Inertia Compensation Reference Manual

Drive
Application
Software
Function Module
Inertia Compensation
Imperial Units
Reference Manual
FM – Inertia Compensation
Important User Information
Users of this Reference Manual must be familiar with the application this Function Module is
intended to support and its usage. Function Modules intended usage are as a building blocks for
a created application. The user must be familiar with the programming tools used to implement
this module, the program platform to be used in the application, and the Rockwell Automation
drive products to be controlled in the application.
Because of the variety of uses for the products described in this publication, those responsible for
the application and use of this control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all performance and safety
requirements, including any applicable laws, regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown in this guide are intended
solely for purposes of example. Since there are many variables and requirements associated with
any particular installation, Rockwell Automation does not assume responsibility or liability (to
include intellectual property liability) for actual use based upon the examples shown in this
publication.
Rockwell Automation publication SGI-1.1, Safety Guidelines for the Application, Installation, and
Maintenance of Solid-State Control (available from your local Rockwell Automation office),
describes some important differences between solid-state equipment and electromechanical
devices that should be taken into consideration when applying products such as those described
in this publication.
Reproduction of the contents of this copyrighted publication, in whole or in part, without written
permission of Rockwell Automation, is prohibited.
Trademarks
RSLogix5000 is a trademark of Rockwell Automation
PowerFlex is a trademark of Rockwell Automation
Application Software – page 2 of 28
FM – Inertia Compensation
Table of Contents
1.0
Precautions ............................................................................................................5
2.0
Definitions ..............................................................................................................6
2.1
Conventions ..........................................................................................................6
2.2
Normalized Quantities...........................................................................................6
2.3
Terminology ..........................................................................................................7
2.3.1
2.3.2
2.3.3
2.3.4
2.3.5
3.0
Web .................................................................................................................................... 7
Strip .................................................................................................................................... 7
Drive ................................................................................................................................... 7
Motor Torque....................................................................................................................... 7
Section................................................................................................................................ 7
Overview .................................................................................................................8
3.1
Feed Forward........................................................................................................8
3.2
Tension-to-Torque Conversion .............................................................................8
4.0
Functional Description ..........................................................................................9
4.1
Overview ...............................................................................................................9
4.1.1
4.1.2
4.1.3
Main Routine ....................................................................................................................... 9
JCalc Routine...................................................................................................................... 9
JLossComp Routine ............................................................................................................ 9
4.2
Main routine ..........................................................................................................9
4.3
JCalc Routine......................................................................................................10
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
4.3.8
4.3.9
4.3.10
4.3.11
4.3.12
4.3.13
4.4
JEC_lbft2 ...........................................................................................................................10
Density_lbft3 ......................................................................................................................10
BuildUpRatio ......................................................................................................................10
Constant_RPMperFPM.......................................................................................................11
Width_in.............................................................................................................................11
GearRatio...........................................................................................................................11
MtrSpdBase_RPM..............................................................................................................11
MtrTrqRated_lbft ................................................................................................................11
WeightRoll_lb.....................................................................................................................11
JRoll_lbft2 ..........................................................................................................................11
J_lbft2 ................................................................................................................................11
J_sec .................................................................................................................................11
J_PU ..................................................................................................................................11
JLossComp Routine............................................................................................12
4.4.1
4.4.2
4.4.3
4.4.4
4.4.5
4.4.6
4.4.7
4.4.8
4.4.9
4.4.10
4.4.11
4.4.12
LineSpdRf_FPM.................................................................................................................14
LineSpdRfRate_FPM..........................................................................................................14
JDiffEnbl.............................................................................................................................14
JDiffSamples ......................................................................................................................14
BuildUpRatio ......................................................................................................................14
Constant_RPMperFPM.......................................................................................................14
J_sec .................................................................................................................................14
JGainQuad1Quad2.............................................................................................................15
JGainQuad3Quad4.............................................................................................................15
Friction_Pct ........................................................................................................................15
Windage_PctRPM ..............................................................................................................15
MtrTrqRated_lbft ................................................................................................................15
Drive Application Software – page 3 of 28
FM – Inertia Compensation
4.4.13
4.4.14
4.4.15
4.4.16
4.4.17
4.4.18
5.0
ReverseRotation ................................................................................................................15
J_lbft2................................................................................................................................15
TrqRfJ_Pct.........................................................................................................................15
TrqRfLoss_Pct ...................................................................................................................15
TrqRfJLoss_Pct..................................................................................................................16
DrvTrqRfJLoss_PU ............................................................................................................16
Setup / Configuration ..........................................................................................17
5.1
Overview.............................................................................................................17
5.2
JCalc JSR Instruction .........................................................................................17
5.2.1
5.2.2
5.2.3
5.3
JLossComp JSR Instruction................................................................................17
5.3.1
5.3.2
5.3.3
6.0
Input Parameters................................................................................................................17
Return Parameters.............................................................................................................17
Default Tags used in Drive Application Software.................................................................17
Input Parameters................................................................................................................17
Return Parameters.............................................................................................................17
Default Tags used in Drive Application Software.................................................................17
Tuning / Startup ...................................................................................................17
6.1
Offline Tuning / Startup.......................................................................................17
6.2
Online Tuning / Startup.......................................................................................17
Appendix A -
Process Line Command & Status Words..........................................17
Appendix B - Block Diagram .....................................................................................17
Appendix C - Parameter (Tag) Table ........................................................................17
Drive Application Software – page 4 of 28
FM – Inertia Compensation
1.0 Precautions
Class 1 LED Product
ATTENTION: Hazard of permanent eye damage exists when using optical transmission
equipment. This product emits intense light and invisible radiation. Do not look into
module ports or fiber optic cable connectors.
