SIMOTION

Winder
Siemens
Manual - V3.2.7 - 10/2018 Industry
Online
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 Table of contents

Table of contents
Legal information ......................................................................................................... 2
Application description ............................................................................................... 5
1 Basic information and data............................................................................... 6
1.1 Technical environment ......................................................................... 6
1.2 Changelog ............................................................................................ 6
1.3 Objective and purpose of this standard application ............................. 6
1.3.1 Task ...................................................................................................... 6
1.4 Winder solution design and structure ................................................... 6
1.4.1 General design and structure ............................................................... 6
1.4.2 Winding technique ................................................................................ 7
1.4.3 Advantages of the standard application SIMOTION Winder ............... 8
2 Functions of the application SIMOTION Winder ............................................ 9
2.1 Tasks that can be implemented using the core function ...................... 9
2.2 Properties and features of the core “winder” functions ........................ 9
3 Automation solution ........................................................................................ 11
4 Selecting the control concept ........................................................................ 12
4.1 Indirect tension control ....................................................................... 12
4.2 Tension control with dancer roll ......................................................... 12
4.3 Tension control with load cell ............................................................. 13
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4.4 Constant V Control ............................................................................. 13

4.5 Comparison of the control concepts ................................................... 14
5 Winder checklist .............................................................................................. 15
5.1 Checklist ............................................................................................. 15
6 Sizing ................................................................................................................ 16
6.1 Formulary ........................................................................................... 16
6.2 Selecting the winding ratio (winding range) ....................................... 19
6.3 Power and torque ............................................................................... 20
6.4 Selecting the motor ............................................................................ 20
6.5 Dimensioning the gearbox.................................................................. 20
6.6 Selecting the drive converter .............................................................. 20
7 Example Project ............................................................................................... 21
7.1 Description of the program units ........................................................ 21
7.2 WinCC Faceplates ............................................................................. 22
8 Converting diagnostic pages (IT-Diag).......................................................... 23
Integrating the core function .................................................................................... 24
9 Integrating into the user program .................................................................. 24
9.1 Importing the source code .................................................................. 24
9.1.1 Copying from the application example ............................................... 24
9.1.2 Integration via XML import ................................................................. 25
9.1.3 Integrating the library.......................................................................... 25
9.2 Technology objects ............................................................................ 26
9.2.1 Configuring the leading axis ............................................................... 27
Leading axis as positioning / synchronous axis ................................. 27
Leading axis as drive axis .................................................................. 28
Leading axis as machine encoder ...................................................... 29
External setpoint input ........................................................................ 30
9.2.2 Configuring the winder axis ................................................................ 31

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 Table of contents

Winder axis as drive axis.................................................................... 31

Winder axis as positioning / synchronous axis................................... 32
9.3 Integrating the core winder function ................................................... 33
9.3.1 Global constants and variables .......................................................... 33
9.3.2 pWinderStartUp .................................................................................. 34
9.3.3 pWinderBackground ........................................................................... 34
9.3.4 pWinderIPO ........................................................................................ 35
9.4 Connection to SINAMICS ................................................................... 36
9.4.1 Technology data block ....................................................................... 36
9.4.2 Interconnecting the Kp adaptation for the speed controller ............... 41
9.4.3 Adapting the parameters in SINAMICS .............................................. 44
Program and function description ........................................................................... 47
10 Application structure ....................................................................................... 47
10.1 Pre-processor commands .................................................................. 47
10.2 Data types and Constants .................................................................. 48
10.2.1 Constants ........................................................................................... 48
10.2.2 Enumeration types ............................................................................. 49
10.2.3 Data structures ................................................................................... 57
10.3 Input and output parameters of the function block ............................. 73
10.4 Abbreviations of the units ................................................................... 78
11 Function description ....................................................................................... 79
11.1 Control Modes .................................................................................... 79
11.1.1 Indirect tension control ....................................................................... 79
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11.1.2 Tension control with load cell via torque limiting ................................ 83
11.1.3 Tension control with load cell via speed setpoint adaption ................ 87
11.1.4 Tension control with dancer roll via speed adaptation ....................... 91
11.1.5 Constant-v-control .............................................................................. 96
11.2 Winder operating modes .................................................................. 101
11.3 Technology data block ..................................................................... 102
11.4 Source of master value .................................................................... 102
11.5 System of units ................................................................................. 104
11.5.1 Units of the velocity setpoint calculation .......................................... 106
11.5.2 Units of the torque calculation .......................................................... 108
11.5.3 Units of the diameter calculation ...................................................... 108
11.6 Web break detection ........................................................................ 110
11.7 Kp adaptation of the speed controller .............................................. 111
11.8 Dancer compensation for diameter calculation ................................ 112
11.9 Application faults and warnings ........................................................ 114
12 Commissioning the winder function ........................................................... 118
12.1 Checking the speed actual value calibration .................................... 118
12.2 Compensating the accelerating torque ............................................ 118
12.2.1 Compensating the constant moment of inertia ................................ 118
12.2.2 Compensating the variable moment of inertia ................................. 119
12.3 Setting the Kp adaptation for the speed controller ........................... 119
12.4 Checking the tension pre-control ..................................................... 120
12.5 Setting and optimizing the technology controller, Kp adaptation ..... 121
12.6 Setting the override value................................................................. 121
13 Appendix ........................................................................................................ 122
13.1 Service and support ......................................................................... 122
13.2 Application support ........................................................................... 123
13.3 Links and literature ........................................................................... 123
13.4 Change documentation .................................................................... 124

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 1 Basic information and data
1.1 Technical environment

Application description
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.
Further, you will be provided with engineering information and instructions in order
to select the most suitable control concept.

This document contains the description about the structure, functionality and data
structures of the function block FBLConWinder.
Sub-functions which are used inside (e.g. FBLConDiameterCalculation) are
described in the documentation of the Converting library LConLib:
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 1 Basic information and data
1.1 Technical environment

1 Basic information and data

1.1 Technical environment
This application was tested with
 SIMOTION SCOUT V4.4 HF 4
 SINAMICS V4.7.0
 Technology package Cam_Ext V4.4.0.4
 SIMATIC STEP 7 V5.5 + SP4 + HF1

1.2 Changelog
All changes of the library “LConLib” are listed in a separate document
“SIMOTION_LConLib_Changelog_en.pdf”. It provides information which needs to
be considered in case of library upgrades.
Furthermore the library contains a unit “aVersion” where all changes from one
version to the next are listed.
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1.3 Objective and purpose of this standard application

1.3.1 Task

The standard application SIMOTION winder was developed with the objective to be
able to handle many of the known winder applications with one single application
engineering package. When required, the application can be engineered or
modified thanks to the openness of the application.
The application SIMOTION Winder allows, using the appropriate equipment and
devices, a winder or unwinder to be engineered for the widest range of
applications. These include, for example, foil machines, printing machines, coating
systems, coilers for wire-drawing machines and textile machines.
In many technological processes, winders are an essential part of an overall
system.
Depending on the particular plant or system, sometimes a finishing/conditioning
process starts with an unwinder or ends with a winder.
Different winding techniques are used depending on the process and the material
that is being wound.

1.4 Winder solution design and structure

1.4.1 General design and structure

Generally, a winder solution comprises a winder drive, a material web and possibly
sensors. The function of a winder is to rewind or unwind a material web with a
defined tension. When winding, the diameter changes. Depending on whether it
involves a rewinder or unwinder, the material is wound or unwound. The motion
control system calculates the actual diameter using several system variables and
controls the motor speed so that the tension of the material web is kept constant.

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 1 Basic information and data
1.4 Winder solution design and structure

To do this, the actual velocity of the material web and the speed of the winder shaft
must be known. If the system must fulfill higher demands regarding the
performance and tension accuracy, then an appropriate range of sensors must be
added to the winder solution. These can include a dancer roll or a load cell.
The dancer roll is a position-controlled measuring system. The material web is
threaded through this dancer roll system. A cylinder with a deflection roll presses,
with an adjustable force against the material web. If tension is established in the
material web then this acts against the pressure from the dancer roll. If the dancer
roll is at its center position, then the material web tension is the same as the
selected dancer roll force. In order to control (closed-loop) the tension in the
material web, the motion control system must ensure that the dancer roll remains
at its center position. If the tension in the system changes, then the position of the
dancer roll also changes – that is in turn coupled with the motion control system via
a position detection function. If such a deviation is detected, then the system would
respond, and e.g. change the drive speed.
The tension measuring transducer directly measures the tension in the system and
transfers this signal to the motion control system. If the tension changes then this
can either be compensated by changing the speed or by changing the motor
torque.

1.4.2 Winding technique

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A differentiation is always made between 2 winding techniques.

Center winder

Figure 1-1 center winder

Load cell
Vset

Speed
master n+

Center winder
Fact

With a center winder, the roll is driven by a central shaft. The diameter range is an
important factor when designing this winder type. The reason for this is that for a
constant web velocity and constant tension, the speed is inversely proportional to
the diameter. This means that the maximum required drive speed is defined by the
minimum roll diameter – whereby the maximum required torque is defined by the
maximum diameter.
The center winder is more complicated and from control perspective more difficult
to handle than the surface winder; however it is still more widely established of the
two winder types.

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 1 Basic information and data
1.4 Winder solution design and structure

Surface winder

Figure 1-2 surface winder

Surface winder

M-
n-controlled controlled

For a surface winder, the roll is driven through one or several rolls that are in
contact with the roll being wound. The drive speed and power depends on the
diameter of the roll being wound. From a mechanical design perspective, this
winder technique is more complicated than that of a center winder.
The contact winder (surface winder) is essentially used if there are no special
requirements placed on the surface quality of the material being wound.

1.4.3 Advantages of the standard application SIMOTION Winder

When the standard application SIMOTION Winder is used, it offers users the
following advantages:
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Reduction of engineering time

When the standard application SIMOTION Winder is used, it is simple to quickly
implement comprehensive winder functionality when programming with SIMOTION.
The core function can be imported into the user program. Additional engineering
steps that are required are explained in this description of the standard application.

Possibility of making changes

The standard application SIMOTION Winder 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.
An explanation regarding background information that is required to expand the
core functions is also included in this description.

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 2 Functions of the application SIMOTION Winder
2.1 Tasks that can be implemented using the core function

2 Functions of the application SIMOTION

Winder
2.1 Tasks that can be implemented using the core function
The application SIMOTION winder is used to control rotating mechanical
equipment to wind or unwind a material web (film, paper, wire, foil, etc.)
The core function conditions the signals that are required to control the winder
shaft – such as speed and torque.
The core function comprises a function block, which generates the setpoints to
control the winder shaft. These setpoints are the setpoint velocity and, depending
on the control mode torque limits, additive torque setpoints as well as variables to
control the controller gain adaptation function.
The block handles all of the essential functions of the winder such as diameter
calculation, moment of inertia calculation, Tension Preparation, Gain Adaption and
Tension Taper Characteristic.
The winder block can be simply changed-over to various control modes by
appropriately parameterizing it. It is not necessary to make any changes to the
program in order to toggle between indirect and direct tension control for example.
However, it is possible to access the code of the winder function blocks as this is
not password protected.
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NOTE The core function Winder implements the operation mode winder control.
Operation modes like feeding in, inching mode or axis control have to be
implemented in addition.

2.2 Properties and features of the core “winder” functions

The following properties form the winder core function:

Diameter calculation
5 different techniques are available to calculate the diameter of the roll being
wound:
 The diameter is calculated using the ratio between the velocity of the material
web and the winder speed
 The diameter is calculated by adding the material thickness
 The diameter comes from extern (sensor)
 The diameter is calculated from the ratio between the material length and the
revolutions of the winder (integration)
 The diameter is calculated by measure the position of the material and the roll

NOTE A detailed description about the diameter calculation modes can be found in the
Converting Library documentation.

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 2 Functions of the application SIMOTION Winder
2.2 Properties and features of the core “winder” functions

Tension taper characteristic

A tension taper characteristic is required if the tension, with which the material is
wound, is to be decreased as the diameter of the roll being wound increases. 5
different techniques are available to calculate the tension taper characteristic:
 No characteristic
 Linear characteristic – the tension is linearly reduced as a function of the actual
diameter
 Hyperbolic characteristic type 1 – the tension decreases according to a
hyperbolic function/characteristic
 Hyperbolic characteristic type 2 – the tension decreases according to a
hyperbolic function/characteristic
 Interpolated characteristic using a table of points – 10 points can be entered to
define the characteristic

NOTE A detailed description of the function "tension taper characteristic" can be found
in the Converting library documentation.

Tension preparation
 Preparing the tension setpoint value for further usage
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 Functions implemented for tension control with dancer roll, tension control with
load cell, indirect tension control and taper characteristic

Controller adaptation
 The gain of the technology controller can be adapted as a function of the
diameter. This permits a higher controller gain at a bigger diameter
 The speed controller gain in the drive can be adapted as a function of the
moment of inertia or the actual diameter of the roll being wound. This is
necessary so that a full roll can also be rapidly accelerated or decelerated

Inertia compensation
While the material web is being accelerated and decelerated, an additive torque
can be switched to the drive in order to respond dynamically (quickly) to velocity
changes.
The inertia compensation avoids tension dips or tension increases due to the
velocity change. This pre-control is required, especially for indirect tension control
but also for tension control with a load cell.
The pre-control is made available to the user as an additive torque at the output of
the winder function block. Instructions for making the appropriate interconnections
are explained step-by-step in Section “Integration of the core function” using as an
example, a SINAMICS drive.

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 3 Automation solution
2.2 Properties and features of the core “winder” functions

3 Automation solution

A SIMOTION platform (controller, PC or drive) is necessary to execute the winder

functionality. A drive system is also required (e.g. SINAMICS).

Figure 3-1 Automation solution

PG / PC

SIMOTION D

Encoder

Motor
Sensor
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Web
Winder
Motor
Dancer roll
Encoder

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 4 Selecting the control concept
4.1 Indirect tension control

4 Selecting the control concept

The standard application SIMOTION Winder allows the following control concepts
to be implemented:
 Indirect tension control (without load cell)
 Tension control with dancer roll or load cell
These control concepts will be briefly explained in the following. A Chapter with
engineering examples is also included in Section “Integration of the core function”
of the documentation.

4.1 Indirect tension control

This technique does not require a device to measure the tension. The technology
controller is not used – instead, the tension setpoint (reference value) is multiplied
by the diameter and the result is directly pre-controlled as torque setpoint. This
means that the motor current linearly increases with increasing diameter and the
tension is kept constant. In this case it is important that the friction and accelerating
torques are precisely compensated so that the pre-controlled torque setpoint
results in the best possible approximation to the required material tension.
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For this control type it must be ensured that the mechanical losses are kept as low
as possible. This means that worm gears may not be used, no open intermediate
gear ratios - and if herringbone gearing is used, then the shaft should rotate in the
direction of the herringbones. It is also important to ensure the lowest possible loss
differences between gearboxes in the warm and cold states.

4.2 Tension control with dancer roll

The material web is fed over a dancer roll. The dancer roll attempts to deflect the
material web with a defined force. The deflection of the dancer roll (dancer roll
position) is detected using a potentiometer – e.g. a field-plate potentiometer – and
this serves as a measure of the material tension.
The material tension depends on the retraction force of the dancer roll suspension.
Often, there are additional factors that influence the tension actual value as a result
of the geometrical arrangement (distance to reversing rollers that maybe used) and
the weight of the dancer roll itself. However, with a careful mechanical design,
these effects can be eliminated or sufficiently minimized.
The controller that is at a higher-level to the speed controller (known as
“technology controller” in this Manual) is used as dancer roll position controller and
corrects the position actual value of the dancer roll in-line with the position setpoint
value (e.g. the dancer roll center position).
Normally, the technology controller outputs a velocity correction setpoint (weighted
with the actual diameter) to the speed controller.
Generally, the position setpoint is not entered from outside, but is parameterized as
fixed value.
For dancer rolls with a support force that can either be pneumatically or
hydraulically adjusted, a decreasing tension taper can be implemented using the

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 4 Selecting the control concept
4.3 Tension control with load cell

tension taper characteristic. To do this, the tension signal is connected to an

analog output and is used as setpoint for the dancer roll support function.
When a dancer roll is used as actual value transmitter, this has the advantage that
the dancer roll (when the stroke is selected long enough) simultaneously serves as
a storage element for the material web. This means that it already is a 'tension
controller’. Although closed-loop dancer roll controls are quite complex, they offer
the best control technique.
The material web storage function has a damping effect on
 Non-round (eccentric) material rolls (out of true)
 Jumps between layers – e.g. when winding cables
 At roll changes

4.3 Tension control with load cell

A load cell (e.g. load cell from FAG Kugel-Fischer or Philips) directly senses the
material tension. Its output signal is proportional to the tension and is fed to the
technology controller as actual value signal. This means that in this case the
technology controller is effective and directly controls the tension of the material
web. For this technique, it is not necessary to intervene in the material web as is
the case for a dancer roll system. However, in this case there is not the advantage
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of having a storage function for the material web.

A difference must be made between the tension control via the torque limits and
the speed setpoint adaption:
In tension control modes via torque limits (including indirect tension control), the
speed controller in the drive operates in saturation (at its end limits). The drive is at
one of the two torque limits and is controlled through these torque limits. The
correction value from the technology controller acts additively on these torque
limits. Supplementary torque setpoints – e.g. from the acceleration pre-control
(inertia compensation) or the tension taper characteristic – are connected-up so
they act additively to the torque limits.
In case of the speed setpoint adaption the correction signal of the technology
controller acts additively to the velocity setpoint which is transformed to a speed
setpoint for the speed controller. Therefore the speed controller does not operate in
saturation and the drive will not be controlled via its torque limits.

4.4 Constant V Control

In this control mode the winder is controlled to run with constant web speed (web
speed command value). No tension control is active.
For the diameter calculation the web speed actual value, measured by a web
tachometer, is necessary. With a nip role and the actual web speed at this point the
tachometer is possibly not needed.
The torque pre control (friction torque) is active, if the technology data block and a
friction characteristic is active. If the web command acceleration is available, it can
also be used for torque pre control.

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 4 Selecting the control concept
4.5 Comparison of the control concepts

4.5 Comparison of the control concepts

The most important criteria when selecting a suitable control concept are
summarized in the following table:

Table 4-1 Comparison of the control concepts

Control Indirect Tension Tension Tension Constant v
concept tension control with control with control with control
control dancer roll load cell via load cell via
torque limits speed
setpoint
adption
Information on No actual Intervenes in Sensitive to Sensitive to no tension
actual tension tension value the material overload, overload, actual value
value sensing sensing web routing, generally does generally does sensing
required ability to store not intervene not intervene
material in the web in the web
routing routing
Winding ratio Up to approx. Empirically up Empirically up up to approx.
Dmax/Dcore 10:1, good Empirically up to approx. to approx. 15:1
compensation to approx. 15:1 15:1, precise 15:1, precise
of dv/dt and dv/dt dv/dt
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friction compensation compensation

required required required
Tension range Up to approx. Can only be Up to approx. Up to approx. not relevant
Zmax/Zmin 6:1 for good set when the 20:1 for 20:1 for
compensation dancer roll precise dv/dt precise dv/dt
of friction and support can be compensation compensation
dv/dt adjusted
Winding ratio x Generally up Depends Up to 100:1, Up to 100:1, not relevant
tension range to 40:1 heavily on how essentially essentially
Dmax Zmax the dancer roll depends on depends on
 support is the tension the tension
Dcore Zmin implemented, actual value actual value
up to approx. signal signal
40:1
Friction From - - - -
force/tension experience,
that cannot be over the
compensated complete
tension range
<1
Web velocity Up to 600 Up to over Up to 2000 Over 2000 depending
m/min for good 2000 m/min m/min with m/min from
compensation precise dv/dt mechanical
compensation construction
Control Sheet steel, Rubber, cable, Paper, thin Elastic, sorter
concept, textiles, paper wire, textiles, foils expandable
preferably used foils, paper material
for
Nip position Yes Yes Yes Yes No
required
Web material No No No No Yes
tachometer
required

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 5 Winder checklist
5.1 Checklist

5 Winder checklist
5.1 Checklist
This checklist should be used to list customer requirements in order to investigate
the feasibility of the winder application. The fields with white background must be
completed; the fields with gray background can be calculated using the appropriate
formulas.

Table 5-1 Checkliste Wickler

Description Value Unit
Application / Machine Type [--]
Rewinder / Unwinder [--]
Minimum diameter Dmin [m]
Maximum diameter Dmax [m]
Diameter ratio Dmax / Dmin [--]

Minimum tension Fmin [N]

Maximum tension Fmax [N]
 Tension ratio Fmax / Fmin [--]

 Minimum torque Mmin [Nm]

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 Maximum torque Mmax [Nm]

 Torque ratio Mmax / Mmin [--]

Motor type (synchronous / induction) [--]

Rated motor torque MN [Nm]
Rated motor frequency fN [Hz]
Rated motor speed nN [U/min]
Motor moment of inertia [kg*m²]
Gearbox moment of inertia [kg*m²]
Motor encoder system (resolver, pulse, encoder) [--]

Maximum web velocity vmax [m/min]

Minimum web velocity vmin [m/min]
Ramp-up /-down time / Emergency stop time [s]
Maximum winder speed for vmax, Dmin [U/min]
Minimum winder speed for vmin, Dmax [U/min]
Gearbox ratio i=n1/n2 [--]
Maximum motor speed for vmax, Dmin [U/min]
Minimum motor speed for vmin, Dmax [U/min]
Maximum field weakening [--]
Tension measuring system (dancer roll, load cell, none) [--]
Required tension accuracy ∆F/Fmax [%]

Diameter sensor (yes/no) [--]

Wound material width B [m]

Wound material length L [m]
Winding material thickness D [m]
Winding material density [kg/m³]
 maximum moment of inertia of the wound roll [kg*m²]
Flying roll change [--]

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 6 Sizing
6.1 Formulary

6 Sizing
6.1 Formulary

Figure 6-1 Schematic Diagram

DKern

D V

J2

J1
Mb b
Z
n1 n2

M
Getriebe (i = n1 / n2)
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mm ;   3 
kg
Following units are base for the formulas: D
 dm 

(1) Winding ratio:

Dmax  mm 
q
DCore  mm 

(2) Speed [rpm]:

V  1 
n
D    min

(3) Winding torque referred to the motor shaft [Nm]:

Z D  N * m
Mw 
2000 i  1 

(4) Winding power [kW:

 Nm 
ZV  min
Pw 
60  103  1 

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 6 Sizing
6.1 Formulary

(5) Gearbox ratio, max. motor speed / max. sleeve/ core speed:

n1   DCore  nmax  mmmin

i 
n2 1000  vmax  m 
 min 

2
(6) Moment of inertia, full cylinder [kg m ]:

m   mm  kg  mm4 
J  D2   b    D4  
8  106 32  1012  dm3 

2
(7) Moment of inertia, hollow cylinder [kg m ]:

J
m
8 10 6

 D 2  D Core
2
 
π
32 1012

 b  ρ  D 4  D Core
4

(8) Moment of inertia reduction through a gearbox:

J
J1  2
i2
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2
(9) Fixed moment of inertia [kg m ]
determined by the fixed parts of the winder (motor, gearbox and core) referred to the
motor shaft

J Core
J F  J Motor  J Gear 
i2
2
(10) Variable moment of inertia [kg m ]

  mm  kg 3mm
4
JV 
 b 
32  1012  i 2

 D 4  DCore
4
 
 dm 

(11) Accelerating torque referred to the motor shaft [Nm] for accelerating time tb

100  i V
Mb   Jf  J V 
3  D tb

(12) Accelerating power [kW]

i V 10  i 2  V V
Pb   Mb    J f  J V 
30  D 9  D2 tb

(13) Rated motor torque [Nm]

9549  PM
MN 
nM

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 6 Sizing
6.1 Formulary

(14) Wound roll storage capacity for flat materials

l
π
4000  d
2

 Dmax  D2Coer 
(15) Wound roll storage capacity for round materials

l
πb
2
 Dmax  D2Core 
2000  3  DR2

(16) Relative storage capability depending on the winding ratio:

q 2 3 4 5 6 7 8 9 10

l 1
 1 75 % 88.9% 93.8% 96% 97.2% 98% 98.4% 98.8% 99%
lmax q2

(17) Winding time [s]:

l
t  60 
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Formulas and dimensions used

b = material width [mm]
bmax = maximum material width of roll [mm],
d = material thickness [mm]
D = actual diameter [mm]
Dcore = core or sleeve diameter [mm]
DMax = maximum diameter [mm]
DR = material diameter for round materials [mm]
i = gearbox ration (refer to (5))
2
J = moment of inertia [kgm ]
JF = fixed moment of inertia referred to the elements of the winder that do not change
2
(motor, gearbox + wound roll core) referred to the motor shaft [kgm ]
l = material length [m]
lmax = maximum material length (for core diameter 0 mm) [m]
2
Jgear = moment of inertia of the gear referred to the motor shaft [kgm ]
2
Jcore = moment of inertia of the core [kgm ]
2
Jmotor = motor moment of inertia [kgm ]
JV = variable moment of inertia caused by the wound material referred to the
2
motor shaft [kgm ] (refer to (10))
m = mass [kg]
Mw = winding torque referred to the motor shaft [Nm]:
Mb = accelerating torque referred to the motor shaft [Nm]
MbF% = percentage accelerating torque as a result of the fixed moment of inertia

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 6 Sizing
6.2 Selecting the winding ratio (winding range)

JF at the minimum diameter [% of MN] (refer to formula (1.2))

MbV% = percentage accelerating torque due to the variable
moment of inertia JV at the maximum diameter and maximum width [% of MN] (refer to
formula (1.5))
MN = rated motor torque [Nm] (refer to (13))
n = speed [RPM]
nmax = maximum motor speed [RPM] (no-load speed for maximum
field weakening)
nN = rated motor speed at the rated voltage and rated motor field current [RPM]
Pb = accelerating power [kW]
PM = required motor power [kW]
PN = rated motor power [kW]
Pw = winding power [kW]
q = winding ratio (refer to (1) )
3
r = specific weight [kg/dm ]
t = winding time [s]
tb = accelerating time [s]
th = ramp-up (accelerating time) of the web velocity from 0 to Vmax [s]
V = web velocity [m/min]
Vmax = maximum web velocity [m/min]
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Z = tension [N]
V = velocity difference [m/min

6.2 Selecting the winding ratio (winding range)

In the following rewinding is addressed. The same essentially applies for
unwinding.
Winding ratio is given by the following quotient:
DMax
q
Dcore

The winding quantity that can be used as a % is given by the following formula
(14):

(D2max - D2core )
4
This means that for a winding ratio of 6:1, the winding length that can be
used is already ~~ 97 %.

