Application example 3/217 SIMOTION Line Tension Control https://support.industry.siemens.com/cs/ww/en/view/56293754
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Table of contents Table of contents Warranty and liability... 2 Application description... 5 1 Basic information and data... 5 1.1 Target group... 5 1.2 Objective and purpose of this standard application... 5 1.2.1 Field of application... 5 1.2.2 Task... 6 1.3 Structure of a tension control system... 6 1.3.1 General design... 6 1.3.2 Solution using the application... 7 1.3.3 Advantages... 8 2 Functions of the application... 9 2.1 Tasks that can be implemented using the core function... 9 2.2 Properties of the core functions... 9 2.3 Control concepts... 1 2.3.1 Draw-Control... 11 2.3.2 Tension control with dancer roll... 11 2.3.3 Indirect tension control... 12 2.3.4 Tension control with load cell... 12 2.3.5 Indirect tension control via speed setpoint correction... 13 Integration... 14 3 Integrating into the user program... 14 3.1 Integrating the library... 14 3.2 Technology objects... 15 3.2.1 Configuring the leading axis... 16 Leading axis as positioning / synchronous axis... 16 Leading axis as driveaxis... 17 Leading axis as machine encoder... 18 External setpoint input... 19 3.2.2 Configuring the web axis... 2 Web axis as driveaxis... 2 Web axis as positioning / synchronous axis... 21 3.3 Integrating into the user program... 22 3.3.1 Global variables... 22 3.3.2 Pre-assignment of the parameters in the start-up task... 23 3.3.3 Calling the function block in the user program... 24 3.4 Connection to SINAMICS... 25 3.4.1 Technology data block... 25 3.4.2 Adapting the parameters in SINAMICS... 3 Program description... 33... 33 4.1 Data types... 33 4.1.1 Overview... 33 4.1.2 Enumeration types... 33 4.1.3 Data structures... 36 4.1.4 Abbreviations of the units... 45 4.2 Input and output parameters of the function block... 46 4.3 Function description... 5 4.3.1 Control Modes... 5 4.3.2 Tension operating modes... 68 Entry-ID: 56293754, V2.2., 3/217 3
Table of contents 4.3.3 Technology data block... 69 4.3.4 Source of master value... 69 4.3.5 System of units... 71 Units of the velocity setpoint calculation... 73 4.3.6 Web break detection... 76 4.3.7 Application errors and warnings... 78 5 Commissioning the function... 81 5.1 Checking the speed actual value... 81 5.2 Compensating the accelerating torque... 81 5.3 Checking the tension control... 82 5.4 Setting and optimizing the technology controller, Kp-Adaption... 83 5.5 Setting the override value... 83 Appendix... 84 6 Collection of formulas... 84 7 Contact partner... 86 8 History of this manual... 86 Entry-ID: 56293754, V2.2., 3/217 4
1 Basic information and data 1.1 Target group Application description Content In Section Application description you ll learn about everything to be able to obtain a complete overview. You will get to know the components used (standard hardware and software components and the additional, developed software) and the principle of function of the technological core function. 1 Basic information and data 1.1 Target group The standard application is intended for all programming engineers and users that want to easily and quickly implement a tension control solution using SIMOTION. 1.2 Objective and purpose of this standard application 1.2.1 Field of application The application is designed for machines which are used to refined continuous materials (webs). Core of the application is thereby the control of the material tension or dancer position in the different tension segments of the machine. Generally the mechanical system in which tension or dancer position control necessary is consists of the material web which s needs to be controlled, of a motor which drives the web and of an equipment which is used to set or measure the web tension. Figure 1-1 Machine overview Typical machines with tension control are for example coating lines, recoilers, slitters, narrow web machines usually running with materials like paper, laminates, wire, foil (plastic or metal), textile or cables. Entry-ID: 56293754, V2.2., 3/217 5
1 Basic information and data 1.3 Structure of a tension control system 1.2.2 Task The standard application was developed with the objective to be able to handle many of the known tension and dancer control applications as a superimposed controller where many of the parameters can even be adjusted on the fly. The application SIMOTION Line tension control allows, using the appropriate equipment and devices, to control the tension of web materials, cables or fibers. The motor will be driven so that the web tension will be precisely maintained and controlled. Components included in the tension control solution typically are part of a bigger machine consisting of additional tension segments or winders. When required, the application can be engineered or modified thanks to the openness of the application. 1.3 Structure of a tension control system 1.3.1 General design A tension regulation system generally consists of one ore more motors, the material web and optionally additional sensors for direct tension measuring or a dancer roll for setting the tension. The task of the controlled motor is to: Transport the material with the defined machine velocity Hold or control the setpoint tension in order to avoid tension drops or increases The motor is typically connected thru a gearbox to a roll which is used to transmit tension and velocity to the material web. It is to be ensured, that with the roll surface and the enlacement the desired tension can be effectively transmitted to avoid slippage and tension drop. Eventually additional mechanical elements are required (nips, s-rolls, etc.). The roll diameter is typically constant. In case of simple concepts the tension is only set and not controlled. This means, that the speed setpoint of the motor is preset and the tension is defined by the friction between the material and the roll surface. If a more sophisticated tension regulation is required then the system is to amended with a tension measuring cell or a dancer system. Closed loop tension control and dancer control requires a controller in this document referenced as the technology controller. The technology controller is realized as a PID controller which is expanded with setpoint conditioning and jerkfree switch-on functionality. Entry-ID: 56293754, V2.2., 3/217 6