General Precautions
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts and
assemblies. Static control precautions are required when installing, testing, servicing or
repairing this assembly. Component damage may result if ESD control procedures are
not followed. If you are not familiar with static control procedures, reference Allen Bradley
publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable
ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component damage or
a reduction in product life. Wiring or application errors such as under sizing the motor,
incorrect or inadequate AC supply, or excessive surrounding air temperatures may result
in malfunction of the system.
ATTENTION: Only qualified personnel familiar with the PowerFlex 700S AC Drive and
associated machinery the products control should plan, program, configure, or implement
the installation, start-up and subsequent maintenance of the system / product. Failure to
comply may result in personal injury and/or equipment damage.
ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus
capacitors has discharged before performing any work on the drive. Measure the DC bus
voltage at the +DC & –DC terminals of the Power Terminal Block (refer to Chapter 1 in the
PowerFlex 700S User Manual for location). The voltage must be zero.
ATTENTION: Risk of injury or equipment damage exists. DPI or SCANport host products
must not be directly connected together via 1202 cables. Unpredictable behavior can
result if two or more devices are connected in this manner.
ATTENTION: Risk of injury or equipment damage exists. Parameters 365 [Encdr0 Loss
Cnfg] - 394 [VoltFdbkLossCnfg] let you determine the action of the drive in response to
operating anomalies. Precautions should be taken to ensure that the settings of these
parameters do not create hazards of injury or equipment damage.
ATTENTION: Risk of injury or equipment damage exists. Parameters 383 [SL CommLoss
Data] - 392 [NetLoss DPI Cnfg] let you determine the action of the drive if communications
are disrupted. You can set these parameters so the drive continues to run. Precautions
should be taken to ensure the settings of these parameters do not create hazards of injury
or equipment damage.
Drive Application Software – page 5 of 28
FM – Inertia Compensation
2.0 Definitions
A Function Module [FM] is a base program designed to perform a specific function (operation) in
an application. Function Modules are not complete applications and will require additional
programming to control a machine section. The additional programming required for the
application and configuration of the overall application is the responsibility of the user.
An Application Module [AM] is a complete program designed to perform a specific machine
sections application (task). Application Modules are complete programs and only require
configuration and integration in order to perform the designated tasks.
2.1 Conventions
The conventions described below are used in programming and documentation of Function
Modules and Application Modules.
1. All FM tags are program scoped.
2. All user connections to the FM are through the Jump to Sub-Routine (JSR)
instruction input and return parameters.
3. Users cannot edit Function Modules.
4. Data format
Data Type
RSLogix Type
Format
B = Boolean
BOOL
x
I = Integer
INT
x
D = Double INT
DINT
x
R = Real (Float)
REAL
x.x
* = Applies to single precision accuracy.
Range
0 to 1
+/- 32767
+/- 2097151
+/-16777215*
Example
0 or 1
8947
74364
3.4 / 13.0
2.2 Normalized Quantities
Often a physical quantity is normalized by dividing the physical quantity by a base quantity
with the same engineering units as the physical quantity. As a result, the normalized quantity
does not have units, but is ‘expressed per-unit’. The normalized quantity has a value of 1.0
[per-unit] when the physical quantity has a value equal to the base quantity.
A good example of this is the physical quantity of motor current. The information that the
motor is drawing 40 amps has little significance. The motor nameplate states that the rated
motor current is 30 amps. The motor is drawing 133% current is significant information. In
the previous illustration the quantity of motor amps was normalized to 133%. In per unit, the
quantity is normalized to 1.33.
Drive Application Software – page 6 of 28
FM – Inertia Compensation
2.3 Terminology
2.3.1 Web
A web is defined as the material that is being transported through the machine. A
web is sometimes referred to as “sheet” or “strip”.
2.3.2 Strip
The strip is defined as the material that is being transported through the machine. A
web is sometimes referred to as “sheet” or “web”. The term “strip tension” is
referencing the tension of the material in the machine.
2.3.3 Drive
The drive is the power device that is transmitting power to the motor. The motor is
connected to a mechanical device that is propelling the material. This manual is
specific to the PowerFlex 700S drive.
2.3.4 Motor Torque
A D.C. Motor has two currents flowing through it. The first current is the flux, also
known as the field current. This is the magnetizing current that allows the motor to
produce torque. The second current is the armature current. This is the actual
torque producing current of the motor.
An A.C. motor has only one current physically flowing through the machine.
However, this current is a combination of both magnetizing and torque producing
current. Motor Torque on an AC motor is the torque producing portion of the total
current flowing through the motor.
2.3.5 Section
A Web Handling Machine is broken up into sections. A section consists of one or
more drives used to propel the material through the line.
An Unwind Section could consist of one drive, one motor, and one spindle
A lead Section could consist of more than one drive and one motor combination.
This could consist of line pacer and then several helper drives. The helper drives
“help” in transporting the strip through the machine.
Typically when more than one drive is in a section, one drive is the leader and the
other drive is the follower. The follower typically follows the leader’s torque
reference.
Drive Application Software – page 7 of 28
FM – Inertia Compensation
3.0 Overview
The torque applied by the motor, in a web handling application, can be separated into three torque
components:
1. Strip Tension Torque
2. Inertia Torque
3. Losses Torque
The Inertia Compensation Function Module calculates inertia torque and losses torque.
3.1 Feed Forward
Speed regulation, dancer position regulation and strip tension regulation can be improved by
feeding inertia and losses torque forward as a torque minor loop reference. The following
block diagram demonstrates how the Inertia Compensation Function Module can be used in
a feed forward path to improve speed regulation.
FeedForward Path
Line
Speed
Reference
Inertia
Compensation
FM
+
-
Speed
Controller
+ +
Torque
Minor
Loop
Motor
Actual
Speed
3.2 Tension-to-Torque Conversion
When strip tension is controlled indirectly by controlling motor torque, strip tension deviation
can be reduced by including inertia and losses torque in tension-to-torque conversion
calculations. The following block diagram demonstrates how the Inertia Compensation
Function Module can be used to convert tension reference to motor torque reference.
