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Winders/SPW2 - RG354768

Description

This function block implements a Speed Programmed Winder.  It is intended to perform the speed demand calculations and associated logic for a closed loop winder.

This function block is made up of seven sub-function blocks (which are described separately): Diameter Calculator, Inertia Compensation, Speed Demand, Web Break Detector, Up to Speed Detector, Tension Demand, and Current Memory.  All logic outputs have built in Logic Senders.

Parameters

Parameters are listed by sections as they appear in the configuration.  If  a parameter is not listed in this section, it cannot be preset and is listed in either Set Methods and/or Get Methods.  Unless otherwise noted, all parameters are persistent and default value is listed in parenthesis at the end of the description.

Diameter Calculator - Main Parameters

Filter Max TC 	Diameter filter value when winder speed is zero (0.94).

Filter Mid TC 	Diameter filter value when winder speed is Filter Mid Speed (0.94).

Filter Min TC 	Diameter filter value when winder speed is 100% (0.94).

Filter Mid Speed 	Winder speed for Filter Mid TC (50%).

Diameter Hold	Initial condition of Diameter Filter (Track).

Preset Enable	Initial condition of Diameter Preset. Preset loads value of Core or External Diameter into Diameter Filter (Disabled).

Min Speed	Line Speed value below which Diameter is held (5%).

Min Diameter	Minimum value of Diameter Calculator output.  100% = Full Roll (10%).

Diameter Tick Time	Clock period for Diameter calculation. Filter Time is proportional to Tick Time (300 ms).

Diameter Calculator - Inertia Compensation

Over-Under	Selects winding direction (Over).

Fixed Inertia	Compensation value for the fixed inertia of the motor, coupling and core shaft.  With the rate cal set as specified below the Fixed Inertia is set to the % current required to accelerate the empty core(below base speed) with the line (0%).

Variable Inertia	Compensation for the roll inertia.  With the rate cal set as specified below the Variable Inertia is set to the % current required to accelerate the full roll with the line (0%).

Width	Width of the web and roll as a percentage of the maximum width (100%).

Base Speed	Compensates for a field weakening range. Base Speed is % that the motor base speed is of the applied full speed.  This should correspond with the 590 calibration.  The Base Speed parameter should be left at 100% with a Torque Demand as in the 620 (100%).

Rate Cal	Normalises the Rate input so  that the Fixed and Variable Inertia parameters can be set directly as %FLC.  With the Rate input from the Master Ramp the Rate Cal should be set to 20%/Ramp time (100%).

Diameter Calculator - Core Parameters

Ext Diameter	Initial value of External Diameter input (100% Full roll).

Ext Dia Select	Selects source of Diameter Preset. see Preset Enable (Core).

Core 1	Value of Core 1 (10% Full roll).

Core 2	Value of Core 2 (20% Full roll).

Core Select	Initial core selection.  Core 1 = false, Core 2 = true (Core 1).

Speed Demand - Speed Parameters

Overspeed	Overspeed added in current control with Current Memory Enabled (12%).

Speed Delta	Ramp increment per Tick Time (Speed Demand Tick determined by update rate of Line Speed SP input, typically 100ms).  2% in 100ms = Ramp time to 100% of 5 seconds (2%).

Jog Speed	Value of Jog Speed (5%).

Start	Initial condition Disabled, cannot be preset.

Jog	Initial condition Disabled, cannot be preset.

E Stop	Initial condition Low (Disabled), cannot be preset.

Health	Initial condition Low (Disabled), cannot be preset.

Stop	Initial condition Low (Disabled), cannot be preset.

Speed Demand - PID Parameters

Setpoint	Dancer Position Setpoint or initial value for Tension Setpoint (50%).

PID Enable	Initial condition of PID Enable (Disabled).

Integral Enable	Initial condition of PID Integral Enable (Enabled).

Integral	Integral Time Constant in seconds (10).

Speed Demand - Profile Parameters

The Gain Profiler provides the ability to vary the gain with diameter.  Three parameters are available:  Max Gain which sets the output at maximum diameter, Min Gain which sets the percentage of Max Gain at minimum diameter, and Exponent which sets the profile between the max and min gain output values.

Drive Max Gain	590 Drive Speed loop proportional Gain at Maximum Diameter, if connected (20).

Drive Min Gain	Drive Speed loop proportional Gain at Minimum Diameter, if connected.  Specified as a % of Max Gain (100%).

Drive Exponent	Drive Speed loop proportional Gain profile between Drive Max gain and Drive Min gain (1).

D Max Gain	PID Derivative Gain at Maximum Diameter (0).

D Min Gain	PID Derivative Gain at Minimum Diameter.  Specified as a % of Max Gain (100%).

D Exponent	PID Derivative Gain profile between D Max Gain and D Min Gain (1).

P Max Gain	PID Proportional Gain at Maximum Diameter (2).

P Min Gain	PID Proportional Gain at Minimum Diameter.  Specified as a % of Max Gain (100%).

P Exponent	PID Proportional Gain profile between P Max Gain and P Min Gain (1).

Speed Demand- Web Break Parameters

WB Delay	Delay between detecting a web break and the Web Break output being set low (5 sec).

WB Threshold	Threshold of Feedback below which a web break is detected (0%).

Tension Demand - Main Parameters

Tension Tick Time	Clock period for Tension Demand calculation (300 ms).

Stall Tension	Tension value when Stall Enabled (50%).

