Winding is a procedure to take up and package material in roll form, for more efficient handling or in preparation for a subsequent operation. In a typical industrial use, a winder is employed to roll up a continuous or limited length of material such as wire, paper, film, metal, or textiles. The winder and finished roll are referred to by different names in different industries.
| Industry | Winder Name | Roll Name |
| Paper, Textile | Winder | Roll |
| Wire | Takeup, Reeler | Reel |
| Wire | Spooler | Spool |
| Metal | Coiler | Coil |
| Textile | Beamer | Beam |
Wound materials may be stretchable or non-stretchable. Winding of stretchable materials is more complex and critical than non-stretchable materials. Selection of winder drives for stretchable materials require considerable analysis and factory consultation is often required.
Materials typically wound include:
Generally, plastic film is extensible (stretchable) material, most other materials can be considered non-extensible. Rolls may be wound by applying drive torque at its center or its surface. As a result the two major categories of winders are:
- Center Winders
- Surface Winders
Winder drives are designed to improve the wound package and eliminate material breakage.
Application Challenges
- Control of a motor under dynamically changing requirements
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- Speed and torque need to be controlled
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- Acceleration to a fixed speed, deceleration to zero speed
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- Changes in speed and torque during operation
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- Detailed sequencing for flying splices and roll changing
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- Changes in processed material
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Applicable Products
Drives Products |
Motion Products
| Drives Products | Features | Benefits |
| PID Control Mode | Line velocity control and diameter consistency can be achieved using the drives PID Mode with dancer position sensors, velocity sensors or diameter sensors. |
| Cooling Fan On/Off Control | Controlling the number of times the drive fan is switched on and off increases the lifespan of the cooling fan and reduces the need for maintenance. |
| Flux Vector Control and Torque Control Mode | Both torque and constant tension control are possible by using Closed loop Vector Control and Torque Control Mode. |
| Zero Servo Mode | The Zero Servo Function in Closed Loop Flux Vector keeps the wire from becoming slack, eliminating the need for a mechanical brake. |
| Kinetic Energy Braking (KEB) | KEB braking function can decelerate the application to stop without damaging the load, even when a power outage occurs. Simply coasting to stop can cause the wire to build-up or break. |
| Torque Detection | Undertorque Detection senses wire breaks so that the drive can automatically stop the application immediately. |
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| Servo and Motion Products | Features | Benefits |
| 48 axis of servo amplifier control from one controller | Complex Winding applications easily handled |
| Ethernet, DeviceNet, Profibus modules all available. | One controller for varying customer specifications |
| Integrated Machine Controller | PLC, I/O, Motion, and Networking functionally in one unit minimizes integration issues. |
| Pre-configured function blocks | Streamlines programming |
| 2 or 4 axis control | One program can synchronize the necessary tension between processes on the same line, and/or coordinate other precision operations (e.g., cutting). |
| Ethernet –Telnet protocol, Modbus TCP master | Auxiliary functions from an unlimited number of additional axes possible via Ethernet. |
| Absolute Encoder Support | Recovery from total system power loss is streamlined – eliminating downtime. |
| Virtual master capability | Eliminates the mechanical disturbances typical with mechanical line shafting – improving tension control. |
| Machine control capabilities in single-axis controller | Reduce third-party devices by combining machine control with motion control |
| DeviceNet communication Option | Sigma II w/ MP940 can act a master or slave device |
| MotionWorks+ Programming Software | Icon based programming makes new production runs only a few mouse clicks away |
| Variable ratio digital gearing | Independently driven axes can be perfectly synchronized |
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Application Details The winder drive supplies the necessary torque at a controlled speed to accomplish material windings.
Different materials require different tensions during winding, with plastic films very light and cable and steel very heavy tensions. Some materials such as plastic films and papers will elongate and separate if over-tensioned.
Winder drives are classified by their method of control and include:
- Constant Tension Center Winder (CTCW)
- Line Speed
- Dancer Position (pot or transducer)
- Torque Regulated Speed Follower (TRSF)
- Hyperbolic or Differential
Typical processes or sectional machines that include winders:
- Printing press in paper and film
- Wire insulation line in wire
- Galvanizing line in metals
- Casting or extruding line in film
Additional Information
The pdf contains the same information as the web, but in some cases may contain more and should be used if a printed version is required.