1 Basic information and data 1.3 Structure of a tension control system Dancer system The dancer control system is a position based measuring system which is used to set the material tension. In conjunction with a dancer the motor controls the position instead of the tension. Typically the system is constructed so that the dancer normally sits in the middle position during production. The position of the dancer is controlled by the drive, for example with the change of the speed setpoint. In the simplest constructions the dancer is strained using a spring, therefore the tension varies as the dancer roll moves. More complex systems can consist of pressure regulated cylinders in order to maintain a constant tension even if the dancer roll is deflected. Figure 1-2: Dancer system P U + - s act Load cell With tension measuring the material tension is directly measured for example using a load cell. The measured value is interpreted by the technology controllers algorithm and is used to adjust the speed or torque setpoint of the drive. Figure 1-3: Load measuring 1.3.2 Solution using the application The application presented here helps to implement the functions shown and a functioning tension control can be quickly developed. The standard application includes, as a core function, pre-configured function block. The necessary functions are implemented in this function block and can be simply parameterized. It is only necessary to control this function block via the user program and interconnect the output parameters of the function block corresponding to the existing drive system. Depending on the required functionality, signal interconnections have to be parameterized in the drive e.g. torque limits. Entry-ID: 56293754, V2.2., 3/217 7
1 Basic information and data 1.3 Structure of a tension control system 1.3.3 Advantages When the standard application is used, it offers users the following advantages: Reduction of engineering time When the standard application is used, it is simple to quickly implement comprehensive tension or dancer position control functionality when programming with SIMOTION. The core function can be imported into the user program by means of parameterization. Possibility of making changes The standard application includes all of the source codes in a commented form. This means that the core functions can be quickly and simply expanded using your own functions. Before making any changes to the application or its core functions you should first get to know the implemented functions with the help of the ST documentation.! WARNING Uncontrolled changes of the core function can lead to injury or death. NOTE Support from Application Centers can only be offered for unchanged applications. If the code is changed in any way there is no support available. Entry-ID: 56293754, V2.2., 3/217 8
2 Functions of the application 2.1 Tasks that can be implemented using the core function 2 Functions of the application 2.1 Tasks that can be implemented using the core function The application is designed to control rotating equipment which is used to transport web materials such as paper, foils, plastics, threads and wire with a superimposed tension control solution. The core function comprises a function block, which generates the setpoints to control the tension and web velocity. These setpoints are speed and torque. The application is created using the programming language Structured Text and is available as a SIMOTION Library. The function block must be parameterized according to the required functionality. The core function can / must be eventually extended outside of the core function block. This is generally the case for: Axis enable Jog mode Free positioning mode NOTE For the implementation of basic axis functionality please take the application SIMOTION Axis Function Block (A427118-A59) into consideration. The described technological functionality can be extended and combined using this application. 2.2 Properties of the core functions Setpoint preparation The following properties and features were taken into account when implementing the core functions and can even be used in user programs that you generate yourself: Preparing the tension and position setpoint value for further usage Functions implemented for tension control with dancer roll, tension control with load cell, indirect tension control and Draw-control Entry-ID: 56293754, V2.2., 3/217 9
2 Functions of the application 2.3 Control concepts Acceleration pre-control While the material is being accelerated and decelerated, a compensating torque can be entered into the drive. This compensating torque is used to dynamically respond to velocity changes. The inertia compensation avoids tension dips or tension increases due to velocity changes. This pre-control is especially required for indirect tension control - but also for tension control using a load cell. The pre-control is made available to the user as an additive torque at the output of the function block. Instructions for making the appropriate interconnections are explained step-by-step in the chapter 3.4 Connection to SINAMICS using as an example, a SINAMICS drive. 2.3 Control concepts The block includes different control methods to set and control the web tension and to guarantee the transport of the material web with the defined velocity. Tension control methods with feedback are: Tension control with load cell via torque limiting Tension control with load cell via speed setpoint correction Dancer position control via speed setpoint correction Tension control methods without feedback are: Indirect tension control with torque limiting Indirect tension control via speed setpoint correction Draw-Control (relative velocity difference) Entry-ID: 56293754, V2.2., 3/217 1
