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Industry: Textile
Project: Constant Speed Winder
Overview: The OEM customer required an AC motor speed control system that would drive the take up reel on a winder so that the material would accelerate to a given linear speed and maintain that linear speed as the reel filled up.  It was also necessary to measure the amount of material put on the reel and stop the process when the desired amount was achieved.
System Objectives
  • Accelerate process at programmable rate
  • Maintain programmable constant linear speed
  • Measure material put on reel and stop process at preset amount
  • Subtract material from reel when it was backed up by operator
 Design Challenges
  • Control AC motor to maintain constant linear material speed
  • Measure material wound on reel and stop at desired amount
  • Subtract material from reel when operator manually backs up
System Solutions
  • Yaskawa V7 drive pulse train PID feature used to maintain constant linear speed from encoder turned by a measuring wheel (speed display and preset scaled in drive to engineering units).
  • Omron preset counter to measure accumulation of material on reel (count display and preset scaled to engineering units)
  • Danaher encoder with marker pulse connected to a measuring wheel to supply speed information to the drive (main encoder output, minimum of 100 PPR) and the counter (marker pulse, 1 PPR).
  • Logic wiring between counter and drive to stop motor when reel is full and subtract counts from counter if reel turns while drive not running (operator is manually backing up reel to clear a jam).
 Customer Benefits
  • Constant material speed maintained during entire winding process
  • Acceleration and speed easily set from drive keypad in engineering units
  • Material accumulation and preset monitored/set from counter keypad in engineering units
  • Accurate amount of material on finished reel because material is automatically subtracted when operator manually backs up machine
 

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