Facebook
Google
GitHub
Linkedin
N
In our jumbo roll converting machine, we are facing a problem in total winding roll length.
The length is controlled via perforation counter (sensor Input). The machine is running with DC Motor Controller with Potentiometer.
The study details: 1. Our machine operation consists three main speed cycles. i.e. a. Acceleration Speed, b. Constant Speed, c. Declaration Speed
Acceleration Speed: The machine starts from zero speed to maximum set speed Constant Speed: The machine running in maximum speed till the counter initiates the stop signal to the motor controller Declaration Speed: The moment, the controller gets the stop signal from counter; the machine starts speed reducing from maximum speed to zero speed.
2. The function of counter is to count the number of perforation or sheets in a Log in order to achieve the required counts (length). When the counter reaches to the “Preset Count value" which is programmed in counter, it rests to zero itself and initiates the stop signal to the machine motor controller and it starts counting again from zero.
3. The sheet “less/increase” problem happens only when we are changing the machine speed from high-to-low or low-to-high in a single log cycle.
4. In a constant speed cycle (m/min), the sheet count (roll Length) will be more accurate and speed declaration time and declaration sheet counts will be the same for each log cycle.
5. If we increase the speed (m/min) from low (0 m/min) to high (400m/min), and the machine is stopping from fast speed (Ex: 400m/min), the declaration sheet count and declaration time will be more, so total length of log will be more (Ex: First production Log).
6. If we reduce the speed from high (400m/min) to low (0 m/min) and the machine is stopping from low speed, the declaration sheet count and declaration time will be less, so, total length of log will be less (Ex: Roll changing or any other speed reduction).
7. The less/increase sheet count process is happening only in machine speed declaration cycle. The less count is happening only, when we are changing the parent roll or any other speed reduction, because the operator is decreasing the speed from high to low in order to avoid sudden web break while running the machine
8. A simple life example is, If you want to stop the car from high speed, the stopping time and the distance taking to stop the car will be high. And If you want to stop the car from low speed, the stopping time and the distance taking to stop the car will be low. The same principle is applying in our machine. So, refer study number 4 and 5.
Please can anyone provide me a good solution for the same?
Thanks,
Nijamudeen
nijam75 @ hotmail. com
The length is controlled via perforation counter (sensor Input). The machine is running with DC Motor Controller with Potentiometer.
The study details: 1. Our machine operation consists three main speed cycles. i.e. a. Acceleration Speed, b. Constant Speed, c. Declaration Speed
Acceleration Speed: The machine starts from zero speed to maximum set speed Constant Speed: The machine running in maximum speed till the counter initiates the stop signal to the motor controller Declaration Speed: The moment, the controller gets the stop signal from counter; the machine starts speed reducing from maximum speed to zero speed.
2. The function of counter is to count the number of perforation or sheets in a Log in order to achieve the required counts (length). When the counter reaches to the “Preset Count value" which is programmed in counter, it rests to zero itself and initiates the stop signal to the machine motor controller and it starts counting again from zero.
3. The sheet “less/increase” problem happens only when we are changing the machine speed from high-to-low or low-to-high in a single log cycle.
4. In a constant speed cycle (m/min), the sheet count (roll Length) will be more accurate and speed declaration time and declaration sheet counts will be the same for each log cycle.
5. If we increase the speed (m/min) from low (0 m/min) to high (400m/min), and the machine is stopping from fast speed (Ex: 400m/min), the declaration sheet count and declaration time will be more, so total length of log will be more (Ex: First production Log).
6. If we reduce the speed from high (400m/min) to low (0 m/min) and the machine is stopping from low speed, the declaration sheet count and declaration time will be less, so, total length of log will be less (Ex: Roll changing or any other speed reduction).
7. The less/increase sheet count process is happening only in machine speed declaration cycle. The less count is happening only, when we are changing the parent roll or any other speed reduction, because the operator is decreasing the speed from high to low in order to avoid sudden web break while running the machine
8. A simple life example is, If you want to stop the car from high speed, the stopping time and the distance taking to stop the car will be high. And If you want to stop the car from low speed, the stopping time and the distance taking to stop the car will be low. The same principle is applying in our machine. So, refer study number 4 and 5.
Please can anyone provide me a good solution for the same?
Thanks,
Nijamudeen
nijam75 @ hotmail. com