2 Functions of the application 2.3 Control concepts 2.3.1 Draw-Control Using this method the web tension is set by the segments velocity ratio, meaning that the velocity of the transport rolls at the segment start is slower than at the segment end. The velocity difference causes material strain which defines the web tension. The resulting tension depends on the material type, the friction between the material and the transport roll (slip) and the transport system itself. T 2 T 1 v C OUT v - v IN IN This method is used for simple tension regulation, specially when any additional measuring system is avoided, but it does not offer a high level tension accuracy. Figure 2-1: Draw-Control T 1 T 2 V line_in M n_1 M n_2 V line_out Motion Control System 2.3.2 Tension control with dancer roll In case of dancer control opposite to tension control with load cell it is not the tension that is controlled but the dancer position. The web tension is set by the dancer system itself. The actual dancer position is measured using an encoder or potentiometer. Position control is based on the difference between the setpoint and the actual position. The controller output is used as additional velocity setpoint in order to maintain the setpoint position. Figure 2-2: Dancer control F Dancer roll V line n+ M+ M Pos act Motion Control System Entry-ID: 56293754, V2.2., 3/217 11
2 Functions of the application 2.3 Control concepts 2.3.3 Indirect tension control With this method the web tension is set on basis of the process parameters. There is no measuring system necessary, as there is no feedback used to control the tension. To set the web tension the tension setpoint is computed into a torque setpoint which is based on the roll diameter and the gear ratio. The motor is operated using this torque setpoint. The friction and acceleration compensation is absolutely necessary to reach an as accurate web tension as possible. In case of this control method is must also be ensured, that the gear ratio of the system is kept as low as possible. This includes an appropriate motor selection and the selection of a highly efficient gearbox with low friction losses. Figure 2-3: Indirect tension control F M n_1 M_1 V line M n_2 M_2 Motion Control System 2.3.4 Tension control with load cell Opposite to the indirect tension control the mechanical system is extended using a web tension measuring equipment which is used to give feedback to the superimposed tension controller. The controller output is either interpreted as additional speed or torque setpoint for the controlled axis. Tension control is used if the accuracy of the indirect tension control is not sufficient anymore, for example if the losses in the transmission are not known or there are disturbances in the system which need to be eliminated. Figure 2-4: Tension control F Load cell V line n+ M+ M F act Motion Control System Entry-ID: 56293754, V2.2., 3/217 12
2 Functions of the application 2.3 Control concepts 2.3.5 Indirect tension control via speed setpoint correction This method is a mixture of the tension control with load cell and of the indirect tension control methods. In this case the actual tension is not measured but calculated from the actual motor torque value. The friction and acceleration compensation is absolutely necessary to reach an as accurate web tension as possible. Using this method the technology controller is activated to control the actual tension value. The calculated tension actual value is taken as feedback signal for the control loop, this will get compared with the ramped tension setpoint and the controllers output is then interppreted as additional velocity setpoint. The accuracy of this method is comparable with the accuracy of indirect tension control. Figure 2-5: Indirect tension control via speed setpoint correction F M n_1 M_1 V line M n_2 M_2 Motion Control System Entry-ID: 56293754, V2.2., 3/217 13
3 Integrating into the user program 3.1 Integrating the library Integration Contents The Section Integration guides you step-by-step through the set-up of the application 3 Integrating into the user program 3.1 Integrating the library The application is available as a SIMOTION library created in Structured Text. The application is implemented in LLTCLib but also relies on the Converting Library LConLib (SIOS-ID: 4885235). In order to be able to use the LLTCLib functionality both libraries must be integrated into the project. XML-Import Using XML import, the library is integrated into the existing user project from an XML file. First must the LConLib library be imported. Table 3-1: Importing the XML file No. Description 1. For the XML import, the Libraries folder must be selected in the user project and then a dialog window is opened with a right mouse click. Using the Import object menu item, a window opens in which the path of the XML file must be specified. 2. The path of the XML file is specified using the Browse button and therefore the library is imported into the user project. Entry-ID: 56293754, V2.2., 3/217 14