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 6 Sizing
6.3 Power and torque

6.3 Power and torque

The power required for winding is constant over the complete winding range if, for
the selected web velocity, the selected winding tension is to be kept constant (also
refer to the formula 4)). Winding power Pw :
Z bd V
PW = s kW
60  10 3
b = operating width in mm
d = operating thickness in mm
V = web velocity in m/min
2
Zs = specific material tension in [N/(mm material cross-section surface)]
The torque required increases linearly with the diameter of the roll being wound.

6.4 Selecting the motor

The standard axial winder application is suitable for both synchronous as well as
induction motors – without any differences in the control behavior. Because an
induction motor can operate in the field-weakening mode, the motor can often be
more favorably dimensioned a synchronous motor.
When selecting induction motors, we recommend that the following points are
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observed:
 An actual value encoder is already integrated in the motor
 Good field-weakening behavior allows a smaller motor to be selected
 The motors are force-ventilated as standard – which means adequate cooling
at low speed and high torque. At field-weakening speeds, there is no increased
fan noise when compared to non-ventilated motors.
Engineering information and instructions for synchronous and induction motors,
refer to the PATH and SIZER engineering programs.

6.5 Dimensioning the gearbox

The gearbox is dimensioned together with the machinery construction company.

6.6 Selecting the drive converter

The drive converter is selected using PATH (Masterdrives) or SIZER (SINAMICS).

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 7 Example Project
7.1 Description of the program units

7 Example Project
7.1 Description of the program units
The SIMOTION Winder example project contains the following program units:

 pMainSequence
The unit pMainSequence contains the program
 pMainSequence
Example control sequence to control different modules.
This sequence coordinates the sub-module sequences.
The example project contains two modules (line axis and winder).
Single modules can also be controlled directly via the respective
module control sequence. In this case the main control sequence is
not necessary.

 pLine
The unit pLine contains the programs

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pLineStartUp
Pre-allocation of configuration data
 pLineBackground
Example control sequence to control a line axis.

 pWinder
The unit pWinder contains the programs
 pWinderStartUp
Pre-allocation of configuration data
 pWinderBackground
Example control sequence to control a winder axis.
 pWinderIPO
FBLConWinder function block call as well as normalization of
diameter sensors and dancer position sensor.

 dConITDiag
This unit contains the global variable definition for usage of the Converting
diagnostic pages (IT-Diag). The actual value copy to these parameters is done
in the program pWinderBackground.

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 7 Example Project
7.2 WinCC Faceplates

 pFault
Template programs for the tasks TechnologicalFaultTask and
PeripheralFaultTask.

 pStartupCheck
The application „SIMOTION StartupCheck“
(https://support.industry.siemens.com/cs/de/de/view/48947625/en) is part of
the example project because of I/O data access to an ET200 in the program
code.
The application can be integrated to a user project with the SIMOTION Project
Generator.

 pGlobalBufferManager
This unit is part of the application „SIMOTION StartupCheck“.

7.2 WinCC Faceplates

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There are example faceplates for WinCC TIA available. They can be integrated
with the library „LCon“ (LCon.al13).
Additionally the library contains master-copies with the variable connection to the
example project.

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8 Converting diagnostic pages (IT-Diag)

8 Converting diagnostic pages (IT-Diag)

The Converting diagnostic pages can be used to display actual values.
The functionality as well as documentation how to use and integrate into the
machine project can be found in the documentation “Converting diagnostic pages”.
https://support.industry.siemens.com/cs/de/de/view/109474896

Figure 8-1

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 9 Integrating into the user program

Integrating the core function

The Section “Integrating the core function” guides you step-by-step through the set-
up and commissioning of the application

9 Integrating into the user program

9.1 Importing the source code

The winder functionality is part of the Converting Library LConLib (SIOS-ID:
48805235). This is available as library in the SIMOTION winder standard
application as well as XML export. In order to be able to use the functionality of the
library, this must be integrated into the user project.

9.1.1 Copying from the application example

Two instances of SIMOTION SCOUT are opened to copy the Converting library
LConLib. The application example is opened and de-archived in the first window, a
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new user project, which already includes the global folder libraries, is created in the
second window.

Table 9-1 Copying the library from the application example

Nr. Description
1. The library is loaded into the buffer
by right clicking on the library in the
standard application and then
selecting Copy.

2. The Converting library LConLib can

be inserted into the user project, if
the Libraries folder is marked and is
then executed using a right click and
selecting Paste.

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 9 Integrating into the user program

9.1.2 Integration via XML import

For XML import, the LConLib Converting library is integrated into the existing user
project from an XML file.

Table 9-2 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 LConLib library is
imported into the user project.
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9.1.3 Integrating 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
USELIB LConLib; // Library import
END_INTERFACE

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 9 Integrating into the user program

9.2 Technology objects

The required technology objects are now listed according to their function:

Leading axis
The leading axis (master axis) is used to enter the material web velocity (leading
velocity) and the position of the material web and is used, for example, to calculate
the speed setpoint of the winder axis and to calculate the diameter of the roll being
wound.
Only a positioning or synchronous axis or an external encoder, whose position unit
is not defined in degrees, can supply the velocity reference. For speed axes, the
velocity value is converted using the roll circumference. Printing applications are
the exception; the leading axis is configured as rotating positioning axis. In this
case, the following applies: 360 degrees corresponds to 1 m.
A leading axis with position reference or a driveaxis with external position signal is
required if the position-based diameter computer is to be used.
An object for a leading axis is not absolutely necessary as the setpoints can also
be externally linked (this can make sense, if many winder instances are used that
access the same values).

Winder
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TO axis configured as speed axis or positioning axis.

If the position-based diameter computer is to be used, then a leading axis with
position reference or a drive axis with external position signal is required.
A technology object is mandatory and is always required if torque precontrol or a
torque based control mode is to be used.

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 9 Integrating into the user program

9.2.1 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 of significance, e.g. if the position information is to be used to calculate
the diameter or the material thickness.

Table 9-3 Setting-up the leading axis as positioning / synchronous axis

No. Description
1. With “Insert axis” a new axis with the
technology Speed Control can be inserted.

2. The axis type can be real or virtual.

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Only linear axis is allowed.

Exception is the use in combination with the

Print Standard. In that way 360° is defined to
1m circumference.
3. 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 WinderConfig.
4. If a modulo axis is used, then for position-
based diameter computers, it must be
ensured that a modulo length must be
traveled through in a minimum of 2 sampling
cycles at the maximum web velocity.

The line axis diameter is not necessary in this configuration.

The previously selected units within the axis configuration define the necessary unit
setting in sWinderConfig.sUnitConfig:

Example:
Unit of axis velocity = [m/min]
Unit of axis acceleration = [m/s²]

sWinderConfig.sUnitConfig.eUnitLineAxisVelocity := M_MIN;
sWinderConfig.sUnitConfig.eUnitLineAxisAcceleration := M_S2;

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 9 Integrating into the user program

Leading axis as drive axis

The axis technology driveaxis, is used if the position and therefore the position
information of the leading axis have no significance.

Table 9-4 Setting-up the leading axis as driveaxis

No. Description
1. With “Insert axis” a new axis with the
technology Speed Control can be
inserted.

Virtual or real axis can be used.

2. 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

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1/s².

The units selected in this dialog box

define the necessary setting in
WinderConfig.

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 sWinderConfig.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]

sWinderConfig.sUnitConfig.eUnitLineAxisVelocity := MM_MIN;
sWinderConfig.sUnitConfig.eUnitLineAxisAcceleration := MM_S2;

As a consequence:
sWinderConfig.r32lineAxisDiameter in [mm]

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 9 Integrating into the user program

Leading axis as machine encoder

In SIMOTION, the external encoder technology object provides the functionality to
connect a machine encoder. Contrary to a real positioning axis, an external
encoder only supplies the position and velocity actual values.

Table 9-5 Setting-up the leading axis as external encoder

No. Description
1. With “Insert external encoder” the
technology object can be inserted.

2. The encoder must be configured as

linear encoder.

Exception is the use in combination

with the Print Standard. In that way
360° is defined to 1m circumference.
3. 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
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…/s² (e.g. m/s²).

The units selected in this dialog box

define the necessary setting in
WinderConfig.
4. If a modulo axis is used, for the
position-based diameter computer,
it must be ensured that a modulo
length is traveled through in a
minimum of 2 sampling cycles at the
maximum web velocity.

The previously selected units within the axis configuration define the necessary unit
setting in sWinderConfig.sUnitConfig:

Example:
Unit of external encoder velocity = [m/min]
Unit of external encoder acceleration = [m/s²]

sWinderConfig.sUnitConfig.eUnitLineAxisVelocity := M_MIN;
sWinderConfig.sUnitConfig.eUnitLineAxisAcceleration := M_S2;

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 9 Integrating into the user program

External setpoint input

If several winders 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 configuration parameter sWinderConfig.toLineAxis is not connected
(= TO#NIL). The leading values are transferred via the function block input
lineAxisMotionVector.

Table 9-6 Transfer parameters

Parameter Significance
lineAxisMotionVector.r64LineSpeed [ LU / TU ] Velocity of the leading axis. The winding
direction is defined for positive line speed.
lineAxisMotionVector.r64LineAcceleration [ LU / s² ] Acceleration of the leading axis
lineAxisMotionVector.r64LineFeedback [ Inc ] Position / counter information of the leading axis

The values have to be defined in a linear unit!

sWinderConfig.sUnitConfig.eUnitLineAxisVelocity = M_MIN, MM_MIN, M_S, MM_S

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sWinderConfig.sUnitConfig.eUnitLineAxisAcceleration = M_S2, MM_S2

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 9 Integrating into the user program

9.2.2 Configuring the winder axis

The winder axis is used to wind or unwind the material web with a defined tension.
Technology objects, type drive-, positioning- or synchronous-axis are
permissible as winding axis.
Only real axes are permitted for winding axes.

Winder axis as drive axis

The axis technology driveaxis, is used if the position and therefore the position
information of the winder axis has no significance. If the position of the winder axis
is not known, then the functions like the position-based diameter computer or the
material thickness calculation cannot be used.

Table 9-7 Setting-up the winder axis as driveaxis

No. Description
1. 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
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not permitted.

2. In the units dialog box of the axis the

winder 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
WinderConfig.
3. 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 sWinderConfig.sUnitConfig:

Example:
Unit of winder axis velocity = [rpm]
sWinderConfig.sUnitConfig.eUnitWinderAxisVelocity := RPM;

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 9 Integrating into the user program

Winder 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. For instance, if the position information is
used to calculate the diameter or material thickness.

Table 9-8 Setting-up the winder axis as positioning/synchronous axis

No. Description
1. With “Insert axis” a new axis with the
technology Positioning or
Synchronous Operation can be
inserted.

Only a real axis can be selected

for the winder axis; a virtual axis
is not permitted.

2. In the units dialog box of the axis the

web axis units will be defined.

The rotatory unit for angular velocity

typically is °/s.
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The unit selected in this dialog box

defines the necessary setting in
WinderConfig.

3. Depending on the control type used,

it is necessary to set-up the
technology data block – or is
optionally possible.

The previously selected unit within the axis configuration defines the necessary unit
setting in sWinderConfig.sUnitConfig:

Example:
Unit of winder axis angular velocity = [°/s]
sWinderConfig.sUnitConfig.eUnitWinderAxisVelocity := DEG_S;

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 9 Integrating into the user program

9.3 Integrating the core winder function

For the basic functionality of the winding function, the FBLConWinder 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 winder function block in a synchronous task

Based on the example program unit “pWinder” the integration of one or more
winder into a machine project is demonstrated.

9.3.1 Global constants and variables

Constants
If there are more winder instances used the function block call in FOR loops is
recommended. For this the following Implementation Global constants are used:
 NUMBER_OF_WINDER : USINT := x

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WINDER_01 : USINT := 0
 WINDER_02 : USINT := 1
 …

NOTE If there is only on winder, the FOR loop and the constants are not required.

Global variables
The following global variables are necessary to use one or more winder:
 gasWinderConfig := : ARRAY [0..NUM_OF_WINDERS-1] OF
sLConWinderConfigType;
 gasWinderDiag := : ARRAY [0..NUM_OF_WINDERS-1] OF
sLConWinderDiagType;

To interconnect the winder function block in- and output parameter in a FOR loop
the following variable structures can be used:
 gasWinderInput := : ARRAY [0..NUM_OF_WINDERS-1] OF
sLConWinderInputType;
 gasWinderOutput := : ARRAY [0..NUM_OF_WINDERS-1] OF
sLConWinderOutputType;

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 9 Integrating into the user program

NOTE If there is only one winder the variables don’t need to be defined in Array form!
The variable structures sWinderInput/Output are not necessary as well due to
input and output parameter can be interconnected directly to the function block.

Global retain variables

 gar32DiameterLatch := : ARRAY [0..NUM_OF_WINDERS-1] OF REAL;

This variable is used to save the calculated diameter.

9.3.2 pWinderStartUp

For assignment of configuration data (sWinderConfig structure) that are not

changed during operation, it makes sense to combine these in one program
(Startup program) and to execute this once in the StartupTask when starting the
controller.
The Startup program must be assigned to the StartupTask in the execution system.
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Figure 9-1 StartupTask assignment

9.3.3 pWinderBackground

The background task program can be used to implement a sequence control.

One possibility to do this is shown in the example project.

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9.3.4 pWinderIPO

The program in which the winder function block is called must always be executed
in clock-cycle synchronous task.
For this a task which is in synchronism with the IPO clock cycle need to be used
(Servo Synchronous, IPO Synchronous task 1 or 2, timer interrupt task).
It is recommended to define the winder instance in the local variable area (if
desired as Array (ARRAY [0..NUM_OF_WINDERS-1] OF FBLConWinder)). Doing
this access to the winder is possible via the global structures only.

The function block input parameter resp. the parameter of the winderInput-structure
need to be interconnected corresponding to the function required in the user
program.
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9.4 Connection to SINAMICS

9.4.1 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.
Chapter 11.3 provides information regarding the necessary steps to configure the
technology data block.

Table 9-9 : 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
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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 9-10 Activating the technology data block in the technology object
Nr Description
1. Option 1:
In the axis configuration, it is possible to
activate the technology data block by
setting the checkbox “Technology data
block”.

2. Option 2: TypeOfAxis.TechnologicalData.Enable = YES

The technology data block can be
activated/deactivated alternatively with
the following variables in the expert list TypeOfAxis.TechnologicalData.TechnologicalDataInInfo.
of the axis logAddress = Start address of the data area for the receive data
(supplementary torque, torque limits)

TypeOfAxis.TechnologicalData.TechnologicalDataOutInfo.

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Nr Description
logAddress = Start address of the data area for the receive data
(actual torque)
3. Using SIMOTION V4.2 and higher and
“Symbolic assignment” is activated
(default setting), the telegram extension
is set by the system automatically.

Whereas the torque parameter are

interconnected automatically the
scaling factor for supplementary torque
1 need to be set to 100% 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 9-11 Configuring the technology data block

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Nr Description
1. The required axes have been set-
up in SINAMICS and the telegram
types defined.

2. Change into the drive overview

3. 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.

4. 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.

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Nr Description
5. 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
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TypeOfAxis.SetpointDriverInfo.DriveData.maxTorque in the TO winder axis, must

be set to the same value as parameter p2003 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 p505 – the same condition
applies to SI units.

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Interconnection in SINAMICS
The interconnection in SINAMICS depends on the configured telegram type.

Table 9-12 Interconnection of the telegram extension

Parameter Description
p1522 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.
p1523 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.
r80 Torque actual value
The actual torque value is sent to the control.
p1512 Scaling factor supplementary torque 1 need to be set to 100% by the user to
make sure the supplementary torque gets effective!
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Figure 9-2 supplementary torque and scaling factor

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Example for a telegram expansion based on telegram 102:

Table 9-13 Configuration example, configuring the telegram

Receive direction Transmit direction
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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.

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9.4.2 Interconnecting the Kp adaptation for the speed controller

To adapt the controller parameters – specifically for the Kp factor – the ratio
between the maximum diameter and actual diameter (or moment of inertia) is
continuously calculated and can be sent to the drive for the Kp adaptation of the
speed controller. The ratio is made available at output kpAdaptionRatio as a %
(4000h = 100%).
The steps necessary to do this are explained in the following using a SINAMICS
drive as example.

Table 9-14 Configuring the telegram expansion – from SIMOTION V4.2

No. Description
1. Open the address list

2. Define a new I/O variable with

the I/O address of “OUT”.
Afterwards assign a drive signal
by clicking on the respective
button.
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3. Select the parameter p1455 by

the checkbox. The assignment
to the I/O variable is done.
The BICO-connection between
the PZD and the drive
parameter just like the telegram
extension itself are set up by the
system automatically.

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Configuration of adaption values

Table 9-15 Configuring the adaption values

No. Description
1. The Kp adaptation must be
parameterized in the configuration
dialog box “Adaptation”; in this
case, the x axis reflects the
diameter ratio and the y axis, the
controller gain. These should be
parameterized corresponding to
your particular application or
determined by optimizing the
controller. The diameter ratio
becomes 100% if the actual
diameter has reached the
maximum diameter. The Kp
(p1460) for the maximum diameter
must be correspondingly set-up. In
order to achieve a certain Kp at
the minimum diameter, the scaling
must be calculated:
Dmax/Dmax ( 100% )  KpDMax
KpDMax = 100% * Kp(p1466)
Dmin/Dmax ( 5%)  KpDMin
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KpDMin = X% * Kp(p1466) X =
20
2. Interconnect output parameter
kpAdaption of the winder block to diameterRatio := FBWinder.kpAdaptionRatio;
the I/O variable set-up in the user
program.

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Configuring the telegram extension – up to SIMOTION V4.2

Without symbolic assignment the telegram extension and the BICO-Connection
must be completed manually.

Table 9-16 Configuring the telegram expansion – up to SIMOTION V4.2

No. Description
1. 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.

2. Change the telegram length and

for the output data, add 1 word
(control reference).

3. Transfer the data to the hardware

configuration. This means that the
hardware configuration is
automatically adapted. The
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address of the word can also be

determined from the table shown
(in this case, 294).

4. Set-up an I/O variable (PQW),

data type WORD (diameterRatio)
at the configured peripheral
address of the additional word.
5. Interconnect the additional signal
in the drive.
In the dialog box “Kp/Tn
adaptation” the diameter ratio
must be parameterized as
adaptation signal for the P gain
(p1455).

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9.4.3 Adapting the parameters in SINAMICS

Table 9-17 Parameter overview

Parameter Description Effect Value
p1227 Setting the monitoring time of the standstill detection. Deactivation of the standstill 300s
Slowing down with AUS1 or AUS3, the standstill is monitoring of the setpoint ->
detected after this time and after the set rotation speed no run out of the motor
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.
p1135 Setting the ramp return runtime from the maximum speed Slowing down at torque limit 0s
to the standstill for the AUS3 command.
p1551 Setting the signal source for switching the torque limits With AUS3 active(r0899.5), r0899.5
between variable and fix torque limits. the torque limits are
switched
r0899.5 No quick stop active (state AUS3) p1551
p1520 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
p1082 Setting the highest possible speed Speed limit for torque control max.
U/min
p1145 Setting the ramp function generator tracking. Only with extended setpoint 0.0
The initial value of the ramp function generator is tracked channel:
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according to the maximum possible drive acceleration. Ramp flattening at ramp

Reference value is the difference at the speed / velocity function generator is
control input, which is necessary to ensure a run-up at the deactivated.
torque / force limit of the drive.
p1400.14 Setting the configuration of the speed control. Torque pre- In vector mode: Always
control No deactivation of the torque active
VECTOR pre-control with overdriven
speed controller
p1580 Efficiency optimization (Flux setpoint adaption) Drive speed is more stable 50%-
VECTOR at low speeds 100%
p1821 Inversion of the direction of the rotating field: Changes the direction of the 0
0: no inversion of direction motor with retention of the
1: inversion of direction sign of the set-point.

p505 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.