Tension
Reference
Diameter &
Gear Ratio
Scaling
Line
Speed
Reference
Inertia
Compensation
FM
Drive Application Software – page 8 of 28
+
+
Torque
Minor
Loop
Motor
Actual
Strip
Tension
FM – Inertia Compensation
4.0 Functional Description
4.1 Overview
The Inertia Compensation Function Module calculates inertia and losses torque using line
speed reference as the primary input. The Inertia Compensation Function Module consists of
a program with three routines in RSLogix5000:
1. Main (Ladder)
2. JCalc (Ladder)
3. JLossComp (Function Block)
The Inertia Compensation Function Module is available in imperial units (English) and
international units (SI or metric). This reference manual describes the Imperial units version
of the Inertia Compensation Function Module.
4.1.1 Main Routine
The Main ladder routine is where the user connects user created controller tags to
the input and output program tags of the Function Module. These links are created in
the Jump to Sub-Routine (JSR) instructions. One JSR is used to call the JCalc
routine and another JSR is used to call the JLossComp routine.
4.1.2 JCalc Routine
The JCalc ladder routine calculates total reflected inertia for a center driven winder by
adding the reflected inertia of the roll (material) to the minimum empty core reflected
inertia. The strip of material extending from the roll to the adjacent drive section is
not included in the calculation.
If the Inertia Compensation Function Module is not used for a center driven winder,
the JCalc routine and corresponding JSR instruction can be deleted.
4.1.3 JLossComp Routine
The JLossComp function block routine calculates inertia torque and losses torque.
Losses torque is calculated by adding friction and windage torque. Friction torque
and windage torque are both functions of angular velocity or motor speed.
4.2 Main routine
The Main routine consists of two rungs of ladder logic programming. A rung comment briefly
describes the Input and Return (output) parameters of the JSR instructions for each routine
called. Temporary tags have been entered for each input parameter and each return
parameter. The tag names entered in the JSR’s are not declared. The user must replace
these tag names with existing project tags or create new tags. The routine will show an error
until all input and return parameters are satisfied. The input parameters may also be entered
as actual values. If an input parameter is set to a value and not a tag, the value cannot be
edited in run mode. Values entered directly in the JSR should be constants that do not
change during machine operation. Specific formatting is required for values entered directly
in the JSR.
NOTE: For Application Module users, the tags in the JSR’s are predefined and configured for
operation. No additional integration is necessary.
Data Type
B = Boolean
I = Integer
R = Real (Float)
Format
x
x
x.x
Example
0 or 1
123
3.4 / 13.0
Drive Application Software – page 9 of 28
FM – Inertia Compensation
If any signal scaling is required to interface the Function Module into the user application, the
user may use the main routine for this programming. Note; any scaling for inputs to the
routines should be done before the JSR and any scaling applied to the return values from the
routines should be done after the JSR.
4.3 JCalc Routine
Material width, material density and diameter are used to calculate the roll inertia.
The roll inertia is reflected to the motor shaft by dividing by the gear ratio squared.
Total reflected inertia is calculated by adding the reflected roll inertia to the minimum
empty core reflected inertia. The total reflected inertia is then normalized two different
ways.
The first method of normalization divides total reflected inertia by minimum empty
core reflected inertia. This results in a normalized inertia that is 1.0 per-unit at core
and greater than 1.0 per-unit as the roll diameter increases.
The second method of normalization multiplies the total reflected inertia by motor
base speed and then divides by rated motor torque. This results in inertia with units
of seconds. Inertia, normalized this way, represents the time to accelerate the total
connected inertia from zero to motor base speed with rated motor torque applied.
Input Parameters
Name
1 JEC_lbft2
2 Density_lbft3
3 BuildUpRatio
4 Constant_RPMperFPM
5 Width_in
6 GearRatio
7 MtrSpdBase_RPM
8 MtrTrqRated_lbft
Return Parameters
Name
1 WeightRoll_lb
2 Jroll_lbft2
3 J_lbft2
4 J_sec
5 J_PU
Type
REAL
REAL
REAL
REAL
REAL
REAL
REAL
REAL
Type
REAL
REAL
REAL
REAL
REAL
Range
NA
NA
NA
NA
5.0 to 500.0
NA
NA
NA
Range
NA
NA
NA
NA
NA
Description
Minimum Empty Core Reflected Inertia
Material Density
Normalized Diameter
Calibration Constant
Material Width
Gear Ratio
Motor Base Speed
Motor Rated Torque
Description
Roll Weight
Roll Reflected Inertia
Total Reflected Inertia
Total Reflected Inertia
Total Reflected Inertia
4.3.1 JEC_lbft2
This input parameter is the minimum empty core reflected inertia in pound/feet2.
Usage – Set equal to the inertia of the machine at empty core in pound/feet2.
4.3.2 Density_lbft3
This input parameter is the material density pound/feet3.
Usage – Set equal to the material density in pound/feet3.
4.3.3 BuildUpRatio
This input parameter is the build-up ratio or normalized roll diameter.
Usage – From the Diameter Calculator Function Module return parameter of the
same name.
Drive Application Software – page 10 of 28
FM – Inertia Compensation
4.3.4 Constant_RPMperFPM
This input parameter is the translational-to-rotational conversion constant in
RPM/FPM.
Usage – From the Diameter Calculator Function Module return parameter of the
same name.
4.3.5 Width_in
This input parameter is the material width in inches.
Usage – Set equal to the material width in inches.
4.3.6 GearRatio
This input parameter is the gear ratio expressed as Motor Speed / Roll Speed.
Usage – Set equal to the gear ratio.
4.3.7 MtrSpdBase_RPM
This input parameter is the motor base speed in RPM.
Usage – Set equal to the motor nameplate base speed in RPM.
4.3.8 MtrTrqRated_lbft
This input parameter is the motor rated torque in pound-feet
MtrTrqRated _ lbft =
HorsePower × 5250
MtrSpdBase _ RPM
Usage – Set equal to the motor rated torque in pound-feet.
