaluation Criteria

Usability

Functionality

Performance


Process throughput time is the time that it takes to receive the feedback (from the motors and tension sensors), process all of the control loops and send the respective commands to the drives.

Performance

The performance of any machine or system will be directly related to the control system's Process Throughput Time.

Speed controller

Current controller ConverterTension

controllerSetpoints (master)


Performance

Three components contribute to the process throughput time;

Speed controller

Current controller Converter

DRIVETension controller

Setpoints (master)

Network

250us

CONTROLLER

Controller scan time or process cycle

Communication network type (sync or async) and cycle time

Drive loop cycle time

1

23


Network Performance – Asynchronous clock cycles

Process Throughput = (Tension control cycle *2) + (Network cycle *2) + (Drive Cycle Time * 2)

Because of the signal timing uncertainty in asynchronous networked systems, process throughput must be calculated as worst case


Network Performance – Synchronous clock cycles

Process Throughput = (Tension control cycle *2) + Drive Cycle Time

Note: Calculation assumes that the data is read in one cycle, processed and transmitted next synchronous cycle.


Performance – Networked Components

Each system component will have different ranges of system cycle or scan time performance.

Device Common Cycle Times Notes:PLC ~5 – 100 ms Depending on Program size and

processor power Drive - (program) ~1 – 8 ms Configurable program cycle time

Drive - (loops) ~62.5 – 250 us Normally fixed

Motion Control ~0.25 - 8 ms Configurable program or background task cycle times

Network ~0.25 – 8 ms Normally configurable


PLC Control Architecture - Performance

Speed controller


DRIVE #1PLC

Machine control Tension controller

Speed controller


DRIVE #2Tension controller

Setpoints (master)

Asynchronous Network

Speed controller


controller

DRIVE #3

To Drive n ...

12ms

2ms

250us

250us

250us

Motor #1

Motor #2

Motor #3

Web Control

Process Throughput = (Tension control cycle *2) + (Network cycle *2) + (Drive Cycle Time * 2)= (12ms * 2) + (2ms*2) + (250us*2) = 28.5ms

Performance Reference: In this example, a web traveling at 600mpm will displace 2.85cm in one tension cycle.


Drive Control Architecture - Performance

Speed controller


DRIVE #1PLC

Machine controlNetwork

Tension controller

Speed controller



Setpoints (master)

Synchronous Drive Peer to Peer

Network

Speed controller


controller

DRIVE #3

To Drive n ...

2ms

2ms

2ms

2ms

2ms

250us

250us

250us

Motor #1

Motor #2

Motor #3

Web Control

Process Throughput = (Tension control cycle *2) + (Drive Cycle Time )= (2ms * 2) + (250us*2) = 4.5ms

Performance Reference: In this example, a web traveling at 600mpm will displace 0.45cm in one tension cycle.


Motion Control Architecture - Performance

PLC

Speed controller


DRIVE #1MOTION CONTROLLER

Machine control Tension controller

Speed controller



Setpoints (master)

Synchronous Network

Speed controller


controller

DRIVE #3

To Drive n ...

2ms 2ms

2ms

250us

250us

250us

Motor #1

Motor #2

Motor #3

Web Control

Process Throughput = (Tension control cycle *2) + (Drive Cycle Time )= (2ms * 2) + (250us*2) = 4.5ms

Performance Reference: In this example, a web traveling at 600mpm, will displace 0.45cm in one tension cycle.


Architecture / Machine Reference

ApplicationExample Machine Type

1-6 Axes

PLC

DRIVE

MOTION

6-50 Axes 50-200 Axes

•Slitter Rewind•Doctor Machine

•Slitter Rewind•Coating Line

•Slitter Rewind•Doctor Machine•Filament Winder•Load Sharing

•Slitter Rewind•Flexo Press •Coating/Lam. Line

•Coating /Lam. Line•Film Line

•Rotary Knife•Core Cutter•Die Cutter

•Paper Sheeter•Offset Press•Gearless Flexo•Narrow Web Press

•Diaper Machine•Tissue/Towel Line

Web Control

Motion Control

Web Control

Web Control

Motion Control


Technology Trends

Integrated Web Server



Integrated Web Servers are now common place in most industrial controllers.

An integrated web server has many benefits, among them; the ability to obtain diagnostics without use of proprietary tools.

Any web-capable PC / notebook / tablet with an Internet browser is typically sufficient.

Custom web pages can be created.

Monitoring and Troubleshooting, without an engineering system

Industrial Ethernet

Internet

PC with Browser / Application



Custom Web Pages



Functionality

Download a programs

Perform Firmware updates

Status overview of specific variables

Evaluate of alarms and faults

Monitoring and change parameters

Archive machine documentation



Then



PLC Drive Motion

Now


Conclusions

Considering the optimum control architecture can be an interesting challenge. Each of the detailed systems has its benefits and limitations.

PLC based solutions offer a medium level of performance with a high level of usability.

Drive base solutions offer a higher level of performance through their distributed control structure. They typically have high usability through optimum engineering tools.

With the continuing demands on production speeds, product quality and considering the general trend of motion based control, integrated drive and motion are not only well suited but becoming common place in the industrial landscape. The concepts and benefits of motion control based solutions can be extremely attractive for both new converting lines and retrofits.


Thank You

William GilbertSiemens Industry, Inc.

5300 Triangle ParkwayNorcross, GA 30092

Phone: +1 (770) 625-5658Mobile: +1 (678) 314-4222E-mail: [email protected]

Website: www.usa.siemens.com/converting

Answers for Converting

mailto:[email protected]

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

- aimcal · tension. wind. ramp. accumulator. setpoint. load share. ... motors and tension...

Documents