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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 (FP2701).
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 = 300s.
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 0, 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 r0899.5. In the case of a fast stop
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the active torque limits are configurable with the parameter p1520 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 0 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 FBLConWinder with
the drive control word bit 8 “travel to fix stop”. Activation and deactivation is
dependent on the active winder control mode:

Table 9-18
Control mode „motor blocked“ hidden
INDIRECT_TENSION_CONTROL Yes
TENSION_CONTROL_TORQUE_LIMITING Yes
DANCER_CONTROL_TORQUE_LIMITING Yes
DANCER_CONTROL_SPEED_SETPOINT_ADAPTION No
TENSION_CONTROL_SPEED_SETPOINT_ADAPTION No
V_CONSTANT_CONTROL No

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Setting the maximum speed

Using a torque controlled winder control mode it is recommended to limit the
maximum motor speed with parameter p1082. 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 0.

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 p1400.14 need to be set to 1.
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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.

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 10 Application structure

Program and function description

Section “Program and function description” describes more detailed the functions
of the winder block. Here you will find parameter lists, diagrams and function
descriptions of the core winder function

10 Application structure
10.1 Pre-processor commands

Using the pre-processor commands which are defined in the library unit “dType”,
specific functionalities can be compiled to the effective source code.
Example:
With the following line in dType the functionality “Web break detection” gets
compiled into the source code. All configuration and diagnostic data sub-structures
for “web break detection” are available after that in the sWinderConfig /
sWinderDiag structure and the functionality can be used.
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#define LCONLIB_OPTION_FBWINDER_WEBBREAK

If the functionality “web break detection” is not required, the pre-processor

command can be commented out easily. The configuration and diagnostic
structures are getting lean thereby.

In the following table all LConLib pre-processor commands are listed:

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Table 10-1 Pre-processor command of LConLib

Pre-processor command Description
LCONLIB_OPTION_FBDIAMETERCALCUL Ramp function generator integrated in
ATION_DIAMETER_RFG diameter calculator
(INTERPOLATION_1,
INTERPOLATION_2)
LCONLIB_OPTION_FBDIAMETERCALCUL Diameter calculation mode
ATION_INTEGRAL DIAM_CALC_INTEGRAL
LCONLIB_OPTION_FBDIAMETERCALCUL Diameter calculation mode
ATION_POSITION DIAM_CALC_POSITION
LCONLIB_OPTION_FBDIAMETERCALCUL Diameter calculation mode
ATION_THICKNESS DIAM_THICKNESS_ADDITION
LCONLIB_OPTION_FBDIAMETERCALCUL Diameter calculation mode DIAM_EXT
ATION_EXT_DIAMETER
LCONLIB_OPTION_FBDIAMETERCALCUL Interpolation mode INTERPOLATION_2
ATION_INTERPOLATION_2
LCONLIB_OPTION_FBDIAMETERCALCUL Interpolation mode INTERPOLATION_3
ATION_INTERPOLATION_3
LCONLIB_OPTION_FBTORQUEPRECONT Friction torque pre-control
ROL_FRICTION_CHAR
LCONLIB_OPTION_FBTORQUEPRECONT Durchmesseränderungs-Vorsteuerung
ROL_DDDT_PRECONTROL
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LCONLIB_OPTION_FBTAPERCHARACTE Wickelhärtenkennlinie
RISTIC_BREAKPOINT_TABLE
LCONLIB_OPTION_FBWINDER_WEBBRE Bahnrisserkennung
AK
LCONLIB_FAST_TASKS_EXISTING Funktionsbausteine und Funktionen
verwendbar in Servo_fast und IPO_fast

10.2 Data types and Constants

Data structures, enumeration types and constants of the library LConLib are
defined in the library unit dType.

10.2.1 Constants

Table 10-2 LConLib constants

Name of constant Description
LCONLIB_PI Kreiszahl Pi
LCONLIB_MAX_LENGTH_AVERAGE_VALUE Längendefinition für Average Value
Array (Durchmesserberechnung)
LCONLIB_MAX_IDX_A FBPolygon Konstante: maximaler Index
LCONLIB_MAX_IDX_B FBPolygon Konstante: maximaler Index
LCONLIB_START_IDX_A FBPolygon Konstante: start-Index
LCONLIB_START_IDX_B FBPolygon Konstante: start-Index

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NOTE Error- and Warning ID’s are defined as constants as well. A detailed description
can be found in chapter 11.9

10.2.2 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 10-3 LConLib enumerations types

Name of the enumeration type Contents
eLConTaskNameType Selects the task in which the block is called.
eLConUnitLineAxisVelocityType Selects the velocity unit of the path axis
eLConUnitLineAxisAccelerationType Selects the acceleration unit of the path axis
eLConUnitWinderAxisVelocityType Selects the velocity unit of the winder axis
eLConWindingModeType Selects the winding direction
eLConDiamModeType Selects the diameter calculation
Selects the interpolation mode of the diameter
eLConInterpolationModeType
calculation
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Selects the integration direction of the diameter

eLConIntegrationDirectionType
calculator.
Selects the technique to adapt the controller gain of the
eLConGainAdaptionModeType
speed controller
eLConPolygonModeType Enables the individual weighting
eLConTaperCharModeType Selects the tension taper characteristic
eLConControlModeType Selects the type of the winder control
eLConWinderFBModeType Selects the operation mode of the winder FB
Material selection to calculate the weight and the
eLConMaterialTypeType
moment of inertia
eLConUnitSystemType Defines the system of units of the material selection
eLConIntegralModeType Integration mode selection of FBPIDController
Source selection of line velocity (used for diameter
eLConLineSpeedSourceType
calculation)
eLConTOType Definition of possible TO types

eTaskNameType
The call level of the blocks is specified using this enumeration type.
Table 10-4
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
SERVO_SYNCHRONOUS_FAST_TASK Servo Synchronous Task _fast
IPO_SYNCHRONOUS_FAST_TASK Ipo Synchronous Task _fast

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NOTICE Using SIMOTION Version 4.1 or below the pre-processor command

#define LCONLIB_FAST_TASKS_EXISTING
in the INTERFACE Part of the library unit fConvTools has to be commented
out!

eLConUnitLineAxisVelocityType
Using this parameter, the units of the velocity of the line axis (lineAxis) are
specified corresponding to the axis configuration.

Table 10-5
Element Description
NOT_DEFINED not defined
M_MIN m/min
MM_MIN mm/min
M_S m/s
MM_S mm/s
FT_MIN ft/min
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INCH_MIN inch/min
FT_S ft/s
INCH_S inch/s
DEG_S_PRINT 360°/s = 1 m/s

eLConUnitLineAxisAccelerationType
This parameter defines the units of the line axis acceleration (lineAxis)
corresponding to the axis configuration.

Table 10-6
Element Description
NOT_DEFINED not defined
M_S2 m/s²
MM_S2 mm/s²
FT_S2 ft/s²
INCH_S2 inch/s²
DEG_S2_PRINT 360°/s² = 1m/s²

eLConUnitWinderAxisVelocityType
This enumeration type is used to define the velocity units of the winder axis
(winderAxis) according to the axis configuration.

Table 10-7
Element Description
NOT_DEFINED not defined

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Element Description
RPM U/min
RPS U/s
DEG_MIN °/min
DEG_S °/s

eLConWindingModeType
The winder type is parameterized using this enumeration type. This parameter
essentially influences the sign of the individual components of the setpoint
calculation.

Table 10-8
Element Description
UNWIND_FROM_ABOVE Unwind from above
UNWIND_FROM_BELOW Unwind from below
REWIND_FROM_ABOVE Rewind from above
REWIND_FROM_BELOW Rewind from below
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eLConDiamModeType
The diameter calculation type of the function block FBDiameterCalculator is
defined using the parameters of this enumeration type.

Table 10-9
Element Description
DIAM_CALC Diameter calculation using V/n
DIAM_CALC_INTEGRAL Diameter calculation with integral distance measurement
DIAM_CALC_POSITION Diameter calculation with position-based distance measurement
DIAM_THICKNESS_ADDITION Diameter calculation by integrating the material thickness
DIAM_EXT External diameter

eLConInterpolationModeType
Parameters of this enumeration type are used to define the diameter interpolation
type of the FBDiameterCalculator function block.

Table 10-10
Element Description
Functions for all diameter calculation types.
INTERPOLATION_1 The diameter change is calculated using the material thickness and the line
velocity and is plausibly limited using a ramp-function generator.
Only for the diameter calculation types DIAM_CALC_POSITION and
DIAM_CALC_INTEGRAL.
INTERPOLATION_2
Interpolates the diameter value using a ramp-function generator based on the
(measured) diameter calculation cycles (without material thickness).
INTERPOLATION_3 Only for diameter calculation types DIAM_CALC_POSITION and

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Element Description
DIAM_CALC_INTEGRAL.
Interpolates the diameter value without ramp-function generator based on the
wound roll integrator (material thickness only used for plausibility limiting).
The calculated resp. measured diameter will not be interpolated.

This interpolation mode can be useful for diameter calculation mode Diam_Ext or
NO_INTERPOLATION Diam_Thickness_Addition.

NOTE: The diamActVal output value smoothing is generally active, but can be
deactivated with setting sDiamConfig.r32SmoothingTimeLayerJump = 0.0.
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eLConIntegrationDirectionType
The parameters of this type are used to set whether the diameter can only increase
(winding) or only decrease (unwinding) – or whether both should be possible. The
parameters are used in the function block FBDiameterCalculator.

Table 10-11
Element Description
DONTCARE RFG-produced ramp can go in both directions
INCREASING only increasing ramp (“away from 0.0”)
DECREASING only decreasing ramp (“towards 0.0”)

eLConGainAdaptionModeType
The technique for Kp adaptation of the speed controller is defined using this
enumeration type.

Table 10-12
Element Description
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NO_ADAPTION No Kp adaption
DIAMETER_RATIO Adaptation using the ratio – diameter / maximum diameter
INERTIA_RATION Adaptation using the ratio – moment of inertia / maximum moment of inertia

eLConPolygonModeType
The parameter of this enumeration type is used to set whether every ordinate value
is individually weighted in the function block FBPolygonA / FBPolygonB.

Table 10-13
Element Description
NO_POLYGON no Polygon calculation Out = IN
ORDINATE_FACTORS_USED each ordinate value can be weighted
ORDINATE_FACTORS_
no weighting of single ordinate values
NEGLECTED

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eLConTaperCharModeType
This enumeration type is used to activate and also to select the tension taper
characteristic.

Table 10-14
Element Description
TAP_CHAR_NO_TAPER No Tension Taper Characteristic
TAP_CHAR_LINEAR Linear Tension Taper Characteristic
TAP_CHAR_HYPERBOLIC_1 Hyperbolic Tension Taper Characteristic (at diamMax reaching full reduction)
TAP_CHAR_HYPERBOLIC_2 Hyperbolic Tension Taper Characteristic (at infinity reaching zero tension)
TAP_CHAR_TABLE Tension Taper characteristic definition by table

NOTE A detailed description of the function "tension taper characteristic" can be found
in the Converting Library documentation.

eLConControlModeType
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The type of the winder control is defined via this enumeration type.

Table 10-15
Element Description
INDIRECT_TENSION_
Indirect tension control
CONTROL
DANCER_CONTROL_SPEED_
Tension control with dancer roll via speed adaptation
SETPOINT_ADAPTION
DANCER_CONTROL_TORQUE_
Tension control with dancer roll via torque limiting
LIMITING
TENSION_CONTROL_SPEED_
Tension control with load cell via speed adaptation
SETPOINT_ADAPTION
TENSION_CONTROL_
Tension control with load cell via torque limiting.
TORQUE_LIMITING
CONSTANT_V_CONTROL Winder controlled to run with constant web speed (command value)

eLConWinderFBModeType
The control behavior of the winder FB is determined via this enumeration type.

Table 10-16
Element Description
NO_AXIS_CONTROL Winder FB is only calculating speed setpoints and torque
AXIS_CONTROL Winder FB is writing results to the axis

Manual SIMOTION Winder

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 10 Application structure

eLConUnitSystemTypeType
The system of units of the automatic material thickness determination is defined in
FBTorquePrecontrol using this enumeration type.

Table 10-17
Element Description
3
METRIC Material density is defined as kg/m .
3
ANGLO_AMERICAN Material density is defined as lb/ft .

eLConMaterialTypeType
The material type and therefore also the material density are defined using this
enumeration type.

Table 10-18
Element Description
USER_DEFINED The material density is defined using parameter r32Density.
ACRYLONITRILE_BUTADIENE_ Pre-assignment of the material density: 1057.2 kg/m3 (66lb/ft3) (acrylonitrile-
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STYRENE butadiene-styrene)
ACRYLIC Pre-assignment of the material density: 1185.4 kg/m3 (74lb/ft3) (acryl)
ALUMINIUM Pre-assignment of the material density: 2723.1 kg/m3 (170lb/ft3) (aluminum)
CELLULOSE_ACETATE Pre-assignment of the material density: 1297.5 kg/m3 (81lb/ft3) (cellulose acetate)
CELLULOSE_ACETATE_ Pre-assignment of the material density: 1185.4 kg/m3 (74lb/ft3) (cellulose acetate
BUTYRATE butyrate)
COPPER Pre-assignment of the material density: 8954.3 kg/m3 (559lb/ft3) (copper)
CPVC Pre-assignment of the material density: 1553.8 kg/m3 (97lb/ft3) (CPVC)
FLUORPLASTICS Pre-assignment of the material density: 2194.5 kg/m3 (137lb/ft3)
NYLON Pre-assignment of the material density: 1145.3 kg/m3 (71,5lb/ft3) (nylon)
PAPER Pre-assignment of the material density: 929.1 kg/m 3 (58lb/ft3) (paper)
PHENOLIC Pre-assignment of the material density: 1681.9 kg/m3 (105lb/ft3) (phenolic resin)
POLYCARBONATE Pre-assignment of the material density: 1185.4 kg/m3 (74lb/ft3) (polycarbonate
(PC))
POLYESTER Pre-assignment of the material density: 1393.6 kg/m3 (87lb/ft3) (polyester)
POLYETHYLENE Pre-assignment of the material density: 961.1 kg/m 3 (60lb/ft3) (polyethylene (PE))
POLYIMIDE Pre-assignment of the material density: 1441.7 kg/m3 (90lb/ft3) (polyimide)
POLYPROPYLENE Pre-assignment of the material density: 913.1 kg/m3 (57lb/ft3) (polypropylene
(PP))
POLYSTYRENE Pre-assignment of the material density: 1057.2 kg/m3 (66lb/ft3) (polystyrene (PS))
POLYURETHANE Pre-assignment of the material density: 1057.2 kg/m3 (66lb/ft3) (polyurethane)
PTFE Pre-assignment of the material density: 2194.5 kg/m3 (137lb/ft3)
(Polytetrafluoroethylene (PTFE))
PVC Pre-assignment of the material density: 1473.7 kg/m3 (92lb/ft3) (polyvinylchloride
(PVC))
STEEL Pre-assignment of the material density: 7849.0 kg/m3 (490lb/ft3) (steel)
VINYL Pre-assignment of the material density: 1473.7 kg/m3 (92lb/ft3) (vinyl)

Manual SIMOTION Winder

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 10 Application structure

eLConIntegralModeType
Integration modes of FBPIDController.

Table 10-19
Element Description
Integral part will be increased/decreased up to controller output
ANTI_WIND_UP_REDUCE_I_TO_ZERO limitation. Integral part in opposite direction (above/below 0.0) is not
possible.
Integral part will be freeze if control output limitation (upperLimit,
ANTI_WIND_UP_FREEZE_I
lowerLimit) is reached.
Integral part will be increased/decreased independent of controller
WIND_UP
output limitation.

eLConLineSpeedSourceType
With this type the line speed which is taken for diameter calculation can be
selected.

Table 10-20
Element Description
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USE_SPEED_SET_VALUE Line speed command value will be used for diameter calculation.
USE_SPEED_ACT_VALUE Line speed actual value will be used for diameter calculation.

eLConTOType
This type defines the possible TO types.

Table 10-21
Element Description
INVALIDTYPE invalid TO type
DRIVEAXISTYPE drive axis
POSAXISTYPE positioning axis
EXTERNALENCODER external encoder

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 10 Application structure

10.2.3 Data structures

Table 10-22 Overview over the data structures

Name of the structure Contents
This structure contains the complete configuration data
of the axis winder as well as the results of each winder
sLConWinderConfigType
block. The configuration data of the single blocks are
deposited as well in this structure.
This structure contains actual and diagnostic data of the
sLConWinderDiagType
winder function block and its internal function blocks.

sLConDiamConfigType Configuration data of the diameter calculator

sLConMomentConfigType Configuration data of the torque pre-control
sLConTensionTaperConfigType Configuration data of the tension taper function
Unit conversion between external (user) and internal
sLConConversionConstantsType
measuring system.
sLConTechnologyControllerConfigType Configuration data of the technology controller
sLConWebBreakDetectionType Configuration data of the web breakage detection.
sLConPidDataType Configuration data of the PID-controller
sLConDynamicsType General definition of axis dynamics
sLConWinderDynamicsType Definition of different winder dynamics
sLConDynamicsInternalType Internal dynamic structure
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sLConUnitConfigType Unit definition of web and winder axis

sLConLineAxisMotionVectorType Web axis motion vector
Configuration for winding with coils different from round
sLConWinderSystemType
(separate documentation)

sLConTechnologyControllerDiagType Actual values of Technology controller

sLConTorquePreControlDiagType Actual values of torque pre-control
sLConDiamDiagType Actual values of diameter calculator
sLConWebBreakDetectionDiagType Actual values of web break detection
sLConCoreCompensationDiagnosticTyp
Actual values of winding with coils different from round
e

Summary of the input parameter of the winder function

sLConWinderInputType
block
Summary of the output parameter of the winder function
sLConWinderOutputType
block

Identification of the structure elements:

[IN]: Values that have to be provided by the user
[OUT]: Results or acknowledgements
[IO]: Values that have to be provided by the user or described by the
function, depending on the connection of the block.

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 10 Application structure

sLConWinderConfigType
This structure provides configuration elements that are generally required for the
axial winder or several of its function blocks. Before enabling the function blocks,
the technological values of the specific application must be loaded.

Table 10-23
I/O Element Data type Description
Winder axis (speed axis or positioning axis)
For winding operation using a torque limit,
IN toWinderAxis ANYOBJECT technology data block at the axis must be
configured and activated.
The winder axis has to be a real axis.
Technology object for presetting the product line
velocity (positioning axis, speed axis or external
encoder). If no object is specified, the values can
also be set from extern.
(sWinderConfig.lineSpeed,
IN toLineAxis ANYOBJECT sWinderConfig.lineAcceleration,
sWinderConfig.lineFeedback).
If an axis is specified, it has to be a real or a
virtual axis.
As axis type, only a linear axis is allowed (expect
printing applications.
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Selects the mode for the axis control.

IN eMovingMode This is only relevant if the winder axis is a
enumMovingMode
positioning axis so that the axis can either be
operated in speed- or position control.
Operational mode of the FBs
AXIS_CONTROL : The FB takes up the axis
control, activates so the necessary interface and
eLConWinder writes to it the calculated values .
IN eFBMode
FBModeType NO_AXIS_CONTROL: The FB takes up no axis
control functionality, only the values necessary
for the winder control are calculated. The values
have to be further processed extern.
Winder mode (defined for positive line speed):
UNWIND_FROM_ABOVE: Unwinder from the
top
UNWIND_FROM_BELOW: Unwinder from
bottom
eLConWindingMo
IN eTypeOfWinder de REWIND_FROM_ABOVE: Unwinder from the
top
Type
REWIND_FROM_BELOW: Unwinder from
bottom
The input can only be changed if enable =
FALSE or during standstill while ctrlEnable =
FALSE and ctrlBusy = FALSE.
Task in which the FB is called:
SERVO_SYNCHRONOUS_TASK:
Servo Synchronous Task
IPO_SYNCHRONOUS_TASK:
eLConTaskName
IN eTaskmode Ipo Synchronous Task
Type
IPO_SYNCHRONOUS_TASK_2:
Ipo Synchronous Task 2
TIMER_INTERRUPT_TASK:
in a Timer Interrupt Task
eLConGainAdapti Mode for the Kp adaptation of the speed
IN eGainAdaptionMode
on controller

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 10 Application structure

I/O Element Data type Description

ModeType NO_ADAPTION: No adaptation
DIAMETER_RATIO: Adaptation in the ratio –
diameter / maximum diameter
INERTIA_RATIO: Adaptation in the ratio –
moment of inertia / maximum moment of inertia
sLConUnitConfigT
IN sUnitConfig Unit configuration structure
ype
sLConWinderDyna
IN sWinderDynamics Winder dynamics configuration structure
micsType
sLConDiamConfig
IN sDiamConfig Un-/Winder Diameter Calculator configuration
Type
sLConTechnology
IN sTechnologyControllerConfig Controller Configuration data of the technology controller
ConfigType
sLConMoment Configuration data of the torque pre-control or
IN sMomentConfig
ConfigType the calculation of the torque limits.

sLConWinderSyst Configuration data for prismatic winding (see

IN sWinderSystem
emType separate documentation)
sLConTension
IN sTensionTaperConfig Un-/Winder Tension Taper configuration
TaperConfigType
sLConWebBreak
IN sWebBreakDetectionConfig Web break detection configuration
DetectionType
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sLConTorqueLimit
IN sTorqueLimitation Torque limitation configuration
ationType
[ LU ] diameter of the master axis, serves for
conversion of [ r / TU] in [ LU / TU ].
IN r32lineAxisDiameter REAL It is only necessary if the input parameter
lineAxis is given an axis reference of the type
rotation speed.
With direct tension control r32StandStillTension
is used as tension setpoint for the technology
controller at standstill (TO.motionState =
STANDSTILL).
IN boEnableStandstillTension BOOL Also the setpoint for tension torque precontrol is
switched to r32StandStillTension during
standstill.
Not used in CONSTANT_C_CONTROL.
IN r32StandstillTension REAL [ Z ] Standstill (zero speed) tension setpoint
[ LU / TU ] speed override for speed controller
(only used in torque controlled control modes).
The value set up here will be ramped internal
using the local variables r32OverrideInternal and
r32OverrideInternalRamped with FBRFG (ramp
IN r32Override REAL function generator).
The parameterization of the FBRFG instance
can only be adapted in the library.
Default settings:
nominal value = 10
ramp up/down time = 370 ms
IN r32DancerIdlePosition REAL Dancer position when machine is switched off

Manual SIMOTION Winder

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 10 Application structure

sLConDiamConfigType
This structure provides the configuration elements that are required, among other
things, for the diameter calculator FBDiameterCalculator. Before enabling the
function blocks, the technological values of the specific application should be
loaded.

Table 10-24
I/O Element Data type Description
USE_SPEED_SET_VALUE:
The speed setpoint value will be used for
diameter calculation.

USE_SPEED_ACT_VALUE:
The speed actual value will be used for
diameter calculation.
eLConLineSpeed toLineAxis <> TO#Nil: Interconnection is done
IN eLineSpeedSource
SourceType function block internal.
toLineAxis = TO#Nil: The actual speed need to
be interconnected via FBLConWinder input
“lineSpeedActValue”

With toLineAxis = EXTERNAL_ENCODER this

parameter is not being evaluated because
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there is only the speed actual value existent.

