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Inertia Compensation Reference Manual

1. Inertia Compensation Gain 8 JGainQuad1Quad2 REAL 0 1 to 3 0 Quadrant 1 and 2 Inertia Compensation Gain 9 JGainQuad3Quad4 REAL 0 1 to 3 0 Quadrant 3 and 4 10 Friction _Pct REAL 0 0 to 50 0 Friction Loss 11 Windage_PctRPM REAL 0 00 to 1 00 Windage Loss 12 MtrTrqRated_Ibft REAL NA Rated Motor Torque 13 ReverseRotation BOOL Oto 1 Reverse Rotation Return Parameters Name Type Range Description 1 TrqRfJ_Pct REAL NA Torque Reference Inertia Part 2 TrqRfLoss_ Pct REAL NA Torque Reference Losses Part 3 TrqRfJLoss Pct REAL NA as Reference Inertia and Losses 4 DrvTraRfJLoss PU REAL NA 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
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 Inertia gt Compensation Speed Controller 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 Line Speed Reference Actual Speed Diameter amp Actual Gear Ratio Strip Scaling Tension Tension Reference Line Inertia Speed Compensation Reference FM Drive Application Software page 8 of 28 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
3. MtrSpdBase _ RPM Usage Set equal to the motor rated torque in pound feet MtrTrqRated _ Ibft 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_Ibft2 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 0 where T is torque J is total inertia 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 li
4. 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 bri
5. 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 Ra
6. 15 44 12 MtrTroRatec_Ibft orrera aeaa R AEREE ON OOOO E EE EE EE EEE EEE EE EEE EE EEE EEE EEE EEE EE EES 15 Drive Application Software page 3 of 28 FM Inertia Compensation 44 13 ReVerseROlatlony icccctenesesetasseeonlevesseeleoesnnabeveaseelecnennabereaeealeehenottevtareabentinea leven seaberbawelaeiets 15 AVAL oh DTD 05 A epioenehcstiecalepicenehestienelavtianstenstits 15 AO TARA Pe e cscs costs A tada 15 44 16 TTQRIEOSS Poli 15 A MORO ll el cedi 16 44 18 Div TrgRtJEoss PU accident 16 5 0 Setup Configuration sess cccccvccece ce cceece cccteccesccsacecacotecoe ctesccee ccetecetacasecasccctecet cceceeecde 17 Dak IMEI Wi A 17 52 JCal ISR ASTUCIA e O O e 17 5 2 1 Input Parameters ccceeeeeeeeeeeceeeeeeeeeeeeeeeeaaaeeeeeeeeeeeeaaaeaeeeeeeeeeeeaaaaaeeeeeeeeeesaaaseeeeeeeeeeesaaa 17 5 2 2 Return ParameterS 0 cccccccccccceeeeeeeeceeeeaeeeeeeeeeeeeeeaaaeeeeeeeeeeeaaaaaeeeeeeeeeesaaaeeeeeeeseeesaaaaeees 17 5 2 3 Default Tags used in Drive Application Software ccocccccnnnnnnnnnnnninnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 17 5 3 alEOSSCOMpP ISR IMNSTUCIONS srta 17 5 3 1 INPUT ParamMelers noit O a hy 17 5 3 2 Return Parameters vic sscstesctscatecstenttadsdeteadd chanedatacacabuendacebacieebsieeagarabasiecubagadacatasadebeandataenbates 17 5 3 3 Default Tags used in Drive Application Software cccccccccnnnnnnnnnnninnnnnnnnnnnnnnnnnnnnnnnnnnnnnnos 17 6 0 MINING AUD eee 17 6 1 Offline FUMI
7. O A In A te ah keith Ol 9 4 1 1 Main A ee a a a a a a a a a 9 4 12 0 Routine eee a ee ee ee 9 44 3 AA te EE Shih heh AEE EE e 9 42 Wali Oued oad E E E E eo trad 9 AS IG A ea ee 10 AOA SEG e ete ere ee ee 10 O A e O A O ee cee 10 4 3 3 BUI UP Ratio E T 10 4 3 4 ES s ee a a 11 AID A A A A A NASES 11 60 A E A i Sot geh aah etsy oot a Lda toe A AAN 11 43 7 iMirspdBases REM ci et ells ete dots doh dons goks sats Sots Lera sols 11 4 3 8 gt MUnirq Ratedilbttaisici 22552255555 delete pedo ds checks gots dobs dots dob dol e Soe Soe 11 4 3 9 AWelghtRoll Decio le ee oe eh Sete 11 43 10 To MDA 2 aca o AE 11 CA EAN o 1 cates ott sets fotetots E bos odo os ots dos Sate Sate tote ote 11 AZ SO o econo i Meee deba Sot AoE CRaED Aero q ReGoEC ache hake fobs totes 11 CA RW as ctztote ie fot sete bods sobs A AO 11 4 4 JLossComp ROU IN oooonccnnnccccccccnnnonnnononcnoncnononnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnanazanass 12 4 4 1 ETATER ee AE i ra N P T ano RR Renoir EN 14 44 23 EineSpdRiRate FPM si a aeaee sues er ea earar Ena onea a les 14 7 W E A A E E A 14 AAAs E AE E A AA E A 14 PN E SORS 8 0 8 0 o 0 Addis 14 44 6 Constant RPMPerEPM iii db 14 E O ella E E O EE OE enna tiOe ea vaesleengn ches E E O N 14 7 W E oSI LEY TIC BT e HEE II T 16 P E EEO S 15 4 4 9 JG aINQUAdBQUADA EA AE 15 A A ON 15 44 11 Windage PctR PM oreraa aranana anaana n EENEN NE sexeen senesced ove cenesnns sass geeeeesesssnsaietyeeaeieieears