4.3.9 WeightRoll_lb
This return parameter is the weight of the roll in pounds.
Usage – Monitor or display only.
4.3.10 JRoll_lbft2
This return parameter is the roll inertia reflected to the motor in Pound-Feet2.
Usage – Monitor or display only.
4.3.11 J_lbft2
This return parameter is the total reflected inertia in Pound-Feet2.
Usage – Monitor or display only.
4.3.12 J_sec
This return parameter is the normalized total reflected inertia in seconds. The value
represents the time to accelerate the total connected inertia from zero to motor base
speed with rated motor torque applied.
Usage – To the JLossComp routine input parameter of the same name.
4.3.13 J_PU
This return parameter is normalized total reflected inertia. The value represents the
ratio of total inertia divided by minimum empty core inertia.
Usage – Monitor or display only.
Drive Application Software – page 11 of 28
FM – Inertia Compensation
4.4 JLossComp Routine
Inertia torque is calculated by multiplying total reflected inertia by angular
acceleration:
T = J ⋅α
where: T is torque
J is total inertia
α is angular acceleration
Angular acceleration is calculated from the rate of change of line speed using the
translational-to-rotational conversion constant and build-up ratio (normalized
diameter). Separate input parameters are provided for line speed reference and line
speed reference rate. If necessary, the JLossComp routine can calculate the line
speed reference rate from line speed reference by differentiating the line speed
reference input.
If the Inertia Compensation Function Module is not used for a center driven winder,
the build-up ratio is typically set equal to one.
Two inertia compensation gains (JGainQuad1Quad2 and JGainQuad3Quad4) can be
used to adjust the calculated inertia torque in two of four operational quadrants.
These gains are typically set equal to one, but can be adjusted slightly to reduce strip
tension deviations during line speed changes.
Friction torque is calculated using the following curve:
Friction
Torque
[%]
Motor
Speed
[RPM]
-2
+2
When the rotational speed reference reaches +/- 2 RPM, the output is a fixed torque,
representing a kinetic friction torque component. A static friction component is not
included.
Windage torque requirements dictate that losses due to rotational speed increase as
the square of speed. In practice for typical winding applications, an approximation of
windage losses has proved more beneficial and simpler to configure. For these
reasons the windage losses compensation has been applied as directly proportional
to rotational speed reference and is calculated using the following curve:
Windage
Torque [%]
Motor
Speed
[RPM]
Drive Application Software – page 12 of 28
FM – Inertia Compensation
The inertia and losses torque return parameter is computed as the sum of inertia
torque, friction torque and windage torque.
Two conventions are used to avoid confusion when applying signal polarities to
translational speed signals, rotational speed signals, and torque signals.
1. Positive torque produces positive rotational speed
2. Positive rotational speed results in positive line speed
A reverse rotation input parameter, allows the second convention to be reversed. In
other words, positive rotational speed results in negative line speed. This function is
necessary for center winder applications with over wind and under wind capability.
Typically, reverse direction is associated with under wind. With the reverse rotation
input parameter set true, the inertia and losses torque resulting from the line speed
reference must be negated. It is important to note that this negation is only applied to
the per-unit inertia and losses torque return parameter.
Input Parameters
Name
1 LineSpdRf_FPM
2 LineSpdRfRate_FPMsec
3 JDiffEnbl
Type
REAL
REAL
BOOL
4
JDiffSamples
INT
5
BuildUpRatio
REAL
6
Constant_RPMPerFPM
REAL
7
J_sec
REAL
8
JGainQuad1Quad2
REAL
9
JGainQuad3Quad4
REAL
10
11
12
13
Friction_Pct
Windage_PctRPM
MtrTrqRated_lbft
ReverseRotation
REAL
Return Parameters
Name
1 TrqRfJ_Pct
2 TrqRfLoss_Pct
REAL
REAL
BOOL
Type
Range
NA
NA
0 to 1
Description
Line Speed Reference
Line Speed Reference Rate
Enable Differentiator
Number of Differentiator
1 to 20
Moving Average Samples
NA
Normalized Diameter
Translational-to-Rotational Conversion
NA
Constant
NA
Total Reflected Inertia
Inertia Compensation Gain
0.1 to 3.0
Quadrant 1 and 2
Inertia Compensation Gain
0.1 to 3.0
Quadrant 3 and 4
0.0 to 50.0 Friction Loss
0.00 to 1.00 Windage Loss
NA
Rated Motor Torque
0 to 1
Reverse Rotation
REAL
Range
NA
NA
REAL
3
TrqRfJLoss_Pct
REAL
NA
4
DrvTrqRfJLoss_PU
REAL
NA
Description
Torque Reference Inertia Part
Torque Reference Losses Part
Torque Reference Inertia and Losses
Part
Drive Torque Reference Inertia and
Losses Part
Drive Application Software – page 13 of 28
FM – Inertia Compensation
4.4.1 LineSpdRf_FPM
This input parameter is the line speed reference in FPM.
Usage – Set equal to the line speed reference in FPM.
4.4.2 LineSpdRfRate_FPM
This input parameter is the rate of change of line speed reference in FPM/second.
Usage – If available, set equal to the line speed reference rate, originating in the
same routine as LineSpdRf_FPM.
4.4.3 JDiffEnbl
This input parameter enables the internal line speed reference differentiator.
Usage – Set true only if a separate LineSpdRfRate_FPM signal is not available.
4.4.4 JDiffSamples
This input parameter is the number of moving average samples used to filter output
of the internal line speed reference differentiator.
Usage – Not used when JDiffEnbl is false. Set to a value between 1 and 20 samples.
Similar to a low pass filter, increasing the number of samples increases the filtering
effect.
4.4.5 BuildUpRatio
This input parameter is the build-up ratio or normalized roll diameter.