[ LU / s ] velocity threshold line velocity for
activation of diameter calculator.
IN r32MinLineSpeed REAL
If abs(lineSpeed) < abs(r32MinLineSpeed) the
diameter is maintained
[ rps ] velocity threshold winder speed for
activation of diameter calculator
IN r32MinWinderSpeed REAL If abs(windingShaftSpeed) <
abs(r32MinWindingShaftSpeed), the diameter
is maintained (always [ rev / s ] also for
winderAxis = TO#posAxis).
IN r32DiamMax REAL [LU] diameter max value
IN r32DiamMin REAL [LU] diameter min value
[ LU ] Thickness of the web, used for the
diameter increase limitation (not if
IN r32WebThickness REAL INTERPOLATION_2 is selected) and used in
calculation mode
DIAM_THICKNESS_ADDITION
[ - ] Factor to adjust diameter
increase/decrease limiting.
IN r32AdjustWebThickness REAL
A higher value corresponds to a smaller
smoothing.
[ms] Layer jump smoothing
IN r32SmoothingTimeLayerJump REAL The layer jumps are smoothed with this
smoothing factor dependent on diamActVal.
Integration direction of the ramp-function
generator
eSelectDiamIntegration eLConIntegration DONTCARE: can integrate in both directions
IN
Direction DirectionType INCREASING: only increasing (away from 0.0)
DECREASING: only decreasing (in direction of
0.0)
Interpolation mode of the diameter calculation:
eLConInterpolatio
n INTERPOLATION_1:
IN eInterpolationMode
ModeType Functions for all diameter calculation types.
The diameter change is calculated from the

Manual SIMOTION Winder

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 10 Application structure

I/O Element Data type Description

material thickness and the path velocity and is
plausibly limited by a ramp-function generator.
INTERPOLATION_2:
Only for diameter calculation types
DIAM_CALC_POSITION and
DIAM_CALC_INTEGRAL.
The diameter value is interpolated using a
ramp-function generator based on the
(measured) diameter calculation cycles
(without material thickness).
INTERPOLATION_3:
Only for the diameter calculation types
DIAM_CALC_POSITION and
DIAM_CALC_INTEGRAL.
The diameter value is interpolated without
ramp-function generator based on the wound
roll integrator.
TRUE: Dancer movements will be
compensated for diameter calculation.
IN boEnableDancerCompensation BOOL Only in DIAM_CALC,
DIAM_CALC_INTEGRAL and
DIAM_CALC_POSITION
[ LU ] Length of material which changes if
IN r32RefWebLengthDancer REAL dancer moves by 100 units in respect to the
defined dancer unit (%, mm, etc.)
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[ ms ] Symmetry filter for line velocity.

IN r32LineBalancingTime REAL Only used with selectDiamMode =
DIAM_CALC and DIAM_CALC_INTEGRAL
[ ms ] Symmetry filter for winder speed.
IN r32WindingShaftBalancingTime REAL Only used with selectDiamMode =
DIAM_CALC and DIAM_CALC_INTEGRAL
[ - ] Number of winder revolutions, which define
a measuring and calculation interval of the
diameter calculator.
IN r32MeasuringRevolutionCount REAL
Only used with selectDiamMode =
DIAM_CALC_INTEGRAL /
DIAM_CALC_POSITION
[ - ] Every <r32DiameterOutputRate>
revolutions a new diameter value will be output
(after the first diameter output).
IN r32DiameterOutputRate REAL
Only used with selectDiamMode =
DIAM_CALC_INTEGRAL /
DIAM_CALC_POSITION
[ - ] Number of revolutions after first diameter
value is output.
IN r32FirstDiameterOutput REAL Only used with selectDiamMode =
DIAM_CALC_INTEGRAL /
DIAM_CALC_POSITION
[ Inc ] Modulo length of the leading axis
(referred to the input lineFeedback).
Only used for selectDiamMode =
DIAM_CALC_POSITION
When using FBLConWinder:
IN r64LineModLength LREAL If lineAxis = TO#posAxis, then the variable is
overwritten with the value
lineAxis.activeConfigData.modulo.length when
FBLConWinder is started.
If the configured axis is not a modulo axis, then
the value is set to 0.0.
[ Inc ] Modulo length of the winder axis
IN r64ShaftModLength LREAL
(referred to the input windingShaftFeedback).

Manual SIMOTION Winder

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 10 Application structure

I/O Element Data type Description

Only used for selectDiamMode =
DIAM_CALC_POSITION
When using WinderFB:
If winderAxis = TO#posAxis, then when
FBLConWinder is started, the variable is
overwritten by the value
winderAxis.activeConfigData.modulo.length.
when FBLConWinder is started
If the configured axis is not a modulo axis, then
the value is set to 0.0.
[rad/Inc] Scaling of 1 revolution in increments
x inc -> 1 rad
IN r64WindingShaftFeedbackScal LREAL
Only used with selectDiamMode =
DIAM_CALC_POSITION
[LU/Inc] Scaling of 1m web in increments
x inc -> 1 m
IN r64LineFeedbackScal LREAL
Only used with selectDiamMode =
DIAM_CALC_POSITION
[ - ] Number of grid points to calculate the
polygon [2 – LCONLIB_MAX_IDX_A+1]
Only used with selectDiamMode =
IN u16DiamExtCurveEntryNum UINT
DIAM_CALC_EXT
diamExtVal is used direct as diameter, if
r32DiamExtCurveEntryNum < 2.
[ - ] Abscissa values for the diameter
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ARRAY
characteristic to linearize the external diameter
[0.. signal (maximum LCONLIB_MAX_IDX_A+1 x-
IN ar32DiamExtCurveAbscissa LCONLIB_MAX_I y-points).
DX_A]
Only used with selectDiamMode =
OF REAL DIAM_CALC_EXT

ARRAY [ LU ] Ordinate values for the diameter

characteristic to linearize the external diameter
[0.. signal (maximum LCONLIB_MAX_IDX_A+1 x-
IN ar32DiamExtCurveOrdinate LCONLIB_MAX_I y points).
DX_A]
Only used with selectDiamMode =
OF REAL DIAM_CALC_EXT

sLConMomentConfigType
This structure provides configuration elements that are required, among other
things for the FBTorquePrecontrol – specifically to calculate the moment of inertia
and torques. Before enabling the function blocks, the technological values of the
specific application should be loaded.

Table 10-25
I/O Element Data type Description
Selection of winder speed value which is used
for torque pre control.
eLConFrictionTorq SETPOINT_SPEED_BASED:
IN eFrictionTorquePreCtrlMode uePreCtrlModeTyp winder setpoint speed minus
e sWinderDiag.r32ActSpeedOverride
ACTUAL_SPEED_BASED:
winder actual speed
[ - ] Gearbox ratio
Ration between the winder motor and winder
IO r32GearRatio REAL shaft
If WinderFB is used:

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 10 Application structure

I/O Element Data type Description

Is overwritten intern at the start of the FB by the
configured gear ratio from the TO winderAxis.
[ m / Lub3 ] Density of the material being wound.
eMaterialType = USER_DEFINED:
Input parameter to define the material density
IO r32Density REAL
eMaterialType <> USER_DEFINED:
Output parameter of the density of the selected
material.
IN r32Width REAL [ Lub ] width of web
[%] Fill factor for the effective material width (e.g.
IN r32Fillfactor REAL
for traversed material)
[ mLUb² ] Fixed moment of inertia on the motor
IN r32Jfix REAL side without the moment of inertia of the mandrel
itself.
[ mLUb² ] Moment of inertia of the mandrel
IN r32Jmandrel REAL This value is being added to the internal total
inertia compensated by r32GearRatio
[ mLUb² ] Moment of inertia on the winder motor
IN r32Jmot REAL
side
[ Lub ] Minimal diameter
If FBLConWinder is used:
IN r32DiamMin REAL Value is overwritten internal by
sDiamConfig.r32DiamMin
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The unit [LU] of sDiamConfig.r32DiamMin is

converted automatically to [LUb].
[ Lub ] Maximum diameter (calculation of max.
moment of inertia)
If FBLConWinder is used:
IN r32DiamMax REAL Value is overwritten internal by
sDiamConfig.r32DiamMax
The unit [LU] of sDiamConfig.r32DiamMax is
converted automatically to [LUb].
Determines the material type to calculate the
mass (weight) and moment of inertia.
eMaterialType = USER_DEFINED
eLConMaterialTyp The material density is defined using parameter
e r32Density.
IN eMaterialType
Type eMaterialType <> USER_DEFINED
The material density is defined using the
material selection parameter. The system of
units must be defined using the eUnitSystem
parameter.
Defines the system of units for the material
density.
eLConUnitSystem This is only relevant if the material density is
IO eUnitSystem
Type defined using the eMaterialType parameter.
When using FBLConWinder, the system defines
the value based on eUnitLineAxisVelocity..
IN r32TensionAdjust REAL [ - ] Weighting factor for tension torque
IN r32AccelAdjust REAL [ - ] Weighting factor for acceleration torque
[ - ] Weighting factor of the pre-control of the
IN r32DddtAdjust REAL diameter change, if r32DddtAdjust = 0.0, then
the compensation is not calculated.
[ - ] Adaptation factor of the friction torque.
0.0: The friction characteristic is not being
IN r32FrictionAdjustment REAL
calculated.
1.0: 100% friction torque pre control
IN u16FrictionCurveEntryNum UINT [ - ] Number of grid points:

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 10 Application structure

I/O Element Data type Description

[2 ≤ u16FrictionCurveEntryNum ≤
LCONLIB_MAX_IDX_A+1]
ARRAY [ rpTU ; °/TU ] Abscissa values for the friction
[0.. characteristic (speed; velocity)
IN ar32FrictionCurveAbscissa LCONLIB_MAX_I [maximum’ LCONLIB_MAX_IDX_A+1’ x-y
DX_A] points], corresponds to the configured units of
OF REAL the winder axis ([ rev / TU ] or [ ° / TU ])
ARRAY
[ M ] Ordinate values for the friction
[0..
characteristic (torque)
IN ar32FrictionCurveOrdinate LCONLIB_MAX_I
[maximum ‘ LCONLIB_MAX_IDX_A+1’ x-y
DX_A]
points]
OF REAL

sLConTensionTaperConfigType
This structure provides configuration elements that are required for tension taper
functionality. Before enabling the function blocks, the technological values of the
specific application should be loaded.

Table 10-26
I/O Element Data type Description
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Tension taper characteristic mode:

TAP_CHAR_NO_TAPER: No characteristic
TAP_CHAR_LINEAR: Linear characteristic
eLConTaperChar TAP_CHAR_HYPERBOLIC_1: Hyperbolic
IN eTensionTaperMode char.1
ModeType
TAP_CHAR_HYPERBOLIC_2: Hyperbolic
char.2
TAP_CHAR_TABLE : Characteristic defined by
a table
IN r32UpperLimitTaper REAL [ % ] Upper limit for tension reduction
IN r32LowerLimitTaper REAL [ % ] Lower limit for tension reduction
[ % ] Max. Tension Reduction
IN r32TensionTaperRatio REAL Not for tensionTaperMode =
TAP_CHAR_TABLE.
[ % ] Start diameter for the characteristic
calculation based on the max. diameter
IN r32TensionTaperDiameterStart REAL sWinderConfig.sDiamConfig.diamMax
Not for tensionTaperMode =
TAP_CHAR_TABLE.
[ % ] Maximum diameter with full reduction
based on the max. diameter sWinderConfig.-
IN r32TensionTaperDiameterMax REAL sDiamConfig.diamMax
Not for tensionTaperMode =
TAP_CHAR_TABLE.
[ - ] Number of grid points to calculate the
polygon [2 – LCONLIB_MAX_IDX+1]
IN u16TensionTaperEntryNum UINT
Only for tensionTaperMode =
TAP_CHAR_TABLE
[ % ] Abscissa values for the diameter
ARRAY (maximum ‘ LCONLIB_MAX_IDX_A+1’ x-y
[0.. points) based on the max. diameter
IN ar32TensionTaperCurveAbscissa
LCONLIB_MAX_I sWinderConfig.sDiamConfig.diamMax
DX_A] OF REAL Only for tensionTaperMode =
TAP_CHAR_TABLE

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 10 Application structure

I/O Element Data type Description

[ % ] Ordinate values for the percentage
ARRAY component
[0.. (maximum ‘ LCONLIB_MAX_IDX_A+1’ x-y
IN ar32TensionTaperCurveOrdinate
LCONLIB_MAX_I points)
DX_A] OF REAL Only for tensionTaperMode =
TAP_CHAR_TABLE

NOTE A detailed description of the function "tension taper characteristic" can be found
in the Converting library documentation.

sLConConversionConstantsType

Table 10-27
I/O Element Data type Description
[ - ] conversion, velocity lineAxis
IO r32LineAxisIntoLUPerSecond REAL
[ LU/TU ]  [ LU/s ]; e.g.: m/min  m/s
[ - ] conversion, length unit lineAxis
IO r32LineAxisIntoLUb REAL
[LU Lub]; e.g.: mm  m
 Siemens AG 2018 All rights reserved

[ - ] conversion, rotary lineAxis into linear

lineAxis with the relationship: 360°/s = 1m/s and
IO r32LineAxisIntoLinear REAL 360°/s² = 1m/s². Only for metric system!
[ °/s ]  [ m/s ], [ °/s² ]  [ m/s² ]
r32LineAxisIntoLUbPer [ - ] conversion, acceleration lineAxis
IO REAL
SquareSecond [ LU/s² ]  [ Lub/s² ]; e.g.: mm/s²  m/s²
[ - ] conversion, speed winderAxis
IO r32WinderAxisIntoPerSecond REAL
[ U/TU ]  [ U /s]; e.g.: U/min  U/s
[ - ] conversion, winderAxis angle into revolutions
IO r32WinderAxisIntoRpTU REAL
[ ° / TU ]  [ U/TU ]; e.g.: °/s  U/s

Manual SIMOTION Winder

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 10 Application structure

sLConTechnologyControllerConfigType

Table 10-28
I/O Element Data type Description
[ - ] x coordinate for Kp adaptation for Kp1
IN r32X1 REAL If r32X1 = r32X2, then the Kp adaptation is
deactivated.
[ - ] Kp value for r32X1.
IN r32Kp1 REAL If the Kp adaptation is deactivated, then this
parameter is used as Kp value.
[ - ] x coordinate for Kp2
IN r32X2 REAL If r32X1 = r32X2, then the Kp adaptation is
deactivated.
[ - ] second Kp value, assigned corresponding to
IN r32Kp2 REAL
r32X2.
[ ms ] ramp-up time of the controller output
limiting.
IN r32LimRampUpTime REAL
This is internally limited to the cycle time as
lower value.
[ ms ] ramp-down time of the controller output
limiting.
IN r32LimRampDownTime REAL
This is internally limited to the cycle time as
lower limit.
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[ Z ] / [ % ] setpoint RFG, reference value for

IN r32SetNominalValue REAL
ramp-up/ramp-down time.
[ ms ] setpoint RFG ramp-up time
IN r32SetRampUpTime REAL This is internally limited to the cycle time as
lower limit.
[ ms ] setpoint RFG ramp-down time
IN r32SetRampDownTime REAL This is internally limited to the cycle time as
lower limit.
[ ms ] time constant for I component
IN r32IntegTime REAL This is internally limited to the cycle time / 2 as
lower limit.
[ ms ] time constant for D component
IN r32DerivTime REAL This is internally limited to the cycle time as
lower limit.
[ ms ] time constant for actual value smoothing
IN r32FilterTime REAL This is internally limited to the cycle time as
lower limit. If r32FilterTime = 0.0, then smoothing
is deactivated.
IN r32IntSetValue REAL [ LU/TU ] / [Z] integrator setting value
PID controller configuration data, refer to the
IN sPidData sPidDataType
type description
IN r32UpperLimit REAL [ LU/TU ] / [Z] controller output, upper limit value
[ LU/TU ] / [Z] controller output, lower limit value.
IN r32LowerLimit REAL
Must be less than r32UpperLimit.

Manual SIMOTION Winder

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 10 Application structure

sLConWebBreakDetectionType
This structure contains configuration parameter for the function web break
detection. This function is optional for each winder operating mode.

Table 10-29
I/O Element Data type Description
FALSE: disable web break detection
IN boEnable BOOL
TRUE: enable web break detection
[ LU / TU ] activation threshold of web break
IN r32MinSpeed REAL detection, only active if
boEnable = TRUE
[ms] delay time for web break detection ->
IN tDelayTime TIME Dancer roll or tension must be within the limit for
this time before web break is detected.
[ Z ] / [ % ] lower error limit for web break
IN r32LowerLimitError REAL
detection
[ Z ] / [ % ] upper error limit for web break
IN r32UpperLimitError REAL
detection

sLConTorqueLimitationType
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This structure contains data to parameterized the torque limitation.

Table 10-30
I/O Element Data type Description
[ % ] Lower torque limit [percentage of nominal
torque, or of maximum torque configured in TO]
Only active, if technology data block has been
IN r32lowerLimitTorqueLimit REAL
configured.
Limit is also active if no torque controlled control
mode is selected.
[ % ] Upper torque limit [percentage of nominal
torque, or of reference torque configured in TO]
Only active, if technology data block has been
IN r32upperLimitTorqueLimit REAL
configured.
Limit is also active if no torque controlled control
mode is selected.
[ms] ramp up time is used to open up the torque
IN r32RFGRampUpTime REAL limits
(nominal value is drive nominalTorque).
[ms] ramp down time is used to reduce the
IN r32RFGRampDownTime REAL torque limits
(nominal value is drive nominalTorque).

Manual SIMOTION Winder

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 10 Application structure

sLConPidDataType
This structure includes configuration data of the FbPidController function block

Table 10-31
I/O Element Data type Description
IN boEnPChannel BOOL TRUE: P component is activated

IN boEnIChannel BOOL TRUE: I component is activated

IN boEnDChannel BOOL TRUE: D component is activated

TRUE: D component is effective in the actual
value branch (after smoothing) and not at the
IN boControlMode BOOL
fault signal. Only active if the D component is
activated.
IN r32DeadBand REAL [ - ] width of the deadband
IN r32ActValueFactor REAL [ - ] scaling factor of the actual value
IN r32ActValueOffset REAL [ - ] offset of the actual value
IN r32OutValueFactor REAL [ - ] scaling factor of the controller output
IN r32OutValueOffset REAL [ - ] offset of the controller output
ANTI_WIND_UP_REDUCE_I_TO_ZERO:
(default)
with integral part ramp um limiting;
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maximum value in opposite direction = 0.

ANTI_WIND_UP_FREEZE_I:
eLConIntegralMod
IN eIntegralMode with integral part ramp um limiting;
eType
integral part will be freeze if controller output limit
is reached
integral part also possible in opposite direction

WIND_UP:
No integral part ramp up limiting

sLConWinderDynamicsType

Table 10-32
I/O Element Data type Description
IN These dynamics are active during
sSynch sLConDynamicsType synchronisation to the master speed
(enable = TRUE; ctrlEnable = FALSE)
IN These dynamics are active during
sOperation sLConDynamicsType “normal” run (enable = TRUE; ctrlEnable
= TRUE)
IN These dynamics are active after falling
sStop sLConDynamicsType
edge of enable

sLConDynamicsType

Manual SIMOTION Winder

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 10 Application structure

Table 10-33
I/O Element Data type Description
velocity
IN r32Velocity REAL The unit coresponds to the TO unit!
default: -1 (TO userdefault Dynamics are used)
acceleration
IN r32Acceleration REAL The unit coresponds to the TO unit!
default: -1 (TO userdefault Dynamics are used)
deceleration
IN r32Deceleration REAL The unit coresponds to the TO unit!
default: -1 (TO userdefault Dynamics are used)
jerk
IN r32Jerk REAL The unit coresponds to the TO unit!
default: -1 (TO userdefault Dynamics are used)

sLConUnitConfigType

Table 10-34 sLConUnitConfigType

Element Data type Description
Velocity units of the leading axis from the axis
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configuration
NOT_DEFINED: not defined
M_MIN: m/min
MM_MIN: mm/min
eUnitLineAxis M_S: m/s
eUnitLineAxisVelocity
VelocityType MM_S: mm/s
FT_MIN: ft/min
INCH_MIN: inch/min
FT_S: ft/s
INCH_S: inch/s
DEG_S_PRINT: 360°/s = 1 m/s
Acceleration units of the leading axis from the axis
configuration
NOT_DEFINED: not defined
eUnitLineAxis M_S2: m/s²
eUnitLineAxisAcceleration
AccelerationType MM_S2 mm/s²
FT_S2: ft/s²
INCH_S2: inch/s²
DEG_S2_PRINT: 360°/s² = 1m/s²
Velocity units of the winder axis from the axis
configuration
NOT_DEFINED: not defined
eUnitWinder
eUnitWinderAxisVelocity RPM: rounds per minute
AxisVelocityType
RPS: rounds per second
DEG_MIN: °/min
DEG_S : °/s

sLConWinderSystemType
For winding with coils different from round a separate manual is available.