3 Integrating into the user program 3.2 Technology objects Including the library The library must be linked into the interface section of the corresponding unit to be able to use the library functions, types, function blocks etc. INTERFACE END_INTERFACE USELIB LLTCLib; // Library import 3.2 Technology objects The following technology objects are necessary to the SIMOTION Line Tension Control application: Web axis The web axis represents the axis which is to be extended with tension control functionality. All axis types (drive axis, positioning axis, following axis) are allowed. The axis type can influence the functionality and the control concept. A technology object is mandatory and is always required if torque precontrol or a torque based control mode is to be used. Leading axis (optional for Speed-coupling) A leading axis is necessary if the web velocity is to be determined from the axis directly (the web velocity can also be directly entered using the appropriate variable). An external encoder might also be used to deliver the leading value. Entry-ID: 56293754, V2.2., 3/217 15
3 Integrating into the user program 3.2 Technology objects 3.2.1 Configuring the leading axis Technology objects, type drive-, positioning- or synchronous-axis as well as external encoder are permissible as leading axis. Real and virtual axes are both permitted for leading axes. Leading axis as positioning / synchronous axis The axis type, positioning or synchronous axis, is used if the position information of the axis is not necessary. Table 3-2: Setting-up the leading axis as positioning / synchronous axis No. Description 3. With Insert axis a new axis with the technology Speed Control can be inserted. 4. The axis type can be real or virtual. Only linear axis is allowed. Exception is the use in combination with the Print Standard. In that way 36 is defined to 1m circumference. 5. In the units dialog box of the axis the leading axis units will be defined. m/min is the typical used unit for the linear velocity. The acceleration must be defined in /s² (e.g. m/s²). The units selected in this dialog box define the necessary setting in LTCConfig. The line axis diameter is not necessary in this configuration. The previously selected units within the axis configuration define the necessary unit setting in sltcconfig.sunitconfig: Example: Unit of axis velocity = [m/min] Unit of axis acceleration = [m/s²] sltcconfig.sunitconfig.eunitlineaxisvelocity sltcconfig.sunitconfig.eunitlineaxisacceleration := M_MIN; := M_S2; Entry-ID: 56293754, V2.2., 3/217 16
3 Integrating into the user program 3.2 Technology objects Leading axis as driveaxis The axis technology driveaxis, is used if the position and therefore the position information of the leading axis have is not necessary. Table 3-3: Setting-up the leading axis as driveaxis No. Description 6. With Insert axis a new axis with the technology Speed Control can be inserted. Virtual or real axis can be used. 7. In the units dialog box of the axis the leading axis units will be defined. rpm or rps is the typical used unit for the speed. The acceleration must be defined in 1/s². The units selected in this dialog box define the necessary setting in LTCConfig. In order to be able to use a driveaxis as leading axis, the diameter of the leading axis must be known and configured so that the application can derive the web velocity. The unit configuration in sltcconfig.sunitconfig results from the time component of the velocity, defined at the axis (rounds per minute or second). Second component is the length unit which can be defined by the user (m or mm). Depending on the selected length unit, r32lineaxisdiameter must be defined in this unit. Example: Unit of axis speed = [rpm] Unit of axis acceleration = [1/s²] sltcconfig.sunitconfig.eunitlineaxisvelocity sltcconfig.sunitconfig.eunitlineaxisacceleration := MM_MIN; := MM_S2; As a consequence: sltcconfig.r32lineaxisdiameter in [mm] Entry-ID: 56293754, V2.2., 3/217 17
3 Integrating into the user program 3.2 Technology objects Leading axis as machine encoder In SIMOTION, the external encoder technology object provides the functionality to connect a machine encoder. Table 3-4: Setting-up the leading axis as external encoder No. Description 8. With Insert external encoder the technology object can be inserted. 9. The encoder must be configured as linear encoder. Exception is the use in combination with the Print Standard. In that way 36 is defined to 1m circumference. 1. In the units dialog box of the axis the leading axis units will be defined. m/min is the typical used unit for the linear velocity. The acceleration must be defined in /s² (e.g. m/s²). The units selected in this dialog box define the necessary setting in LTCConfig. The previously selected units within the axis configuration define the necessary unit setting in sltcconfig.sunitconfig: Example: Unit of external encoder velocity = [m/min] Unit of external encoder acceleration = [m/s²] sltcconfig.sunitconfig.eunitlineaxisvelocity sltcconfig.sunitconfig.eunitlineaxisacceleration := M_MIN; := M_S2; Entry-ID: 56293754, V2.2., 3/217 18
3 Integrating into the user program 3.2 Technology objects External setpoint input If several web axes follow a leading axis, then it makes sense to implement the leading value coupling via the external setpoint input. The reason for this is that the leading values then only have to be read-out from the TO leading axis at one position in the code only. To do this, the input parameter lineaxis is not connected at the function block (lineaxis = TO#NIL). The leading values are transferred via the input lineaxismotionvector. Table 3-5: Transfer parameters Parameter lineaxismotionvector.r64linespeed lineaxismotionvector.r64lineacceleration Significance Velocity of the leading axis. Acceleration of the leading axis The values have to be defined in a linear unit! sltcconfig.sunitconfig.eunitlineaxisvelocity sltcconfig.sunitconfig.eunitlineaxisacceleration = M_MIN, MM_MIN, M_S, MM_S = M_S2, MM_S2 Entry-ID: 56293754, V2.2., 3/217 19
