Traction Controller Parameterization for Web Tension at Standstill
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current web processing machines face challenges in automatically and efficiently parameterizing tension controllers, requiring extensive user knowledge and time-consuming processes to ensure precise tension control, especially under varying conditions such as geometric irregularities and irregular winding.
Innovation Solution
A method that involves a standstill test to determine standstill controller parameters using a frequency characteristic method, followed by creep and speed tests to optimize controller parameters, allowing for automatic determination of traction controller settings without the need for extensive user expertise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual parameterization of tension controller is performed, then precise tension control can be achieved, but extensive user knowledge and time-consuming process are required
Solution Approach 1:
The tension controller automatically determines its own parameters by executing test sequences and evaluating measured values. The controller performs standstill tests, creep tests, and speed tests, then automatically calculates optimal parameters without requiring external user input or expertise, thus eliminating time-consuming manual parameterization while maintaining precision
Solution Approach 2:
The system performs preliminary test sequences (standstill tests, creep tests, speed tests) before actual production operation to automatically determine controller parameters. These preliminary actions prepare the controller with optimized parameters in advance, eliminating the need for time-consuming manual parameterization during setup while ensuring precise tension control from the start
2Loss of time
If automatic parameterization is implemented, then parameterization time is reduced, but extensive user knowledge is still needed for proper configuration
Solution Approach 1:
The tension controller autonomously executes the entire parameterization process by automatically performing test sequences, measuring system responses, calculating parameters, and configuring itself. The controller requires no user input, knowledge, or intervention throughout the process, making it equally easy to operate for users regardless of their expertise level while achieving rapid automatic parameterization
3Stability of the object's composition
If both rollers are controlled to maintain tensile force, then tension stability is improved, but system instability occurs
Solution Approach 1:
The control system is segmented into a master roller (typically the winder) and a slave roller (typically the tension roller). The master roller's speed is actively controlled to maintain tensile force, while the slave roller operates passively or with minimal control. This segmentation prevents the instability that occurs when both rollers are actively controlled, while still achieving adequate tension stability through the master roller's control actions
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
A traction force controller (9) regulates the rotational speed (vg) of a controlled roller (2) of a web processing machine (1) in order to transport a material (3) at a line speed (v), subjected to a traction force (F), from the controlled roller (2) to another roller (6) or from another roller (6) to the controlled roller (2). To parameterize a traction force controller (9) of the controlled roller (2). During a standstill test (T0) at a line speed (v) of zero, the tractive force (F) is increased to an identification tractive force (Fw2), preferably 90% of a predetermined standstill tractive force operating point (Fop), in order to determine standstill track parameters of the tractive force track (GF,0) and to determine standstill controller parameters (RF,o) of the tractive force controller (9) from the standstill track parameters of the tractive force track (GF,0), preferably by means of a frequency characteristic curve method.The traction force controller (9) is parameterized with the standstill controller parameters (RF,o).