Application Note

CTAN #299

This Application Note is pertinent to the Commander SK Family

Simple Commander SK Torque Winder

The Commander SK AC drive may be used in simple open loop torque winding
applications. The drive may be set up as a simple torque control. This method of
control does have some limitations since it is not closed loop (i.e. it does not have a
true inner current loop) and therefore the torque producing current is calculated based
on measured (and entered) motor parameters. In essence, this means that the ability
to control motor torque is limited to approximately a 5:1 range with reasonable
accuracy. The useable speed range should also be kept in the range of 6 to 60 Hz
(180 to 1800rpm on a 4-pole motor) with a typical build up ratio of no more than
approximately 4:1. For best results, the motor should be geared in such that at core
and maximum line speed the motor runs at rated speed.

Torque
Pot

Gear Box
5:1

Questions: Ask the author ??

Steve Zaleski Email: mailto:[email protected] Tel: 716-774-0093

CTAN299.doc V1.2 Page 1 of 9 9/4/2008

Typical Example:
Core Diameter: 6”
Full Roll Diameter: 24”
Buildup: 4:1
Web Width: 60”
Tension: 2 PLI @ core ( Pounds per linear inch )
Line Speed: 500fpm
Taper: Hyperbolic

Motor Sizing
Maximum Motor RPM = fpm (feet per minute) x Gear Ratio
fpr (feet per revolution i.e. Roll circumference)

Note: Roll circumference = π x core diameter = 3.14 x Core Diameter

= Feet 1
Minute x Gear Ratio = Minute x Gear Ratio
Feet 1
Revolution Revolution

= Revolution x Gear Ratio = rpm

Minute

= [500fpm / ( π x core diameter)] x gear ratio

= 500 x 5 = 500 X 5 = 1592 rpm

π (6in/12in/ft) 1.57

Motor Torque (for web tension)

= PLI (pounds per linear inch) x Web width (inches) x Core radius (inches)
Gear Ratio

= pounds x ( inches )
inches x inches = pounds - inches
gear ratio

pounds – inches = pounds – feet = lb - ft

12 inches
1 foot

= (2lb/in x 60in) x (core radius)

gear ratio

= (2lb/in x 60in )x (3in/12in/ft) = 6 lb-ft

5

Motor HP (for web tension) = Motor Torque x Motor Base Speed

5250

= 6lb-ft x 1800RPM
5252

= 2.06 Hp

Recommended Motor Hp = 3.0Hp ( to include machine losses)

Suggests Drive Model: SKC3400220
CTAN299.doc V1.2 Page 2 of 9 9/4/2008
Drive Programming and Setup

The system is to be setup in the following manner:

1. Analog input #1 is the torque reference 0 to 10vdc = 0 to 100% motor torque.

In this example, the torque reference would be set to ~66 % (6 Ft-Lbs), not
counting machine losses.
2. Menu 0 (keypad menu) Setup

Menu 0 Actual Function Setting / Comment

Parameter Menu
01 1.07 Minimum Speed Set to 0
02 1.06 Maximum Speed Set to 60 Hz
03 2.11 Acceleration Time 33 (20 sec to 60 Hz)
04 2.21 Deceleration Time 33 (20 sec from 60 Hz)
05 11.27 Drive Configuration Pr (preset speeds)
06 5.07 Motor Current Per motor
07 5.08 Motor Full Load RPM 0
08 5.09 Motor Voltage Per motor
09 5.10 Motor Power Factor Per motor
10 11.44 Security L3
18 1.21 Preset Speed 1 Core speed
19 1.22 Start Torque Level 60 = 150%
20 1.23 Analog Torque Reference From remote analog signal
40 5.11 Motor Poles Per motor
41 5.14 Voltage mode UrA

3. The rotating auto tune should be used for best results (set parameter # 38 to 2)
before running the motor (motor must be uncoupled from the load).

To see how to perform the AutoTune you could click the link below:

CTVI102

CTAN299.doc V1.2 Page 3 of 9 9/4/2008

 Speed Reference

Preset
“Core”
Speed

150%*

0 – 100%*

Torque
References

Analog Torque
Analog
Torque
Reference

150%* -- 0 to 60 equals 0 to 150% Torque

Note:
Parameter #7.08 above (scaling) may be used to scale the maximum external torque
reference. With it being set to 1.000, the max torque would be 0 to 150%. Change
#7.08 to 0.67 for 0 to 10 vdc = 0 to 150%. Parameter #4.24 , User current maximum
scaling, should also be set to 150%.

CTAN299.doc V1.2 Page 4 of 9 9/4/2008

 Torque Reference Selection

[01.23]=16.6

Preset
speed
registers
holding
Torque
[01.22]=16.6
values

This circuit selects a 150% torque setting if the speed is less than 10% for jogging and
initial starting purposes. The full roll motor speed should always be greater than 10%
motor speed. Once 10% speed is exceeded, the drive switches to the torque reference
set by the reference potentiometer. Current loop gains (#4.13 and #4.14) may need to
be adjusted for good dynamic response.

CTAN299.doc V1.2 Page 5 of 9 9/4/2008

The tension verses build up radius is shown in the graph below. Keep in mind that
machine losses are not taken into account and therefore the actual results may vary.
Note that the full roll tension is down to 0.5 pli vs. 2.0 at core. This is typical of a
constant torque rewind which exhibits a hyperbolic tension profile.