3 Integrating into the user program 3.2 Technology objects 3.2.2 Configuring the web axis Web axis as driveaxis The web axis is used to transport the material web with a defined tension. The axis technology driveaxis, is used if the position and therefore the position information of the axis is not required. Table 3-6: Setting-up the web axis as driveaxis No. Description 11. With Insert axis a new axis with the technology Speed Control can be inserted. Only a real axis can be selected for the web axis; a virtual axis is not permitted. 12. In the units dialog box of the axis the web axis units will be defined. 1/min or 1/s is the typical used unit for the velocity. The unit selected in this dialog box defines the necessary setting in LTCConfig. 13. Depending on the control type used, it is necessary to set-up the technology data block - or optionally possible. The previously selected unit within the axis configuration defines the necessary unit setting in sltcconfig.sunitconfig: Example: Unit of web axis velocity = [rpm] sltcconfig.sunitconfig.eunitltcaxisvelocity := RPM; Entry-ID: 56293754, V2.2., 3/217 2
3 Integrating into the user program 3.2 Technology objects Web axis as positioning / synchronous axis The axis technology positioning axis (or synchronous axis), is used if the position information of the axis is of significance or position control is necessary. Table 3-7: Setting-up the web axis as positioning/synchronous axis No. Description 14. With Insert axis a new axis with the technology Positioning or Synchronous Operation can be inserted. 15. Only a real axis can be selected for the web axis; a virtual axis is not permitted. As positioning axis linear and rotatory axis are available. 16. In the units dialog box of the axis the web axis units will be defined. m/min is the typical used unit for the linear velocity. The rotatory unit for angular velocity typically is /s. The unit selected in this dialog box defines the necessary setting in LTCConfig. 17. Depending on the control type used, it is necessary to set-up the technology data block - or is optionally possible. The previously selected axis type and unit within the axis configuration defines the necessary unit setting in sltcconfig.sunitconfig: sltcconfig.sunitconfig.eunitltcaxisvelocity := M_MIN; (linear axis) sltcconfig.sunitconfig.eunitltcaxisvelocity := DEG_S; (rotatory axis) Entry-ID: 56293754, V2.2., 3/217 21
3 Integrating into the user program 3.3 Integrating into the user program 3.3 Integrating into the user program For the basic functionality of the application, the FBLTC function block must be integrated into the user program. To do this, the following steps have to be performed: 1. Create and parameterize needed structures and variables 2. Call the function block in a synchronous task 3.3.1 Global variables In order to supply the function block with parameters a variable of the sltcconfigtype is necessary. This structure contains all of the data required to parameterize the function as well as part of the calculation results and feedback signals. We recommend that the instance of the function block as well as the configuration variables are defined in the global interface part of a unit. The reason for this is to be able to access the instance also from other units which link-in this unit. For every web axis it is necessary to have a dedicated instance of the function block and the parameter structure. As an example, here, a unit called dglobal is to be set-up in which all global program variables are centrally declared. Table 3-8: Variable declaration and block instantiating Declaration example in ST Declaration example in LAD // Unit dglobal INTERFACE //------------- Import ------------------------- USELIB LLTCLib; //------------- Device Global Variables -------- VAR_GLOBAL gfbltc : FBLTC; gsltcconfig : sltcconfigtype; END_VAR END_INTERFACE In order to be able to access the declaration of the configuration data and that of the function block in the unit, the LLTCLib library must be linked-in (also refer to Chapter 3.1). Entry-ID: 56293754, V2.2., 3/217 22
3 Integrating into the user program 3.3 Integrating into the user program 3.3.2 Pre-assignment of the parameters in the start-up task For assignments in configuration data that are not changed in operation, it makes sense to combine these in one program (pstartup program) and to execute this once in the StartupTask when starting the controller. Values are then assigned to the variables. Generating this program based on the variable declarations from Chapter 3.3.1 is shown as an example in this chapter. Table 3-9 Program example in ST Program example in LAD // Unit pstartup INTERFACE //------------- Import ------------------------- USES dglobal; //------------- Export ------------------------- PROGRAM pstartup; END_INTERFACE IMPLEMENTATION PROGRAM pstartup // Config unit of measurements gsltcconfig.eunitlineaxisvelocity := M_MIN; gsltcconfig.eunitlineaxisacceleration := M_S2; END_PROGRAM END_IMPLEMENTATION The pstartup program must be assigned the StartupTask in the execution system. Fig. 3-1: StartupTask Entry-ID: 56293754, V2.2., 3/217 23