Manual SIMOTION Winder

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 10 Application structure

sLConWinderDiagType

Table 10-35
I/O Element Data type Description
TO type of winding axis
OUT eWinderAxisType eLConTOType
(INVALIDTYPE, DRIVEAXIS, POSAXIS)
TO type of web axis
OUT eLineAxisType eLConTOType (INVALIDTYPE , DRIVEAXIS, POSAXIS,
EXTERNALENCODER)
sLConLineAxisMotion
OUT sActLineAxisMotionVector actual motion vector of web axis
VectorType
OUT sDiamDiag sLConDiamDiagType actual values of diameter calculation
sLConTechnologyCon
OUT sTechnologyControllerDiag actual values of technology controller
trollerDiagType
sLConTorquePreCont
OUT sTorquePreControlDiag actual values of torque pre-control
rolDiagType
sLConCoreCompensa actual values for prismatic winding(see separate
OUT sCoreCompensation
tionDiagnosticType documentation)
sLConWebBreakDete
OUT sWebBreakDetectionDiag actual values of web break detection
ctionDiagType
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[ Z ] actual tension setpoint after taper

OUT r32SetpointTaper REAL
characteristic
OUT r32ActSpeedOverride REAL velocity override (to reach torque limits)
OUT boControlModeChangeActive BOOL control mode change active

sLConLineAxisMotionVectorType

Table 10-36
Element Data type Description
r64LineSpeed LREAL [ LU / TU ] Velocity of the master axis
r64LineAcceleration LREAL [ LU / s² ] Acceleration of the master axis
[Inc] Position / counter information of the master
r64LineFeedback LREAL axis

sLConDiamDiagType

Table 10-37
Element Data type Description
[ LU ]Feedback signal, diameter calculator:
Calculated material thickness value
r32CalculatedWebThickness REAL Only for DIAM_CALC_INTEGRAL or
DIAM_CALC_POSITION mode.
Otherwise, the value is set to 0.0.
FALSE: Calculated diameter <
sDiamConfig.r32diamMax
boDiamActUpperLimitReached BOOL
TRUE: Calculated diameter >
sDiamConfig.r32diamMax

Manual SIMOTION Winder

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 10 Application structure

Element Data type Description

FALSE: Calculated diameter >
sDiamConfig.r32diamMin
boDiamActLowerLimitReached BOOL
TRUE: Calculated diameter <
sDiamConfig.r32diamMin
FALSE: Diameter calculator is enabled
boDiamIsHold BOOL
TRUE: Diameter calculator is in the stop condition
eActInterpolationMode eLConInterpolationM actual interpolation mode
odeType

sLConTechnologyControllerDiagType

Table 10-38
Element Data type Description
r32EffectiveKp REAL [ - ] effective controller gain after Kp adaptation
[ Z ] / [ LU ] / [ % ] Setpoint (tension or dancer roll
r32SetpointRFG REAL position) after the ramp-function generator in the
technology controller
TRUE: The setpoint ramp-function generator in
boSetpointReached BOOL the technology controller has reached the
setpoint.
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TRUE: The output of the setpoint ramp-function

boSetpointZero BOOL generator is zero.
TRUE: The output of the technology controller is
boControllerULReached BOOL limited, upper limit value
TRUE: The output of the technology controller is
boControllerLLReached BOOL limited, lower limit value.

sLConTorquePreControlDiagType

Table 10-39
Element Data type Description
[ mLUb² ] Total moment of inertia of the
r32TotalInertia REAL mechanical system, reflected to motor side
[ mLUb² ] Max. moment of inertia at max.
r32MaxInertia REAL Diameter
r32Mass REAL [ m ] mass of web on mandrel
r32PreCtrlMotor REAL [ M ] Torque precontrol
[ M ] Total precontrol torque based on motor shaft
r32TotalTorquePreCtrl REAL / Torque limitation
[ mLUb² ] Variable moment of inertia (inertia of
r32VariableInertia REAL material), reflected to motor side
r32TensionTorque REAL [ M ] Tension torque
r32FrictionTorque REAL [ M ] Friction torque

sLConWebBreakDetectionDiagType

Manual SIMOTION Winder

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 10 Application structure

Table 10-40
Element Data type Description
FALSE: web break detection is deactivated
boWebbreakDetectionActive BOOL
TRUE: web break detection is activated
boLowerLimitErrorWebbreak TRUE: Lower Error Limit for Webbreak Detection
BOOL reached
Reached
boUpperLimitErrorWebbreak TRUE: Upper Error Limit for Webbreak Detection
BOOL reached
Reached

sLConCoreCompensationDiagnosticType
For winding with coils different from round a separate manual is available.

sLConWinderInputType
This structure summarizes the FBLConWinder input parameter.
For more information see chapter 10.3 Input and output parameters of the function
block
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sLConWinderOutputType
This structure summarizes the FBLConWinder output parameter.
For more information see chapter 10.3 Input and output parameters of the function
block

Manual SIMOTION Winder

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 10 Application structure

10.3 Input and output parameters of the function block

FBWinder

BOOL enable busy BOOL

eLConControlMode active BOOL

controlMode
Type
ctrlBusy BOOL
eLConDiamMode selectDiamMode
Type
error BOOL
eLConLineAxisMotion
lineAxisMotionVector
VectorType
errorID DWORD

BOOL ctrlEnable
kpAdaptionRatio WORD

BOOL setDiamCalc
diameter REAL

BOOL holdDiamCalc
diameterFactor REAL

BOOL blockPIDCorrection
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velocity REAL

REAL tensionSetpoint
additiveVelocity REAL

REAL positionSetpoint
controllerOutput REAL

LREAL lineSpeedActValue
additiveTorque LREAL

REAL diamExtVal
additiveTorqueActive BOOL
REAL diamSetVal

torqueLimitNegative LREAL
REAL actValuePID

torqueLimitNegativeActive BOOL

torqueLimitPositive LREAL

torqueLimitPositiveActive BOOL

webBreak BOOL

sWinderDiag sLConWinder
DiagType

sWinderConfig sLConWinder
sWinderConfig
Type ConfigType

REAL LatchDiamCalc REAL

Manual SIMOTION Winder

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 10 Application structure

Input Parameter

Name Data type Initial value Description

FALSE: No calculation of output values
TRUE: Free the interface and calculate winder
values
enable BOOL FALSE With the edge from L->H the parameter values
given in sWinderConfig are checked for plausibility.
With errors, the process is broken. A new enabling
can only be generated with another edge.
Choose Control Mode of the winder:
INDIRECT_TENSION_CONTROL:
Indirect tension control
DANCER_CONTROL_SPEED_SETPOINT_
ADAPTION:
DANCER_ Tension control with dancer roll via speed
CONTROL_ adaptation
eControlMode DANCER_CONTROL_TORQUE_LIMITING:
controlMode SPEED_
Type Tension control with dancer roll via torque limiting
SETPOINT_
TENSION_CONTROL_SPEED_SETPOINT_
ADAPTION
ADAPTION:
Tension control with load cell via speed adaptation
TENSION_CONTROL_TORQUE_LIMITING:
Tension control with load cell via torque limiting
CONSTANT_V_CONTROL: Winder controlled to
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run with constant web speed (command value)

Selects the diameter calculation mode
DIAM_CALC: v/n calculation
DIAM_CALC_INTEGRAL: Integrating up from the
winding speed and web velocity
eDiamMode DIAM_CALC_POSITION: Measures the position of
selectDiamMode DIAM_CALC
Type the winding angle and material web
DIAM_THICKNESS_ADDITION: The material
thickness is continually added
DIAM_EXT: The external diameter value is used
Can not be changed while enable = TRUE.
Leading value for winding axis.
IF sWinderConfig.toLineAxis <> TO#NIL the leading
value is interconnected internal.
IF sWinderConfig.toLineAxis = TO#NIL this
structure need to be interconnected:
sLConLineAxis r64LineSpeed:
lineAxisMotionVector MotionVectorT -
[ LU / TU ]
ype
r64LineAcceleration:
[ LU / s² ] (used for torque pre-control)
r64LineFeedback:
(used for diameter calculation
DIAM_CALC_POSITION)

Manual SIMOTION Winder

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 10 Application structure

Name Data type Initial value Description

TRUE: Activate winder operation:
FALSE: Deactivate winder operation, setpoints are
fed back
INDIRECT_TENSION_CONTROL:
The tension setpoint is routed via the setpoint ramp-
function generator. The technology controller
remains inactive, the velocity override is activated in
order to overdrive the speed controller. The tension
torque is pre-controlled (if it can be parameterized).
DANCER_CONTROL_SPEED_SETPOINT_
ADAPTION:
The dancer roll position setpoint is routed via the
position setpoint ramp-function generator and the
ctrlEnable BOOL FALSE technology controller activated. The tension torque
is not pre-controlled.
TENSION_CONTROL_SPEED_SETPOINT_
ADAPTION:
The tension setpoint is routed via the tension
setpoint ramp-function generator and the technology
controller activated. The output of the technology
controller is interconnected with the winder velocity.
The tension torque is pre-controlled (if this can be
parameterized).
TENSION_CONTROL_TORQUE_LIMITING:
The tension setpoint is routed via the tension ramp-
function generator and the technology controller
switched-in and the velocity override activated.
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TRUE: Set diameter to preset value

(diamSetVal).
setDiamCalc BOOL FALSE The input can only be changed if enable = FALSE or
during standstill while ctrlEnable = FALSE and
ctrlBusy = FALSE
holdDiamCalc BOOL FALSE TRUE: Holds the actual diameter
TRUE: The impact of the controller is not added to
the control variable.
FALSE: The impact of the controller is added to the
blockPIDCorrection BOOL FALSE
control variable
No signification with indirect tension control
No rounding is done with switching on.
[ Z ] For tension control with load cell, the tension
setpoint acts as the setpoint for the technology
controller.
The value is also used for tension torque precontrol:
tensionSetpoint REAL 0.0 In case dancer position control the value is used
without ramping.
For indirect tension control or tension control with
load cell the setpoint is used with ramp.
Not used in CONSTANT_V_CONTROL.
[ %] / [ LU ] For tension control with dancer roll acts
as setpoint for the technology controller .
positionSetpoint REAL 0.0
This is not used for tension control with load cell or
for indirect tension control.
[ LU / TU ] actual line speed from web tachometer
lineSpeedActValue LREAL 0.0 used for diameter calculation (for
CONSTANT_V_CONTROL only)
Input parameter for the extern diameter.
The standardization can either be done in
FBDiameterCalculator
(sWinderConfig.sDiamConfig) or defined extern.
diamExtVal REAL 0.0
The standardization has to comply with the
convention of [ LU ].
The parameter is only used in the diameter mode
DIAM_EXTERN.

Manual SIMOTION Winder

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 10 Application structure

Name Data type Initial value Description

diamSetVal REAL 0.0 [ LU ] diameter setpoint value
[ Z ] / [ LU ] / [ % ] Feedback for the technology
controller (actual tension value or actual dancer
position value). The internal ramp function generator
actValuePID REAL 0.0 is set to this value after enabling the setpoints.
In case of indirect tension control, this value is not
used or a free observation may be parameterized.

Input-/Output Parameters

Name Data type Initial value Description

[ LU ] Retain variable, saves the last calculated
LatchDiamCalc REAL 0.0
diameter
Structure for the winder configuration data.
sWinder
sWinderConfig - Details of this structure are provided in the
ConfigType
description of the type definitions.

Output Parameters
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Name Data type Init-value Description

FALSE: FB not active
busy BOOL FALSE
TRUE: FB is active and in process
FALSE: axis interface (enable interface) is not
active
active BOOL FALSE TRUE: Winder is active and generates setpoints
With falling edge the speed controller I-part will be
reset using the torque controlled control modes.
TRUE: Technology controller active
ctrlBusy BOOL FALSE
FALSE: Technology controller inactive
FALSE: No error
TRUE: An error has occurred, refer to error
error BOOL FALSE identification
In case of error the handling and the calculation of
the process values is not broken up.
Error identification, refer to error messages
errorId DWORD 16#0000_0000 errorId <= 16#000_8000: warning
errorId >= 16#0000_8000: error
Diameter or moment of inertia relation for KP
kpAdaptionRatio WORD 16#0000
adaption of the speed controller (4000h = 100%)
diameter REAL 0.0 [ LU ] Actual roll diameter
[ 1 / LU ] Weighting factor for the path velocity for
diameterFactor REAL 0.0 external interconnection (converts the path
velocity to the velocity at the winder axis)
velocity REAL 0.0 [ r / TU ] or [ ° / TU ] Velocity setpoint of the winder
[ LU / TU ] Supplementary velocity of the winder
axis in the units of the leading axis
additiveVelocity REAL 0.0 (interconnection for formal object in the print
standard). With appropriately adjusted sign for a
multiplication with the output diameterFactor.
[ LU / TU ] / [ Z ] actual controller output of the
controllerOutput REAL 0.0
winder control
additiveTorque LREAL 0.0 [ M ] pre-control torque

Manual SIMOTION Winder

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 10 Application structure

Name Data type Init-value Description

FALSE: Pre-control torque is not calculated
additiveTorqueActive BOOL FALSE
TRUE: Pre-control torque is calculated
torqueLimitNegative LREAL 0.0 [ M ] Negative torque limit
FALSE: Negative torque limit is not calculated
torqueLimitNegativeActive BOOL FALSE
TRUE: Negative torque limit is calculated
torqueLimitPositive LREAL 0.0 [ M ] Positive torque limit
FALSE: Positive torque limit is not calculated
torqueLimitPositiveActive BOOL FALSE
TRUE: Positive torque limit is calculated
FALSE: No web break detected
webBreak BOOL FALSE TRUE: Web break detected, technology controller
deactivated.
Structure for the winder actual data.
sLConWinder
sWinderDiag - Details of this structure are provided in the
DiagType
description of the type definitions.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 10 Application structure

10.4 Abbreviations of the units

The abbreviations of the units used for the speed and positioning axes are shown
in following table in order to ensure consistency for the metric as well as the Anglo-
American dimension system. LU stands for a length unit, TU stands for a time unit.

Table 10-41 Abbreviations of the units

Measurement Units Metric Anglo-American
quantity
Length LU e.g.: m (Meter) e.g.: ft (feet)
Length (basis unit) Lub m (meters) ft (feet)
Velocity LU / TU e.g.: mm / min e.g.: inch / min
Acceleration LU / TU² e.g.: m / s² e.g.: ft / s²
Speed rpTU o. ° / TU e.g.: rev / min e.g.: rpm
Mass, weight m kg lb
Density m / Lub³ kg / m³ lb / ft³
Moment of inertia J = mLUb² kgm² lbft²
Torque M = mLUb²/s² Nm = kgm² / s² lbf ft = lbft² / s²
Tension, force Z = mLUb/s² N = kg m / s² lbf = lb ft / s²
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

11 Function description
11.1 Control Modes
11.1.1 Indirect tension control

For the indirect tension control, the tension is controlled using the parameterized
process quantities. The web tension is not controlled using a closed control loop.

Figure 11-1 Indirect tension control

Winding axis

Master axis
FTension [N]

velocity setpoint
Velocity setpoint
velocity / position

velocity override
<sWinderConfigType>
setpoint

Actual speed
.r32Override

Power unit
value
Acceleration setpoint

Auxiliary Torque limit

torque
diameter Speed setpoint speed setpoint
Diameter
calculation
Winding axis +
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speed/position <FBDiameter (overridden) <FBWinder>.

Calculation>. velocity Speed Control
diamActVal controller loop

Winding drive
Torque torque precontrol
tension setpoint Setpoint precontrol <FBWinder>.additiveTorque
preparation tension setpoint
<FBWinder>.tension after RFG
(Ramp generator) torque limits
Setpoint
Torque limiting
<FBWinder>.torquelimitnegative
<FBWinder>.torquelimitpositive

NOTE The blue variables have to be connected by the user.

The green variables are interconnected in the winder function block internal.

For the indirect tension control, the drive speed controller is overdriven and is
operated at the torque limit. Winding operation is activated using the ctrlEnable
input, i.e. the velocity offset – that is set using the sWinderConfig.r32Override
parameter – and tension operation (tension torque) are activated. The tension
setpoint can be influenced during winding using the winding hardness
characteristic (Tension Taper Characteristic) as a function of the diameter. The
required torque is generated from the frictional torque, the accelerating torque
(machine acceleration) and the tension torque and transferred to the drive as pre-
control torque and as speed limit using the technology data coupling.

For this control type, a precise compensation of the friction and accelerating
torques is important in order that the pre-controlled torque setpoint results in the
best possible approach to the desired material tension.
The tension setpoint is entered using the tensionSetpoint input parameter of the
winder function block and its rate of rise is limited using a ramp-function generator
that can be appropriately parameterized.

Manual SIMOTION Winder

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 11 Function description

Table 11-1 Parameter and settings of the indirect tension control

Parameter Value / Attribute Parameter Value / Attribute
TO-Configuration:
Technology data block Necessary

FBLConWinder- inputs: FBLConWinder - outputs:

enable Used busy Status

controlMode INDIRECT_TENSION_CONTROL active Status

selectDiamMode Used ctrlBusy Status

lineAxisMotionVector Optional (toLineAxis) error Status
ctrlEnable Used errorID Diagnostics
setDiamCalc, holdDiamCalc Used kpAdaptionRatio Optional (kpAdaption)
blockPIDCorrection Not used diameter Diagnostics
tensionSetpoint Used diameterFactor Optional (Print Standard)
positionSetpoint Not Used velocity Diagnostics
lineSpeedActValue Optional (eLineSpeedSource) additiveVelocity Optional (Print Standard)
diamExtVal Optional (selectDiamMode) controllerOutput Not used
Diagnostics (Technology data
diamSetVal Used additiveTorque / additiveTorqueActive
block necessary)
torqueLimitNegative /
actValuePID Not used Diagnostics
torqueLimitNegativeActive
torqueLimitPositive /
LatchDiamCalc Used Diagnostics
torqueLimitPositiveActive
webBreak Status
 Siemens AG 2018 All rights reserved

sWinderConfig: sWinderDiag:
.toWinderAxis Necessary .eWinderAxisType Diagnostics
.toLineAxis Optional (lineAxisMotionVector) .eLineAxisType Diagnostics
.eMovingMode SPEED_CONTROLLED .sActLineAxisMotionVector Diagnostics
AXIS_CONTROL
.eFBMode (Print Standard: .sDiamDiag Diagnostics
NO_AXIS_CONTROL)
.eTypeOfWinder Necessary .sTechnologyControllerDiag Diagnostics
.eTaskMode Necessary .sTorquePreControlDiag Diagnostics
.eGainAdaptionMode Optional .sWebBreakDetectionDiag Diagnostics
.sUnitConfig Necessary .r32SetpointTaper Diagnostics (eTensionTaperMode)
.sWinderDynamics Necessary .r32ActSpeedOverride Diagnostics
.sDiamConfig Necessary .boControlModeChangeActive Diagnostics
.sTechnologyControllerConfig Necessary
.sMomentConfig Necessary
.sTensionTaperConfig Optional (eTensionTaperMode)
.sWebbreakDetectionConfig Optional
.sTorqueLimitation Necessary
.r32lineAxisDiameter Only if lineAxis = TO#driveAxis
.boEnableStandstillTension Optional
.r32StandstillTension Optional
.r32Override Necessary

Manual SIMOTION Winder

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 11 Function description

Figure 11-2 Signal diagram, indirect tension control

Active
winderAxis.control 1
0
Aktivierungs- und Deaktivierungszeit
1
enable 0

1
busy 0

1
active 0

1
ctrlEnable 0

r32SetpointRFG
0

1
boSetpointReached
0

1
boSetpointZero
0

controllerOutput
0

r32LineSpeed
0
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speedOffset
(Override) 0

1.) Before activating the function block, the winder axis must be enabled
2.) With enable = TRUE, busy is set to TRUE
3.) The time from enable = TRUE up to active = TRUE and enable = FALSE up to
busy = FALSE can vary depending on which interfaces have been activated. If
fbMode = NO_AXIS_CONTROL, then active is set to TRUE in the same cycle.
4.) If active = TRUE, then the setpoints are written to the axis TO
5.) With ctrlEnable = TRUE, the tension setpoint ramp and the velocity override
are activated.
6.) With ctrlEnable = FALSE, the tension setpoint is ramped down to zero. If the
setpoint reached zero, then the technology controller is inactive,
boSetpointReached is set to FALSE and the override deactivated.

The winder block is switched on with a rising edge at the enable input (the busy
output changes to TRUE). If the required interfaces are activated, the active output
is switched to TRUE. Calculations are not made if the active output = FALSE.
The tension setpoint can be enabled as soon as the active output is at TRUE. The
enable is realized using input ctrlEnable. Using the ramp-function generator, the
rate-of-rise of the tension setpoint is limited. At the same time, the override is
activated; as a result, the speed controller of the winder axis is overdriven with the
parameterized velocity offset and the torque limit is activated. As long as the
override is inactive the motor torque is not limited (speed controller is effective).
The switch-off sequence is obtained as follows: The web velocity is ramped down
to zero. The tension setpoint is then completely “integrated down” by switching-out
the ctrlEnable input. The override is again switched-in when the tension setpoint is
zero.

Manual SIMOTION Winder

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 11 Function description

Correspondingly, the winder block can be switched off again by resetting the
enable signal. As long as the busy output had not changed to FALSE, the block is
still in the deactivation phase and cannot be switched on again.

NOTE When switching-in the winder functionality, it must be observed that the block
does not explicitly support catching-up a material loop. This functionality must be
implemented in the user program by programming the appropriate logic.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

11.1.2 Tension control with load cell via torque limiting

For this control type, the material tension is directly sensed using a tension
transducer. Its output signal is proportional to the tension force and is fed to the
technology controller as actual value signal via the actValuePID input. This means
that the technology controller is effective here and directly controls the tension of
the material web.

Figure 11-3 Tension control with load cell via torque limiting
Winding axis

Master axis
FTension [N]

setpoint velocity

velocity setpoint
Geschwindigkeits-
velocity / position

Override
<sWinderConfigType>
setpoint

Actual speed
.r32Override

Power unit
value
acceleration setpoint

Auxiliary Torque limit

torque
Speed setpoint speed setpoint
Diameter
speed / position
calculation
diameter
Winding axis
(overridden) <FBWinder>.
+
velocity Speed Control
<FBDiameter controller loop
Calculation>.
 Siemens AG 2018 All rights reserved

diamActVal

tension actual value

Winding drive
<FBWinder>.actValuePID
Tension
correction value

tension controller
Setpoint
setpoint
preparation (Ramp
<FBWinder>. generator) precontrol
tensionSetpoint
torque
Torque <FBWinder>.additive
tension setpoint precontrol
RFG + Torque

Torque limiting torque limits

<FBWinder>.torquelimitnegative
<FBWinder>.torquelimitpositive

NOTE The blue variables have to be connected by the user.

The green variables are interconnected in the winder function block internal.

For this control type, the material tension is measured using a tension transducer.
Deviations from the specified tension setpoint are compensated by the technology
controller. The technology controller is configured as PID controller. The tension
setpoint can be influenced during winding depending on the diameter using the
winding hardness characteristic (Tension Taper characteristic). The technology
controller component that is obtained is added to the total pre-control torque.
The resulting torque acts as limiting torque at the speed controller output. In order
that the torque limiting can be effective in tension controlled operation, an
additional path velocity can be switched-in (sWinderConfig.r32Override); this
results in a speed controller being over controlled. The tension is directly set using
the torque limiting.

For tension control with load cell via torque limiting, the same data are transferred
to the drive as for tension control with dancer roll via speed adaption as well as in
addition the values for the positive and negative torque limits.

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 11 Function description

Table 11-2 Parameters and settings of the tension control with load cell via torque limiting
Parameter Value / Attribute Parameter Value / Attribute
TO-Configuration:
Technology data block Necessary

FBLConWinder- inputs: FBLConWinder - outputs:

enable Used busy Status
TENSION_CONTROL_TORQUE_
controlMode active Status
LIMITING
selectDiamMode Used ctrlBusy Status
lineAxisMotionVector Optional (toLineAxis) error Status
ctrlEnable Used errorID Diagnostics
setDiamCalc, holdDiamCalc Used kpAdaptionRatio Optional (kpAdaption)
blockPIDCorrection Optional diameter Diagnostics
tensionSetpoint Used diameterFactor Optional (Print Standard)
positionSetpoint Not Used velocity Diagnostics
lineSpeedActValue Optional (eLineSpeedSource) additiveVelocity Optional (Print Standard)
diamExtVal Optional (selectDiamMode) controllerOutput Diagnostics
Diagnostics (Technology data
diamSetVal Used additiveTorque / additiveTorqueActive
block necessary)
torqueLimitNegative /
actValuePID Used Diagnostics
torqueLimitNegativeActive
torqueLimitPositive /
LatchDiamCalc Used Diagnostics
torqueLimitPositiveActive
webBreak Status
 Siemens AG 2018 All rights reserved

sWinderConfig: sWinderDiag:
.toWinderAxis Necessary .eWinderAxisType Diagnostics
.toLineAxis Optional (lineAxisMotionVector) .eLineAxisType Diagnostics
.eMovingMode SPEED_CONTROLLED .sActLineAxisMotionVector Diagnostics
AXIS_CONTROL
.eFBMode (Print Standard: .sDiamDiag Diagnostics
NO_AXIS_CONTROL)
.eTypeOfWinder Necessary .sTechnologyControllerDiag Diagnostics
.eTaskMode Necessary .sTorquePreControlDiag Diagnostics
.eGainAdaptionMode Optional .sWebBreakDetectionDiag Diagnostics
.sUnitConfig Necessary .r32SetpointTaper Diagnostics (eTensionTaperMode)
.sWinderDynamics Necessary .r32ActSpeedOverride Diagnostics
.sDiamConfig Necessary .boControlModeChangeActive Diagnostics
.sTechnologyControllerConfig Necessary
.sMomentConfig Necessary
.sTensionTaperConfig Optional (eTensionTaperMode)
.sWebbreakDetectionConfig Optional
.sTorqueLimitation Necessary
.r32lineAxisDiameter Only if lineAxis = TO#driveAxis
.boEnableStandstillTension Optional
.r32StandstillTension Optional
.r32Override Necessary

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 11 Function description

Figure 11-4 Signal diagram, tension control with load cell via torque limiting
Active
winderAxis.control 1
0
Aktivierungs- und Deaktivierungszeit
1
enable 0

1
busy 0

1
active 0

1
ctrlEnable 0

r32SetpointRFG
0

1
boSetpointReached 0

1
boSetpointZero 0

upperLimit
controllerOutput
0

lowerLimit

r32LineSpeed
0
 Siemens AG 2018 All rights reserved

speedOffset
(Override) 0

1.) Before activating the function block, the winder axis must be enabled
2.) With enable = TRUE, busy is set to TRUE
3.) The time from enable = TRUE up to active = TRUE and enable = FALSE up to
busy = FALSE can vary depending on which interfaces are activated. If fbMode
= NO_AXIS_CONTROL, then active is set to TRUE in the same cycle.
4.) If active = TRUE, then the setpoints are written to the axis TO
5.) With ctrlEnable = TRUE, the technology controller and the override are
activated and the setpoint and output limiting ramped-up.
6.) With ctrlEnable = FALSE, the technology controller is deactivated, the setpoint
and output limiting are ramped down to zero. If the controller output is
completely limited, then the technology controller is inactive,
boSetpointReached is set to FALSE and the override deactivated

The winder block is switched on with a rising edge at the enable input (the busy
output changes to TRUE). If the required interfaces are activated, the active output
switches to TRUE. No calculations are made if the output active = FALSE.
Winder operation can be enabled as soon as the active output is at TRUE. The
enable signal is realized using input ctrlEnable¬. The initial rate of rise of the
tension setpoint is limited using the ramp-function generator. At the same time, the
technology controller and the override are activated. As a consequence, the winder
axis speed controller is overdriven with the parameterized velocity offset and the
torque limit becomes active. The output of the technology controller (manipulated
variable) can be monitored at the controllerOutput output.
The switch-off sequence is obtained as follows: The web velocity is ramped down
to zero. By switching-out input ctrlEnable, the tension setpoint and the output

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 11 Function description

limiting of the technology controller are subsequently completely “integrated down”.

