Web Drive Control for Faster Ramp Times
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Solution Overview
Problem
Existing methods for accelerating and decelerating continuous webs of material in machines like paper, foil, and steel processing machines are inefficient due to high mass inertia, leading to prolonged ramp times, and often require drives with higher power and torque limits than necessary.
Innovation Solution
A method that optimizes the acceleration and deceleration of web material by specifying definable torque and power limits for the drive unit, adjusting current setpoints based on actual values, and utilizing nominal power and torque when feasible, allowing for faster ramp times and reduced energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional acceleration and deceleration values are used to prevent overload, then machine reliability is maintained, but acceleration and deceleration times become excessively long
Solution Approach 1:
The patent applies dynamics by making the torque and power outputs adaptive rather than fixed. The control system continuously adjusts the torque and power based on actual machine state and predefined limits, enabling the acceleration and deceleration values to dynamically change during the process. This resolves the contradiction by allowing the system to operate at higher performance levels without causing overload, thus reducing ramp times while maintaining reliability.
Solution Approach 2:
The patent changes the parameters of torque and power from fixed conventional values to dynamically adjustable values with predefined limits. By specifying maximum torque and power outputs that adapt to the machine state, the system can push beyond traditional conservative settings, achieving faster acceleration and deceleration while preventing electrical or mechanical overload through the predefined limits.
2Speed
If higher power and torque limits are used to reduce ramp times, then acceleration performance is improved, but drive unit size and cost increase
Solution Approach 1:
The patent applies partial or excessive action by allowing torque and power to temporarily exceed conventional limits up to predefined maximums during acceleration and deceleration, rather than being constrained by conservative continuous operating limits. This enables faster ramp times using existing drive units without requiring larger, more expensive equipment, as the higher outputs are only used temporarily during transient phases.
Solution Approach 2:
The system dynamically adjusts torque and power outputs during acceleration and deceleration phases, allowing temporary increases up to predefined limits rather than maintaining fixed conservative values. This dynamic approach enables existing drive units to achieve better performance without upgrading to larger, more expensive equipment.
3Reliability
If conservative acceleration values are used to prevent overload, then drive unit safety is maintained, but production time decreases
Solution Approach 1:
The patent implements feedback by continuously monitoring the actual state of the drive unit and material web, and using this information to adjust torque and power outputs in real-time. The control system compares actual values with predefined limits and adjusts the acceleration and deceleration values accordingly, enabling faster operation while maintaining drive unit safety through continuous feedback control.
Solution Approach 2:
The system changes the operating parameters from fixed conservative values to dynamically adjusted values with predefined safety limits. By allowing torque and power to vary within defined boundaries based on actual machine state, the system achieves faster acceleration and deceleration that improves production time while maintaining drive unit safety through the predefined limit structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces the time required for starting and stopping machines, achieves nearly optimal ramp times, and maximizes acceleration while minimizing energy usage and mechanical stress.
Implementation Method 1
high inertias that depend on the amount of material wound onto them, so that acceleration and deceleration times can take several minutes
Implementation Method 2
electrically driven rollers and cylinders
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a method for moving a material web by way of conveying means which can be driven by at least one drive unit. Furthermore, the invention relates to a controller and a machine having at least one drive unit and having conveying means which can be driven by the at least one drive unit. Furthermore, the invention relates to a computer program and a computer program product. In order to reduce times for accelerating and braking a material web by way of existing drives and/or in order for it to be possible to use drives with lower power-output and torque limits with the same time requirements, it is proposed to move a material web by way of conveying means which can be driven by at least one drive unit, with the use of the following method steps: stipulation of setpoint current values to the at least one drive unit in such a way that the conveying means are accelerated by the at least one drive unit with a predefinable torque if a power output which is required for this purpose is smaller than a predefinable power output of the at least one drive unit, and the conveying means are accelerated by the at least one drive unit with the predefinable power output if a torque which is required for this purpose is smaller in quantitative terms than the predefinable torque of the at least one drive unit, ending of the acceleration operation as soon as a desired movement of the material web has been achieved.