3 Integrating into the user program 3.3 Integrating into the user program 3.3.3 Calling the function block in the user program The function block can, after integrating the library and linking the library, be called using the user program. The function block can be called either from a MCC chart, a ST program or a LAD/FBD program. The program in which the function block is called must always be executed in clock-cycle synchronism. This is the reason that only a call may only be used in a IPO clock cycle synchronous task (Servo Synchronous, IPO Synchronous task 1 or 2, Timer-task). The call parameters of the block must be interconnected corresponding to the function required in the user program. In the following example, the program pltc in the unit (pipo2) is used to call the program and the program is assigned to the IPOsynchronousTask_2 in the execution system. Fig. 3-2: Assignment in the execution system A connection must be established using USES so that the global declarations of the unit dglobal can be used in the unit pipo2. Table 3-1: Programming example Program example in ST Program example in LAD // Unit pipo2 INTERFACE //------------- Import -------------------------------------------------------------- USES dglobal; END_INTERFACE Entry-ID: 56293754, V2.2., 3/217 24
3 Integrating into the user program 3.4 Connection to SINAMICS 3.4 Connection to SINAMICS 3.4.1 Technology data block If the pre-control torque and the torque limits have to be transferred to the drive, it is necessary to extend the telegram, defined for the communication, with the technology data block. The technology data block transfers an additive torque (Add_Torque) as well as the limits of the torques (TorqueLimit_Neg and TorqueLimit_Pos) to the drive. Then the data have to be connected in the drive correspondingly. Chapter4.3.3 provides information regarding the necessary steps to configure the technology data block. Table 3-11 : Structure of the technology data block Direction Word No. Designation in SIMOTION SCOUT SIMOTION -> Drive 1 (Axis).DefaultAdditiveTorque 2 (Axis).DefaultTorqueLimitPositive 3 (Axis).DefaultTorqueLimitNegative Drive -> SIMOTION 1 (Axis).ActualTorque.Value A detailed description on the topic Technology data block can be found in the SIMOTION SCOUT Function Manual, TO Axis Electric / Hydraulic, External Encoder. Activating the technology data block at the axis: There are two ways of activating the technology data block: Table 3-12 Activating the technology data block in the technology object Nr Description 18. Option 1: In the axis configuration, it is possible to activate the technology data block by setting the checkbox Technology data block. 19. Option 2: The technology data block can be activated/deactivated alternatively with the following variables in the expert list of the axis TypeOfAxis.TechnologicalData.Enable = YES TypeOfAxis.TechnologicalData.TechnologicalDataInInfo. logaddress = Start address of the data area for the receive data (supplementary torque, torque limits) TypeOfAxis.TechnologicalData.TechnologicalDataOutInfo. Entry-ID: 56293754, V2.2., 3/217 25
3 Integrating into the user program 3.4 Connection to SINAMICS Nr Description 2. Using SIMOTION V4.2 and higher and Symbolic assignment is activated (default setting), the telegram extension is set by the system automatically. logaddress = Start address of the data area for the receive data (actual torque) Whereas the torque parameter are interconnected automatically the scaling factor for supplementary torque 1 need to be set to 1% by the user. Technology data block without symbolic assignment If symbolic assignment is not used the telegram to the drive need to be extended and interconnected by the user. Table 3-13 Configuring the technology data block Nr Description 21. The required axes have been setup in SINAMICS and the telegram types defined. 22. Change into the drive overview 23. Change the telegram configuration to free telegram configuration with BICO. The generated links are then as a result, not deleted. The telegram length can therefore be changed. 24. Change the telegram length and for the input data, add 1 word and for the output data, 3 words (controller reference). If the value for the Kp adaptation should also be sent to the drive, then the output data can also be extended by 4 words. Entry-ID: 56293754, V2.2., 3/217 26
3 Integrating into the user program 3.4 Connection to SINAMICS Nr Description 25. Transfer the data to the hardware configuration. This means that the hardware configuration is automatically adapted. NOTE By changing the telegram length, the assigned addressed can be shifted if the address gap is not large enough. Setting the reference torque In order that torque values can be transferred between SIMOTION and SINAMICS, the reference torque must adapted in the winder axis; this means the parameter TypeOfAxis.SetpointDriverInfo.DriveData.maxTorque in the TO winder axis, must be set to the same value as parameter p23 in SINAMICS. The user must ensure that the system of units of the SINAMICS drive object and the winder application are consistent. If the Anglo-American units are used for length, velocity and mass (weight), then in the drive object, the Anglo-American system of units must be selected using parameter p55 the same condition applies to SI units. Entry-ID: 56293754, V2.2., 3/217 27
3 Integrating into the user program 3.4 Connection to SINAMICS Interconnection in SINAMICS The interconnection in SINAMICS depends on the configured telegram type. Table 3-14 Interconnection of the telegram extension Parameter Description p1522 p1523 Upper torque limit This parameter is/must be interconnected with the value for the upper torque limit from the technology data block if the drive is to be operated in torque controlled mode. Lower torque limit The parameter is/must be interconnected with the value for the lower torque limit from the technology data block, if the drive is to be operated in torque controlled mode. p1511 Supplementary torque 1 This parameter is/must be interconnected with the supplementary torque from the technology data block. The pre-controlled torque is transferred with this link. r8 p1512 Torque actual value The actual torque value is sent to the control. Scaling factor supplementary torque 1 need to be set to 1% by the user to make sure the supplementary torque gets effective! Figure 3-3 supplementary torque and scaling factor Entry-ID: 56293754, V2.2., 3/217 28
