Plug & Play

Plug & Play Winder for Universal Tension Control
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Plug & Play

Dancer, Torque, Lazy Loops

What am I reading? Is it about dancing, instrumentation, or knitting?
This case study is about an exceptionally creative development by long-term project partners who are very experienced machine builders with in-depth mechanical expertise, providing bespoke, effective, and reliable machines worldwide.
For this machine, whether it's Winding or Unwinding, Overwinding or Underwinding, to achieve the desired parameters on demand, imagine winding and shifting pathways and connections, with a versatile Winder slotting in and out where required to be a Plug & Play hero on the factory floor.

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During the running of the machine and due to a requirement for autonomous operation, a complex method of calculating the response of the unwind/rewind shaft in relation to the:
  • Dancer Position,
  • Motor Torque, and
  • Lazy Loop Position

has to be carried out at all times.

This functionality relies on other parameters being set to allow the machine to calculate the correct response. This includes:
  • Material Density, and
  • Material Width & Diameter
to calculate the roll inertia.
Using the calculated roll diameter and inertia information, a PID control loop is varied with:
  • Roll Diameter, and
  • Speed
to maintain the dancer in the central running position. This image illustrates that material wound onto rolls for industrial use also includes metal sheets.

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PID Parameters

PID stands for Proportional, Integral, and Derivative.

It is a commonly used System for controlling response effects of a dynamic system.

PID my be achieved by developing and embedding automatic tuning for the settings, or by inputting bespoke parameters based on observing trial runs with continual refinements and incremental changes.

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Clever Winder

In summary, this clever Winder has been developed to be independent of other controls and system, and has the ability to connect to these  when required on the most up to date equipment.

A maximum mechanical speed of 50 metres per minute was set by 2M whilst developing this Control System.