Usage – For center winder applications, from the Diameter Calculator Function
Module return parameter of the same name. For constant diameter applications,
typically set to 1.0.
4.4.6 Constant_RPMperFPM
This input parameter is the translational-to-rotational conversion constant in
RPM/FPM.
Usage – For center winder applications, from the Diameter Calculator Function
Module return parameter of the same name. For constant diameter applications,
calculate per the following equation:
Constant_RPMperFPM =
GearRatio
π 
  × RollDiameter [in ]
 12 
4.4.7 J_sec
This input parameter is the normalized total reflected inertia.
Usage – For center winder applications, use the JCalc routine return parameter of the
same name. For constant diameter applications, use the value returned from drive
self-tuning function or calculate the value using the following equation:
J_sec =
TotalReflectedInertia × MtrSpdBase_RPM
308 × MtrTrqRated_lbft
Drive Application Software – page 14 of 28
FM – Inertia Compensation
4.4.8 JGainQuad1Quad2
This input parameter is the inertia compensation gain for operational quadrants 1 & 2.
This parameter is entered as a real number where 1.0 = 100% gain.
Quadrant 1 – Positive Speed, Positive Inertia Torque (acceleration forward)
Quadrant 2 – Negative Speed, Positive Inertia Torque (deceleration reverse)
Usage – Typically set to 1.0, however if strip tension deviations occur in quadrant 1 &
2 only, inertia compensation can be adjusted slightly to reduce tension deviations by
adjusting slightly above or below a value of 1.0.
4.4.9 JGainQuad3Quad4
This input parameter is the inertia compensation gain for operational quadrants 3 & 4.
This parameter is entered as a real number where 1.0 = 100% gain.
Quadrant 3 – Negative Speed, Negative Inertia Torque (acceleration reverse)
Quadrant 4 – Positive Speed, Negative Inertia Torque (deceleration forward)
Usage – Typically set to 1.0, however if strip tension deviations occur in quadrant 3 &
4 only, inertia compensation can be adjusted slightly to reduce tension deviations by
adjusting slightly above or below a value of 1.0.
4.4.10 Friction_Pct
This input parameter determines the kinetic friction losses in percent of rated motor
torque.
Usage – Tune for best operation (See section 6, Tuning / Start-up).
4.4.11 Windage_PctRPM
This input parameter determines the windage losses in percent of rated motor torque
per motor speed in RPM.
Usage – Tune for best operation (See section 6, Tuning / Start-up).
4.4.12 MtrTrqRated_lbft
This input parameter is the motor rated torque in pound-feet
MtrTrqRated _ lbft =
HorsePower × 5250
MtrSpdBase _ RPM
Usage – Set equal to the motor rated torque in pound-feet.
4.4.13 ReverseRotation
This input parameter negates the DrvTrqRfJLos_PU return parameter below.
Usage – For center winder applications, set false for over wind operation and true for
under wind operation. (Assuming positive rotational speed produces positive line
speed during over wind operation.) For constant diameter applications, set false.
4.4.14 J_lbft2
This return parameter is the total reflected inertia in Pound-Feet2.
Usage – Monitor or display only.
4.4.15 TrqRfJ_Pct
This return parameter is the inertia torque component in percent of rated motor
torque.
Usage – Monitor or display only.
4.4.16 TrqRfLoss_Pct
This return parameter is the friction and windage losses torque component in percent
of rated motor torque.
Drive Application Software – page 15 of 28
FM – Inertia Compensation
Usage – Monitor or display only.
4.4.17 TrqRfJLoss_Pct
This return parameter is the sum of the inertia and losses torque components in
percent of rated motor torque.
Usage – Monitor or display only.
4.4.18 DrvTrqRfJLoss_PU
This return parameter is the sum of the inertia and losses torque components in perunit rated motor torque with ReverseRotation negate applied.
Usage – Added to the drive torque reference during tension to torque conversion,
subtracted from the drive torque feedback during torque to tension conversion, or
used as a feed forward signal to the torque minor loop.
Drive Application Software – page 16 of 28
FM – Inertia Compensation
5.0 Setup / Configuration
5.1 Overview
All setup and configuration is done in the Main routine. The Inertia Compensation Function
Module is connected to the balance of the application software by placing application tag
names in the Jump to Sub-Routine (JSR) instructions. One JSR is used to call the JCalc
routine and a second JSR is used to call the JLossComp routine. When JSR instruction input
parameters are configured with tags, which are intended to be tuned by the user at
commissioning, it is recommended that the (z prefix) naming convention be used for tags of
this type.
5.2 JCalc JSR Instruction
Note: The JCalc routine and JSR instruction are only used for center winder applications. For
constant diameter applications, delete the JCalc routine and JSR instruction. If the JCalc
routine is deleted, the Total Reflected Inertia input parameter (JLossComp – In8) must be
calculated using the equation shown in the description for this input parameter as described
in section 4.
5.2.1 Input Parameters
5.2.1.1
Minimum Empty Core Reflected Inertia
Enter an application tag for the Minimum Empty Core Reflected Inertia input
parameter (JCalc – In1). If the application tag values are not in units of poundfeet2, add a rung to the Main routine that will scale the tag value to pound-feet2.
5.2.1.2
Material Density
Enter an application tag for the Material Density input parameter (JCalc – In2). If
the application tag value is not in units of pounds per feet3, add a rung to the Main
routine that will scale the tag value to pounds per feet3.
5.2.1.3
Normalized Diameter
Enter an application tag for the Normalized Diameter input parameter (JCalc –
In3). This tag must be normalized such that the value is equal to 1.0 at minimum
empty core diameter. If the Diameter Calculator Function Module is used, enter
the tag used as the return parameter in the DiamCalc JSR instruction.
5.2.1.4
Translational-to-Rotational Conversion Constant
Enter an application tag for the Translational-to-Rotational Conversion Constant
input parameter (JCalc – In4). This conversion constant must be calculated using
the minimum empty core diameter. If the Diameter Calculator Function Module is
used, enter the tag used as a return parameter in the DiamCalc JSR instruction.