3 Integrating into the user program 3.4 Connection to SINAMICS Example for a telegram expansion based on telegram 12: Table 3-15 Configuration example, configuring the telegram Receive direction Transmit direction NOTE A friction characteristic can either be realized in the control or in the drive. On SINAMICS for both control types the friction characteristic addition point is located after the torque limit and must therefore no longer be taken into account in the torque calculation (pre-control torque, torque limit). NOTE The output of the internal friction characteristic is limited by the effective torque limits (r1538/r1539), i.e. at an operating point, in which the tension torque is less than the friction torque, then the friction torque is also limited. Entry-ID: 56293754, V2.2., 3/217 29
3 Integrating into the user program 3.4 Connection to SINAMICS 3.4.2 Adapting the parameters in SINAMICS Table 3-16 Parameter overview Parameter Description Effect Value p1227 p1135 p1551 Setting the monitoring time of the standstill detection. Slowing down with AUS1 or AUS3, the standstill is detected after this time and after the set rotation speed has fallen below the speed limit (p1226). After that, the brake control is started, the closing time in p1217 is awaited and then the pulses are deleted. Setting the ramp return runtime from the maximum speed to the standstill for the AUS3 command. Setting the signal source for switching the torque limits between variable and fix torque limits. Deactivation of the standstill monitoring of the setpoint -> no run out of the motor Slowing down at torque limit With AUS3 active(r899.5), the torque limits are switched 3s s r899.5 r899.5 No quick stop active (state AUS3) p1551 p152 Setting the fix upper or the motor torque limit Parameterizable upper torque value for AUS3 p1521 Setting the fix lower or the dynamic torque limit. Parameterizable lower torque value for AUS3 p182 Setting the highest possible speed Speed limit for torque control max. U/min p1145 Setting the ramp function generator tracking. The initial value of the ramp function generator is tracked according to the maximum possible drive acceleration. Reference value is the difference at the speed / velocity control input, which is necessary to ensure a run-up at the torque / force limit of the drive. p14.14 Setting the configuration of the speed control. Torque precontrol VECTOR Only with extended setpoint channel: Ramp flattening at ramp function generator is deactivated. In vector mode: No deactivation of the torque pre-control with overdriven speed controller - -. Always active p158 p1821 Efficiency optimization (Flux setpoint adaption) VECTOR Inversion of the direction of the rotating field: : no inversion of direction 1: inversion of direction Drive speed is more stable at low speeds Changes the direction of the motor with retention of the sign of the set-point. p55 Selecting the system of units With this parameter the system of units can be chosen for the drive object, it must be consistent wit the winder application. 5%- 1% Entry-ID: 56293754, V2.2., 3/217 3
3 Integrating into the user program 3.4 Connection to SINAMICS Behavior OFF3 / Braking at torque limit The pulse enable of the winder axis is controlled by the observation of the standstill threshold besides the control signals. This observation provides an analysis of the actual speed value as well as of the setpoint. If the one of these values falls below the speed threshold, this causes a pulse disable after a delay time (FP271). In the case of an activation of the OFF3 function, it may cause the braking of the drive with the maximal torque, but the drive torque doesn t suffice to decelerate the winder according to the ramp. If the setpoint falls below the speed threshold of the standstill detection, the pulses are inhibited activated after the parameterized delay time (p1227) and the motor runs down slowly. To avoid this behavior the standstill observation of the setpoint may be deactivated by setting the parameter p1227 = 3s. In the parameter p1135 the ramp down time from the maximum speed to the standstill in case of an activation of OFF3 is parameterized. For a winder axis it may be useful to set the value to, to achieve a braking at the torque limit, because the ramp down time does not fit in all operating points to the speed of the winder axis and rapid braking not warranted. If in the case of tension control by torque limits the function OFF3 is activated, the limits have to be reset to the maximum torque, if necessary, to be able to brake with the adequate deceleration. This may be parameterized in SINAMICS by connecting the parameter p1551 to the binector r899.5. In the case of a fast stop the active torque limits are configurable with the parameter p152 and p1521. Using the extended set-point channel and the torque control by override of the speed controller, the speed controller is given a velocity setpoint that can not be reached. If the torque limit is switched with the activation of the AUS3 function, the speed controller makes up the velocity difference between the actual (overridden) setpoint and the actual value and is able to accelerate the motor before shutting down at the AUS3 ramp. To avoid this behavior, either the AUS3 ramp may be set to or the ramp function generator is to be set with the activation of the AUS3 command. Deactivating of motor blocked fault If the winder is torque control mode (velocity override to reach torque limits) the torque limit monitoring in the drive need to be hidden. Otherwise the drive will stop with the fault motor blocked. The monitoring is activated/deactivated automatically in the FBWinder with the drive control word bit 8 travel to fix stop. Activation and deactivation is dependent on the active winder control mode: Table 3-17 Control mode INDIRECT_TENSION_CONTROL TENSION_CONTROL_TORQUE_LIMITING DANCER_CONTROL_TORQUE_LIMITING DANCER_CONTROL_SPEED_SETPOINT_ADAPTION TENSION_CONTROL_SPEED_SETPOINT_ADAPTION V_CONSTANT_CONTROL motor blocked hidden Yes Yes Yes No No No Entry-ID: 56293754, V2.2., 3/217 31