Stall Select	Stall value - "Fixed" = Stall Tension, "Proportional" = Stall Tension * Set Tension (Proportional).

Stall Enable	Initial condition of Stall Enable (Disabled).

Boost	Determines Boost value when Boost Enabled (0%).

Boost Select	Boost value - "Fixed" = Boost, "Proportional" = Boost x Set Tension (Proportional).

Boost Enable	Initial condition of Boost Enable (Disabled).

Tension SP	Initial value of Tension Setpoint (0%).

Taper SP	Initial value of Taper Setpoint (0%).

Taper Select	Selects "Linear" or "Hyperbolic" Taper profile (Linear).

Tension Demand - Output Parameters

Dancer Cal	Scaling of output for Dancer loading (100%).

Tension Delta	Tension Ramp increment per Tension Tick Time.
For Tension Tick Time of 300 ms and Tension Delta of 33%, 100% ramp time = 1 second (33%).

Current Memory - Main Parameters

CM Boost	Increase in current when CM Boost Enable enabled (0%).

CM Boost Select	Boost value - "Fixed" = Boost, "Proportional" = Boost x Measured Current (Fixed).

CM Boost Enable	Enables Boost in Current Memory (Disabled).

Memory Enable	Initial condition of Current Memory Enable, Memory Enable also enables Memory Hold (Disabled).

Memory Hold	Initial condition of Memory Track and Hold, use if the current must be sampled before enabling current memory (Track).

Memory Filter	Memory Filter value = exp(-Tick Time/Filter Time), if Tick Time = 300ms and Filter Time = 1 second, then Filter value = 0.74 (.74).

Miscellaneous Parameters

UTS Threshold	Up to Speed Threshold.  Up to Speed Output is true when Winder Surface Speed is within Threshold of Line Speed (5%).

Tension Enable	Initial condition of Tension Enable. Enables diameter calculator (Disabled).

Range Non-Extn	Trim range, as a percentage of full speed, of the PID loop when Extensible Web is Disabled (10%).

Range Extn	Trim range, as a percentage of full speed, of the PID loop when Extensible Web is Enabled (15%).

Extensible Web	Selects the PID Trim Range for two web types: Extensible or Non-Extensible (Disabled).

Other Enable	Disconnects Dancer Loading output when other spindle Tension is Enabled (Disabled).

Set Methods

Armature Current	Current Memory input.  Expects a value between -200% and 200%.

Base Speed	Inertia Comp input.   Expects a value between -120% and 120%.

Boost	Tension Demand input.  Expects a value between -100% and 100%.

Boost Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Boost Select	Tension Demand input.  Expects Proportional (true) or Fixed (false).

CM Boost	Current Memory input.  Expects Proportional (true) or Fixed (false).

CM Boost Enable	Current Memory input.  Expects Enabled (true) or Disabled (false).

CM Boost Select	Current Memory input.  Expects a value between -100% and 100%.

Core 1	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Core 2	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Core Select	Diameter Calc. input.  Expects Core 2 (true) or Core 1 (false).

D Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

D Max Gain	Speed Demand input.  Expects a value between -5 and 5.

D Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

Dancer Cal	Tension Demand input.  Expects a value between -100% and 100%.

Diameter Filter	Diameter Calc. input.  Expects a value between 0 and 1.0.

Diameter Hold	Diameter Calc. input.  Expects Hold (true) or Track (false).

Drive Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

Drive Max Gain	Speed Demand input.  Expects a value between 0 and 200.

Drive Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

E Stop	Speed Demand input.   Expects Active (low) or Inactive (high).

Ext Dia Select	Diameter Calc. input.  Expects External (true) or Core (false).

Ext Diameter	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Extensible Web	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Feedback	Speed Demand input.  Expects a value between -100% and 100%.

Forward-Reverse	Diameter Calc. input.  Expects Forward (true) or Reverse (false).

Filter Max TC	Diameter Calc. input. Expects a value between 0 and 1.0

Filter Mid Speed	Diameter Calc. input. Expects a value between -120% and 120%

Filter Mid TC	Diameter Calc. input. Expects a value between 0 and 1.0

Filter Min TC	Diameter Calc. input. Expects a value between 0 and 1.0

Fixed Inertia	Speed Demand input.  Expects a value between  0% and 100%.

Health	Speed Demand input.   Expects Active (low) or Inactive (high).

Integral	Speed Demand input.  Expects a value between 0-.1 and 15.

Integral Enable	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Jog	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Jog Speed	Speed Demand input.  Expects a value between -120% and 120%.

Line Speed	Diameter Calc. input.  Expects a value between -120% and 120%.

Line Speed SP	Speed Demand input.  Expects a value between -120% and 120%.

Memory Enable	Current Memory input.  Expects Enabled (true) or Disabled (false).

Memory Filter	Current Memory input.  Expects a value between 0 and 1.0.

Memory Hold	Current Memory input.  Expects Hold (true) or Track (false).

Min Diameter	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Min Speed	Diameter Calc. input.  Expects a value between -120% and 120%.

Neg FB Limit	Speed Demand input.  Expects a value between -100% and 100%.

Other Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Over-Under	Tension Demand input.  Expects Over (true) or Under (false).

Overspeed	Speed Demand input.  Expects a value between -120% and 120%.

P Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

P Max Gain	Speed Demand input.  Expects a value between -30 and 30.

P Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

PG Limit	Speed Demand input.  Expects a value between -100% and 100%.

PID Enable	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Pos FB Limit	Speed Demand input.  Expects a value between -100% and 100%.

Preset Enable	Diameter Calc. input.  Expects Enabled (true) or Disabled (false).

Range Extn	Speed Demand input.  Expects a value between -100% and 100%.

Range Non-Extn	Speed Demand input.  Expects a value between -100% and 100%.

Rate 	Speed Demand input.  Expects a value between -1.0 and 1.0

Rate Cal	Speed Demand input.  Expects a value between -100% and 100%.

Rate SP	Speed Demand input.  Expects a value between -120% and 120%.

Setpoint	Speed Demand input.  Expects a value between 0 and 100%.

Speed Delta	Speed Demand input.  Expects a value between 0 and 100%.

Stall Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Stall Select	Tension Demand input.  Expects Proportional (true) or Fixed (false).

Stall Tension	Tension Demand input.  Expects a value between -100% and 100%.

Start	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Stop	Speed Demand input.   Expects Active (low) or Inactive (high).

Taper SP	Tension Demand input.  Expects a value between -100% and 100%.

Taper Select	Tension Demand input.  Expects Hyperbolic (true) or Linear (false).

Tension Delta	Tension Demand input.  Expects a value between 0 and 1.0.

Tension Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Tension SP	Tension Demand input.  Expects a value between -100% and 100%.

UTS Threshold	Up to Speed input.  Expects a value between -120% and 120%.

Variable Inertia	Speed Demand input.  Expects a value between 0 and 100%.

WB Threshold	Speed Demand input.  Expects a value between 0 and 100%.

WB Delay	Speed Demand input.  Expects a value between 0 and 3000 sec.

Width	Speed Demand input.  Expects a value between 0 and 100%.

Winder Speed	General input.  Expects a value between -120% and 120%.

Get Methods

Get Aux Current Demand	Returns the current state:  Value between -200% and 200%.

Get Base Speed	Returns the current state:  Value between -120% and 120%.

Get Boost	Returns the current state:  Value between -100% and 100%.

Get Boost Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Boost Select	Returns the current state:  Proportional (true) or Fixed (false).

Get CM Boost	Returns the current state:  Value between -100% and 100%.

Get CM Boost Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get CM Boost Select	Returns the current state:  Proportional (true) or Fixed (false).

Get Core	Returns the current state:  % (Full Roll = 100%).

Get Core 1	Returns the current state:  % (Full Roll = 100%).

Get Core 2	Returns the current state:  % (Full Roll = 100%).

Get Core Select	Returns the current state:  Core 2 (true) or Core 1 (false).

Get D Exponent	Returns the current state:  Ordinal 1 to 10.

Get D Max Gain	Returns the current state:  Value between 0% and 100%.

Get D Min Gain	Returns the current state:  % of Max Gain.

Get Dancer Cal	Returns the current state:  Value between -100% and 100%.

Get Derivative	Returns the current state:  Value between -5% and 5%.

Get Diameter	Returns the current state:  % (Full Roll = 100%).

Get Diameter Hold	Returns the current state:  Holding (true) or Tracking (false).

Get Diameter Preset	Returns the current state:  % (Full Roll = 100%).

Get Drive Exponent	Returns the current state:  Ordinal 1 to 10.

Get Drive Max Gain	Returns the current state:  Value between 0 and 200.

Get Drive Min Gain	Returns the current state:  % of Max Gain.

Get Drive P Gain	Returns the current state:  Value between 0 and 200.

Get Drive Start	Returns the current state:  Enabled (true) or Disabled (false).

Get E Stop	Returns the current state:  Active (low) or Inactive (high).

Get Ext Dia Select	Returns the current state:  Enabled (true) or Disabled (false).

Get Ext Diameter	Returns the current state:  % (Full Roll = 100%).

Get Extensible Web	Returns the current state:  Enabled (true) or Disabled (false).

Get Feedback	Returns the current state:  Value between -100% and 100%.

Get Filter Max TC	Returns the current state:  Value between 0 and 1.0.

Get Filter Mid  Speed	Returns the current state:  Value between -120% and 120%.

Get Filter Mid TC	Returns the current state:  Value between 0 and 1.0.

Get Filter Min TC	Returns the current state:  Value between 0 and 1.0.

Get Filter  TC	Returns the current state:  Value between 0 and 1.0.

Get Filtered Current	Returns the current state:  Value between -200% and 200%.

Get Fixed Inertia	Returns the current state:  Value between 0% and 100%.

Get Health	Returns the current state:  Active (low) or Inactive (high).

Get In Tension	Returns the current state:  Enabled (true) or Disabled (false).

Get Inertia Comp	Returns the current state:  Value between -200% and 200%.

Get Integral	Returns the current state:  Value between 0.1 and 15.

Get Integral Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Jog	Returns the current state:  Enabled (true) or Disabled (false).

Get Jog Speed	Returns the current state:  Value between -120% and 120%.

Get Line Speed	Returns the current state:  Value between -120% and 120%.

Get Line Speed SP	Returns the current state:  Value between -120% and 120%.

Get Memory Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Memory Filter	Returns the current state:  Value between 0 and 1.0.

Get Memory Hold	Returns the current state:  Holding (true) or Tracking (false).

Get Min Diameter	Returns the current state:  % (Full Roll = 100%).