The technology controller is automatically switched-off if the output limit is zero.
Correspondingly, by withdrawing the enable signal, the winder block is switched off
again. As long as the busy output has not changed to FALSE, the block is still in
the deactivation phase and must not be switched on again.

NOTE When switching-in the winder functionality, it must be observed that the block
does not explicitly catch-up a material loop. This functionality must be
implemented in the user program using the appropriate logic.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

11.1.3 Tension control with load cell via speed setpoint adaption

For this control type, the material tension is directly sensed using a tension
transducer. Its output signal is proportional to the tension force and is fed to the
technology controller as actual value signal via the actValuePID input. This means
that the technology controller is effective here and directly controls the tension of
the material web.

Figure 11-5 Tension control with load cell via speed setpoint adaption
Winding axis

Master axis
FTension [N]

Setpoint velocity
Velocity setpoint
Acceleration setpoint

Velocity/position

Actual speed
setpoint

Power unit
value
+ Speed
Auxiliary
torque
Torque limit

Diameter Speed setpoint setpoint

Speed/position
calculation
diameter
Winding axis <FBWinder> +
.velocity Speed Current
<FBDiameter controller controller
Correection value

Calculation>.
diamActVal
 Siemens AG 2018 All rights reserved

Winding drive
Tension actual value
<FBWinder>.actValuePID
Tension
Tension controller
Setpoint
setpoint
preparation
<FBWinder>. (Rampgenerator)
tensionSetpoint
Precontrol
Torque torque
precontrol <FBWinder>.additive
Torque

NOTE The blue variables have to be connected by the user.

The green variables are interconnected in the winder function block internal.

For this control type, the material tension is measured using a tension transducer.
Deviations from the specified tension setpoint are compensated by the technology
controller. The technology controller is configured as PID controller. The tension
setpoint can be influenced during winding depending on the diameter using the
winding hardness characteristic (Tension Taper characteristic). The technology
controller component that is obtained is added to velocity setpoint.
Generally, the technology controller is operated as P controller with D component.
Under certain circumstances, the controller can also be configured as a PID
controller; however, this can result in oscillation due to the fact that there are
several integral components in the system.
The resulting web velocity setpoint is converted into a speed setpoint using the
actual diameter.
In contrast to the “tension control with load cell via torque limiting” the speed
controller will not operate at the torque limits, but will control the tension via the
speed of the winder axis (shaft).

Manual SIMOTION Winder

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 11 Function description

Table 11-3 Parameters and settings of the tension control with load cell via speed setpoint adaption
Parameter Value / Attribute Parameter Value / Attribute
TO-Configuration:
Technology data block Optional (only if the torque pre-control is used)

FBLConWinder- inputs: FBLConWinder - outputs:

enable Used busy Status
TENSION_CONTROL_ SPEED_
controlMode active Status
SETPOINT_ADAPTION
selectDiamMode Used ctrlBusy Status
lineAxisMotionVector Optional (toLineAxis) error Status
ctrlEnable Used errorID Diagnostics
setDiamCalc, holdDiamCalc Used kpAdaptionRatio Optional (kpAdaption)
blockPIDCorrection Optional diameter Diagnostics
tensionSetpoint Used diameterFactor Optional (Print Standard)
positionSetpoint Not Used velocity Diagnostics
lineSpeedActValue Optional (eLineSpeedSource) additiveVelocity Optional (Print Standard)
diamExtVal Optional (selectDiamMode) controllerOutput Diagnostics
Diagnostics (Technology data
diamSetVal Used additiveTorque / additiveTorqueActive
block necessary)
torqueLimitNegative /
actValuePID Used Diagnostics
torqueLimitNegativeActive
torqueLimitPositive /
LatchDiamCalc Used Diagnostics
torqueLimitPositiveActive
webBreak Status
 Siemens AG 2018 All rights reserved

sWinderConfig: sWinderDiag:
.toWinderAxis Necessary .eWinderAxisType Diagnostics
.toLineAxis Optional (lineAxisMotionVector) .eLineAxisType Diagnostics
.eMovingMode SPEED_CONTROLLED .sActLineAxisMotionVector Diagnostics
AXIS_CONTROL
.eFBMode (Print Standard: .sDiamDiag Diagnostics
NO_AXIS_CONTROL)
.eTypeOfWinder Necessary .sTechnologyControllerDiag Diagnostics
.eTaskMode Necessary .sTorquePreControlDiag Diagnostics
.eGainAdaptionMode Optional .sWebBreakDetectionDiag Diagnostics
.sUnitConfig Necessary .r32SetpointTaper Diagnostics (eTensionTaperMode)
.sWinderDynamics Necessary .r32ActSpeedOverride Diagnostics
.sDiamConfig Necessary .boControlModeChangeActive Diagnostics
.sTechnologyControllerConfig Necessary
.sMomentConfig Optional
.sTensionTaperConfig Optional (eTensionTaperMode)
.sWebbreakDetectionConfig Optional
.sTorqueLimitation Optional
.r32lineAxisDiameter Only if lineAxis = TO#driveAxis
.boEnableStandstillTension Optional
.r32StandstillTension Optional
.r32Override Not used

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 11 Function description

Figure 11-6 Signal diagram, Tension control with load cell via speed setpoint adaption
Active
winderAxis.control 1
0
Aktivierungs- und Deaktivierungszeit
1
enable 0

1
busy 0

1
active 0

1
ctrlEnable 0

r32SetpointRFG
0

1
boSetpointReached 0

1
boSetpointZero 0

upperLimit
controllerOutput
0

lowerLimit

r32LineSpeed
0
 Siemens AG 2018 All rights reserved

speedOffset
(Override) 0

1.) Before activating the function block, the winder axis must be enabled
2.) With enable = TRUE, busy is set to TRUE
3.) The time from enable = TRUE up to active = TRUE and enable = FALSE up to
busy = FALSE can vary depending on which interfaces are activated. If fbMode
= NO_AXIS_CONTROL, then active is set to TRUE in the same cycle.
4.) If active = TRUE, then setpoints are written to the axis TO
5.) With ctrlEnable = TRUE, the technology controller is activated, the setpoint and
output limiting are ramped-up.
6.) With ctrlEnable = FALSE, the technology controller is deactivated, setpoint and
output limiting are ramped-down to zero. If the controller output is completely
limited, then the technology controller is inactive, boSetpointReached is set to
FALSE.

The winder block is switched on with a rising edge at the enable input (the busy
output changes to TRUE). If the required interfaces are activated, then active
output switches to TRUE. No calculations are made if the active output = FALSE.
Winding operation can be switched-on as soon as the control interfaces have been
activated (active = TRUE). Winding operation is activated by setting the ctrlEnable
input = TRUE. This enables the tension setpoint (tensionSetpoint) and the
technology controller is activated. The rate-of-rise of the tension setpoint is limited
using the ramp-function generator. The technology controller output (manipulated
variable) can be monitored using the controllerOutput output as status signal.

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 11 Function description

The switch-off sequence is obtained as follows: The path velocity is ramped-down

to zero. As soon as a velocity of zero is reached, winding operation is deactivated
using ctrlEnable = FALSE. This means that the tension setpoint is ramped down to
zero and the technology controller is deactivated.
Correspondingly, by withdrawing the enable signal, the winder block can be
switched off. As long as the busy output does not change to FALSE, the block is
still in the deactivation phase and cannot be switched on again.

NOTE When switching-in the winder functionality, it should be observed that the block
does not explicitly support catching-up a material loop. This functionality should
be implemented using the appropriate logic in the user program.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

11.1.4 Tension control with dancer roll via speed adaptation

The material web is routed across a dancer roll. The dancer roll tries to deflect the
material with a defined force. The deflection of the dancer roll (dancer roll position)
is detected using a potentiometer or encoder and this is used as a measure of the
material tension.

Figure 11-7 Dancer position control using speed adaptation

dancer counterforce

Winder axis

Master axis
FTension [N]
+
setpoint velocity

-
velocity setpoint
velocity / position
acceleration setpoint

setpoint

Actual speed

Power unit
value
+ speed
setpoint
Auxiliary
torque Torque
limit
Diameter Speed setpoint
speed / position
calculation
diameter
winder axis <FBWinder>
+
.velocity Speed Current
<FBDiameter controller controller
Calculation>.
correction value
 Siemens AG 2018 All rights reserved

diamActVal

position
Winder drive
setpoint position
Setpoint RFG
<FBWinder>. setpoint after
RFG Position
positionSetpoint controller
position actual value
<FBWinder>.actValuePID

Torque torque precontrol

Optional precontrol <FBWinder>.additive
tension setpoint
Setpoint RFG Torque
<FBWinder>.
tensionSetpoint

NOTE The blue variables have to be connected by the user.

The green variables are interconnected in the winder function block internal.

The material tension depends on the opposing force generated by the dancer roll
suspension mechanism. Often, as a result of the geometrical arrangement
(distance to other guide rolls that are possibly being used) and the weight of the
dancer roll itself, the tension actual value is subject to additional effects. However,
these can be avoided or sufficiently minimized by ensuring the appropriate
mechanical design. For the tension control with dancer roll the tension is adjusted
using the dancer roll. This means that the tension in the material web depends on
the selected operating point of the dancer roll.
If the required tension of the material web is to be changed, then the counter-
pressure (opposing force) of the dancer roll must be influenced.
For the tension control with dancer roll used here, the input parameter
positionSetpoint represents the dancer roll position setpoint. The feedback
parameter is the position actual value of the dancer roll actValuePID. Any deviation
in the dancer roll position is regulated by correcting the setpoint speed of the
winder axis (speed adaptation). Generally, the technology controller is operated as

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 11 Function description

P controller with D component. Under certain circumstances, the controller can

also be configured as a PID controller; however, this can result in oscillation due to
the fact that there are several integral components in the system.

The resulting web velocity setpoint is converted into a speed setpoint using the
actual diameter.
The winding hardness can be influenced during the winding process using a
winding hardness characteristic (Tension Taper Characteristic). For instance, the
characteristic can be provided as setpoint at an analog output, which can define
the dancer roll counter pressure (opposing force) (this is generally a pneumatic
system).
In addition to the setpoint velocity, the diameter ratio or the moment of inertia ratio
for the Kp adaptation of the speed controller – as well as the pre-control torque –
can be transferred to the drive. Depending on the application, the sensors for the
roll diameter and the dancer position can be connected-up via the drive or directly
to the control system.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

Table 11-4 Parameters and settings of the tension control with dancer roll via speed adaptation
Parameter Value / Attribute Parameter Value / Attribute
TO-Configuration:
Technology data block Optional (only if the torque pre-control is used)

FBLConWinder- inputs: FBLConWinder - outputs:

enable Used busy Status
DANCER_CONTROL_ SPEED_
controlMode active Status
SETPOINT_ADAPTION
selectDiamMode Used ctrlBusy Status
lineAxisMotionVector Optional (toLineAxis) error Status
ctrlEnable Used errorID Diagnostics
setDiamCalc, holdDiamCalc Used kpAdaptionRatio Optional (kpAdaption)
blockPIDCorrection Optional diameter Diagnostics
tensionSetpoint Optional (tension torque precontrol) diameterFactor Optional (Print Standard)
positionSetpoint Used velocity Diagnostics
lineSpeedActValue Optional (eLineSpeedSource) additiveVelocity Optional (Print Standard)
diamExtVal Optional (selectDiamMode) controllerOutput Diagnostics
Diagnostics (Technology data
diamSetVal Used additiveTorque / additiveTorqueActive
block necessary)
torqueLimitNegative /
actValuePID Used Diagnostics
torqueLimitNegativeActive
torqueLimitPositive /
LatchDiamCalc Used Diagnostics
torqueLimitPositiveActive
webBreak Status
 Siemens AG 2018 All rights reserved

sWinderConfig: sWinderDiag:
.toWinderAxis Necessary .eWinderAxisType Diagnostics
.toLineAxis Optional (lineAxisMotionVector) .eLineAxisType Diagnostics
.eMovingMode SPEED_CONTROLLED .sActLineAxisMotionVector Diagnostics
AXIS_CONTROL
.eFBMode (Print Standard: .sDiamDiag Diagnostics
NO_AXIS_CONTROL)
.eTypeOfWinder Necessary .sTechnologyControllerDiag Diagnostics
.eTaskMode Necessary .sTorquePreControlDiag Diagnostics
.eGainAdaptionMode Optional .sWebBreakDetectionDiag Diagnostics
.sUnitConfig Necessary .r32SetpointTaper Diagnostics (eTensionTaperMode)
.sWinderDynamics Necessary .r32ActSpeedOverride Diagnostics
.sDiamConfig Necessary .boControlModeChangeActive Diagnostics
.sTechnologyControllerConfig Necessary
.sMomentConfig Optional
.sTensionTaperConfig Optional (eTensionTaperMode)
.sWebbreakDetectionConfig Optional
.sTorqueLimitation Optional
.r32lineAxisDiameter Only if lineAxis = TO#driveAxis
.boEnableStandstillTension Optional (tension torque precontrol)
.r32StandstillTension Optional (tension torque precontrol)
.r32Override Not used

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 11 Function description

Figure 11-8 Signal diagram, tension control with dancer roll via speed adaptation
Active
winderAxis.control 1
0
Aktivierungs- und Deaktivierungszeit
1
enable 0

1
busy 0

1
active 0

1
ctrlEnable 0

r32SetpointRFG
0

1
boSetpointReached 0

1
boSetpointZero 0

upperLimit
controllerOutput
0

lowerLimit

r32LineSpeed
0
 Siemens AG 2018 All rights reserved

speedOffset
(Override) 0

7.) Before activating the function block, the winder axis must be enabled
8.) With enable = TRUE, busy is set to TRUE
9.) The time from enable = TRUE up to active = TRUE and enable = FALSE up to
busy = FALSE can vary depending on which interfaces are activated. If fbMode
= NO_AXIS_CONTROL, then active is set to TRUE in the same cycle.
10.) If active = TRUE, then setpoints are written to the axis TO
11.) With ctrlEnable = TRUE, the technology controller is activated, the setpoint and
output limiting are ramped-up.
12.) With ctrlEnable = FALSE, the technology controller is deactivated, setpoint and
output limiting are ramped-down to zero. If the controller output is completely
limited, then the technology controller is inactive, boSetpointReached is set to
FALSE.

The winder block is switched on with a rising edge at the enable input (the busy
output changes to TRUE). If the required interfaces are activated, then active
output switches to TRUE. No calculations are made if the active output = FALSE.
Winding operation can be switched-in as soon as the control interfaces have been
activated (active = TRUE). Winding operation is activated by setting the ctrlEnable
input = TRUE. This enables the dancer roll position setpoint (postionSetpoint), the
technology controller is activated and the output of the setpoint ramp-function
generator is set to the actual value of the dancer roll position. The rate-of-rise of
the dancer roll position setpoint is limited using the ramp-function generator. The
technology controller output (manipulated variable) can be monitored using the
controllerOutput output as status signal. As soon as the ramp-function generator

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 11 Function description

has integrated the position setpoint conditioning up to the reference position, a

path velocity can be entered via the leading axis.
The switch-off sequence is obtained as follows: The path velocity is ramped-down
to zero. As soon as a velocity of zero is reached, winding operation is deactivated
using ctrlEnable = FALSE. This means that the dancer roll position setpoint is
ramped down to 0 and the technology controller is deactivated.
Correspondingly, by withdrawing the enable signal, the winder block can be
switched off. As long as the busy output does not change to FALSE, the block is
still in the deactivation phase and cannot be switched on again.

NOTE When switching-in the winder functionality, it should be observed that the block
does not explicitly support catching-up a material loop. This functionality should
be implemented using the appropriate logic in the user program.
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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 11 Function description

11.1.5 Constant-v-control

In this control mode the winder gets the web speed set value as command value.
Web tension has to be generated by a nip role.

Figure 11-9 Constant-V-Control

Winding axis

line speed actual value

<FBWinder>.lineSpeedActValue

Actual speed

Power unit
value
velocity setpoint (line axis) Auxiliary Torque limit
torque
Speed setpoint speed setpoint
<sWinderConfigType>.r64LineSpeed
Winding axis <FBWinder>. +
velocity
Speed Current
controller controller

diameter
<FBDiameterCalculation>
Diameter .diamActVal Winding drive
calculation

speed/
position
 Siemens AG 2018 All rights reserved

Precontrol torque

Torque <FBWinder>.additiveTorque
acceleration setpoint (line axis) precontrol
<sWinderConfigType>.r64LineAcceleration
optional

NOTE The blue variables have to be connected by the user.

The green variables are interconnected in the winder function block internal.

With Constant-v-control (without line axis) the winder gets the web speed
command value transferred via the sWinderConfigType structure variable
<sWinderConfigType.r64LineSpeed> (external setpoint input).
To do this, the winder input parameter <lineAxis> is not connected at the function
block (lineAxis = TO#NIL) (see chapter 9.2.1 Configuring the leading axis).
Ramp function generator and rounding of the setpoint has to be realized external!
It’s recommended to use a virtual axis for the setpoint transfer because of the
internal ramp function generator of the technology object “axis”. Alternatively the
functions blocks FBRFG (basic ramp-function generator) or FBRFGJerkLimit
(ramp-function generator with rounding-off) of the converting library can be used.

If there is a master axis with a nip role available the winder input <lineAxis> can be
interconnected directly with its SIMOTION technology object. In this way there is no
external setpoint input necessary.

The friction torque pre control is active if the technology data block and a friction
characteristic are active.

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 11 Function description

If the web acceleration command value is available it can also be used for torque
pre control. Using external setpoint input the acceleration command value hast to
be interconnected with the structure variable <sWinderConfigType.
r64LineAcceleration> additionally.

For a diameter calculation the web speed actual value is necessary. In this control
mode the actual value is measured by a web tachometer usually. If there is a
master axis with nip role available the web speed command value can be used
alternatively. If the actual web speed is not available, the external diameter mode
can be used instead of a calculation mode.
The web speed actual value has to be connected with the winder input
<lineSpeedActValue>.
Be sure that the unit of this signal matches with the unit of the line axis
(<sWinderConfigType.eUnitLineAxisVelocity>).
 Siemens AG 2018 All rights reserved

Manual SIMOTION Winder

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Table 11-5 Parameter and settings of the constant-v-control

Parameter Value / Attribute Parameter Value / Attribute
TO-Configuration:
Technology data block Optional (only if the torque pre-control is used)

FBLConWinder- inputs: FBLConWinder - outputs:

enable Used busy Status

controlMode CONSTANT_V_CONTROL active Status

selectDiamMode Used ctrlBusy Status

lineAxisMotionVector Optional (toLineAxis) error Status
ctrlEnable Used errorID Diagnostics
setDiamCalc, holdDiamCalc Used kpAdaptionRatio Optional (kpAdaption)
blockPIDCorrection Not used diameter Diagnostics
tensionSetpoint Not used diameterFactor Optional (Print Standard)
positionSetpoint Not used velocity Diagnostics
lineSpeedActValue Necessary (for diameter calculation) additiveVelocity Optional (Print Standard)
diamExtVal Optional (selectDiamMode) controllerOutput Not used
Diagnostics (Technology data
diamSetVal Used additiveTorque / additiveTorqueActive
block necessary)
torqueLimitNegative /
actValuePID Not used Diagnostics
torqueLimitNegativeActive
ttorqueLimitPositive /
LatchDiamCalc Used Diagnostics
torqueLimitPositiveActive
webBreak Not used
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sWinderConfig: sWinderDiag:
.toWinderAxis Necessary .eWinderAxisType Diagnostics
.toLineAxis Optional (lineAxisMotionVector) .eLineAxisType Diagnostics
.eMovingMode SPEED_CONTROLLED .sActLineAxisMotionVector Diagnostics
AXIS_CONTROL
.eFBMode (Print Standard: .sDiamDiag Diagnostics
NO_AXIS_CONTROL)
.eTypeOfWinder Necessary .sTechnologyControllerDiag Diagnostics
.eTaskMode Necessary .sTorquePreControlDiag Diagnostics
.eGainAdaptionMode Optional .sWebBreakDetectionDiag Diagnostics
.sUnitConfig Necessary .r32SetpointTaper Diagnostics (eTensionTaperMode)
.sWinderDynamics Necessary .r32ActSpeedOverride Diagnostics
.sDiamConfig Necessary .boControlModeChangeActive Diagnostics
.sTechnologyControllerConfig Not used
.sMomentConfig Necessary
.sTensionTaperConfig Not used
.sWebbreakDetectionConfig Not used
.sTorqueLimitation Optional
.r32lineAxisDiameter Only if lineAxis = TO#driveAxis
.boEnableStandstillTension Not used
.r32StandstillTension Not used
.r32Override Not used

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Figure 11-10 Signal diagram, constant-v-control

Active
winderAxis.control 1
0
Aktivierungs- und Deaktivierungszeit
1
enable 0

1
busy 0

1
active 0

1
ctrlEnable 0

r32SetpointRFG
0

1
boSetpointReached 0

1
boSetpointZero 0

controllerOutput
0

lineSpeed
command value 0
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speedOffset
(Override) 0

1.) Before activating the function block, the winder axis must be enabled
2.) With <enable> = TRUE, <busy> is set to TRUE
3.) The time from <enable> = TRUE up to <active> = TRUE and <enable> =
FALSE up to <busy> = FALSE can vary depending on which interfaces are
activated. If <fbMode> = NO_AXIS_CONTROL, then <active> is set to TRUE
in the same cycle.
4.) If <active> = TRUE, then setpoints are written to the axis TO
5.) In this control mode <ctrlEnable> has not to be activated because the
technology controller isn’t used. The setpoint ramping has to be realized
externally.
The winder block is switched on with a rising edge at the enable input (the busy
output changes to TRUE). If the required interfaces are activated, then active
output switches to TRUE. No calculations are made if the active output = FALSE.
Winding operation starts as soon as the control interfaces have been activated
(active = TRUE) and a velocity setpoint (web speed command value) is transferred
to <sWinderConfigType.r64LineSpeed> (<lineAxis> = TO#NIL) or (if available)
directly to <lineAxis>.
Ramp-function and rounding of the setpoint have to be realized externally. Using a
virtual axis with internal ramp-function generator is recommended. Otherwise the
converting library function blocks “FBRFG” or “FBRFGJerkLimit” can be used.
In this control mode no web tension control is active!
The switch-off sequence is obtained as follows: The velocity setpoint has to be
ramped down to zero. As soon as a velocity of zero is reached the winder block
can be switched off with <enable> = FALSE. As long as the busy output does not

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change to FALSE, the block is still in the deactivation phase and cannot be
switched on again.

