FAST Winder Dancer-controlled

The Winder Dancer-controlled technological module by Lenze is an advanced control system designed for precise control of winding drives in industrial processes. This module is part of the Lenze FAST software platform and is intended for systems where maintaining precise tension and material positioning during winding is critical. The system uses advanced methods for controlling the tension and position of the dancer, which is crucial for processes requiring stability and precision, such as textile, paper, and plastic industrial processes.

Basic Functional Elements of the Module

The Winder Dancer-controlled technological module is a comprehensive system with multiple layers of control and diagnostics. The system's basic functional elements are divided into three main versions: Base, State, and High. Each of these versions extends the module's functions and provides greater flexibility for various applications.

Dancer Position Control

The dancer control is one of the key functions of the module. A sensor is placed in the dancer mechanism that measures the position of the dancer and transmits this data to the control system. The system compares the current position with the reference value. If there is a deviation, the PI controller automatically adjusts the winding speed to return the dancer to the correct position. This process is critical for maintaining the correct tension of the material.

Dancer Position Learning

The module provides a manual "learning" option for the dancer's limit positions, allowing the system to remember these positions and use them for reliable operation.

Tension Control via Characteristic Function

The system allows controlling the material's tension depending on the diameter of the wound material. This is achieved using a "tension characteristic curve" that defines how the tension decreases as the diameter of the wound roll increases. For each type of material (paper, foil, textile), a different tension characteristic can be set. Three tension control modes are available:

• Linear Tension Profile – Suitable for materials that require a constant tension decrease.
• Torque Profile – Uses linear torque for materials where torque affects tension.
• User-Defined Characteristic – Allows defining a custom tension curve using 64 points.

Acceleration Compensation

Every acceleration or deceleration of the winder can disrupt the material's tension, as acceleration affects the balance between force and tension. The Winder Dancer-controlled module provides an acceleration compensation function, which calculates the required torque and automatically adds it to the tension, ensuring that the tension remains constant during speed changes.

Line Speed Synchronization

In systems where it is necessary to synchronize the winder's speed with the main production line, the module offers synchronization. The module uses the line speed signal to synchronize the winding speed, ensuring that the material winds at a constant speed even when the line speed changes.

Roll Diameter Calculation and Winding Control 

One of the module's key functions is calculating the current diameter of the wound roll. This calculation is based on the integrated line speed and winder speed. For accuracy, fast or slow calculation modes can be set, where the fast mode enables a quick response to changes in material diameter.

• Dancer-Based Diameter Correction
  The module can correct the wound material's diameter based on the dancer's movements. If the winding speed significantly differs from the line speed, the system automatically accounts for these differences and adjusts the material's diameter to match the real situation.
• Manual Control (Jogging)
  For maintenance or manual control, the module provides a "manual jog" function. This allows the winder to be manually controlled in both directions, adjusting its speed and position.

Safety Features and Diagnostics

The Winder Dancer-controlled module is equipped with robust safety features that protect the system and material from damage. In the event of critical incidents, such as material breakage or reaching the dancer's limit positions, the system automatically stops operation and triggers an alert. Diagnostic outputs, such as error codes and ID outputs, provide detailed information about the system's status.

Material Breakage Monitoring

The module offers two methods for monitoring material breakage:

• Diameter Change Monitoring – If the diameter starts decreasing in the wrong direction (opposite to winding), the system detects a breakage.
• Dancer Position Monitoring – If the dancer reaches the lower limit position, the system automatically detects a breakage.

System Adaptation for Various Applications

The Winder Dancer-controlled technological module is designed for a wide range of applications. The system is capable of working with various material types, and its flexible architecture allows easy integration into existing control systems.

Conclusion

The Winder Dancer-controlled technological module is a modern solution for precise and flexible control of material winding in industrial applications. With advanced features such as dancer position control, acceleration compensation, and tension control, it provides a high level of precision and reliability. Its versatility and easy integration make it an ideal solution for a wide range of industrial processes.

For more technical details, including specific parameter values and diagnostic information, we recommend studying the attached full technical manual for the module.

The Winder Dancer-controlled technological module is part of the FAST Application software designed for precise control of winding and unwinding materials in automated industrial processes. This module is specifically developed for applications where tension control is achieved through the movement of a tensioning pulley (dancer). In the following section, we will focus on the technical details and basic functions provided by the module.