Get Min Speed	Returns the current state:  Value between -120% and 120%.

Get Neg FB Limit	Returns the current state:  Value between -100% and 100%.

Get Neg Clamp	Returns the current state:  Value between -200% and 200%.

Get Other Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Over-Under	Returns the current state:  Over (true) or Under (false).

Get Overspeed	Returns the current state:  Value between -120% and 120%.

Get P Exponent	Returns the current state:  Ordinal 1 to 10.

Get P Max Gain	Returns the current state:  Value between 0% and 100%.

Get P Min Gain	Returns the current state:  % of Max Gain.

Get PG Limit	Returns the current state:  Value between 0% and 100%.

Get PID Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get PID Output	Returns the current state:  Value between -100% and 100%.

Get Pos FB Limit	Returns the current state:  Value between -100% and 100%.

Get Pos Clamp	Returns the current state:  Value between -200% and 200%.

Get Preset Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Proportional	Returns the current state:  Value between 0 and 200.

Get Ramped Speed	Returns the current state:  Value between -120% and 120%.

Get Range	Returns the current state:  Value between -100% and 100%.

Get Range Extn	Returns the current state:  Value between -100% and 100%.

Get Range Non-Extn	Returns the current state:  Value between -100% and 100%.

Get Rate Cal	Returns the current state:  Value between -100% and 100%.

Get Rate SP	Returns the current state:  Value between -120% and 120%.

Get Scaled Rate	Returns the current state:  Value between -100% and 100%.

Get Setpoint	Returns the current state:  Value between -100% and 100%.

Get Speed Delta	Returns the current state:  Value between 0% and 100%.

Get Speed Demand	Returns the current state:  Value between -120% and 120%.

Get Stall Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Stall Select	Returns the current state:  Proportional (true) or Fixed (false).

Get Stall Tension	Returns the current state:  Value between -100% and 100%.

Get Start	Returns the current state:  Started (true) or Off (false).

Get Start Latch	Returns the current state:  Enabled (true) or Disabled (false).

Get Stop	Returns the current state:  Active (low) or Inactive (high).

Get Taper SP	Returns the current state:  Value between -100% and 100%.

Get Taper Select	Returns the current state:  Hyperbolic (true) or Linear (false).

Get Tension Delta	Returns the current state:  Value between -100% and 100%.

Get Tension Demand	Returns the current state:  Value between -100% and 100%.

Get Tension Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Tension SP	Returns the current state:  Value between -100% and 100%.

Get UTS Threshold	Returns the current state:  Value between -120% and 120%.

Get Up to Speed	Returns the current state:  true or false.

Get Variable Inertia	Returns the current state:  Value between 0% and 100%.

Get WB Delay	Returns the current state:  Value between 0 and 3000 sec.

Get WB Threshold	Returns the current state:  Value between 0% and 100%.

Get Web Break	Returns the current state:  Enabled (true) or Disabled (false).

Get Width	Returns the current state:  Value between 0% and 100%.

Get Winder Speed	Returns the current state:  Value between -120% and 120%.


Diameter Calculation

This block performs the Diameter calculation used by the other sub-function blocks. the Diameter is calculated by dividing the absolute value of the Line Speed by the absolute value of the Winder Speed.  This result is scaled by the Min Diameter parameter.  This result goes to a filter block who's output can be held and is then clamped giving the final Diameter output.

A Filter Profiler is used to set the filter time constant for the filter.  The Filter TC (Filter TC = exp(-Tick Time/Filter Time), if Tick Time = 300ms and Filter Time = 5 seconds, then Filter TC = 0.94) decreases with increasing Winder Speed.  The Filter Profiler has two slopes with the break at Filter Mid Speed.

The diameter input to the filter is held when the Line Speed is less than Min Speed or Diameter Hold is true.  Note that only the input diameter is held, the filter output may continue to change in the held state until it matches the held diameter. Min Diameter is the minimum diameter value for the clamp.  The Diameter output will not go below this value.

It is also possible to use a Diameter Preset (Core 1, Core2 and External Diameter, selected by Core Select and Ext Dia Select).  The Diameter Preset is used as both the input and output of the filter if Preset Enable is true and Tension Enable is false or Line Speed is less than Min Speed.  The Diameter Preset is also loaded into the filter whenever the module is restarted.

Diameter Tick Time can only be preset and specifies the rate at which the diameter is calculated.


Inertia Compensation

Inertia Compensation provides the additional torque to accelerate or decelerate  the roll during line speed changes while maintaining constant tension.

The Fixed Inertia and Variable Inertia are calculated from the diameter and Width and multiplied by the Scaled Rate to provide the torque demand. The Scaled Rate is generated from the Rate input (from the Master Ramp) or the Rate SP (from a Line speed) divided by the Rate Cal.  The torque demand is modified by the Winder speed and Base Speed to produce the Aux Current Demand.


Speed Demand

This block calculates the Speed Demand output. Start sets the Start Latch which is reset by Stop, E Stop and Health.  Start Latch or Jog sets the Drive Start output and selects whether the Line Speed SP or the Jog Speed is input into the ramp.  The ramp output is summed with the scaled PID trim and divided by the signed Diameter (determined by Over-Under) to produce the Speed Demand output.

See the PID and Profiler data sheets for a description on how the PID output is generated.  This output is multiplied by the selected Range and added as a trim to the Speed Demand being calculated.