NOTE When switching-in the winder functionality, it should be observed that the block
does not explicitly support catching-up a material loop. This functionality should
be implemented using the appropriate logic in the user program.
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11.2 Winder operating modes

The following table shows the different winder operating modes and the orientation
of velocity, tension and torque.

Table 11-6 Winder operating modes

Operating mode Representation Description
Mf+ Mf+ V: Machine velocity
V+ , F+ F+ , V + F: Tension in material line
n+ MP+ MP+ n+
Rewind from above
n: speed of winder
MT+ MT+
nO: velocity override for speed
no+ no+ controller overdrive

Mf- Mf- Mf: Friction torque

n- MP- MP- n- MP: Pre-control torque
Rewind from below MT: Tension torque
V+ , F+ MT- MT- F+ ,+V
no- no-

Mf- Mf-
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n- MP- MP- n-

Unwind from below

MT+ MT+
F+, +V V+ , F+
no+ no+

Mf+ M f+
F+, +V MP+ MP+
V+ , F+
n+ n+
Unwind from above
MT- MT-

no+ no+

NOTE The winding direction is defined for positive line speed. If the line speed is
negative the winding mode will be automatically inverted (e.g. a rewinder from
above will become an unwinder from above).

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11.3 Technology data block

In order to transmit the axis-TO torque values to the drive, a technology data block
has to be configured (see also FAQ 22700107). The following table shows the
different controllers and if the axis has to be run torque controlled, i.e. with
technology data block.

Table 11-7 Overview technology data block

Control mode Torque control Comment
Indirect tension control Technology data block is
X essential
via torque limiting
Tension control with load cell Technology data block is
X
via torque limiting essential
Tension control with load cell Technology data block optional
via speed adaption (only necessary for torque pre-
control)
Tension control with dancer roll Technology data block is
X essential
via torque limiting
Tension control with dancer roll Technology data block optional
via speed adaption (only necessary for torque pre-
control)
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If the axis is run speed controlled (tension control via speed adaption, dancer
position control via speed adaption) and a torque pre-control is not necessary, the
technology data block is not necessary.

11.4 Source of master value

Via the function block FBLConWinder a velocity coupling between a master axis
(central machine ramp function generator, virtual axis, extern encoder etc.) and a
slave axis (winder axis) is established. Depending on the specification of the
setpoint source via the configuration parameter sWinderConfig.toLineAxis, the
function block executes the accordant calculations or conversions.

Table 11-8 Overview, leading value sources

Source of Description
master value
toLineAxis = No technology object has been specified as setpoint source. To ensure the working of the of
TO#NIL the function block even so, the accordant couplings have to be implemented outside of the FB
(e.g. in case of the use of an extern encoder as setpoint source).
The internal signal of standstill detection is generated by the values of r64LineSpeed and
r64LineAcceleration (switch to standstill tension). The valid limits are stored in the FB as
constants (SPEED_HYSTERESIS, ACC_HYSTERESIS).
This coupling is also useful to minimize the accesses to system variables and if several winder
FBs should be calculated.
The leading values are transferred via the function block input lineAxisMotionVector.
lineAxisMotionVector Specifies the actual machine velocity, unit is [ LU / TU ], e.g. m/min,
.r64LineSpeed ft/min. This coupling is essential since otherwise the function block
has no master velocity.
lineAxisMotionVector Specifies the actual acceleration, unit is [ LU / s² ]. This coupling is
.r64LineAcceleration only necessary if the winder should be run with torque pre-control.

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Source of Description
master value
lineAxisMotionVector Input of the position / counter information of the master axis. The
.r64LineFeedback coupling is only necessary if the position based diameter calculator
should be used. The value standardization is done in the diameter
calculator (see FBLConDiameterCalculation).

toLineAxis = A speed axis was specified as technology object, the FB accesses automatically to the existing
TO#driveAxis values of the master axis and converts them according to the configuration
sWinderConfigType.¬r32LineAxisDiameter.
The internal standstill signal is derived from the variable
toDriveAxis.MotionStateData.motionState.
lineAxisMotionVector Basis of the machine limit determination is the variable
.r64LineSpeed toDriveAxis.motionStateData.commandVelocity. The machine velocity
is calculated as follows:
r64 LineSpeed  commandvelocity  r 32LineAxisDiameter   
The gear factor i is determined by the TO configuration of the axis.
The velocity units depend on the axis configuration and are specified
using the configuration parameter
sWinderConfig.sUnitConfig.eUnitLineAxisVelocity [ LU / TU ].
lineAxisMotionVector The acceleration is derived from the variable
.r64LineAcceleration toDriveAxis.MotionStateData.commandAcceleration, with the following
conversion:

r64 LineAccele ration  commandAcc eleration  r 32 LineAxisDiameter    

r 64 LineSpeed
abs(r 64 LineSpeed )
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The axis acceleration units are as follows [ LU / s² ] .

lineAxisMotionVector Input of the position / counter information of the master axis. The
.r64LineFeedback coupling is done external and it is only necessary if the position based
diameter counter should be used. The standardization of the values is
done in the diameter counter (see FBLConDiameterCalculation).
toLineAxis = A positioning axis was configured as setpoint source. The values are transferred directly.
TO#posAxis
The internal standstill signal is derived from the variable
toDriveAxis.MotionStateData.motionState.
lineAxisMotionVector The machine velocity is derived from the variable
.r64LineSpeed toPosAxis.MotionStateData.commandVelocity.
r 64LineSpeed  abscommandVel ocity 
The velocity units depend on the axis configuration and are specified
using the configuration parameter
sWinderConfig.sUnitConfig.eUnitLineAxisVelocity [ LU / TU ]
lineAxisMotionVector The acceleration is transferred from the variable
.r64LineAcceleration toPosAxis.MotionStateData.commandAcceleration, the following sign
adaption is done:
r 64LineSpeed
r 64LineAccele ration  commandAcc eleration 
abs(r 64LineSpeed )
lineAxisMotionVector The position / counter information is transferred from the variable
.r64LineFeedback toPosAxisPositioningState.ActualPosition, none conversions are done.
toLineAxis = An external encoder is configured as setpoint source. The values are directly accepted.
TO#external
The internal standstill signal is derived from the toExternalEncoderType.¬MotionState.-
EncoderType
stillstandVelocity variable.
lineAxisMotionVector The machine velocity is derived from the variable
.r64LineSpeed toExternalEncoderType.MotionState.velocity.
r 64LineSpeed  absvelocity
The velocity units depend on the axis configuration and are specified
using the configuration parameter
sWinderConfig.sUnitConfig.eUnitLineAxisVelocity [ LU / TU ].

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Source of Description
master value
lineAxisMotionVector The acceleration is taken from the variable
.r64LineAcceleration toExternalEncoderType.MotionState.acceleration, the following sign
adaptation is made:
r 64LineSpeed
r 64LineAcceleration  acceleration 
abs(r 64LineSpeed)
lineAxisMotionVector The position and/or counter information is taken from the variable
.r64LineFeedback toExternalEncoderType.MotionState.position, no conversions are
made.

11.5 System of units

The block is designed so that any units are possible when it comes to the
configuration of the leading axis (lineAxis) and the winder axis (winderAxis). The
conversion factors are determined in the block itself as a result of the configuration.
The leading axis units are specified as follows:

Table 11-9 Specification of the leading axis units

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Configuration data Values

sWinderConfig.sUnitConfig.eUnitLineAxisV M_MIN, MM_MIN, M_S, MM_S, FT_MIN, INCH_MIN,
elocity FT_S, INCH_S, DEG_S_PRINT
sWinderConfig.sUnitConfig.eUnitLineAxisAc M_S2, MM_S2, FT_S2, INCH_S2, DEG_S2_PRINT
celeration

The constants [DEG_S_PRINT] and [DEG_S2_PRINT], are required for print

applications using a rotary leading axis, resulting in an internal conversion of the
rotary velocity into a linear velocity with the proportional relationship 360°/s = 1m/s
or 360°/s² = 1m/s². The parameters involved therefore have the following units
[LU/TU] = [m/s] or [LU/TU²] = [m/s²].
The winder axis units are specified as follows:

Table 11-10 Specification of the winder axis units

Configuration data Value
sWinderConfig.sUnitConfig.eUnitWinderAxi RPM, RPS, DEG_MIN, DEG_S
sVelocity

The following table shows the abbreviations used for the speed and position axis
units – in order to remain consistent for the metric as well as also the Anglo-
American dimension system. LU stands for a length unit, TU stands for time unit.

Table 11-11 Used units

Measured variable Unit Metric Anglo-American
Length LU e.g.: m (meter) e.g.: ft (foot)
Length (bigger unit) LUb M (meter) Ft (foot)
Velocity LU / TU e.g.: m / min e.g.: ft / min

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Measured variable Unit Metric Anglo-American

Acceleration LU / s² e.g.: m / s² e.g.: ft / s²
Speed r / TU or °/TU e.g.: U / min e.g.: rpm
Mass, weight m kg lb
Density m / Lub³ kg / m³ lb / ft³
Mass inertia J = mLUb² kgm² lbft²
Torque M = mLUb²/s² Nm = kgm²/s² lbf ft = lbft²/s²
Load, tension Z = mLUb/s² N = kg m / s² lbf = lb ft / s²

The conversion factors are assigned constants using the specification made,
whereby users do not have to get involved with the internal conversion factors.

Table 11-12 Parameterizing the lineAxis corresponding to the axis configuration

Measured quantity Metric Anglo-American
Units Enum Units Enum
Velocity m / min M_MIN ft / min FT_MIN
mm / min MM_MIN inch / min INCH_MIN
m/s M_S ft / s FT_S
mm / s MM_S inch / s INCH_S
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360° / s = 1m DEG_S
/s _PRINT
Acceleration m / s² M_S2 ft / s² FT_S2
mm / s² MM_S2 inch / s² INCH_S2
360° / s² = 1m DEG_S2_PRI
/ s² NT

For the case toLineAxis = TO#driveAxis, the units of the leading axis diameter
((sWinderConfig).r32LineAxisDiameter) define the units of the velocity and
acceleration of the lineAxis.

Table 11-13 Parameterizing the winderAxis corresponding to the axis configuration

Measured quantity Metric Anglo- American
Units Enum Units Enum
Velocity / speed rev / min RPM rpm RPM
rev / s RPS rps RPS
° / min DEG_MIN ° / min DEG_MIN
°/s DEG_S °/s DEG_S

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11.5.1 Units of the velocity setpoint calculation

The velocity setpoint is given by the master axis and stored in the variable
sWinderDiag.sActLineAxisMotionVector.r64LineSpeed. If the axis control
(sWinderConfig.eFBMode = AXIS_CONTROL) is activated, the setpoint is
converted and written on the variable winderAxis.defaultMotionIn.velocity in the
winder axis TO. The conversion factors guarantee the conversion into the TO-
specific units. The result is also displayed at the FB at the output velocity.
The unit of the variable sWinderDiag.sActLineAxisMotionVector.r64LineSpeed is
[LU / TU ], (e.g. m/min at the metric system) and depends on the configured unit in
the master TO or on the external presetting.
The conversion constants determined by the system will now be explained using
two examples.

Example 1
Table 11-14 Example 1
Configured units Configuration of the units Conversion constants Result
at the TO (sWinderConfig)
lineAxis: [m / min] eUnitLineAxisVelocity= M_MIN lineAxisIntoLinear r64LineSpeed -> [ m / min ]
lineAxis: [m / s²] eUnitLineAxisAcceleration= M_S2
= 1.0 [ LU / TU  LU / TU ] velocity (output) -> [ 1 / min ]
lineAxisIntoLUb
winderAxis: [rpm] eUnitWinderAxisVelocity =
= 1.0 [ LU  LUb ] LU : [m]
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RPM
lineAxisIntoLUPerSecond Lub : [m]
= 1.0 / 60.0 [ LU / TU  LU / s ] TU lineAxis: [ min ]
lineAxisIntoLUbPerSquareSecond TU winderAxis : [ min ]
= 1.0 [ m / s²  LUb / s² ]
winderAxisIntoPerSecond diameter -> [ m ]

= 1.0 / 60.0 [ U / TU  U / s] (refer to the units, diameter

calculator)
winderAxisIntoRpTU
= 1.0 [U / TU  U / TU]

Example 2
Table 11-15 Example 2
Configured units Configuration of the units Conversion constants Result
at the TO (sWinderConfig)
lineAxis: [mm / s] eUnitLineAxisVelocity= MM_S lineAxisIntoLinear r64LineSpeed -> [ mm / s ]
lineAxis: [m / s²] eUnitLineAxisAcceleration= M_S2
= 1.0 [ LU / TU  LU / TU ] velocity (output) -> [ ° / min ]
lineAxisIntoLUb
winderAxis: [° / min] eUnitWinderAxisVelocity =
DEG_MIN = 1.0 / 1000.0 [ LU  LUb ] LU : [ mm ]
lineAxisIntoLUPerSecond Lub : [m]
= 1.0 [ LU / TU  LU / s ] TU lineAxis: [s]
lineAxisIntoLUbPerSquareSecond TU winderAxis : [ min ]
= 1.0 / 1000.0 [ mm / s²  Lub / s² ]
winderAxisIntoPerSecond diameter) -> [ mm ]

= 1.0 / 60.0 [ U / TU  U / s ] (refer to the units, diameter

calculator
winderAxisIntoRpTU
= 1.0 / 360.0 [ ° / TU  U / TU ]

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Example 3:
Table 11-16: Example 3
Configured Configuration of the units Conversion constants Result
units at the TO (sWinderConfig)
lineAxis: [1 / min] eUnitLineAxisVelocity= M_MIN lineAxisIntoLinear r64LineSpeed -> [ m / min]
lineAxis: [1/ s²] eUnitLineAxisAcceleration= M_S2
= 1.0 [ LU / TU  LU / TU ]
lineAxisIntoLUb velocity (output) -> [ 1 / min ]
Note:
The LU configuration of the unit = 1.0 [ LU  LUb ]
relates from r32LineAxisDiameter lineAxisIntoLUPerSecond LU : [m]
which need to be defined in [m] in
this case! = 1.0 / 60 [ LU / TU  LU / s ] LUb : [m]
lineAxisIntoLUbPerSquareSecond TU lineAxis: [ min ]
winderAxis: [rpm] eUnitWinderAxisVelocity = RPM = 1.0 [ mm / s²  LUb / s² ] TU winderAxis: [ min ]
winderAxisIntoPerSecond
= 1.0 / 60.0 [ LU / TU  LU / s] diameter -> [ m ]
winderAxisIntoRpTU (refer to the units, diameter
calculator)
= 1.0 [U / TU  U / TU]

Example 4: Winder in Print Standard

Table 11-17: Example 4
Configured Configuration of the units Conversion constants Result
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units at the TO (sWinderConfig)

lineAxis: [° / s eUnitLineAxisVelocity= lineAxisIntoLinear r64LineSpeed -> [ m / s]
lineAxis: [° / s²] DEG_S_PRINT
= 1.0 / 360 [ ° / TU  LU / TU ] r64LineAcceleration
eUnitLineAxisAcceleration =
DEG_S2_PRINT lineAxisIntoLUb -> [ m / s²]
Note:
The line axis is a = 1.0 [ LU (m)  LUb (m) ]
rotatory positioning Note:
lineAxisIntoLUPerSecond additiveVelocity (output) ->
axis when operating The virtual circumference of the Print [°/s]
with Print Standard! Standard axis VA_GM, which is = 1.0 [ LU / s  LU / s ]
usually used as master axis for the lineAxisIntoLUbPerSquareSecond
winder, is 1m (360° = 1m)! LU : [m]
= 1.0 [ m / s²  LUb / s² ]
LUb : [m]
winderAxisIntoPerSecond
winderAxis: [° / s] eUnitWinderAxisVelocity = RPM TU lineAxis: [s]
= 1.0 [ LU / TU  LU / s]
TU winderAxis: [s]
winderAxisIntoRpTU
= 1.0 / 360 [° / TU  U / TU]
diameter -> [ m ]
(refer to the units, diameter
calculator)

NOTE When using the Motion Interface by the command _runVelocityBasedMotionIn

the following has to be regarded:
When transmitting the command with default values, the dynamic data of
userDefaultDynamics at this moment are used and can be changed after that
only by a new call of the command. Therefore a cyclic change of the dynamic
values is not possible via userDefaultDynamics. To change the dynamic values
nevertheless, it is possible to minimize the maximum and the minimum limits via
plus/minus-limitsofdynamics.positiveaccel or. Plus/minus-
limitsofdynamics.negativeaccel. But reaching a limit, a message appears that
can be acknowledged or removed.

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11.5.2 Units of the torque calculation

Using a winder application, the necessary torque is consists of 3 components:

 Friction torque: typically gathered as friction characteristic curve either in the
drive or in the superposed control
 Pre-control torque: derived from the acceleration of the central machine ramp
function generator or a master axis
 Load torque: Torque for setting the material load

For special applications there is also the possibility to pre-control the acceleration
component that results from the diameter changes:
 Pre-control torque based on the diameter change

Table 11-18 Torque calculation

Components Calculation Metric Anglo-
American
Friction torque Characteristic curve Mfrict = [ kgm²/s² ] = [Nm ] Mfrict = [ lbft²/s² ] = [ lbf ft ]
= Mfrict
Pre-control torque Macc = J * α J = [ kgm² ] J = [ lbft² ]
acceleration α = [ 1/s² ] α = [ 1/s² ]
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Maccl = [ kgm²/s² ] = [Nm ] Macc = [ lbft²/s² ]

Tension Torque Mload = F * r F = [ N ] = [ kgm/s² ] F = [ lbf ] = [ lbft/s² ]
r=[m] r = [ ft ]
Mload = [ kgm²/s² ] = [ Nm ] Mload = [ lbft²/s² ] = [ lbf ft ]
Pre-control torque MD = J * v / J = [ kgm² ] J = [ lbft² ]
diameter change (π * dt) v=[m/s] v = [ ft / s ]
* (1/dn – 1/dn-1) d=[m] d = [ ft ]
dt = [ s ] dt = [ s ]
MD = [ kgm²/s² ] = [Nm ] Mdiameter = [ lbft²/s² ] = [ lbf ft ]

Generally, all of the parameters for the torque calculation should be configured
in the basis units (exception, friction characteristic in the units of the
winderAxis). The default units for the torque when creating an axis is [ Nm ];
the units must be converted to [ lbf ft ] for the Anglo-American dimension
system.
11.5.3 Units of the diameter calculation

Calculation mode: DIAM_CALC, DIAM_CALC_INTEGRAL:

using the factor
sConversionConstantsType.r32LineAxisIntoLUPerSecond and the winder velocity

sConversionConstantsType.r32WinderAxisIntoPerSecond, before the values are

further conditioned for the diameter calculation. Using the factor
sConversionConstantsType.r32WinderAxisIntoRpTU, the winder velocity is
converted into [ U / TU ] already when the parameter is transferred.
Calculation mode: DIAM_THICKNESS_ADDITION

sConversionConstantsType.r32LineAxisIntoPerSecond before the values are

further conditioned for the diameter calculation.
Calculation mode: DIAM_CALC_POSITION

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The counter or position value of the winder axis is normalized to the number of
winder revolutions using the factor sDiamConfig.r64WindingShaftFeedbackScal
and the counter or position value of the material axis is normalized to the length
units using the factor sDiamConfig.r64LineFeedbackScal.

Example:
Counter or position information of the winder axis in [ ° ]
Counter or position information of the material in [ m ]
This means that the feedback signal of the winder axis is evaluated using this
factor sDiamConfig.r64WindingShaftFeedbackScal = 360.0 and the feedback of
the material length measuring system is evaluated using the factor
sDiamConfig.r64LineFeedbackScal = 1.0 (as a consequence: LU = [m]).
Diameter conditioning:
For the plausibility check and the diameter rate-of-rise limit, the reference is
defined by the material thickness; this means that the material thickness must
always be specified in LU.
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11.6 Web break detection

The integrated web break detection monitors the actual value of the technology
controller (input value actValuePID) or in case of indirect tension control the actual
torque – depending on the configured control mode. The Monitoring consists of
limits and the following switch-on delay. By the limits a lower and an upper error
limit is described.

NOTICE With CONSTANT_V_CONTROL, web break detection is not possible.

The web break detection is activated via the variable boEnable in of the structure
sWinderConfig.sWebBreakDetection. In addition a velocity threshold (for line axis
speed) can be defined by the variable
sWinderConfig.sWebBreakDetection.r32MinSpeed, that activates the monitoring.
The active monitoring is displayed using the
sWinderDiag.sWebBreakDetectionDiag.boWebBreakDetectionActive feedback
signal.
The actual value is provided for the FB in the input variable actValuePID, for
indirect tension control the actual torque is determined from the axis object itself.
The limits are adjusted via the parameters r32LowerLimitError, and
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r32UpperLimitError in the structure sWinderConfig.sWebbreakDetectionConfig.

Crossing a limit is displayed by the acknowledgement
boLowerLimitErrorWebbreakReached and boUpperLimitErrorWebbreakReached.
In addition the output webBreak is set at the FB when crossing an error limit. The
response time of the feedback signals is parameterized using the tDelayTime
response time. In case of indirect tension control the limit values are defined in
percentage of the reference torque.
Internally, the signal deactivates the technology controller (except for indirect
tension control); all other responses to the web break detection must be
programmed in the user program.
In case of indirect tension control the difference between the setpoint and actual
torque is evaluated. The difference is interpreted as a percentage value of the
reference torque value.

abs(torqueSetpoint  torqueActual)
errorSigna l   100.0%
torqueNomi nal

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 11 Function description

Figure 11-11 Web break detection

boEnable
[LU/TU]
r64LineSpeed boWebbreak
x & DetectionActive
>
[LU/TU] y
r32MinSpeed

[Z] / [%] / [LU]

r32UpperLimitErro
r

controlMode boUpperLimit
[Z] / [LU] / [%] & ErrorWebbreak
actValuePID LU LUR TON q
<> INDIRECT
Reached
?
[M] + [%] X X
Mset ÷ ?
≥ webBreak
- = INDIRECT
[M] LL LLR PT
Mact
boLowerLimit
[M]
Mref & ErrorWebbreak
TON q
[Z] / [%] / [LU] Reached
r32LowerLimitErro
r X
[ms]
tDelayTime PT

Web break detection and flying control mode change

If a flying control mode change is performed during web break detection is active,
the web break detection configuration parameter
sWinderConfig.sWebBreakDetectionConfig.r32LowerLimitError und
r32UpperLimitError need to be changed dependent on the new control mode.
 Siemens AG 2018 All rights reserved

E.g. change from position limit (during dancer position control) to torque limit
(tension control torque limiting with load cell).

