Winding drive: Simpler design and easier commissioning

First of all, it is necessary to understand the process of winding

Winding drives are used to store successive materials before and after the machining process. Depending on the winding process, these drives are primarily operated in a quasi-static manner. Winding drives operated in a synchronous way can be used, e.g. for intermittent operation of equipment (presses, cutting units...). ）。 The types and form factors that will be rolled up are very wide. They can be flat (paper, plastic, foil, weaving, mesh fabric or fabric board, etc.) or round (silk, rope, yarn, thread). According to the data and equipment type, the flat data adopts the center winding machine or the end winding machine. In a center winder, the drive sits in the center of the reel; In the face winding machine, the drive sits around the perimeter. In mathematical terms, rolling up and winding data (a scroll) is a spiral action, and in a flat data network, it is a layer by layer; In circular data, each layer is next to each other and then superimposed and wound. The winding material is wound with a defined variable or fixed tension, and the production speed depends on the quality of the material and the current diameter. Depending on the product, the winding system is available in a very wide range of tension scales, from approx. 0.5 N to 30,000 N. The production speed is also available on a wide scale, from approx. 5 to 2,000 m/min. Drive power ranges from 0.1 kW to 400 kW.

Selected by DSD control

The size of the motor is determined by the torque. In the case of center winders, the maximum value required to fix the drive torque occurs at the maximum reel diameter and the speed is at its lowest point when this value is reached. For these requirements, the advantages of asynchronous motors operating on a weak magnetic scale are particularly significant. The unit rating of the drive system generated by the tension velocity of the center-wound machine is significantly greater than the process power of the practical winding process. Although high speed and high torque do not occur at the same time during the winding process, it is necessary for the drive to have the ability to cope with both at the same time. This combined power is called the underlying process power. The center winder with defined data tension is primarily planned for stationary operating conditions. The dynamic overcurrent reserves of the frequency converter enable the drive in a critical situation to be quickly decelerated at the desired moment even under most conditions. However, given the high moment of inertia and the short braking intervals, it is necessary to take into account the braking torque parameters in the selection process. In the form of intermittent operation of the winder, this dynamic drive torque generally determines the selection process. Due to the complexity and experience required for the selection of the winding drive and the corresponding selection of the correct drive components, the winding machine and the motor control process have been put into the DSD. In this way, the software makes it easy for each machine engineer to handle the selection process and find a viable solution at any time. In addition to the physical drive selection and product kitting, our new "DSD Winding Skill Assistant" can help you check if you have exceeded your system limits and provide you with valuable suggestions for several alternative solutions.

Prototype selection for the center winding of the printing machine

The mission is to roll 80g/mm2 of paper with a base weight onto tubes with a size of 80 mm to 800 mm. The paper movement speed on this printing machine is 400m/min. The tension requires a minimum diameter of 250 N and a maximum diameter of 200 N.

The DSD guides the user step-by-step through all the selection processes required. First of all, the engineering planning engineers were able to select the simplest and most efficient "open-loop torque tension control form". Based on this format, DSD performs a device set skill check, followed by input of the reel's dimensions and data, tension, velocity and acceleration data, abort phases, and equipment energy efficiency values. The process depiction is completed by the input of primary and environmental data, which DSD uses to identify the specific requirements (torque, speed, and power) for the reel. In addition, the diameter corrected during the acceleration phase is actively included in the calculation; It's also a tip to get the best solution plan. This results in a fixed winding power of 1.5 kW and a base process power of 11 kW. After confirming the electrical and mechanical planning of the drive shaft and the drive concept, the most suitable motor is selected. Here's another tip: In this critical selection process, the weak magnetic field can be interactively conditioned in the DSD in order to generate the minimum drive system power.

All operations can be performed using torque-speed characteristic curves. This results in a gear unit, brakes, encoders, frequency converters and an optional electrical braking circuit. It is worth mentioning that the DSD online help also provides valuable advice on how to best select the process.

In our example, we used asynchronous skill accounting to generate a 4kW energy efficiency motor (MH series) with a rotary encoder, a 45Nm tension spring brake, an i=3 toothed belt, a servo-operated 5.5kW inverter (9400 series) and a 120W braking resistor for emergency abort. After a complete selection, DSD conducts a comprehensive system analysis with variable graphs, utilization rates, and skill coefficients. The entire selection process and documentation generation takes about 10-20 minutes, so there's no faster or more convenient way to do it! We also recommend that you consider different solutions. This data can be quickly generated by DSD. DSD allows you to list and compare these solutions in a compact format. In this way, you will be able to evaluate the benefits and disadvantages of different drive concepts and products, and you will also have a clear basis for identifying a suitable solution plan.