Web Break Detector

The Web break detector monitors the Feedback (loadcell or dancer).  If the Feedback falls below the WB Threshold the Diameter filter is held and after the WB Delay the Web Break output goes false.  The Web Break is overridden if Stall Enable is true.


Up to Speed Detector

This block compares a computed line speed (uses Winder Speed, Diameter and Min Diameter) with Line Speed SP.  If the absolute value of the difference is less than UTS Threshold, the Up to Speed output is set true.


Tension Demand

This block computes a tension demand.  The first part of the tension demand calculation involves computing a taper term.  This term is based on Diameter, Taper SP, the selected core (Core 1  or Core 2), and the type of Taper Select (see drawings for details).  The taper term is multiplied by Tension SP, and if Stall Enable and Boost Enable are false, is the input to the ramp.  If Stall Enable is true, this term is multiplied by Stall Tension and input into the ramp if Stall Select is proportional, otherwise, just the Stall Tension term is presented to the ramp.  If Boost Enable is true and Stall Enable is false, a boost is added before the value is input to the ramp.  The amount of boost is based on Boost Select.  If it is fixed, the amount of boost will be Boost.  If it is proportional, the amount will Boost multiplied by the tension term. Tension Delta controls the ramp rate and specifies the amount the ramp may change each Tension Tick Time (the rate at which tension demand is calculated).  The ramp output is also the Tension Demand output.  The tension demand can be multiplied by Dancer Cal to compute the Dancer Loading output.  This message is sent only when  Tension Enable is true and Other Enable is false.  This condition also sets the In Tension output.


Current Memory

The Current Memory monitors the drive current and uses the memorised value as the current limit to provide short term open loop tension control.

The Armature Current input is filtered (Memory Filter specifies the filter time constant) and then passed through a track and hold block.  The hold function is enabled by either the Memory Hold or the Memory Enable.  The held value has CM Boost (selected by CM Boost Select) added to it when CM Boost Enable is enabled. When the Memory Enable is true, Overspeed is added to the Speed Demand and the current limit (Positive Clamp or Negative Clamp dependant on Over-Under) is set at the memorised current and can be boosted if required.


Description

This function block implements a Speed Programmed Winder.  It is intended to perform the speed demand calculations and associated logic for a closed loop winder.

This function block is made up of seven sub-function blocks (which are described separately): Diameter Calculator, Inertia Compensation, Speed Demand, Web Break Detector, Up to Speed Detector, Tension Demand, and Current Memory.  All logic outputs have built in Logic Senders.


Parameters

Parameters are listed by sections as they appear in the configuration.  If  a parameter is not listed in this section, it cannot be preset and is listed in either Set Methods and/or Get Methods.  Unless otherwise noted, all parameters are persistent and default value is listed in parenthesis at the end of the description.

Diameter Calculator - Main Parameters

Filter Max TC 	Diameter filter value when winder speed is zero (0.94).

Filter Mid TC 	Diameter filter value when winder speed is Filter Mid Speed (0.94).

Filter Min TC 	Diameter filter value when winder speed is 100% (0.94).

Filter Mid Speed 	Winder speed for Filter Mid TC (50%).

Diameter Hold	Initial condition of Diameter Filter (Track).

Preset Enable	Initial condition of Diameter Preset. Preset loads value of Core or External Diameter into Diameter Filter (Disabled).

Min Speed	Line Speed value below which Diameter is held (5%).

Min Diameter	Minimum value of Diameter Calculator output.  100% = Full Roll (10%).

Diameter Tick Time	Clock period for Diameter calculation. Filter Time is proportional to Tick Time (300 ms).

Diameter Calculator - Inertia Compensation

Over-Under	Selects winding direction (Over).

Fixed Inertia	Compensation value for the fixed inertia of the motor, coupling and core shaft.  With the rate cal set as specified below the Fixed Inertia is set to the % current required to accelerate the empty core(below base speed) with the line (0%).

Variable Inertia	Compensation for the roll inertia.  With the rate cal set as specified below the Variable Inertia is set to the % current required to accelerate the full roll with the line (0%).

Width	Width of the web and roll as a percentage of the maximum width (100%).

Base Speed	Compensates for a field weakening range. Base Speed is % that the motor base speed is of the applied full speed.  This should correspond with the 590 calibration.  The Base Speed parameter should be left at 100% with a Torque Demand as in the 620 (100%).

Rate Cal	Normalises the Rate input so  that the Fixed and Variable Inertia parameters can be set directly as %FLC.  With the Rate input from the Master Ramp the Rate Cal should be set to 20%/Ramp time (100%).

Diameter Calculator - Core Parameters

Ext Diameter	Initial value of External Diameter input (100% Full roll).

Ext Dia Select	Selects source of Diameter Preset. see Preset Enable (Core).

Core 1	Value of Core 1 (10% Full roll).

Core 2	Value of Core 2 (20% Full roll).

Core Select	Initial core selection.  Core 1 = false, Core 2 = true (Core 1).

Speed Demand - Speed Parameters

Overspeed	Overspeed added in current control with Current Memory Enabled (12%).

Speed Delta	Ramp increment per Tick Time (Speed Demand Tick determined by update rate of Line Speed SP input, typically 100ms).  2% in 100ms = Ramp time to 100% of 5 seconds (2%).

Jog Speed	Value of Jog Speed (5%).

Start	Initial condition Disabled, cannot be preset.

Jog	Initial condition Disabled, cannot be preset.

