converting applications made easy rotary knife flying saw ... center wind zone tension control web...
TRANSCRIPT
Converting Applications Made Easy Presented by Jeff Reese
Manufacturing in America │ March 14-15, 2018
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Before we start… A Penny for Your Thoughts
At the end of the session, share your feedback via MiA App -
and get a chance to win tickets to the Detroit Tigers baseball game!
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What is Converting??
The Siemens Converting Toolbox
Web Handling with SIMOTION, SINAMICS and SIMATIC
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Converting is Web Handling & Web Processing
Webs include paper, film, foil, nonwovens, and other thin flexible continuous materials.
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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
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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
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Coating & Laminating Slitter Rewind
Converting Machines / Applications
Sheeter / Rotary Knife Tissue / Towel Lines
Label / Die Cut Core Winder
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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
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Yesterdays Converting Solutions
Then
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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
Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.
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
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
Unrestricted © Siemens 2018 All rights reserved. Community. Collaboration. Innovation.
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
Engineering time saving
Time-tested, reliable functions
Global Toolbox support
Available without charge
Every control platform
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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
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PLC-Based Solutions
SIMATIC Converting Module
SIMATIC HMI
SIMATIC PLC
Synchronous
Motors
Asynchronous
Motors
SINAMICS
S120 with
safety
integrated
Architecture
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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
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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
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Drive-Based Solutions
SINAMICS (DCC) Converting Module
Features
• Drive-based performance
• Drive-based Graphical programming editor (DCC)
Converting
Library
Center Wind Zone Tension
Control
Web Server /
Diagnostics
Harmonic
Compensation
Unwind Flying
Splice Traversing Axis
Control
Rotary Knife Flying Saw Load Sharing
Electronic
Gearing
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Motion-Based Solutions
SIMOTION Converting Module
SIMATIC HMI
SIMATIC PLC
Synchronous
Motors
Asynchronous
Motors
SIMOTION D
Motion controller
Architecture
SINAMICS
S120 with
safety
integrated
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Motion-Based Solutions
SIMOTION Converting Module
Features
• Highest level of performance
• Include HMI application
• Can be demonstrated via SIMOTION demo
• Open source code
Converting
Library
Center Wind Zone Tension
Control
Web Server /
Diagnostics
Unwind Flying
Splice Traversing Axis
Control
Rotary Knife Flying Saw
Accumulator
Control
Electronic
Gearing
Project
Generator Register
Control
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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
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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
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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
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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
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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
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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.
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Performance Review - Diameter Calculation Methods
RED - V/n diameter
GREEN - INTEGRAL diameter
BLUE - POSITION diameter
Constant web speed: 100 m/min
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Performance Review - Diameter Calculation Methods
RED - V/n diameter
GREEN - INTEGRAL diameter
BLUE - POSITION diameter
Acceleration profile: 50 m/min > 300 m/min > 10 m/min
Update (sampling) time: 6 ms
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Performance Review - Diameter Calculation Methods
RED - V/n diameter
GREEN - INTEGRAL diameter
BLUE - POSITION diameter
Acceleration profile: 50 m/min > 300 m/min > 10 m/min
Update (sampling) time: 1 ms
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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
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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
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The Converting Toolbox (Integrated Web Server)
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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
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The Converting Toolbox on Flash Drive
Ask for yours
• It’s free!
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How did we do? Share your thoughts to win!
Got 1 minute? Rate this seminar via MiA App for a chance to
win Detroit Tigers tickets:
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Seminar Slides
After MiA, seminar slides will be available at:
http://www.usa.siemens.com/mia-seminars
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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