11.7 Kp adaptation of the speed controller

The diameter – and therefore also the moment of inertia of the wound roll –
permanently changes as the roll is wound. This is the reason that it is necessary to
adapt the controller gain of the speed controller to the mechanical relationships at
the winder (especially for speed controlled winding types).
The block provides the scaling factor for the speed controller adaptation at output
kpAdaptionRatio. The adaptation factor is configured using the configuration
variable sWinderConfig.eGainAdaptionMode.

Table 11-19 Kp adaption

eGainAdaptionMode Description
NO_ADAPTION The output kpAdaptionMode is set to 100% = 16#4000.
DIAMETER_RATIO The kpAdaptionMode output is formed from the
diameter/maximum diameter ratio and corresponds to
100% if the actual diameter corresponds to the maximum
diameter.
INERTIA_RATIO The kpAdaptionMode output is formed from the ratio,
moment of inertia / maximum moment of inertia and
corresponds to 100% if the actual diameter corresponds
to the maximum diameter.

The kpAdaptionRatio output must be manually interconnected. In this case, the

telegram to the drive must be extended by one word so that the value of this
scaling is sent to the drive.

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 11 Function description

11.8 Dancer compensation for diameter calculation

Using the diameter calculation modes DIAM_CALC, DIAM_CALC_INTEGRAL and

DIAM_CALC_POSITION the actual winder diameter is calculated considering the
line velocity resp. line position feedback.
Is the winder controlled by a dancer, dancer movements are influencing the
calculated diameter.
The functionality dancer compensation for diameter calculation determines the web
length change caused by a dancer movement and compensates, dependent on the
selected diameter calculation mode, the line velocity or line position.

The compensation can be activated with the configuration parameter

sWinderConfig.sDiamConfig.boEnableDancerCompensation.

NOTE The winder must operate in a dancer controlled winding control mode.

NOTE Only for diameter calculation modes DIAM_CALC, DIAM_CALC_INTEGRAL and

 Siemens AG 2018 All rights reserved

DIAM_CALC_POSITION

The compensation is based on the configuration parameter

sWinderConfig.sDiamConfig.r32RefWebLengthDancer
The parameter defines the web length change if the dancer moves by 100 units in
respect to the defined dancer unit (%, mm, etc.).
The value must be defined in [LU].

The following examples explain the parameter setting:

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 11 Function description

Configuration example 1:
 Tänzerposition in [%] VLine [mm/s]
 Bahngeschwindigkeit
in [mm/s]
 LU = [mm]
 Tänzerhub = 200 mm 100 %

Bei einer Änderung der

Tänzerposition um 100 % ergibt

200 mm
sich hierfür eine
Bahnlängenänderung um den 50 % actValuePID
doppelten Tänzerhub

r32RefWebLengthDancer = 400
mm
0%

Configuration example 2:
 Tänzerposition in VLine [mm/s]
[mm]
 Bahngeschwindigkeit
in [mm/s]
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 LU = [mm] 200 mm
 Tänzerhub = 200 mm
Bei einer Änderung der
200 mm

Tänzerposition um 100 mm
ergibt sich hierfür eine 100 mm actValuePID
Bahnlängenänderung um den
doppelten Tänzerhub

r32RefWebLengthDancer = 200 0 mm
mm [LU]

Configuration example 3:
 Tänzerposition in VLine [m/min]
[cm]
 Bahngeschwindigkeit
in [m/min]
 LU = [m] 20 cm
 Tänzerhub = 20 cm
Bei einer Änderung der
Tänzerposition um 100 cm
20 cm

ergibt sich hierfür eine 10 cm actValuePID

Bahnlängenänderung um den
doppelten Tänzerhub

r32RefWebLengthDancer = 2 m 0 mm
[LU]

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 11 Function description

11.9 Application faults and warnings

Application faults and warnings will be displayed at the FBLConWinder outputs

error and errorID.

The errorID is composed of two parts:

 The first part – the FB-ID – gives information about the function or function
block where the current fault occurred.
 The second part is the real error/warning ID, which gives information about the
current fault.

The error-ID 16#0000_8001 (the functions block is called in a wrong task) can
appear in combination with different FB-ID’s.

FB-ID’s

Table 11-20 FB-ID’s

FB-ID Beschreibung
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16#0207_0000 FBLConWinder
16#0206_0000 FBLConSetUnits
16#0201_0000 FBLConDiameterCalculation
16#0203_0000 FBLConTorquePreControl
16#0205_0000 FBLConTaperCharacteristic
16#0209_0000 FBLConThicknessAverage
16#010F_0000 FCLConCalculateDistance
16#010C_0000 FBLConLevelControl
16#010D_0000 FBLConAverageValue
16#010E_0000 FBLConRFGJerkLimit
16#0101_0000 FBLConPT1
16#0102_0000 FBLConINT
16#0103_0000 FBLConDIF
16#0104_0000 FBLConDT1
16#0105_0000 FBLConPolygonA
16#0106_0000 FBLConPolygonB
16#0107_0000 FBLConRFG
16#0108_0000 FBLConFrictionMeasurement
16#0109_0000 FBLConEnableInterface
16#0110_0000 FBLConPIDController
16#0208_0000 FBLConTechnologyController
16#0301_0000 FBLConSpliceSequence
16#0302_0000 FBLConSpliceCalculation
16#0303_0000 FBLConTapeDetection

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Warnings
 error = FALSE
 errorID <> 16#000_000

Table 11-21 Application warnings

ErrorID Beschreibung
16#xxxx_0000 no warning
16#xxxx_4002 Invalid configuration
16#0201_4002 FBDiameterCalculation specific description:
The latchDiamCalc variable contains a value that is outside of the defined limits. Probably no
or a wrong diameter has been set.
FBPIDController specific description:
Invalid parameter. Parameter are limited internal if
16#0110_4002
derivTime < Tcycle,
integTime < Tcycle / 2
16#xxxx_4005 No value was found in the table of the entered values
16#xxxx_4008 The table of the entered values is not monotonically increasing
16#xxxx_4051 The winder axis was deactivated during operation (winder.control <> ACTIVE).
16#xxxx_4052 Invalid interpolation mode selected. Interpolation_1 is used instead.
16#xxxx_4053 Control mode change not possible. The old control mode has been maintained
 Siemens AG 2018 All rights reserved

16#xxxx_4054 Dancer compensation for diameter calculation only possible with DIAM_CALC,
DIAM_CALC_INTEGRAL and DIAM_CALC_POSITION
16#xxxx_4055 Dancer compensation for diameter calculation only possible with dancer controlled control
modes
16#xxxx_4056 sWinderConfig.sDiamConfig.r32RefWebLengthDancer is <= 0.0

Faults
 error = TRUE
 errorID <> 16#000_000

Table 11-22 Application faults

errorID Beschreibung
16#xxxx_0000 no fault
16#xxxx_8001 The FB is called in a wrong task.
16#xxxx_8003 Number of polygon table entries too small
16#xxxx_8004 Number of polygon table entries too big
16#xxxx_8005 Invalid configuration data – one or more parameter are invalid
16#0207_8005 FBLConWinder specific description:
Invalid configuration data:
Only with lineAxis = driveAxis:
r32lineAxisDiameter <= 0.0
Only with technology data block:
r32LowerLimitTorqueLimit > 0 or r32LowerLimitTorqueLimit < -200.0
r32UpperLimitTorqueLimit > 0 or r32UpperLimitTorqueLimit < -200.0
The winder functionality is not activated.
16#0201_8005 FBDiameterCalculation specific description:
One or more configuration data are not valid or wrong.

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 11 Function description

errorID Beschreibung
R32DiamMin <= 0.0
r32DiamMax <= r32DiamMin
r32WebThickness <= 0.0
r32AdjustWebThickness <= 0.0
FBPIDController / FBTechnologyController specific description:
Invalid parameter:
16#0110_8005
sTechnologyControllerConfig.r32Upperlimit <=
16#0208_8005
sTechnologyControllerConfig.r32Lowerlimit
sTechnologyControllerConfig.r32SetNominalValue <= 0.0
16#0205_8005 FBTaperCharacteristic specific description:
Invalid input parameters.
diamActVal <= 0.0
sTensionTaperConfig.r32UpperLimitTaper < sTensionTaperConfig.-r32LowerLimitTaper
sTensionTaperConfig.r32LowerLimitTaper < 0.0
For TAP_CHAR_LINEAR, TAP_CHAR_HYPERBOLIC_1, TAP_CHAR_HYPERBOLIC_2:
sTensionTaperConfig.r32TensionTaperDiameterStart < 0.0
sTensionTaperConfig.r32TensionTaperDiameterMax <= sTensionTaperConfig.-
r32TensionTaperDiameterStart
sTensionTaperConfig.r32TensionTaperRatio < 0.0
sTensionTaperConfig.r32ensionTaperRatio > 100.0
16#0203_8005 FBTorquePreControl specific description:
One or more configuration data are not valid or they are outside of the defined limits:
sMomentConfig.r32GearRatio <= 0.0
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sMomentConfig.r32Density < 0.0

sMomentConfig.r32DiamMin <= 0.0
sMomentConfig.r32DiamMax < sMomentConfig. R32DiamMax
sMomentConfig.r32Width < 0.0
sMomentConfig.r32Jfix < 0.0
sMomentConfig.r32Jmandrel < 0.0
sMomentConfig.r32Jmot < 0.0
16#0209_8005 FBThicknessAverage specific description:
One or more configuration data are not valid :
ThicknessMeasuringRevCount < DiameterMeasuringRevCount
DiameterMeasuringRevCount <= 0
16#0206_8005 FBSetUnits specific description:
The requested dimension unit is not implemented
16#xxxx_8006 The diameter value is not valid:
diamActVal <= 0.0
diamActVal < sMomentConfig.r32DiamMin
16#xxxx_8007 Measuring unit is wrong or not existent
DIAM_CALC_POSITION
sDiamConfig.r64WindingShaftFeedbackScal <= 0.0
sDiamConfig.r64LineFeedbackScal <= 0.0
16#xxxx_8051 The winder axis is not activated (winderAxis.control <> ACTIVE).
16#xxxx_8065 Error rewind monitoring:
At control with torque Limits the winding axis is not allowed to turn more than 50 rpm in the
opposite direction. This error is preventing a runaway of the winder in case of e.g. webbreak
by set full torque Limits and Setpoint zero. The Velocity of 50 is a constant in the Winder FB
and can be adjusted if required.
The Error can only be reset by switch off the winder.
16#xxxx_8100 Error while activating the axis. The return value of _enableAxis() is not 0.
16#xxxx_8101 Error while move command of the axis. The return value of _move() is not 0.
16#0109_8101 Error while deactivating the MotionIn interface.
The return value of the command _move is not 0.

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 11 Function description

errorID Beschreibung
16#xxxx_8103 Error while stopping the axis. The return value of _stop() is not 0.
16#xxxx_8104 Error while deactivating the axis. The return value of _disableAxis() is not 0.
16#xxxx_8105 Error while activating the MotionIn interface with velocity-reference.
The return value of the command _runVelocityBasedMotionin is not 0.
16#xxxx_8106 Error while activating the additive torque interface.
The return value of the command _enableAxisAdditiveTorque is not 0.
16#xxxx_8107 Error while activating the negative torque limit interface.
The return value of the command _enableAxisTorqueLimitNegative is not 0.
16#xxxx_8108 Error while activating the positive torque limit interface.
The return value of the command _enableAxisTorqueLimitPositive is not 0.
16#xxxx_8109 Error while deactivating the positive torque limit interface.
The return value of the command _disableaxistorquelimitpositive is not 0.
16#xxxx_810A Error while deactivating the negative torque limit interface.
The return value of the command _disableaxistorquelimitnegative is not 0.
16#xxxx_810B Error while deactivating the additive torque interface.
The return value of the command _disableAxisadditiveTorque is not 0.
16#xxxx_810C
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Error while deactivating the MotionIn interface.

The return value of the command _runPositionBasedMotionIn is not 0.
16#xxxx_810D Diameter calculation mode “DIAM_CALC_POSITION“ is not possible with a drive axis
16#xxxx_C000 Invalid case step in case loop
16#xxxx_C001 No axis specified at input axis
16#0207_C001 No axis specified at input winderAxis
16#xxxx_C002 Error in the axis or in the winder configuration. The winder functionality has been configured
for the operation with torque limits, but the axis contains no technology data block.
16#xxxx_C004 Invalid axis type. There are only real axes admitted for the winder axis and for the line axis
only real or virtual axes, that means either
winderAxis.typeOfAxis <> REAL_AXIS or
lineAxis.typeOfAxis <> VIRTUAL_AXIS or
lineAxis.typeOfAxis <> REAL_AXIS
16#xxxx_C005 The setpoint inversion of the winder axis has been activated. In order to change the rotation
direction, but to maintain the polarity of the setpoint and the actual values, the rotation
direction has to be changed in the converter (see also parameter 1821).
16#xxxx_C013 Time monitoring (watchdog) when switching the interfaces.
An interface was not able to be activated or deactivated within one second.

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 12 Commissioning the winder function

12 Commissioning the winder function

12.1 Checking the speed actual value calibration
Principle
The maximum speed occurs at the maximum web velocity and minimum diameter.

Procedure
 Set the actual diameter the same as the core diameter of the roll to be wound
(diamSetVal= core diameter und setDiamCalc = TRUE)
 Enter the web velocity setpoint (approx. 20% of VMax)
(lineAxisMotionVector.r64lineSpeed or with TO toLineAxis)
 Operate the winder with an empty roll, switched off diameter calculation and
with the tension control switched-off (holdDiamCalc = TRUE, ctrEnable =
FALSE)
 Using a handheld tachometer, check the circumferential velocity at the roll –
this must be the same as the web velocity
 If required, check the axis setting, gearbox factor and units
 Secure the wound roll so that the material cannot fly off, measure, enter, set
and inhibit the diameter (diamSetVal = diameter setvalue, setDiamCalc =
 Siemens AG 2018 All rights reserved

TRUE, holdDiamCalc = TRUE)

 Repeat this operation with a larger diameter and higher material web velocity

12.2 Compensating the accelerating torque

Applications
If the accelerating torque is not negligibly low when compared to the other torque,
then the inertia compensation for the winder with indirect tension control and for
tension control with load cell should be set. For the tension control with dancer roll,
under certain circumstances, it is not necessary to compensate the accelerating
torque.

12.2.1 Compensating the constant moment of inertia

Principle
The fixed moment of inertia does not depend on the diameter of the roll. At the
minimum diameter (Dmin = Dcore), the total moment of inertia is equal to the fixed
moment of inertia.

Procedure
 Measure, enter and inhibit the core diameter (diamSetVal = core diameter,
setDiamCalc = TRUE , holdDiamCalc = TRUE)
 Connect the variables to calculate the moment of inertia
(sWinderConfigType.sMomentConfig.r32Jmot,
sWinderConfigType.sMomentConfigType.r32Jfix,
sWinderConfigType.sMomentConfigType.r32Jmandrel, etc)
 Accelerate and decelerate the winder with the machine ramp

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 12 Commissioning the winder function

 The speed controller output r1480 (monitor in the drive) must be at a minimum.

The speed controller output while accelerating must be minimum. If this is not the
case, the values for the fixed moment of inertia must be checked
(sWinderConfigType.sMomentConfigType.r32Jmot,
sWinderConfigType.sMomentConfigType.r32Jfix,
sWinderConfigType.sMomentConfigType.r32Jmandrel).

12.2.2 Compensating the variable moment of inertia

Principle
The variable component of the moment of inertia is defined by the wound material
and therefore depends on the diameter of the roll being wound.
For gearboxes with high ratios, frequently, the component of the variable moment
of inertia can be neglected.

Procedure
Carry-out the steps described above in the general procedure for a half, full and
completely unwound roll. It is important that the roll is tied and secure and cannot
accidentally unwind!
The speed controller output must be at a minimum while accelerating. If this is not
 Siemens AG 2018 All rights reserved

the case, the values for the variable moment of inertia must be checked
(sWinderConfigType.sMomentConfigType. r32width,
structWinderConfig.sMomentConfigType. r32density).
Repeat the measurement with a full wound roll.

12.3 Setting the Kp adaptation for the speed controller

Measure required
The proportional gain of the speed controller should be generally adapted to the
variable moment of inertia. For a ratio Dmax/Dmin > 3, it is absolutely necessary to
optimize the Kp adaptation for good winding characteristics and fast
commissioning.

Procedure
Set the actual diameter of the roll using the command diamSetVal = Dact and
setDiamCalc = TRUE, with which the speed controller is to be optimized.
Generally, this is the minimum and maximum diameter of the roll.
The adaptation is carried-out using a polygon characteristic with 2 points along the
characteristic in the drive. The actual moment of inertia is the input quantity for the
characteristic – that is provided from the winder FB in the output variables
kpAdaptionRatio as an scaled WORD (0-100%) and can be transferred to the drive
via the extended Profibus telegram. The adaptation is set in the drive using
parameters P1456 to P1459 (SINAMICS S120). The output of the adaptation acts
as weighting on the selected Kp. This means that the Kp is set for the full wound
roll and then is reduced to the Kp determined for an empty roll along the adaptation
characteristic.

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12.4 Checking the tension pre-control

With load cell
 Check the control sense – if the sign is incorrect, invert the analog input e.g. in
SINAMICS
 Filter the tension actual value signal; we recommend that you use the analog
inputs of the SINAMICS drive or a fast I/O module (TB30/TM31) as this can be
appropriately quickly sampled. Depending on the dynamic response of the
application, the actual value signal of the load cell should be appropriately
scaled and filtered.
 De-activate tension (ctrlEnable = FALSE), thread the material web and clamp
 Check the diameter and if required correct it
 Enter a fixed tension setpoint (tensionSetpoint)
 Switch-on the tension at standstill (ctrlEnable = TRUE)
 The pre-control must set the required tension

For dancer rolls

 Check the control sense – if the sign is incorrect, invert the analog input

 Siemens AG 2018 All rights reserved

Filter the position actual value signal; we recommend that you use the analog
inputs of the SINAMICS drive or a fast I/O module (TB30/TM31), as this can be
appropriately quickly sampled. Depending on the dynamic response of the
application, the actual value signal of the dancer roll position should be
appropriately scaled and filtered.
 De-activate the tension (ctrlEnable = FALSE), thread the material web and
clamp
 Check the diameter and if required correct it
 Enter a fixed position setpoint (positionSetpoint) (center position)
 Switch-in the tension at standstill (ctrlEnable = TRUE)
 The setpoint (reference) position of the dancer roll is approached
(positionSetpoint)

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 12 Commissioning the winder function

12.5 Setting and optimizing the technology controller, Kp

adaptation
For tension control with load cell it is necessary to adapt to the variable moment of
inertia. Indirect tension control does not require any adaptation and also the
technology controller does not have to be set (as it is not used).

Optimizing the technology controller

The technology controller is optimized according to the usual technique; this is
done, for example, by entering a low supplementary tension setpoint and
monitoring the tension actual value. A dampened stabilizing sequence must always
be able to be monitored. The optimization should be carried-out at various diameter
values. While optimizing, a start should be made with extremely “slow” controller
settings and the controller output limited
(sWinderConfigType.sTechnologyControllerConfigType.r32UpperLimit und
sWinderConfigType.sTechnologyControllerConfigType.r32LowerLimit).

Table 12-1 Important Parameters for Optimization of Technology Controller

Parameters Description
 Siemens AG 2018 All rights reserved

sWinderConfigType.sTechnologyControllerConfigType. Activate P Action component

sPIDData.boEnPChannel
sWinderConfigType. sTechnologyControllerConfigType. Activate I Action component
sPIDData.boEnIChannel
sWinderConfigType. Activate D Action Component
sTechnologyControllerConfigType.sPIDData.boENDChannel
sWinderConfigType.sTechnologyControllerConfigType. KP P-Action coefficient incl. adaption
r32Kp1 / r32Kp2 / r32X1 / r32X2
sWinderConfigType. TN integration time [ms]
sTechnologyControllerConfigType.r32IntegTime
sWinderConfigType. TD Derivative Time [ms]
sTechnologyControllerConfigType.r32DerivTime
sWinderConfigType. Upper Limit of controller Output
sTechnologyControllerConfigType.r32LowerLimit
sWinderConfig.sDatasetPID.lowerLimit Lower Limit of controller Output

12.6 Setting the override value

For tension control via torque limiting, the value should be selected so that the
speed controller, under normal operating conditions, is always at its limit. It only
leaves this when the web breaks and prevents the winder from accelerating in an
uncontrolled fashion, e.g. 5% of the max. machine speed.

NOTE For tension control via speed adaptation, the override factor
sWinderConfig.r32Override is not active.

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 13 Appendix

13 Appendix
13.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
Siemens Industry Online Support offers round the clock access to our entire
service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
https://support.industry.siemens.com/

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts. Please send queries
to Technical Support via Web form:
 Siemens AG 2018 All rights reserved

https://www.siemens.com/industry/supportrequest

SITRAIN – Training for Industry

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
https://www.siemens.com/sitrain

Service offer
Our range of services includes the following:
 Plant data services
 Spare parts services
 Repair services
 On-site and maintenance services
 Retrofitting and modernization services
 Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
https://support.industry.siemens.com/cs/sc

Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for Apple iOS, Android and Windows

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 13 Appendix

Phone:
https://support.industry.siemens.com/cs/ww/en/sc/2067

13.2 Application support

Siemens AG
Digital Factory Division
Factory Automation
Production Machines
DF FA PMA APC
Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: [email protected]

13.3 Links and literature

Table 13-1
No. Topic
\1\ Siemens Industry Online Support
 Siemens AG 2018 All rights reserved

https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/35818687
\3\ SIMOTION/SIMATIC/SINAMICS – Converting Toolbox
https://support.industry.siemens.com/cs/ww/en/view/109744606

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 13 Appendix

13.4 Change documentation

Table 13-2
Version Date Modifications
V1.0 31.01.2005 first edition
V1.1 13.06.2005 Communication via Ethernet
Add-On Inputs
Add-On Outputs
V1.2 03.15.2006 Changes “General Notes”
V1.3 04.12.2006 Scout 4.0
V2.0 12.31.2006 complete revision of winder concept –
Re-adjust Documentation
V2.0.1 31.07.2007 Bug Fixes
V2.1 22.04.2008 new Winder Configuration Structure, Adapt to ST Style
Guide 3.5, HMI revision
V2.1.1 30.05.2008 Possibility of using any combination of units for the path and
winder axis
V2.2.0 14.09.2009 simplifications / styleguide
V2.2.1 20.07.2010 Direction reversal with negative line speed, bug fixes
 Siemens AG 2018 All rights reserved

V2.2.2 23.09.2011 Web break detection for indirect tension control, bug fixes
V2.2.3 26.01.2012 No changes in Winder, LconLib update
V2.3.0 08.04.2013 New control mode “constant-v-control”, bug fixes
V3.0.0 06.08.2015 Functionality extensions, reorganization of structures
V3.1.0 23.03.2016 Minor corrections in this document
V3.1.2 01.11.2016 New config parameter; Dancer compensation for diameter
calculation; Description of unit configuration revised
V3.2.3 02.03.2017 Prefix LCon added to FC/FB names;
Structures, FCs/FBs for winding with coils different from
round
V3.2.4 20.07.2017 Minor changes
V3.2.5 06/2018 No change in the manual!
V3.2.6 09/2018 No change in the manual!
V3.2.7 10/2018 No change in the manual!

Manual SIMOTION Winder

SIOS-ID: 35818687, V3.2.7, 10/2018 124