E Stop	Initial condition Low (Disabled), cannot be preset.

Health	Initial condition Low (Disabled), cannot be preset.

Stop	Initial condition Low (Disabled), cannot be preset.

Speed Demand - PID Parameters

Setpoint	Dancer Position Setpoint or initial value for Tension Setpoint (50%).

PID Enable	Initial condition of PID Enable (Disabled).

Integral Enable	Initial condition of PID Integral Enable (Enabled).

Integral	Integral Time Constant in seconds (10).

Speed Demand - Profile Parameters

The Gain Profiler provides the ability to vary the gain with diameter.  Three parameters are available:  Max Gain which sets the output at maximum diameter, Min Gain which sets the percentage of Max Gain at minimum diameter, and Exponent which sets the profile between the max and min gain output values.

Drive Max Gain	590 Drive Speed loop proportional Gain at Maximum Diameter, if connected (20).

Drive Min Gain	Drive Speed loop proportional Gain at Minimum Diameter, if connected.  Specified as a % of Max Gain (100%).

Drive Exponent	Drive Speed loop proportional Gain profile between Drive Max gain and Drive Min gain (1).

D Max Gain	PID Derivative Gain at Maximum Diameter (0).

D Min Gain	PID Derivative Gain at Minimum Diameter.  Specified as a % of Max Gain (100%).

D Exponent	PID Derivative Gain profile between D Max Gain and D Min Gain (1).

P Max Gain	PID Proportional Gain at Maximum Diameter (2).

P Min Gain	PID Proportional Gain at Minimum Diameter.  Specified as a % of Max Gain (100%).

P Exponent	PID Proportional Gain profile between P Max Gain and P Min Gain (1).

Speed Demand- Web Break Parameters

WB Delay	Delay between detecting a web break and the Web Break output being set low (5 sec).

WB Threshold	Threshold of Feedback below which a web break is detected (0%).

Tension Demand - Main Parameters

Tension Tick Time	Clock period for Tension Demand calculation (300 ms).

Stall Tension	Tension value when Stall Enabled (50%).

Stall Select	Stall value - "Fixed" = Stall Tension, "Proportional" = Stall Tension * Set Tension (Proportional).

Stall Enable	Initial condition of Stall Enable (Disabled).

Boost	Determines Boost value when Boost Enabled (0%).

Boost Select	Boost value - "Fixed" = Boost, "Proportional" = Boost x Set Tension (Proportional).

Boost Enable	Initial condition of Boost Enable (Disabled).

Tension SP	Initial value of Tension Setpoint (0%).

Taper SP	Initial value of Taper Setpoint (0%).

Taper Select	Selects "Linear" or "Hyperbolic" Taper profile (Linear).

Tension Demand - Output Parameters

Dancer Cal	Scaling of output for Dancer loading (100%).

Tension Delta	Tension Ramp increment per Tension Tick Time.
For Tension Tick Time of 300 ms and Tension Delta of 33%, 100% ramp time = 1 second (33%).

Current Memory - Main Parameters

CM Boost	Increase in current when CM Boost Enable enabled (0%).

CM Boost Select	Boost value - "Fixed" = Boost, "Proportional" = Boost x Measured Current (Fixed).

CM Boost Enable	Enables Boost in Current Memory (Disabled).

Memory Enable	Initial condition of Current Memory Enable, Memory Enable also enables Memory Hold (Disabled).

Memory Hold	Initial condition of Memory Track and Hold, use if the current must be sampled before enabling current memory (Track).

Memory Filter	Memory Filter value = exp(-Tick Time/Filter Time), if Tick Time = 300ms and Filter Time = 1 second, then Filter value = 0.74 (.74).

Miscellaneous Parameters

UTS Threshold	Up to Speed Threshold.  Up to Speed Output is true when Winder Surface Speed is within Threshold of Line Speed (5%).

Tension Enable	Initial condition of Tension Enable. Enables diameter calculator (Disabled).

Range Non-Extn	Trim range, as a percentage of full speed, of the PID loop when Extensible Web is Disabled (10%).

Range Extn	Trim range, as a percentage of full speed, of the PID loop when Extensible Web is Enabled (15%).

Extensible Web	Selects the PID Trim Range for two web types: Extensible or Non-Extensible (Disabled).

Other Enable	Disconnects Dancer Loading output when other spindle Tension is Enabled (Disabled).


Set Methods

Armature Current	Current Memory input.  Expects a value between -200% and 200%.

Base Speed	Inertia Comp input.   Expects a value between -120% and 120%.

Boost	Tension Demand input.  Expects a value between -100% and 100%.

Boost Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Boost Select	Tension Demand input.  Expects Proportional (true) or Fixed (false).

CM Boost	Current Memory input.  Expects Proportional (true) or Fixed (false).

CM Boost Enable	Current Memory input.  Expects Enabled (true) or Disabled (false).

CM Boost Select	Current Memory input.  Expects a value between -100% and 100%.

Core 1	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Core 2	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Core Select	Diameter Calc. input.  Expects Core 2 (true) or Core 1 (false).

D Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

D Max Gain	Speed Demand input.  Expects a value between -5 and 5.

D Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

Dancer Cal	Tension Demand input.  Expects a value between -100% and 100%.

Diameter Hold	Diameter Calc. input.  Expects Hold (true) or Track (false).

Drive Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

Drive Max Gain	Speed Demand input.  Expects a value between 0 and 200.