8. Roll Weight Pounds RetZ Rx x JRoll lbftZ2 Roll Reflected Inertia Pound Feet 2 Ret 3 Rx x J_lbftzZ Total Reflected Inertia Pound Feet 2 Ret4 Rx x J_sec Total Reflected Inertia sec Ret S Rx x J_PU Total Reflected Inertia Per Unit Inertia Calculation SR Jump To Subroutine Routine Name JCale Input Par JEC_lbftz Input Par Density_lbft3 Input Par BuildUpRatio Input Par Constant RPMPerFPM Input Par Width_in Input Par GearRatio Input Par MtrSpdBase RPM Input Par MtrTrqRated lbft Return Par WeightRoll 1b Return Par JRoll_1bft2 Return Par J_lbftz Return Par J_sec Return Par J_PU 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
9. 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 Type Range Description 1 JEC_Ibft2 REAL NA Minimum Empty Core Reflected Inertia 2 Density_Ibft3 REAL NA Material Density 3 BuildUpRatio REAL NA Normalized Diameter 4 Constant_RPMperFPM REAL NA Calibration Constant 5 Width_in REAL 5 0 to 500 0 Material Width 6 GearRatio REAL NA Gear Ratio 7 MtrSpdBase_RPM REAL NA Motor Base Speed 8 MtrTrqRated_Ibft REAL NA Motor Rated Torque Return Parameters Name Type Range Description 1 WeightRoll_lb REAL NA Roll Weight 2 Jroll_Ibft2 REAL NA R
10. 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
11. 0 MtrSpdBase _ RPM Usage Set equal to the motor rated torque in pound feet MtrTrqRated _ Ibft 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 per unit 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 tensi
12. 64 297 4800 Fax 1 864 281 2433 Europe Rockwell Automation Br histraBe 22 D 74834 Elztal Dallau Germany Tel 49 6261 9410 Fax 49 6261 17741 Asia Pacific Rockwell Automation 55 Newton Road 11 01 02 Revenue House Singapore 307987 Tel 65 351 6723 Fax 65 355 1733 U S Allen Bradley Drives Technical Support Tel 1 262 512 8176 Fax 1 262 512 2222 Email support drives ra rockwell com Online www ab com support a bdrives Publication 9329 RM003A EN E March 2003 Copyright O 2003 Rockwell Automation All rights reserved Printed in USA
13. JE 746 144 TE spr 201 a step Conveyor or Step C fini Stat UP Check UE 8 Drive 2 Application a o NAAA Software Function Module Inertia Compensation Imperial Units Reference Manual Allen Bradley RELIANCE ELECTRIC Automation FM Inertia Compensation APPLICATION SOFTWARE 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 inte
14. Motor Overtemperature FIt Over temperature alarm from drive 22 Motor Blower Loss Fault Motor blower has stopped or tripped off 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Reserved 30 Operate Permissive Use in line control logic to command a coordinated line ramp stop Loss of permissive resets start command 31 On Permissive 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 Appendix C Parameter Tag Table Input Tags for Inertia Compensation Function Module FM Inertia Compensation Name Type Source Tag from Routine Default i ie JCalc Routine JEC_Ibft2 Rx x ZDLx_JEC_Ibft2 NA 5 0 Density_Ibft3 Rx x ZDLx_Density_Ibft3 NA 43 2 BuildUpRatio Rx x DLx_BuildUpRatio DiamCalc NA Constant_RPMperFPM Rxx DLx_Constant_RPMperFPM DiamCalc NA Width_in Rxx ZDLx_Width_in NA 24 0 GearRatio Rx x ZDLx_GearRatio NA 5 0 MtrSpdBase_RPM Rxx DLx MtrSpdBase_RPM USER E NA MtrTrqRated_Ibft Rxx DLx_MtrTrqRated_Ibft UA NA JLossComp Routine LineSpdRf_FPM Rx x DLx_LineSpdRf_FPM RunJogSpdRf NA LineSpdRfRate_FPMsec Rx x DLx_LineSpdRfRate_FPMsec RunJogSpdRf NA JDiffEnbl Bx zDLx_JDiffEnbl NA 0 JDiffSamples Ix zDLx_JDiffSamples NA 3 BuildUpRatio R
15. 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 Inert
