SINAMICS DCC Winder

Introduction

The standard application SINAMICS DCC winder realizes a winder or unwinder, e.g. for film lines,
printing machines, coating lines, spoolers or textile machines.

The winder application can be used on:

SINAMICS S120, S150, G130, G150
SINAMICS DCM
SINAMICS Integrated in SIMOTION D4xx-2
The variant with splice control or support of the DCB traversing application can be used with
SINAMICS S120 and S150 and additionally uses DCB Extension.
SINAMICS DCC Winder
Scope of Functionality

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
• Output of control cams for gluing roller and knife(only for
extended winder with DCB extension)
SINAMICS DCC Winder
Scope of Functionality using the example of dancer position control
SINAMICS DCC Winder
Scope of Functionality
SINAMICS DCC Winder
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:
• Torque Control (Indirect Tension Control)
• Dancer Position Control with Speed Correction
• Tension Control with Torque Limitation
• Constant V control
• Tension Control with Speed Correction for Special Applications
SINAMICS DCC Winder
Scope of Functionality – Indirect Tension Control

• No measured tension value feedback

• Web velocity is specified by nip
• Tension is set in an open loop via the torque
setpoint
• Good compensation of acceleration and friction
torque required
• Diameter range up to approx. 10:1
• Tension range up to approx. 6:1
• Winding torque range up to approx. 40:1
• Web velocity up to approx. 600 m/min
• Preferably for sheet metal, textile and paper
SINAMICS DCC Winder
Scope of Functionality - Tension control with torque limiting

• Measured variable ( tension measured value) is fed

back via closed loop controller
• Web velocity is set by the nip
• Tension is set directly via the torque
• Nip required, load cell is sensitive to overload
• good compensation of acceleration torque required
• Diameter range up to approx. 15:1
• Tension range up to approx. 20:1
• winding torque range up to approx. 100:1
• web velocity up to approx. 2000 m/min
• Adjustment of the torque limitation
• Preferably for paper and thin foils
SINAMICS DCC Winder
Scope of Functionality - Dancer position control with speed setpoint correction

• Measured process variable (position measured value)

is fed back via a closed loop controller
• Web velocity is preset by nip
• Tension torque is adjusted by an additional speed set
point
• nip required, dancer roller intervenes in the web path
• Diameter range up to approx. 15:1
• Tension range can only be changed with adjustable
dancer support
• Winding torque range up to approx. 40:1, depending
on the dancer support design
• Web velocity up to approx. 2000 m/min
• Preferably for rubber, cable, textile, foil and paper
SINAMICS DCC Winder
Scope of Functionality – constant v-control

• Web velocity is read in via web tachometer

• Web velocity is not specified by nip point
• Tension torque cannot be influenced by the winder
• No nip required
• Diameter range up to approx. 15:1
• Web velocity dependent on mechanical design
• Preferably for sorting winders
SINAMICS DCC Winder
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:

• integrating calculation method
• division method
• the possibility to interconnect a diameter sensor
• method with layer counting
available
SINAMICS DCC Winder
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 (0)
• Max. tension reduction at specified diameter (1)
• Linear characteristic with tension reduction when maximum diameter is reached (2)
• Free characteristic using 10 points (3)
SINAMICS DCC Winder
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
SINAMICS DCC Winder
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
SINAMICS DCC Winder
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
SINAMICS DCC Winder
Scope of Functionality – Maneuvering input

The maneuvering input can e.g. be connected with an analog input to influence
the internal speed setpoint.
SINAMICS DCC Winder
Scope of Functionality – Jog

• 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
SINAMICS DCC Winder Scope of Functionality – machine ramp function,
synchronize and stop web setpoint

• winder can operate as velocity ramp function generator 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
y
HLZ RLZ Web velocity ramp function
Bahngeschwindigkeits-
x
generator
hochlaufgeber
y

dy/dt VZ VZ VZ VZ VZ VZ VZ VZ

y
Tup_eff Tdn_eff
SINAMICS DCC Winder
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
SINAMICS DCB Extended Winder
Scope of Functionality – Splice control

• flying roll change with optional application “Extended Winder”*

• cam outputs to control knife and splice roll
• “rewinding after splice” for unwinder

* for splice control the DCB-Extension library “GMC” and a DCB-Extension license 6SL3077-0AA00-0AB0 are required
SINAMICS DCB Extended Winder
Scope of Functionality – Master for DCB Traversing Drive

• The Extended Winderapplication* is operated as

master for the separate available DCB Traversing
Drive
• Traversing describes the accurate positioning of the
material on the coil
• While the winder is responsible for the rotation of
the coil, the traversing drive is responsible for the
controlled positioning of the material
• For e.g. wire, cables, textil threads, …