5.2.1.5
Material Width
Enter an application tag for the Material Width input parameter (JCalc – In5). If
the application tag value is not in units of inches, add a rung to the Main routine
that will scale the tag value to inches.
5.2.1.6
Gear Ratio
Enter an application tag or immediate value for the Gear Ratio input parameter
(JCalc – In6).
5.2.1.7
Motor Base Speed
Enter an application tag or immediate value for the Motor Base Speed input
parameter (JCalc – In7).
5.2.1.8
Motor Rated Torque
Enter an application tag or immediate value for the Motor Rated Torque input
parameter (JCalc – In8).
Drive Application Software – page 17 of 28
FM – Inertia Compensation
5.2.2 Return Parameters
5.2.2.1
Roll Weight and Roll Reflected Inertia
Enter application tags, for the Roll Weight and Roll Reflected Inertia return
parameter (JCalc - Ret1, Ret2).
5.2.2.2
Total Reflected Inertia [pound-feet2]
Enter an application tag, for the Total Reflected Inertia return parameter (JCalc –
Ret3).
5.2.2.3
Total Reflected Inertia [Seconds]
Enter an application tag, for the Total Reflected Inertia return parameter (JCalc –
Ret4). This tag should be used in the JLossComp JSR instruction input
parameter (JLossComp – In8).
5.2.2.4
Total Reflected Inertia [Per-Unit]
Enter an application tag, for the Total Reflected Inertia return parameter (JCalc –
Ret5).
5.2.3 Default Tags used in Drive Application Software
Drive Application Software – page 18 of 28
FM – Inertia Compensation
5.3 JLossComp JSR Instruction
5.3.1 Input Parameters
5.3.1.1
Line Speed Reference
Enter an application tag for the Line Speed Reference input parameter
(JLossComp – In1). If the application tag value is not in units of FPM, add a rung
to the Main routine that will scale the tag value to FPM.
5.3.1.2
Line Speed Reference Rate
If available, enter an application tag for the Line Speed Reference Rate input
parameter (JLossComp – In2). If the application tag value is not in units of FPM
per second, add a rung to the Main routine that will scale the tag value to FPM per
second.
5.3.1.3
Enable Differentiator
Enter an application tag or immediate value for the Enable Differentiator input
parameter (JLossComp – In3).
5.3.1.4
Number of Differentiator Moving Average Samples
Enter an application tag for the Number of Differentiator Moving Average Samples
input parameter (JLossComp – In4).
5.3.1.5
Normalized Diameter
Enter an application tag for the Normalized Diameter input parameter
(JLossComp – In5). This tag must be normalized such that the value is equal to
1.0 at minimum empty core diameter. If the Diameter Calculator Function Module
is used, enter the tag used as a return parameter in the DiamCalc JSR instruction.
For constant diameter applications, an application tag or an immediate value of
1.0 can be used.
5.3.1.6
Translational-to-Rotational Conversion Constant
Enter an application tag for the Translational-to-Rotational Conversion Constant
input parameter (JLossComp – In6). This conversion constant must be calculated
using the minimum empty core diameter. If the Diameter Calculator Function
Module is used, enter the tag used as a return parameter in the DiamCalc JSR
instruction.
5.3.1.7
Motor Base Speed
Enter an application tag or immediate value for the Motor Base Speed input
parameter (JLossComp – In7).
5.3.1.8
Total Reflected Inertia [seconds]
Enter an application tag, for the Total Reflected Inertia input parameter
(JLossComp – In8). If the JCalc routine is used, enter the tag used as a return
parameter in the JCalc JSR instruction (JCalc – Ret4).
5.3.1.9
Inertia Compensation Gain
Enter application tags, for the Inertia Compensation Gain Quadrant 1 and 2 and
Inertia Compensation Gain Quadrant 3 and 4 input parameters (JLossComp –
In9, In10).
5.3.1.10
Friction Loss
Enter an application tag for the Friction Loss input parameter (JLossComp –
In11).
5.3.1.11
Windage Loss
Enter an application tag for the Windage Loss input parameter (JLossComp –
In12).
5.3.1.12
MtrTrqRated_lbft
Enter an application tag or immediate value for the Motor Rated Torque input
parameter (JLossComp – In2).
Drive Application Software – page 19 of 28
FM – Inertia Compensation
5.3.1.13
ReverseRotation
Enter an application tag for the ReverseRotation input parameter (JLossComp –
In7). For center winder applications, this tag should be derived from the
application program overwind and underwind logic. For constant diameter
applications, an application tag or an immediate value of 1 can be used.
5.3.2 Return Parameters
5.3.2.1
Torque Reference Inertia Part, and Torque Reference Losses Part
Enter application tags, for the Torque Reference Inertia Part and the Torque
Reference Losses Part return parameters (JLossComp - Ret1, Ret2).
5.3.2.2
Torque Reference Inertia and Losses Part [Percent]
Enter an application tag, for the Torque Reference Inertia and Losses Part return
parameter (JLossComp - Ret3).
5.3.2.3
Drive Torque Reference Inertia and Losses Part [Per-Unit]
Enter an application tag, for the Drive Torque Reference Inertia and Losses Part
return parameter (JLossComp – Ret4). This tag should be used in the application
software feed forward or tension-to-torque conversion function.
5.3.3 Default Tags used in Drive Application Software
Drive Application Software – page 20 of 28
FM – Inertia Compensation
6.0 Tuning / Startup
6.1 Installing the Application Module
Perform the following operations in the order listed to ensure proper signal connections between
the DriveLogix controller and the PowerFlex 700S firmware.