Drive Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

E Stop	Speed Demand input.   Expects Active (low) or Inactive (high).

Ext Dia Select	Diameter Calc. input.  Expects External (true) or Core (false).

Ext Diameter	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Extensible Web	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Feedback	Speed Demand input.  Expects a value between -100% and 100%.

Forward-Reverse	Diameter Calc. input.  Expects Forward (true) or Reverse (false).

Filter Max TC	Diameter Calc. input. Expects a value between 0 and 1.0

Filter Mid Speed	Diameter Calc. input. Expects a value between -120% and 120%

Filter Mid TC	Diameter Calc. input. Expects a value between 0 and 1.0

Filter Min TC	Diameter Calc. input. Expects a value between 0 and 1.0

Fixed Inertia	Speed Demand input.  Expects a value between  0% and 100%.

Health	Speed Demand input.   Expects Active (low) or Inactive (high).

Integral	Speed Demand input.  Expects a value between 0-.1 and 15.

Integral Enable	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Jog	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Jog Speed	Speed Demand input.  Expects a value between -120% and 120%.

Line Speed	Diameter Calc. input.  Expects a value between -120% and 120%.

Line Speed SP	Speed Demand input.  Expects a value between -120% and 120%.

Memory Enable	Current Memory input.  Expects Enabled (true) or Disabled (false).

Memory Filter	Current Memory input.  Expects a value between 0 and 1.0.

Memory Hold	Current Memory input.  Expects Hold (true) or Track (false).

Min Diameter	Diameter Calc. input.  Expects a value 0.1% to 100% Full Roll.

Min Speed	Diameter Calc. input.  Expects a value between -120% and 120%.

Neg FB Limit	Speed Demand input.  Expects a value between -100% and 100%.

Other Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Over-Under	Tension Demand input.  Expects Over (true) or Under (false).

Overspeed	Speed Demand input.  Expects a value between -120% and 120%.

P Exponent	Speed Demand input.  Expects an ordinal between 1 and 10.

P Max Gain	Speed Demand input.  Expects a value between -30 and 30.

P Min Gain	Speed Demand input.  Expects a value 0 to 100% (of Max Gain).

PG Limit	Speed Demand input.  Expects a value between -100% and 100%.

PID Enable	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Pos FB Limit	Speed Demand input.  Expects a value between -100% and 100%.

Preset Enable	Diameter Calc. input.  Expects Enabled (true) or Disabled (false).

Range Extn	Speed Demand input.  Expects a value between -100% and 100%.

Range Non-Extn	Speed Demand input.  Expects a value between -100% and 100%.

Rate 	Speed Demand input.  Expects a value between -1.0 and 1.0

Rate Cal	Speed Demand input.  Expects a value between -100% and 100%.

Rate SP	Speed Demand input.  Expects a value between -120% and 120%.

Setpoint	Speed Demand input.  Expects a value between 0 and 100%.

Speed Delta	Speed Demand input.  Expects a value between 0 and 100%.

Stall Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Stall Select	Tension Demand input.  Expects Proportional (true) or Fixed (false).

Stall Tension	Tension Demand input.  Expects a value between -100% and 100%.

Start	Speed Demand input.  Expects Enabled (true) or Disabled (false).

Stop	Speed Demand input.   Expects Active (low) or Inactive (high).

Taper SP	Tension Demand input.  Expects a value between -100% and 100%.

Taper Select	Tension Demand input.  Expects Hyperbolic (true) or Linear (false).

Tension Delta	Tension Demand input.  Expects a value between 0 and 1.0.

Tension Enable	Tension Demand input.  Expects Enabled (true) or Disabled (false).

Tension SP	Tension Demand input.  Expects a value between -100% and 100%.

UTS Threshold	Up to Speed input.  Expects a value between -120% and 120%.

Variable Inertia	Speed Demand input.  Expects a value between 0 and 100%.

WB Threshold	Speed Demand input.  Expects a value between 0 and 100%.

WB Delay	Speed Demand input.  Expects a value between 0 and 3000 sec.

Width	Speed Demand input.  Expects a value between 0 and 100%.

Winder Speed	General input.  Expects a value between -120% and 120%.


Get Methods

Get Aux Current Demand	Returns the current state:  Value between -200% and 200%.

Get Base Speed	Returns the current state:  Value between -120% and 120%.

Get Boost	Returns the current state:  Value between -100% and 100%.

Get Boost Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Boost Select	Returns the current state:  Proportional (true) or Fixed (false).

Get CM Boost	Returns the current state:  Value between -100% and 100%.

Get CM Boost Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get CM Boost Select	Returns the current state:  Proportional (true) or Fixed (false).

Get Core	Returns the current state:  % (Full Roll = 100%).

Get Core 1	Returns the current state:  % (Full Roll = 100%).

Get Core 2	Returns the current state:  % (Full Roll = 100%).

Get Core Select	Returns the current state:  Core 2 (true) or Core 1 (false).

Get D Exponent	Returns the current state:  Ordinal 1 to 10.

Get D Max Gain	Returns the current state:  Value between 0% and 100%.

Get D Min Gain	Returns the current state:  % of Max Gain.

Get Dancer Cal	Returns the current state:  Value between -100% and 100%.

Get Derivative	Returns the current state:  Value between -5% and 5%.

Get Diameter	Returns the current state:  % (Full Roll = 100%).

