SIMATIC Converting.pdf
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Converting Toolbox
Application Manual, 12/2011
9
Technology overview
2
2.1 Tension control principles
Generally the mechanical system in which tension or dancer position control is necessary
consists of the material web which needs to be controlled, of a motor which drives the web
and of an equipment which is used to set or measure the web tension.
Typical machines with tension control are for example coating lines, rewinders, slitters,
narrow web machines usually running with materials like paper, laminates, wire, foil and film
(plastic or metal), textiles or cables.
The task of the controlled motor is to:
● transport the material with the defined machine velocity
● hold or control the setpoint tension in order to avoid tension drops or increases
● the motor is typically connected via a gearbox to a roll which is used to transmit tension
and velocity to the material web. It must be ensured that the roll surface and the roll
surface contact area can transmit the desired tension effectively to avoid slippage and
tension drop. Additional mechanical elements may be required (nips, s-rolls, etc.). The
roll diameter is typically constant.
● In case of simple concepts the tension is only set and not controlled. This means that the
speed setpoint of the motor is preset and the tension is defined by the friction between
the material and the roll surface.
If a more sophisticated tension control is required then the system must be amended to
include a tension measuring cell or a dancer system. Closed-loop tension control and dancer
control require a controller – in this document referenced as the technology controller or
TPID. The technology controller is realized as a PID controller which includes setpoint
conditioning and jerk-free switch-on functionality.
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