1. Download the RSLogix 5000 [.acd] file to the DriveLogix controller
2. Download the DriveExecutive [.dno] file to the PowerFlex 700S
Note, order of these events are critical as the DriveLogix controller must send the Peer
Communication format to the PowerFlex 700S firmware before the PowerFlex 700S will
accept all the configuration settings provided in the DriveExecutive file. Manually setting the
Peer Communication format in the drive will not be effective until configured in DriveLogix. If
this sequence of operation is not followed, the DriveLogix controller may not communicate
with the PowerFlex 700S.
6.2 Drive Tuning & Configuration
For basic commissioning of the application, the drive must first be tuned to regulate the
motor. The following steps will guide you through the basic requirements of drive tuning
when using an application module.
1. Set param 153 bit 8 high. This will set the start/stop control to 3 wire for
operation via the HIM. When the start up is complete this must be set to low for
2 wire operation from DriveLogix.
2. From the HIM, select the “Start-Up” function and follow the directions. In this
section you will perform the following steps.
a. Motor Control
i. FOC – for Induction Motor
ii. PMag – for Permanent Magnet Motor
b. Motor Data – Enter all motor data for the attached motor, check # poles
c. Feedback Config – Select feedback type
d. Pwr Circuit Diag
e. Direction Test – (NOTE, the motor will run) recommend always changing
wires and not software, this is for maintenance purposes, if the program
is restored it will default to the standard direction setting.
f. Motor Tests – (NOTE, the motor will run)
g. Inertia Measure – (NOTE, the motor will run)
h. Speed Limits
i. Select “+/- Speed Ref”
ii. Fwd Speed Limit
iii. Rev Speed Limit
iv. Abs Overspd Lim – Max over speed past the Fwd and Rev
Speed Limit. This is where the drive will fault
i. Do not complete the remainder of the Start-Up procedure in the drive
j. Scroll down to “Done/Exit”
3. Tune the speed regulator. Depending on the inertia of the machine and other
factors, the speed regulator bandwidth (param 90) should be set for 15 to 50
radians.
4. Set param 153 bit 8 Low. This will set the start/stop control to 2 wire for
operation via DriveLogix
Drive Application Software – page 21 of 28
FM – Inertia Compensation
6.3 Offline Tuning / Startup
Verify that the number and order of JSR input parameters and JSR return parameters agree
with the JSR rung comment and section 4 of this user manual.
Verify that the data type of all JSR instruction input and return parameters agree with the data
type described in the JSR instruction rung comment and section 4 of this user manual. If
immediate values are used for input parameters, the immediate value data type can be
controlled by using or excluding a decimal point. For example, if the JSR instruction input
parameter is designated as type REAL, and the desired value is zero, use “0.0” in the JSR
instruction input parameter. An Input entered a “0” is used as an INTEGER value.
Check the value of all JSR instruction input parameter tags. If the tag is calculated by other
Logix instructions, verify that the tag will be calculated in the correct engineering units. If the
tag is not calculated by other Logix instructions, preset the tag per section 4 of this user
manual.
6.4 Online Tuning / Startup
The following JSR inputs can be adjusted online:
1. JCalc In1
- Empty Core Reflected Inertia [Pound-Feet**2]
2. JCalc In2
- Material Density [Pounds/Feet**3]
3. JLossComp In4
- Number of Differentiator Moving Average Samples
4. JLossComp In8
- Total Reflected Inertia [sec]
5. JLossComp In9
- Inertia Compensation Gain Quadrant 1 and 2
6. JLossComp In10 - Inertia Compensation Gain Quadrant 3 and 4
7. JLossComp In11 - Friction Loss [Percent Load]
8. JLossComp In12 - Windage Loss [Percent Load/RPM]
All other JSR inputs will only require offline tuning.
The following steps can be followed when tuning these parameters:
1. Configure drive to run as a speed regulator with the Drive Torque Reference Inertia and
Losses Torque Part (JLossComp – Ret4) used as a feed forward signal. See the
Tension Regulator Reference Manual for selecting operation as speed mode. Do not
change drive configuration parameters to activate speed control.
2. Set Friction Loss (JLossComp - In11) and Windage Loss (JLossComp - In12) to zero.
3. Set Inertia Compensation Gain Quadrant 1 and 2 (JLossComp - In9) and Inertia
Compensation Gain Quadrant 3 and 4 (JLossComp – In10) to 1.0.
4. If Enable Differentiator (JLossComp – In3) is true, set the Number of Differentiator
Moving Average Samples (JLossComp – In4) to 2.
5. If a center winder application, set up the winder with an empty core or mandrel and
preset the diameter calculator to minimum empty core diameter so that the Normalized
Diameter is 1.0.
6. Setup a trend with the Line Speed Reference (JLossComp - In11) and speed regulator PI
output signal.
7. If a center winder application, accelerate/decelerate the drive and adjust the Empty Core
Reflected Inertia (JCalc - In1) until deviations in the speed PI output are minimized. If a
constant diameter application, accelerate/decelerate the drive and adjust Total Reflected
Inertia (JLossComp - In1) until deviations in the speed PI output are minimized.
8. If Enable Differentiator (JLossComp – In3) is true, add the Torque Reference Inertia Part
to the trend, run the drive at a steady speed, and adjust the the Number of Differentiator
Moving Average Samples (JLossComp – In4) to minimize signal noise.
9. If a constant diameter application, skip to step 13.
10. Place the largest diameter roll available on the winder and set Material Width (JCalc In5) to the actual roll width.
11. Accelerate/decelerate the drive and adjust the Material Density (JCalc - In2) until
deviations in the speed PI output are minimized.
12. Remove the roll.
Drive Application Software – page 22 of 28
FM – Inertia Compensation
13. Run the drive with a steady Line Speed Reference that results in a motor speed of just
over 2 RPM.
14. Adjust Friction Loss (JLossComp - In11) until the speed PI output is near zero.
15. Run the drive with a steady Line Speed Reference that results in a motor speed near
75% of full speed.