Get Diameter Hold	Returns the current state:  Holding (true) or Tracking (false).

Get Diameter Preset	Returns the current state:  % (Full Roll = 100%).

Get Drive Exponent	Returns the current state:  Ordinal 1 to 10.

Get Drive Max Gain	Returns the current state:  Value between 0 and 200.

Get Drive Min Gain	Returns the current state:  % of Max Gain.

Get Drive P Gain	Returns the current state:  Value between 0 and 200.

Get Drive Start	Returns the current state:  Enabled (true) or Disabled (false).

Get E Stop	Returns the current state:  Active (low) or Inactive (high).

Get Ext Dia Select	Returns the current state:  Enabled (true) or Disabled (false).

Get Ext Diameter	Returns the current state:  % (Full Roll = 100%).

Get Extensible Web	Returns the current state:  Enabled (true) or Disabled (false).

Get Feedback	Returns the current state:  Value between -100% and 100%.

Get Filter Max TC	Returns the current state:  Value between 0 and 1.0.

Get Filter Mid  Speed	Returns the current state:  Value between -120% and 120%.

Get Filter Mid TC	Returns the current state:  Value between 0 and 1.0.

Get Filter Min TC	Returns the current state:  Value between 0 and 1.0.

Get Filter  TC	Returns the current state:  Value between 0 and 1.0.

Get Filtered Current	Returns the current state:  Value between -200% and 200%.

Get Fixed Inertia	Returns the current state:  Value between 0% and 100%.

Get Health	Returns the current state:  Active (low) or Inactive (high).

Get In Tension	Returns the current state:  Enabled (true) or Disabled (false).

Get Inertia Comp	Returns the current state:  Value between -200% and 200%.

Get Integral	Returns the current state:  Value between 0.1 and 15.

Get Integral Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Jog	Returns the current state:  Enabled (true) or Disabled (false).

Get Jog Speed	Returns the current state:  Value between -120% and 120%.

Get Line Speed	Returns the current state:  Value between -120% and 120%.

Get Line Speed SP	Returns the current state:  Value between -120% and 120%.

Get Memory Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Memory Filter	Returns the current state:  Value between 0 and 1.0.

Get Memory Hold	Returns the current state:  Holding (true) or Tracking (false).

Get Min Diameter	Returns the current state:  % (Full Roll = 100%).

Get Min Speed	Returns the current state:  Value between -120% and 120%.

Get Neg FB Limit	Returns the current state:  Value between -100% and 100%.

Get Neg Clamp	Returns the current state:  Value between -200% and 200%.

Get Other Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Over-Under	Returns the current state:  Over (true) or Under (false).

Get Overspeed	Returns the current state:  Value between -120% and 120%.

Get P Exponent	Returns the current state:  Ordinal 1 to 10.

Get P Max Gain	Returns the current state:  Value between 0% and 100%.

Get P Min Gain	Returns the current state:  % of Max Gain.

Get PG Limit	Returns the current state:  Value between 0% and 100%.

Get PID Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get PID Output	Returns the current state:  Value between -100% and 100%.

Get Pos FB Limit	Returns the current state:  Value between -100% and 100%.

Get Pos Clamp	Returns the current state:  Value between -200% and 200%.

Get Preset Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Proportional	Returns the current state:  Value between 0 and 200.

Get Ramped Speed	Returns the current state:  Value between -120% and 120%.

Get Range	Returns the current state:  Value between -100% and 100%.

Get Range Extn	Returns the current state:  Value between -100% and 100%.

Get Range Non-Extn	Returns the current state:  Value between -100% and 100%.

Get Rate Cal	Returns the current state:  Value between -100% and 100%.

Get Rate SP	Returns the current state:  Value between -120% and 120%.

Get Scaled Rate	Returns the current state:  Value between -100% and 100%.

Get Setpoint	Returns the current state:  Value between -100% and 100%.

Get Speed Delta	Returns the current state:  Value between 0% and 100%.

Get Speed Demand	Returns the current state:  Value between -120% and 120%.

Get Stall Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Stall Select	Returns the current state:  Proportional (true) or Fixed (false).

Get Stall Tension	Returns the current state:  Value between -100% and 100%.

Get Start	Returns the current state:  Started (true) or Off (false).

Get Start Latch	Returns the current state:  Enabled (true) or Disabled (false).

Get Stop	Returns the current state:  Active (low) or Inactive (high).

Get Taper SP	Returns the current state:  Value between -100% and 100%.

Get Taper Select	Returns the current state:  Hyperbolic (true) or Linear (false).

Get Tension Delta	Returns the current state:  Value between -100% and 100%.

Get Tension Demand	Returns the current state:  Value between -100% and 100%.

Get Tension Enable	Returns the current state:  Enabled (true) or Disabled (false).

Get Tension SP	Returns the current state:  Value between -100% and 100%.

Get UTS Threshold	Returns the current state:  Value between -120% and 120%.

Get Up to Speed	Returns the current state:  true or false.

Get Variable Inertia	Returns the current state:  Value between 0% and 100%.

Get WB Delay	Returns the current state:  Value between 0 and 3000 sec.

Get WB Threshold	Returns the current state:  Value between 0% and 100%.

Get Web Break	Returns the current state:  Enabled (true) or Disabled (false).

Get Width	Returns the current state:  Value between 0% and 100%.

Get Winder Speed	Returns the current state:  Value between -120% and 120%.