Functional Description of the Module

The Winder Dancer-controlled technological module is used in applications where high precision in material winding control is required, such as cables, textiles, paper, or foils. This module offers features such as dancer position control, tension control, and diameter calculation during winding.

Dancer Position Control

In dancer position control, the winding drive is operated in a closed speed loop. The line speed signal is multiplied by the reciprocal value of the wound material diameter, which serves as pre-control for the speed. The dancer position is constantly monitored and compared to the reference value. If a deviation is detected, the dancer position controller (PI controller) adjusts the speed reference signal to eliminate the deviation.

Material Diameter Calculation

In winding processes, correctly determining the current diameter of the material is crucial. Integrated speed values are used in the calculation, allowing for precise averaging and stable control. The module enables dynamic adaptation of speed and movement based on the current diameter.

Module Applications

The Winder Dancer-controlled module is optimized for various types of materials and winding processes. Typical applications include:

• Winding cables and wires,
• Winding textiles, foils, and paper,
• Applications with high demands for material tension accuracy.

The system is designed for lines with speeds up to 1000 m/min, providing high accuracy in tension control.

Key Module Functions

a) Manual Jogging

The module allows for manual control of the winder's movement. Control is activated using xJogPos and xJogNeg inputs, enabling movement in positive or negative directions. The position is adjusted based on current speed and acceleration parameters.

b) Homing

The homing process is a basic function of the module, ensuring that the winder is correctly set to its home position. This process is initiated by activating the xHomeExecute input, and the module monitors the reference switch until it reaches the home position.

c) Tension Control

The module enables material tension control through characteristic curves. Three basic types of control are available:

1. Linear tension characteristic,
2. Linear torque characteristic,
3. User-definable characteristic with 65 interpolated points.

These characteristics are defined based on the material's diameter, adjusting tension as needed. The characteristics can be modified to suit specific application needs.

d) Acceleration Compensation

Acceleration and deceleration of the line can disrupt the winding process. The module provides an acceleration compensation function that takes into account the movement dynamics and automatically adjusts the torque. This ensures that material tension remains constant even during speed changes.

Monitoring and Diagnostics

The module provides extensive monitoring and diagnostic capabilities. Key indicators include:

• xDancerMinPos and xDancerMaxPos: Indicate when the dancer reaches the lower or upper limit position,
• xWebBreakMonit: Activates material break monitoring based on diameter changes or dancer position.

Adaptive Speed Controller Gain

For applications where the diameter of the wound material significantly changes during the process, the module is equipped with an adaptive speed controller gain function. This gain is automatically adjusted based on the current material diameter or inertia, ensuring better control of the material's movement under varying conditions.

Conclusion

The Winder Dancer-controlled technological module offers a robust solution for precise winding and unwinding control of materials. With advanced features such as tension control, dynamic diameter calculation, acceleration compensation, and material break monitoring, it is ideal for applications that require high accuracy and reliability.

For more technical details, including specific parameter values and diagnostic information, we recommend reviewing the complete technical manual for the module.

​

The main differences between versions V1 and V2 of the FAST Technology module Winder Tension-Controlled are as follows:

Additional Features and Improvements

• V2 includes additional features compared to V1, such as Quick Stop, which allows for faster and safer stopping of the winding process. This feature is not mentioned in V1.
• V2 also adds a function for terminating the winding process and includes the ability to monitor web breaks, ensuring better quality control.

Support for Different Axis Control Versions

• V2 includes support for L_MC1P_AxisBasicControlV2, which is a newer version of the axis control function block, while V1 uses an older version of this block.

Speed Controller Gain Adaptation

• In V2, the speed controller gain adaptation has been improved, allowing for more precise and smoother speed regulation during winding, depending on the inertia of the winder. This feature was not as detailed in V1.

Support for Virtual Axes and Simulation

• V1 did not support simulation in the "PLC Designer" and lacked support for virtual axes. V2 changed this, adding support for Modulo traversing range for more precise positioning during winding.

Improved Tension Control

• Closed-loop tension control in V2 is improved to better compensate for friction and acceleration. This improvement ensures more constant tension on the material during winding, which was not as well developed in V1.

Speed Control

• V2 includes the possibility of speed limitation during the winding process, helping to prevent unwanted accelerations and decelerations. This feature is not mentioned in the older version (V1).

In summary, V2 offers greater flexibility, improved precision, and better integration with newer technology solutions for tension and speed control during material winding processes.