Roll Build-up chacteristics

2.5

2.0

PLI
(Pounds / 1.5
linear inch)

1.0

0.5

0.0
0 0.2 0.4 0.6 0.8 1 1.2

Roll Radius
(feet)

Parameter Settings
(other than menu 0)

Parameter # Setting Comments

#1.21 53 Core speed per example 53Hz = 1590rpm
#1.22 60 Start / Jog Torque setting, typically 150% (60 = 150%)
#1.23 --- Torque reference set by the analog input
#4.24 150 User current maximum scaling
#7.10 1.23 Analog input destination (Torque reference)
#7.08 0.67 Scale factor to scale analog input to 0 to 100%
#12.03 2.01 Comparator input – Core speed reference
#12.04 10 Comparator threshold, 10% speed
#12.05 5 Comparator hysteresis level – 5%
#12.06 1 Comparator output invert
#12.07 12.10 Comparator destination (control bit, variable selector 1)
#12.08 1.23 Variable selector source 1, analog torque reference
#12.09 1.22 Variable selector source 2, 150% torque reference
#12.11 4.07 Variable selector output destination, drive current limit

CTAN299.doc V1.2 Page 6 of 9 9/4/2008

 System Enhancements
Suppose that a hyperbolic taper produced too light a tension at full roll. In a more
complicated system, perhaps a system capable of calculating or measuring the radius
of the roll, a constant tension profile would be achieved. With the goal of keeping costs
to a minimum (i.e. drive only) the goal will be to produce some profile which provides
something better than a hyperbolic taper. In order to do this, the PID menu will be
used. The basic idea is to come up with a signal related to core vs. actual motor rpm
and use it to provide an additional torque reference as the roll builds up. This will
provide a higher tension as the roll builds. created by the difference between the core
speed (frequency) minus the actual motor frequency times the proportional gain
(#14.10).

Additions / Changes to original programming

Torque
PID Loop
reference from
Potentiometer New
Torque
reference

Core Speed
Reference
Frequency

Motor Actual
Frequency

Note: #14.08 is set to 1 to enable the PID and #14.09 is set to 1.11 to hold the PID
reset until the drive is placed in run.

The PID circuit shown above is used to add an additional torque signal to the “core”
torque level as set by the external torque potentiometer. The additional reference is
created by the difference between the core speed (frequency) minus the actual motor
frequency times the proportional gain (#14.10) and the scale factor (#14.15).

CTAN299.doc V1.2 Page 7 of 9 9/4/2008

As an example, let’s try setting up the system such that we produce a motor torque of
6 ft-lbs at core and 12 ft-lbs at full roll.

What values would we set in the gain parameter #14.10 and the core torque
level? What would the build-up PLI profile look like?
We will we need to recalculate the motor horsepower for full roll tension and the
full roll rpm.
Motor HP @ Full Roll (for web tension)

= 12lb-ft x 1800RPM
5252

= 4.12 Hp ---- Use 5 Hp motor and SKC3400400

Full Roll Motor RPM = [500fpm / ( π x core diameter)] x gear ratio

= 500 x 5 = 500 x 5 = 398 rpm

π (24in/12in/ft) 6.28

The rated torque of a 5 Hp motor is :

Torquemotor = HP x 5250 = 14.58 ft-lbs , 150% = 21.87

1800

Since the torque required at core is 6 ft-lbs, the external torque pot needs to be set
such that register #1.26 is equal to :

#1.26 = 6 ft-lbs x 100% = 27.4 (% of 5Hp motor torque)

21.87 ft-lbs

Since the torque required at full roll is 12 ft-lbs, the torque reference needs to be:

#1.23 = 12 ft-lbs x 100% = 54.8 (% of 5Hp motor torque)

21.87 ft-lbs

at Full roll speed of 398 rpm.

The output of the pid (#14.01) must equal the difference between the required torque
reference (#1.28) at full roll and the fixed core speed torque reference (#1.26) which in
this example is # 14.01 = 54.8(#1.28) – 27.4(#1.26) = 27.4.

The gain factor would be calculated bases on the following equation:

Since the PID error ( #14.22) at full roll speed is:

#14.22 = Core speed – full roll speed x 100% = 1592 – 398 x 100% = 66.3%
Motor Base Speed 1800

The gain factor, #14.10 is then the ratio of #14.01 / #14.22

#14.10 = #14.01 = 27.4 = 0.431
#14.22 66.3

CTAN299.doc V1.2 Page 8 of 9 9/4/2008

 The graph below shows the new roll build-up characteristics. It is approximately a
linear taper of 2:1 with a 4:1 roll build up.

Roll Build-up Characteristics

2.5

2.0

1.5
PLI
(Pounds /
linear inch) 1.0

0.5

0.0
0 0.2 0.4 0.6 0.8 1 1.2
Roll Radius
(feet)

NOTE: As described above, the external “core” torque reference input must
write to register #1.26 for the enhanced example.
Analog Torque
Reference

Enhanced Parameter Settings

Parameter # Setting Comments

#14.02 1.26 Analog torque reference input
#14.03 1.03 Core speed reference
#14.04 5.01 Motor speed
#14.08 1 Enable PID
#14.09 1.11 Optional PID enable (only enable while in run)
#14.10 0.431 Gain setting per application
#14.14 0 No negative values
#14.16 1.23 Motor torque reference

CTAN299.doc V1.2 Page 9 of 9 9/4/2008