Tractive Force Controller Parameterization Using Standstill Tests
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Solution Overview
Problem
Current tractive force controllers in web-processing machines require extensive user knowledge and are time-consuming to parameterize, especially when dealing with geometric irregularities and fluctuating tractive forces, which can lead to instability and poor material processing quality.
Innovation Solution
A method for automatic parameterization of tractive force controllers using a standstill test, creep test, and speed test, where the tractive force is increased to an identification point to determine system and controller parameters, allowing for quick and efficient determination of PI controller parameters without requiring extensive control technology knowledge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual parameterization of tractive force controller is performed, then controller can be adapted to specific requirements, but it requires extensive user knowledge and is time-consuming
Solution Approach 1:
The tractive force controller performs self-parameterization by automatically determining system parameters through standstill tests, creep tests, and speed tests. The controller executes these tests autonomously and calculates optimal PI controller parameters without requiring external intervention or expert knowledge, thus eliminating time loss while maintaining parameter accuracy.
Solution Approach 2:
The system performs preliminary identification tests (standstill test, creep test, speed test) to determine system parameters before actual production operation. By conducting these tests in advance, the controller prepares optimal parameters beforehand, avoiding time-consuming manual adjustment during production while ensuring accurate parameterization.
2Manufacturing precision
If extensive control technology knowledge is required for parameterization, then accurate controller parameters can be obtained, but the operation becomes complex and time-consuming
Solution Approach 1:
The tractive force controller autonomously performs system identification and parameter optimization without requiring user expertise in control technology. The controller automatically executes tests, analyzes system response, and determines optimal PI parameters, making the operation simple while maintaining high manufacturing precision through accurate parameterization.
Solution Approach 2:
The system performs preliminary identification tests to characterize the tractive force system before production. By determining system parameters in advance through automated tests, the controller eliminates the need for complex manual tuning during operation, simplifying ease of operation while ensuring manufacturing precision through pre-optimized parameters.
3Productivity
If geometric irregularities and fluctuating tractive forces are present, then material transport continues, but tractive force stability deteriorates
Solution Approach 1:
The tractive force controller dynamically adapts to geometric irregularities and fluctuating tractive forces by continuously monitoring system behavior and adjusting control parameters. The controller performs identification tests under actual operating conditions and adapts PI parameters to maintain tractive force stability while ensuring continuous material transport productivity.
Solution Approach 2:
The system implements feedback control by measuring actual tractive force and comparing it with target values. The controller uses this feedback to continuously adjust the controlled roller speed, compensating for geometric irregularities and fluctuating forces. This feedback mechanism maintains tractive force stability while ensuring uninterrupted material transport.
Data Source
AI summary
Method and parameterization unit for parameterization of a tractive force controller of a controlled roller of a web-processing machine, the tractive force controller controlling a speed of the controlled roller in order to transport a material on the web-processing machine from the controlled roller to a further roller or from a further roller to the controlled roller at a line speed and while being subjected to the tractive force. The method includes, during a standstill test at a line speed of zero, increasing the tractive force to an identification tractive force, preferably 90% of a predetermined standstill tractive force operating point, to determine standstill system parameters of the tractive force system, to calculate standstill controller parameters of the tractive force controller from the standstill system parameters of the tractive force system, preferably by a frequency characteristic method, and to parameterize the tractive force controller using the standstill controller parameters.