Drive and Control Systems: Technical Update John A. Looser Faustel, Incorporated
Coating and Laminating Equipment Key Control Areas Variable Speed Drives Programmable Logic Controllers (PLC) Human Machine Interface (HMI) Data Collection and Management Communication and Distributed Input / Output (I/O)
Variable Speed Drives Purpose Web Handling / Transport Control Web Speed Coordination of Sections Control Web Tension Tension Feedback, Draw / Ratio Modes Position / Register Control Printing, Imprinting, Coat to Print Registration Miscellaneous Turret Rotation, Coating Supply, Dryer Fans
Variable Speed Drives Evolution Mechanical Drives Adjustable Sheaves: cone, disc, ring,. Slip Couplings Eddy Current Drives Analog DC Drives Variable DC Output Voltage Digital DC Drives Variable DC Output Voltage Digital AC Drives Pulse Width Modulated Output
Variable Speed Drives Digital AC Drives AC Input - DC Rectified - PWM Output 460 V 3φ 60 Hz DC Rectifier (Common DC Rectifier Section) IGBT s (Insulated Gate Bi-Polar Transistor)
Variable Speed Drives Digital AC Drives Pulse Width Modulation High Frequency Output Voltage (up to 15 khz) Induced Sinusoidal Motor Current
Variable Speed Drives AC Drive Configurations Simple Inverters Operating Modes: V/Hz Control, Constant V/Hz Ratio, 7.67 V/Hz V/Hz Control with Slip Compensation Sensorless Vector: Field Oriented Control w/o FDBK Open Loop Control No Motor Feedback Speed Regulation = 0.5 1.0% Typical Applications: Supply Fans Coating Pumps Turret Rotation
Variable Speed Drives AC Drive Configurations (continued) Vector Control Operating Modes: Simple Inverter Modes Sensorless Vector: Field Oriented Control w/o FDBK Closed Loop Vector: Field Oriented Control with FDBK Closed Loop Torque Control Closed Loop Control 1024 / 2048 Pulses Per Revolution Speed Regulation = 0.005 0.01% Typical Applications: Web Handling Sections: Pull Rolls, Laminators, etc Coating Rolls Winding / Unwinding Spindles
Variable Speed Drives AC Drive Configurations (continued) Servo / Motion Control Operating Modes: Closed Loop Vector: Field Oriented Control with FDBK Closed Loop Position Control Drive / Motor Matched Closed Loop Control: 16,800,000 PPR, 4096 revolutions Typical Applications: Position / Angular Synchronization Precision Coating Rolls: Low Torque Ripple Printing: Plate Cylinders Coat to Print Registration: Patterned Coating Rolls
Variable Speed Drives Technical Highlights Totally Enclosed AC Induction Motor Low Maintenance Costs (no brushes / commutators - DC Motors) High Torque to Inertia Ratios High Torque Bandwidth 150-200% Rated Torque Output Precise Speed / Torque Regulation 0.005 0.001 Speed Regulation 2000:1 Constant Torque Speed Range Increased Speed Range Smooth Rotation at Low Speeds 0-400 Hz Output Frequency, (typical motor, up to 120 Hz)
Variable Speed Drives Technical Highlights (continued) Digital Microprocessor Control No Set-Point Drift Repeatable Settings High Speed Communication PLC to Drive = 12 Mbaud,, Drive to Drive = 11 Mbaud High Data Transfer Rates = Very Responsive System Internal Drive Diagnostics and Self-Tuning Easy to Maintain and Troubleshoot Easy Initial Start-up Compact / Modular Design Less Panel Space Required Smaller Cabinet Footprint
Variable Speed Drives Drive System Feedback Diagnostic Information Drive Performance 09/22/04 16:45:11
Variable Speed Drives Typical Drive System Cabinet Common DC Bus 8 AC Vector Drives: 3-15 HP Cabinet Dimensions: 9 W x 7 7 H x 2 2 D
Programmable Logic Controllers Basic Definition A micro-processor based controller that monitors electrical inputs, makes decisions based on its program, and controls electrical outputs to automate a process or machine.
Programmable Logic Controllers Purpose Monitors Electrical Inputs Inputs: switches, transducers 4-204 ma,, all sensing devices,. Performs Numerical Calculations Roll Diameters, Speed, Splice Timing Delays,. PID: dryer temperature, web tension control, LEL Machine Logic / Sequencing and Timing Evaluates Conditions (input data) for Line Control Transfer System Paste Roll and Knife Timing Controls Electrical Outputs Discrete Outputs: pilot lights, solenoids, motor starters, etc.. Analog 4-204 ma: : temperature, I/P tension, LEL control, etc.. Distributes Control Drive System, Web Guides, Moisturizer, Treater,.
