Real time dynamic simulation of a paper winder
Abstract
Typically, large portions of the winder control system software are tested during the commissioning process. This is inefficient since production is shut down and financial pressures limit the time available for testing. The reason for this practice is that it is not economically feasible to integrate the winder and the electrical drive system before the installation. Recent advances in the computational capabilities of programmable logic controllers (PLCs) have made it possible to simulate the winder, web, and drive system dynamics in greater detail than was previously possible. Shipping roll build up, parent roll build down, additional web spans, mechanical brakes, and more sophisticated drive regulation algorithms can now be simulated in real time. The increased realism allows additional control system software features to be tested before winder installation. This paper describes a winder simulator that was used to test control system software and train operators before a new winder was installed. The simulator consisted of a dedicated PLC that solved differential equations in real time in order to model the dynamic behavior of the winder and web. The web tension and seeds of the winder model were controlled by difference equations that simulated various drive regulation algorithms. The simulator PLC used these models to provide signals for the winder PLC that would normally be supplied by the drive system and sensors on the winder. The simulator was verified by comparing the data it generated to data from a previously installed winder. A discussion of how the simulator was used before the installation of a new winder identifies the benefits of pre-installation software testing and training.
Citation
Bettendorf, R. (2003, June). Real time dynamic simulation of a paper winder. Paper presented at the Seventh International Conference on Web Handling (IWEB), Stillwater, OK.