Test plan: Use a tuner

The sizing process for a drive typically uses a reference plan and a worst-case plan. In practice, the device handles a wide range of products as well as formulas. For winding equipment, the winding speed of data varies depending on the thickness. In order to ensure that the winding equipment can also use the operation plan, the application tuner that can select the process and motion variables and actively calculate them as alternative plans is used to provide support for the equipment after the primary selection process has been performed. A direct comparison of all relevant results shows changes on the process side and the driver side. In this way, you will be able to immediately establish a clear concept of utilization, limit size or energy efficiency balance.

Evaluate energy efficiency

Over the past few years, there has been an increased focus on energy consumption and the resulting environmental impact and transparency of operating costs. Lenze responds to this problem at an early stage: the "Energy Efficiency Certification for Drive Solution Plans" in DSD and its carefully planned functions provide professional support for plant engineering planning. This means that once the energy efficiency requirements, energy costs, CO2 emissions and optimization potentials have been identified and graphically prepared in the background for the user to use the winding application inputs and the selected drive system, these are eventually mirrored based on the application situation. Through this comparison, it is possible to evaluate the different solutions and answer questions, such as "which motor efficiency level is the most suitable for use", "which reducer type can be used to minimize losses", "what affects the acceleration in the energy efficiency balance", "how much energy will occur during the braking process", "how much capital will be paid, how much operating cost will be caused", "how long can a specific solution plan be generated", and so on.

In particular, the use of winding offers great potential for energy efficiency optimization solutions. In particular, the calculation of multi-axis systems, the selection of power supply modules and the expression of energy efficiency can be done in DSD. This makes it possible to use the uncoiled regenerative energy in other drive shafts connected to each other. The primary load is reduced to a minimum and the energy efficiency is increased to the maximum.

Energy efficiency for the engineering chain

Once the drive solution plan is selected and optimized, DSD provides multiple connection points to perform more engineering planning work. For example, a DSD can define a variety of product features, such as the color of the geared motor, the location of flanges and terminal boxes, plugs, accessories, sensors, and other special planning requirements, and then supply all price-related factors and prepare content availability. The CAD viewer used immediately shows the user what the driver selection looks like and provides the planning engineer with different CAD data formats. Users can also check in their own CAD that the gearmotors and frequency converters are mechanically integrated correctly. Here, specific protocols under different scales and layouts are the main points. Not only are they used to document the solution plan, but they also reserve information for many other engineering planning missions, making it possible to complete many other functions. For example, most of the important debugging data is available instantly. This starts with the process depiction, which includes the process parameters that have been entered so far, as well as the minimum and maximum reel diameters, acceleration moments, linear velocities, and so on. However, the calculated parameters are also useful, such as the total moment of inertia that can be used for torque feed-forward manipulation; This provides better stability and more accurate handling. In addition, a good understanding of the selected product facilitates the smooth commissioning process.

In order to simplify the engineering planning process, Lenze always supplies standard, mechatronic modules (parameterization only) throughout the entire engineering planning process. On the DSD planning page you can find a description of the mechanical process for winding. During the commissioning phase, we supplied the FAST skill module for winding. The module contains the function block structure and logic manipulation for the winding process, and can be used to parameterize the reserve information in the DSD. This accelerates and simplifies the engineering planning process of the equipment and gives it more room to concentrate on its own needs.

In terms of the simplicity of the product itself, DSD is simple but not simplistic. The success of this engineering planning software is also due to the fact that all functions and processes of this product are planned according to the planning mission, and its data preparation makes commissioning faster and easier. This makes the interaction between Lenze and the mechanical engineers more efficient, and at the same time ensures the best possible plant engineering planning, simplifying and efficiently reducing the total cost of the machine and responding to the market faster. It is worth mentioning that DSD can be used not only for the engineering of winding equipment, but also for almost all other types of equipment.

DSD selection software provides the following functions:

o Provide the best support to cope with the mission of driving selection

o Plan the drive chain from the perspective of the mechatronic system

o Intervention in engineering planning through equipment depiction (process, action, environment).

o Support the physical requirements, utilization rate and functional values of accounting

o Create the required drive structures for each

o Fully integrate Lenze's years of professional experience and expertise and related solution plan experience

o Goal-oriented product selection and inspection

o System testing skills, feasibility, and optimal solution plan

o Product equipment to ensure that the solution plan is plannable and market-oriented

o Comparison and optimization between support-driven solution plans

o Use tuner: Quickly compare solution plans for different application parameters

o Energy Efficiency Utility Certification - Driven Solution Plan: Accounting to support a specific solution plan

o Supply solution plan and related documents (selection records, bill of materials, etc.)

o Generate CAD data for the selected product

o Support the processing of the world project (support 13 languages, use of global units)

Winding drive: Simpler design and easier commissioning

Winding drive: Simpler design and easier commissioning

Sections viewed

Contact

working hours