Success Story – Herstellerunabhängige Wickelapplikation

Success Story

Man­u­fac­tur­er-inde­pen­dent Wind­ing Application

The use of PLC-based modules enables the drives to be controlled regardless of the manufacturer in the operating modes dancer or tension control.

Reg­u­la­tion of the winder

To process wind­ing goods such as wires, fiber optics, foils or tex­tile webs, it is nec­es­sary to reg­u­late the winder and thus the ten­sion of the mate­r­i­al in order to enable con­tin­u­ous mate­r­i­al trans­port. Var­i­ous con­trol meth­ods can be used.


Indi­vid­ual man­u­fac­tur­ers offer these reg­u­la­tions as part of their con­vert­er tech­nol­o­gy. The advan­tage is that with this imple­men­ta­tion a very fast reg­u­la­tion with­out SPS inter­ven­tion is pos­si­ble. How­ev­er, this results in a depen­den­cy on the man­u­fac­tur­er and only a small trans­fer of infor­ma­tion to the high­er-lev­el con­trol. In order to be able to offer our cus­tomers ven­dor-inde­pen­dent solu­tions, espe­cial­ly in case of retro­fits, Mar­cel Mar­tis devel­oped a PLC-based solu­tion as part of his bach­e­lor thesis.

Test-Set­up

In order to be able to test the soft­ware under approx­i­mate­ly real con­di­tions, a mod­el from Fis­chertech­nik was built with elec­tri­cal hard­ware. A feed unit in the mid­dle between the two wind­ing units ensures a con­stant web speed. In a real appli­ca­tion, for exam­ple, a cal­en­der could be used here. The dancer reg­u­la­tion was imple­ment­ed on the left side. With this method, the mate­r­i­al is guid­ed behind the winder via a ver­ti­cal­ly freely mov­able dancer. The dancer should always stay in a mid­dle posi­tion, the reg­u­la­tion reacts to devi­a­tions from this posi­tion. The dis­place­ment mea­sure­ment is car­ried out by a slide poten­tiome­ter. For the sec­ond method, the ten­sion con­trol, a fixed deflec­tion roller is used, with force sen­sors attached to the foun­da­tion. Here the ten­sion is used as a con­trol variable.

Expan­sion of the pos­si­ble use

The Siemens library LCon is used for the PLC-based con­trol. It already con­tains all the nec­es­sary com­po­nents for com­pen­sat­ing of fric­tion and accel­er­a­tion and for imple­ment­ing the var­i­ous con­trol process­es. The mod­ules were used and para­me­ter­ized in soft­ware for con­trol­ling the entire sys­tem. Using the mod­el, a com­plete man­u­fac­tur­er-inde­pen­dent imple­men­ta­tion of both oper­at­ing modes could be achieved.
All data aris­ing in the process are vis­i­ble on the user inter­face on the sys­tem, con­trol para­me­ters can be adjust­ed there direct­ly. This not only results in greater flex­i­bil­i­ty, but also faster com­mis­sion­ing is pos­si­ble. The mod­el is used for fur­ther devel­op­ments and training.

Contact Person
Marcel Martis
Marcel Martis, B. Eng.
Software Engineer
Specializations: Control Engineering, Motion Technology
Our philosophy

Only if our systems are integrated at the customer completely they develop their entire performance potential. Therefore it is important for us that our customers are integrated in the process from the very first day of the project carry out. Communication is about it the most important connecting part between us and our customers.

Customer targets
  • Maximum production efficiency and quality
  • Stable industrial processes
  • Well trained personal
  • Low service costs
  • Most favorable conditions
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