16. Adjust Windage Loss (JLossComp - In12) until the speed PI output is near zero.
17. After threading the machine, if tension deviates during accleration/deceleration, adjust
Inertia Compensation Gain Quadrant 1 and 2 (JLossComp – In9) and Inertia
Compensation Gain Quadrant 3 and 4 (JLossComp – In10) as necessary to reduce
tension deviations.
Drive Application Software – page 23 of 28
FM – Inertia Compensation
Appendix A - Process Line Command & Status Words
The following table is a functional list of the Process Line command word
[wDLx_DrvCmmdProcLn]
Bit
00
01
02
03
04
05
06
07
Input Signal
Clear Fault
Run (2 Wire)
Reserved
Coast Stop
Jog Forward
Jog Reverse
08
Stall Tension
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Tension Control
Torque Control
Dancer Control
Torque Trim
Speed Trim
Draw Trim Off
Torque Follower Control
Diam Preset 1
Diam Preset 2
Diam Preset 3
Diam Preset Increase
Diam Preset Decrease
Diam Calc Increase Enable
Diam Calc Decrease Enable
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Torque Mem Enable
30
Torque Mem Boost Enable
31
Torque Mem Knife Cut
Reverse Rotation (Under Wind)
Tension Control Enable
Drive Application Software – page 24 of 28
Description
Clear all Faults
1 = Start, transition to 0 = Stop
not supported in rev 110101
Jog in Forward direction
Jog in Reverse direction
Under wind selection
Activates selected mode of Tension Control
User determines how and when to activate
Stall Tension
Selects Tension Control Mode - Tension
Selects Tension Control Mode - Torque
Selects Tension Control Mode - Dancer
Selects Trim type – Torque is trimmed
Selects Trim type – Speed is trimmed
Zeros the Draw trim signal
Special Control mode for torque follower
Commands preset 1 for Diam Calc
Commands preset 2 for Diam Calc
Commands preset 3 for Diam Calc
Manual increase for Diameter Calc
Manual decrease for Diameter Calc
Releases Diameter Clac for Increase
Releases Diameter Calc for Decrease
Memorizes running torque
Boosts the memorized torque by user set
percentage.
Boosts the memorized torque by user set
percentage.
FM – Inertia Compensation
The following table is a functional list of the Process Line status word
[DLx_DrvStatProcLn]
Bit
00
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
Output Signal
Fault
Running
Reserved
Motor Ctrl On
Reserved
Jogging
30
Operate Permissive
31
On Permissive
Rotational Reverse
Tension Control On
Zero Speed
Diameter Calculation Active
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Enable Loss Fault
Fail to Run fault
Communication fault
Message fault
Motor Overload Fault
Motor Overtemperature Flt
Motor Blower Loss Fault
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Reserved
Description
Drive Fault or a System Fault
Drive is Running / not stopping
Motor is being control (Motor POWER)
section Jogging
Under Wind
Selected mode of Tension control is enabled
Below Zero Line speed set point
Future
Drive Enable lost
Drive failed to start
NA – not support
NA – not support
Overload alarm from drive
Over temperature alarm from drive
Motor blower has stopped or tripped off
Use in line control logic to command a
coordinated line ramp stop.
Loss of permissive resets start command.
The drive will coast stop or ramp stop
depending on configuration
Drive Application Software – page 25 of 28
FM – Inertia Compensation
Appendix B - Block Diagram
NA
Drive Application Software – page 26 of 28
FM – Inertia Compensation
Appendix C - Parameter (Tag) Table
Input Tags for Inertia Compensation Function Module
Name
Type
Source Tag
from Routine
Default
User
Value
JCalc – Routine
JEC_lbft2
R x.x
zDLx_JEC_lbft2
NA
5.0
Density_lbft3
R x.x
zDLx_Density_lbft3
NA
43.2
BuildUpRatio
R x.x
DLx_BuildUpRatio
DiamCalc
NA
Constant_RPMperFPM
R x.x
DLx_Constant_RPMperFPM
DiamCalc
NA
Width_in
R x.x
zDLx_Width_in
NA
24.0
GearRatio
R x.x
zDLx_GearRatio
NA
5.0
CalcAndDisplay – Main
or USER Programming
CalcAndDisplay – Main
or USER Programming
MtrSpdBase_RPM
R x.x
DLx_MtrSpdBase_RPM
MtrTrqRated_lbft
R x.x
DLx_MtrTrqRated_lbft
LineSpdRf_FPM
R x.x
DLx_LineSpdRf_FPM
RunJogSpdRf
NA
LineSpdRfRate_FPMsec
R x.x
DLx_LineSpdRfRate_FPMsec
RunJogSpdRf
NA
Bx
zDLx_JDiffEnbl
NA
JDiffSamples
Ix
zDLx_JDiffSamples
NA
BuildUpRatio
R x.x
DLx_BuildUpRatio
DiamClac
NA
Constant_RPMPerFPM
R x.x
DLx_Constant_RPMperFPM
DiamClac
NA
NA
NA
JLossComp – Routine
JDiffEnbl
0
3
J_sec
R x.x
DLx_J_lbft2
JCalc or USER
NA
JGainQuad1Quad2
R x.x
zDLx_JGainQuad1Quad2
NA
1.0
JGainQuad3Quad4
R x.x
zDLx_JGainQuad3Quad4
NA
1.0
Friction_Pct
R x.x
zDLx_Friction_Pct
NA
0.0
Windage_PctRPM
R x.x
zDLx_Windage_PctRPM
NA
0.0
MtrTrqRated_lbft
R x.x
DLx_MtrTrqRated_lbft
ReverseRotation
Bx
DLx_DrvStatProcLn.6
CalcAndDisplay – Main
or USER Programming
LogicAndReference –
Logic
NA
NA
Drive Application Software – page 27 of 28
www.rockwellautomation.com
for Drive Application Software www.ab.com/drives/drvappsw
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Publication: 9329-RM003A-EN-E March 2003
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