* for traversing drive the DCB-Extension library “GMC” and a DCB-Extension license 6SL3077-0AA00-0AB0 are required
SINAMICS DCC Winder
Scope of Functionality – Execution groups

The required components of the application are enabled via execution groups:
SINAMICS DCC Winder
Scope of Functionality – Project assistant

The
The project
project assistant
assistant provides a guided
offers a guided commissioning
commissioning of the
of the winder and winder and
is available in aavariant
graphical
for
diagnostic support.
Startdrive as AddIn and for Starter on Excel basis
SINAMICS DCC Winder
Scope of Functionality – Control with LMCSINA

For controlling the DCC Winder

with SIMATIC S7-1500 or S7-
1200 the SIMATIC library
LMCSINA is available:
https://support.industry.siemens.com/cs/ww/en/view/109
479491
SINAMICS DCC Winder
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.

Normierung Bahngeschwindigkeit p21000[0]
[m/min] p21516 (30) Normierung Bahngeschwindigkeit BI: Glättung der DMR
p21539 IntegrierenderDurchmR
Ausgänge bei Integrations-
Bahngeschwindigkeit Istwert [m/min] (0)
verfahren [1=AUS; 0=EIN] p21000[1]
r21517 Durchmesserrechner
Geschwindigkeits- p21515
istwert Bahn Berechneter Durchmesser [m]
(0) Durchmesserrechner
r21545
Minimaler
Durchmesser Berechneter Durchmesser
Aktueller Duchmesser
Materialgeschwindigkeit
relativ [%]
Dmax r21546

Getriebefaktor Lastumdrehungen
p21520 (1) Getriebefaktor Multiplikator Sollwertkanal [1/m]
x
Getriebefaktor Motorumdrehungen y Maximaler
r21547
Wickeldurchmesser
p21521 (1)
M Getriebeübersetzung
Motordrehzahl

Umdrehungen Wickel per

Integrationsintervall Δt (Integrationsintervall)
p21525 (1)

Normierung p21511 Normierung Drehzahl

Drehzahl [min-1 ] (r2700)
r21512
Drehzahlistwert p21510
Motordrehzahl Istwert [min-1 ]
Motorgeber (r63)

Setzwert
Durchmesser fest [m] [WI1010.5] Durchmesser
∫ Bahngeschwindigkeit Getriebeübersetzung
Setzwert
gespeicherten
p21522 (0.1)
Durchmesserwert als Setzwert ∫Motordrehzahl Durchmesser wirksam [m]
r21524
<>0
p21523 0
Durchmessersetzwert Durchmesserwert gespeichert
(0)
=0 (netzausfallsicher) [m]
Setzwert 1 r21548
Durchmesser normiert Nichtflüchtiger Speicher
auf Maximaldurchmesser für Durchmesserwert gespeicherter Durchmesserwert gültig
Maximaler r21549
Durchmesser
p21534 (2 m)
Minimaler
Durchmesser
p21535 (0.1m)
Symmetrierung Bahngeschwindigkeit
Integrationsverfahren p21536 (0 ms)
Glättung Durchmesser Integrations- Durchmesser wird auf
verfahren [ms] p21537 (100.000) Maximaldurchmesser [WI1020.4]
begrenzt
[WI1030.7] Durchmesser setzen Durchmesser wird auf
[WI1030.7] Durchmesser halten Minimaldurchmesser [WI1020.4]
[WI1010.4] wickeln von unten begrenzt

1 2 3 4 5 6 7 8
DO: SERVO, VECTOR, DC_CTRL Wickler_DCC_V3_de.VSD Function diagram
- WI1101 -
Durchmesserrechner Integrationsverfahren (p21538=1, p21540=0, p21541=0) 29.11.10 V03.00.00 SINAMICS
SINAMICS DCC Winder
Tools for sizing

Sizing winders the engineering tool Sizer is used:

https://support.industry.siemens.com/cs/ww/en/view/54992004
Disclaimer

© Siemens 2021

Subject to changes and errors. The information in this document

contains only general descriptions or performance features which do
not always apply as described in the specific application or which may
change as a result of further development of the products. The desired
performance characteristics are only binding if they are expressly
agreed upon conclusion of the contract.

All product names may be trademarks or other rights of Siemens AG,

its affiliates or third parties, the use of which by third parties for their
own purposes may infringe the rights of the respective owners.
Contact
Published by Siemens AG
Technology Team
DI FA PMA APC1
Frauenauracher Str. 80
91056 Erlangen
E-Mail: [email protected]