Winder Control Function Block Library (dwOPTION -06)


This library contains the tools you need to create easy solutions to all web and cable winding and unwinding applications. Simple applications may be solved with this library and the standard Basic Function Block Library. More complex applications may require additional libraries such as the Process Control FBL or the Encoder FBL. Note that you can create multiple instances of the winder control function blocks in any

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Winder/Unwinder applications include:
  • Center core winding
  • Surface driven winding
  • Slip core winding
  • Multi-turret winding
  • Helical winding
  • Laminar winding
These applications can all be with either open loop tension control or closed loop tension control with load cell feedback. The core elements for winder control are diameter calculation, taper tension control and friction and torque compensation.

Here are the three primary function blocks involved:

Diameter Calculator FB:

This block performs the calculation Line Speed ÷ Winder Speed to provide a signal proportional to diameter. It also includes all of the additional features you need to ensure reliable operation such as, core diameter presetting, diameter preset and hold, web break sensing, output filtering, memory persistence, minimum speed for calculation (0÷0 is obviously meaningless!) and speed signal polarity correction.

 

All of these features are managed in an intuitive, organized manner:

 

Winder FBL - Diameter Calculator

Taper Tension Calculator FB:

This function block automatically links to the selected diameter calculator block to ensure that the correct diameter data is applied. It then calculates the required taper from the machine operator’s setting to ensure that the core pressure is controlled and “telescoping” is prevented. Both linear taper and hyperbolic taper can be applied.

 

Winder FBL - Taper Tension

Torque Compensation FB:

This function block is used in open loop winder systems to provide torque compensation for factors such as dynamic friction, static friction, windage, inertia and other external torque issues. Its mode of operation can be reversed on the fly for reversing winding/unwinding applications. Again, this block can be automatically linked to its associated diameter calculator to ensure accurate and complete functionality.

 

Winder FBL - Torque Compensator

Winder Apps:

Complete winder control systems will also require other functions (such as PID, arithmetic and logic) from other libraries.  Please note that there are several generic complete winder configurations available for you to use and edit to suit your particular application.