16. NG SAND pcs heen hate ee hee te ee a ee eee i 17 6 2 Online Tuning Startup cis a as ae ee ee ee ee ele 17 Appendix A Process Line Command amp Status Words ccccsssssseeeseeeeeeeees 17 Appendix B Block DidgraM cian 17 Appendix C Parameter Tag Table ooooonnnonononocononononcccnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnnnnnns 17 Drive Application Software page 4 of 28 FM Inertia Compensation 1 0 Precautions Class 1 LED Product gt 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 Dbbbbb D 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
17. RfRate FPMsec Input Par JDiffEnbl Input Par IDiffSamples Input Par BuildUpRatio Input Par Constant RPMPerFPM Input Par MtrSpdBase RPM Input Par J_sec Input Par JGainQuadlQuadZ Input Par JGainQuad3Quad4 Input Par Friction Pct Input Par Windage Pct RPM Input Par ReverseRotation Return Par TrqRfJ_Pect Return Par TrqRfLoss_ Pct Return Par TrqRfJLoss_Pect Drive Application Software page 20 Return Par DrvTrqRfJLoss_PU 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 amp Configuration For basic commissioning of the application the drive must first be tuned to regulate the motor The following steps will guide you thr
18. 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 GearRatio o RollDiameter in 12 Constant_RPMperFPM 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 _ TotalReflectedInertia x MtrSpdBase_RPM 308 x MtrTrqRated_Ibft J_sec 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 amp 2 This parameter is entered as a real number
19. a 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 Type Range Description 1 LineSpdRf_FPM REAL NA Line Speed Reference 2 LineSpdRfRate_FPMsec REAL NA Line Speed Reference Rate 3 JDiffEnbl BOOL 0 to 1 Enable Differentiator 4 JDiffSamples INT 1 to 20 Number of Differentiator Moving Average Samples 5 BuildUpRatio REAL NA Normalized Diameter 6 Constant_RPMPerEPM REAL NA Translational to Rotational Conversion Constant 7 J sec REAL NA Total Reflected Inertia
20. efly 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 Format Example B Boolean x Oor 1 Integer x 123 R Real Float X X 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
21. et Decrease Manual decrease for Diameter Calc 21 Diam Calc Increase Enable Releases Diameter Clac for Increase 22 Diam Calc Decrease Enable Releases Diameter Calc for Decrease 23 Reserved 24 Reserved 25 Reserved 26 Reserved 27 Reserved 28 Reserved 29 Torque Mem Enable Memorizes running torque 30 Torque Mem Boost Enable Boosts the memorized torque by user set percentage 31 Torque Mem Knife Cut Boosts the memorized torque by user set percentage Drive Application Software page 24 of 28 FM Inertia Compensation The following table is a functional list of the Process Line status word DLx_DrvStatProcLn Bit Output Signal Description 00 Fault Drive Fault or a System Fault 01 Running Drive is Running not stopping 02 Reserved 03 Motor Ctrl On Motor is being control Motor POWER 04 Reserved 05 Jogging section Jogging 06 Rotational Reverse Under Wind 07 Tension Control On Selected mode of Tension control is enabled 08 Zero Speed Below Zero Line speed set point 09 Diameter Calculation Active Future 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Reserved 16 Enable Loss Fault Drive Enable lost 17 Fail to Run fault Drive failed to start 18 Communication fault NA not support 19 Message fault NA not support 20 Motor Overload Fault Overload alarm from drive 21