Programmable Logic Evolution Controllers Relay Replacement - Digital Logic On / Off Analog Input / Output Capability Limited Math - Addition / Subtraction Serial Communication - Proprietary Enhanced Programming - Windows Advanced Math Open Communication Protocols
Programmable Logic Controllers Technical Highlights Precise Control / Fast Response Quick Program Scan Times (msec( range) Common Platform Single Controller: Machine Logic, Temperature Control, etc One Location for Program Quick Program Development Enhanced Programming - Windows On-Line De-bugging Features Open Communication Not Limited to a Single Vendor
Programmable Logic Controllers Process Controller Compact Controller Machine Controller Compact Controller Machine Controller Process Controller Memory: Prog / Data 8 Kbyte / 4 Kbyte 64 Kbyte / 64 Kbyte 8000 Kbyte / 2000 Kbyte Input / Output 168 digital / 32 analog 1024 digital / 256 analog 65536 digital / 4096 analog Execution Time 1K Binary 0.37 msec 0.1 msec 0.08 msec
Human Machine Interface Purpose Means for Operator Control of Machine Line Start, Stop, Jog, Set-up,. Enter Machine Set-Points: speed, tensions, temperatures,.. Select Machine Modes Feedback on Machine Conditions Actual Speed, Tensions, Temperature,. Coating Thickness, Moisture,. Graphical Information Web Path Diagrams Intuitive Control
Human Machine Interface Evolution Discrete Devices Push-buttons, Pilot Lights, Potentiometers, Analog Meters,. Annunciator Panels, Chart Recorders Simple LED Displays Numbers, Letters, Short Words, Bar Graphs,. Character Graphic Displays Simple Characters: lines, circles, squares, letters,. Difficult to Program Bitmap Graphic Displays Current Technology: scanned images, CAD,, word processor Windows Based Programming Software
Human Machine Interface Technical Highlights Intuitive Machine Control Graphical Displays Prompt Operator Control / Settings Presents the Information in a Useable Format Organizes / Compiles Machine Data Critical Information is Displayed at Multiple Locations Information is Immediately Available for Analyzing Operators Set Up and Fine Tune Machine on Most Current Information Quicker Installation / Easier Maintenance Serial Communication vs. Hardwired Devices Alarm Annunciation: view conditions from multiple locations simultaneously
Human Machine Interface Simple Text Display Local Control Station Main Operator Control Station
Human Machine Interface Local Control
Human Machine Interface Local Control Pendant Arm or Machine Mounted Web Path Diagrams Intuitive Operation
Human Machine Interface MOCS (Main Operator Control Station)
Human Machine Interface MOCS: Main Screen Customer s s Name Street Address City, State Zip Code Sample Film / Film Lamination 16:15:40 09/22/04
Human Machine Interface MOCS: Rewind Sectional View Rewind Tension Set Point Customer s s Name Street Address City, State Zip Code
Data Collection / Management Purpose Collect and Archive Machine Process Data Monitor Process Recipe Control Configure Machine with Product Specific Set-Points Down-Load Set-Point Groups Format Collected Data Useable Reports for Operations, Management, Customers
Data Collection / Management Evolution Manual Paper Based Stand-Alone Computer Custom Software Required Hard Coded Reports Integrated Computer Networked Computers Paperless System Standardized Software Packages
Data Collection / Management Technical Highlights More Information Recorded More Variables Data Collected More Frequently Immediate Access to Information Reliable and Readable Documentation No Transcription Errors Laser Printer Generated Reports Quick and Repeatable Machine Set-ups Consistent Products
Data Collection / Management Process Recipes Operators can enter comments in these lines. Data and comments entered will appear on reports.
Data Collection / Management Order Report 9/22/04 9/22/04 Customer s s Name Street Address City, State Zip Code
Data Collection / Management History Report 9/22/04
Communication Purpose Electronically Pass Information from One Device to Another Share Data and Resources Decentralization
Communication Benefits Lower Installation Cost Quicker Update Times More Flexibility Higher Reliability Simple Testing and Diagnostics
Communication
I / O Networking Parallel Wiring Serial Connection PLC & I/O Cards (Located in MCC) PLC (Located in MCC) Field Wiring (100 s s of wires) Field Wiring (1 cable = 2 wires) Junction Box (Located on Machine) Junction Box (Located on Machine) Machine Sensors (2 wires per sensor / 100 s s of conductors) Machine Sensors (2 wires per sensor / 100 s s of conductors)
Centralized Control System MOCS PLC Digital Analog I/O Variable Speed Drive System LAN / MIS Modem Modem Motors Operator Interface Operator Interface Operator Interface Operator Interface Operator Interface U/W #2 Laminator R/W Machine Sensors U/W #1 Coater Coating / Web Handling Equipment Dryer Sensors Dryer
Industry Trends De-Centralized Control Machine Mounted Cabinets Modular Retrofit Maintenance and Troubleshooting Electrically Isolate a Specific Section Localize Trouble Area Installation / Commissioning Advantage Cabinets are Pre-Wired, Minimal Field Wiring. System is Easily Tested at OEM, Shorter Start-up
Industry Trends De-Centralized Control System MOCS Dryer Unwind Coater
Industry Trends De-Centralized Control System
Industry Trends Modular Drive Controllers Common Form Factor V/HZ, AC Vector, and Servo Efficient Panel Layout Plug N Play Replacement Minimal Disassembly / Reassembly Required Common DC Bus Reduce Component Count Single Rectifier, Multiple Inverters Reduced Hardware Reduced Power Consumption
Industry Trends Modular Drive Controllers Typical Form Factor Modular Form Factor Simple Inverter AC Vector AC Servo Simple Inverter AC Vector AC Servo
Industry Trends Totally Integrated Automation Integrated Architecture Reduced Development Time Integrated Engineering Environment Common Data Base Across Technologies Simultaneous Program Development Reduced Capital Cost Common Platforms Across Technologies PLC doubles as Servo Controller Reduced Install Time Single Point Access to All Technologies Easier / Quicker Equipment Checkout
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