3 Integrating into the user program 3.4 Connection to SINAMICS Setting the maximum speed Using a torque controlled winder control mode it is recommended to limit the maximum motor speed with parameter p182. E.g. machine speed + offset or maximum speed of the motor gear. Ramp flattening Using overdriven speed controller and extended setpoint channel, the default setting of the ramp flattening leads to the speed setpoint values is not being transferred from SIMOTION to the drive speed controller. In cause of that the speed controller is not overridden. This behavior can be switched off setting p1145 to. Interconnection additional torque using overdriven speed controller Using a drive in vector mode the additional torque is only added if the speed controller is active. If the speed controller is overridden, this signal goes to FALSE and so no more additional torque is added. To prevent this behavior and adding the addition torque always, the parameter p14.14 need to be set to 1. Speed inversion To invert the direction of rotation the parameter p1821 (inversion of the direction of the rotating field) can be used. The encoder will be inverted automatically. In that way the sign of the setpoint remains. Entry-ID: 56293754, V2.2., 3/217 32
4.1 Data types Program description Section Program description describes, in more detail, the functions of the function block. Here you will find parameter lists, diagrams and function descriptions of the core function 4.1 Data types 4.1.1 Overview Enumeration types Type declarations of enumeration types are provided for a part of the input and output parameters of function blocks. Various modes and behavior types can be pre-set using these parameters. Data structures The parameterization of the function blocks is done via data structures that have to be created for each function block. For each function block a structure is provided that has the corresponding parameters. The process values are preset via different input / output parameters of the function blocks. Note Elements of the individual structures are completely described in the following program sections. A detailed description of the structure elements used in the blocks is provided in the block description. 4.1.2 Enumeration types Type declarations of enumeration types provided for some of the input and output parameters. Various modes and behavioral types can be pre-set (default settings) using these parameters. The following enumeration types are available: Table 4-1 Name of the enumeration type elcontasknametype elconunitlineaxisvelocitytype elconunitlineaxisaccelerationtype eltcunitltcaxisvelocitytype eltcdrivemodetype eltccontrolmodetype eltcfbmodetype Contents Selects the task in which the block is called. Selects the velocity unit of the path axis Selects the acceleration unit of the path axis Selects the velocity unit of the web axis Selects the control direction Selects the type of the tension control Selects the operation mode of the FB (axis control or only setpoint calculation) Entry-ID: 56293754, V2.2., 3/217 33
4.1 Data types elcontasknametype The call level of the blocks is specified using this enumeration type. Table 4-2 Element Description SERVO_SYNCHRONOUS_TASK Servo Synchronous Task IPO_SYNCHRONOUS_TASK Ipo Synchronous Task IPO_SYNCHRONOUS_TASK_2 Ipo Synchronous Task 2 TIMER_INTERRUPT_TASK Timer Task elconunitlineaxisvelocitytype Table 4-3 Using this parameter, the units of the velocity of the line axis (tolineaxis) are specified corresponding to the axis configuration. Element Description NOT_DEFINED M_MIN MM_MIN M_S MM_S FT_MIN INCH_MIN FT_S INCH_S DEG_S_PRINT not defined m/min mm/min m/s mm/s ft/min inch/min ft/s inch/s 36 /s = 1 m/s elconunitlineaxisaccelerationtype Table 4-4 This parameter defines the units of the line axis acceleration (tolineaxis) corresponding to the axis configuration. Element Description NOT_DEFINED M_S2 MM_S2 FT_S2 INCH_S2 DEG_S2_PRINT not defined m/s² mm/s² ft/s² inch/s² 36 /s² = 1m/s² Entry-ID: 56293754, V2.2., 3/217 34
4.1 Data types eltcunitltcaxisvelocitytype Table 4-5 This enumeration type is used to define the velocity units of the web axis (toltcaxis) according to the axis configuration. Element Description NOT_DEFINED M_MIN MM_MIN M_S MM_S FT_MIN INCH_MIN FT_S INCH_S DEG_S_PRINT RPM RPS DEG_S DEG_MIN not defined m/min mm/min m/s mm/s Ft/min Inch/min Ft/s Inch/s 36 /s = 1 m/s rev/min rev/s /s /min eltcdrivemodetype With this data type is the control direction selected. Table 4-6 Element Description PULL The tension or dancer position will be controlled in the segment before the axis. HELD The tension or dancer position will be controlled in the segment after the axis. eltccontrolmodetype The type of the tension control is defined via this enumeration type. Table 4-7 Element Description INDIRECT_TENSION_ CONTROL DANCER_CONTROL_SPEED_ SETPOINT_ADAPTION DANCER_CONTROL_TORQUE_ LIMITING TENSION_CONTROL_SPEED_ SETPOINT_ADAPTION TENSION_CONTROL_ TORQUE_LIMITING DRAW_CONTROL INDIRECT_TENSION_ CONTROL_SPEED_ADAPTION Indirect tension control Tension control with dancer roll via speed adaptation Tension control with dancer roll via torque limiting Tension control with load cell via speed adaptation Tension control with load cell via torque limiting. Draw-Control Indirect tension control via speed adaptation Entry-ID: 56293754, V2.2., 3/217 35