22. he application software feed forward or tension to torque conversion function 5 3 3 Default Tags used in Drive Application Software Subroutine Inputs Inl Rx x LineSpdRf_FPM Line Speed Reference FPM In2 Rx x LineSpdRfRate FPMsec Line Speed Reference Rate FPM second In3 Bx JDiffEnbl Enable Differentiator In4 Ixx JDiffSamples Number of Differentiator Moving Average Samples InS Rx x BuildUpRatio Normalized Diameter 1 0 Empty Core In Rx x Constant RPMPerFPM Calibration Constant RPM Per FPH In Rx x J_lbft2 Total Reflected Inertia Pound Feet 2 Ing Rx x JGainQuadlQuadZ Inertia Compensation Gain Quadrant 1 and Z In9 Rx x JGainQuad3Quad4 Inertia Compensation Gain Quadrant 3 and 4 InlO Rx x Friction_Pct Friction Loss Percent Load Inll Rx x Windage_ PctRPM Windage Loss Percent Load RPM InlZ Rx x MtrTrqRated lbft Motor Rated Torque Pound Feet In13 Bx ReverseRotation Reverse Rotation Subroutine Outputs Retl Rx x TrqRfJ_Pct Torque Reference Inertia Part Percent Motor Rated Torque Ret2 Rx x TrqRfLoss Pet Torque Reference Losses Part Percent Motor Rated Torque Ret 3 Rx x TrqRfJLoss_Pct Torque Reference Inertia and Losses Part Percent Motor Rated Torque Ret4 Rx x DrvTrqRfJLoss_PU Drive Torque Reference Inertia and Losses Part Per Unit Inertia and Losses Compensation SR Jump To Subroutine Routine Name JLossComp Input Par LineSpdRf_FPM Input Par LineSpd
23. ia 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_Ibft 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 t
24. llectual 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 LO PreCautions a ee et 5 2 0 DGTINITIONS a coer crease cette ce a aaa raa aa cece tac A Aaa r te Aaaa SE ANES 6 A N a N NEA em a 6 2 2 Normalized Quantities solis caci n 6 LIS Terminology A TALA AAA ADA AAA 7 2 3 1 Web ita O a o or thet et roer ie roo tob 7 2 3 2 cis 7 2 3 3 DVE fis cest sec tesk ooo a a a a a a a a cine 7 2 3 4 Motor Tor qUe cc nia 7 PAR A sack seek bo cactvlict E A fe aiehabotatudateteteiatetataieds 7 BO OVA iia 8 A A A A E at le ee 8 3 2 Tension to Torque Conversion coccccccccnooconoccccnnnccnnnnnnnnnnnnnnnnnncnnnnnnnnnnncnnnnnnnnnnnnnnnns 8 4 0 Functional Description do a eailcin 9
25. n9 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 Ifa 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 Pl output signal 7 Ifa center winder application accelerate decelerate the drive and adjust the Empty Core Reflected Inertia JCalc In1 until deviations in the speed PI
26. ne 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 inerti
27. 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 amp 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 Precauti
28. oll Reflected Inertia 3 J_Ibft2 REAL NA Total Reflected Inertia 4 J sec REAL NA Total Reflected Inertia 5 J PU REAL NA Total Reflected Inertia 4 3 1 JEC_Ibft2 This input parameter is the minimum empty core reflected inertia in pound feet 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 HorsePower X5250
29. on 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 pound feet2 add a rung to the Main routine that will scale the tag value to pound feet2 5 2
30. ons 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 Range Example B Boolean BOOL Xx O to 1 0 or 1 Integer INT X 32767 8947 D Double INT DINT X 2097151 74364 R Real Float REAL X X 16777215 3 4 13 0 Applies to single precision accuracy 2 2 No
31. op 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 Ing Total Reflected Inertia sec 5 JLossComp I
32. ough 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 papos mh i j Motor Control i FOC for Induction Motor ii PMag for Permanent Magnet Motor Motor Data Enter all motor data for the attached motor check poles Feedback Config Select feedback type Pwr Circuit Diag 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 Motor Tests NOTE the motor will run Inertia Measure NOTE the motor will run Speed Limits i Select Speed Ref ii Fwd Speed Limit li Rev Speed Limit iv Abs Overspd Lim Max over speed past the Fwd and Rev Speed Limit This is where the drive will fault Do not complete the remainder of the Start Up procedure in the drive 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 st
33. output are minimized If a constant diameter application accelerate decelerate the drive and adjust Total Reflected Inertia JLossComp In1 until deviations in the speed Pl 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 Ifa 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 Pl output are minimized 12 Remove the roll Drive Application Software page 22 of 28 13 14 15 16 17 FM Inertia Compensation Run the drive with a steady Line Speed Reference that results in a motor speed of just over 2 RPM Adjust Friction Loss JLossComp In11 until the speed PI output is near zero Run the drive with a steady Line Speed Reference that results in a motor speed near 75 of full speed Adjust Windage Loss JLossComp In12 until the speed PI output is near zero 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 JLossCom
34. p In10 as necessary to reduce tension deviations Drive Application Software page 23 of 28 FM Inertia Compensation Appendix A Process Line Command amp Status Words The following table is a functional list of the Process Line command word wDLx_DrvCmmdProcLn Bit Input Signal Description 00 Clear Fault Clear all Faults 01 Run 2 Wire 1 Start transition to O Stop 02 Reserved 03 Coast Stop not supported in rev 110101 04 Jog Forward Jog in Forward direction 05 Jog Reverse Jog in Reverse direction 06 Reverse Rotation Under Wind Under wind selection 07 Tension Control Enable Activates selected mode of Tension Control User determines how and when to activate 08 Stall Tension Stall Tension 09 Tension Control Selects Tension Control Mode Tension 10 Torque Control Selects Tension Control Mode Torque 11 Dancer Control Selects Tension Control Mode Dancer 12 Torque Trim Selects Trim type Torque is trimmed 13 Speed Trim Selects Trim type Speed is trimmed 14 Draw Trim Off Zeros the Draw trim signal 15 Torque Follower Control Special Control mode for torque follower 16 Diam Preset 1 Commands preset 1 for Diam Calc 17 Diam Preset 2 Commands preset 2 for Diam Calc 18 Diam Preset 3 Commands preset 3 for Diam Calc 19 Diam Preset Increase Manual increase for Diameter Calc 20 Diam Pres
35. rmalized 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
36. ted 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 Subroutine Inputs Inl Rx x JEC_lbft2 Empty Core Reflected Inertia Pound Feet 2 In2 Rx x Density_lbft3 Material Density Pounds Foot 3 In3 Rx x BuildUpRatio Normalized Diameter 1 0 Empty Core In4 Rx x Constant_RPMPerFPM Calibration Constant RPM Per FPH InS Rx x Width_in Material Width Inches In6 Rx x GearRatio Gear Ratio In Rx x MtrSpdBase RPM Motor Base Speed RPM Ing Rx x MtrTrqRated lbft Motor Rated Torque Pound Feet Subroutine Outputs Ret1l Rx x WeightRoll lb
37. 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 amp 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 amp 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 amp 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_Ibft This input parameter is the motor rated torque in pound feet HorsePower X525
38. x x DLx_BuildUpRatio DiamClac NA Constant_RPMPerFPM Rxx DLx_Constant_RPMperFPM DiamClac NA J_sec Rxx DLx_J_lbft2 JCalc or USER NA JGainQuad1Quad2 Rxx ZDLx_JGainQuad1Quad2 NA 1 0 JGainQuad3Quad4 Rx x ZDLx_JGainQuad3Quad4 NA 1 0 Friction_Pct Rx x ZDLx_Friction_Pct NA 0 0 Windage_PctRPM Rx x ZDLx_Windage_PctRPM NA 0 0 MtrTrqRated_Ibft Rxx DLx MtrTrqRated_Ibft R A NA ReverseRotation Bx DLx_DrvStatProcLn 6 LogicAndReference NA Logic Drive Application Software page 27 of 28 APPLICATION SOFTWARE www rockwellautomation com for Drive Application Software www ab com drives drvappsw Corporate Headquarters Rockwell Automation 777 East Wisconsin Avenue Suite 1400 Milwaukee WI 53202 5302 USA Tel 1 414 212 5200 Fax 1 414 212 5201 Headquarters for Allen Bradley Products Rockwell Software Products and Global Manufacturing Solutions Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Rockwell Automation SA NV Vorstlaan Boulevard du Souverain 36 BP 3A B 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation 27 F Citicorp Centre 18 Whitfield Road Causeway Bay Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Headquarters for Dodge and Reliance Electric Products Americas Rockwell Automation 6040 Ponders Court Greenville SC 29615 4617 USA Tel 1 8

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