ver the last 25 years SAELachieved a strong experiencewithin the Paper Mill industry

SAEL s.r.l.... the trasformation

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R&D, DEVELOPMENT, FLEXIBILITY ANDAFTER SALES. THOSE ARE THE ELEMENTSOF THE SAEL SHARE GAIN OVER THE LASTTWELVE YEARS OF ACTIVITY.PAPER MILL DRIVES AS MUCH ASTRANSFORMATION PLANTS AWARDED SAEL ASA 360° SKILLED COMPANY ON PAPERINDUSTRY. TODAY SAEL OFFERS HI-TECHSOLUTIONS BEING THE BEST AUTOMATIONPARTNER FROM THE SMALLEST TRAFO UP TOTHE COMPLETE PAPER MILL.

by: PPPPPaolo aolo aolo aolo aolo Andrighetti SAEL sAndrighetti SAEL sAndrighetti SAEL sAndrighetti SAEL sAndrighetti SAEL s.r.r.r.r.r.l..l..l..l..l.

Bielomatik sheter, Burgo Sora, Cutting system REVAMPING

OOOOOelectronic automation: special plants,production and paper transformation.The engine of this acknowledgment hasbeen the continuous challenge of thecustomers to create innovativesolutions for their specific needs.Back to the 90’s the shearers, therewinders, the embossers wereconsidered “low tech automation”. Fewyear s later the new technologyapplication based on PC andmicroprocessor systems gave the rightvalue selling to those applications.From the mechanical management forall the moving part by piston road andPIV regulators - syncro shearers - tothe electronic systems and motiontransmission to the knifes. The naturalevolution brought ourselves to an high-tech rise increasing quality andautomation along the way. Today SAELoffers a huge variety of automation:Electronic syncro shearers; fix blademachines; shearers by register cut;Unwinders; Rewinders; Embossers;Coupling lines; etc..).SAEL equipments are present overmany End Customers: from the smallestmanufacturer up to the biggest PaperMill. Over the last 5 years, the key of

this success have bee the REBORNsystem - fit for old equipmentrevampings -.The Company internationalization andthe continuous learning behaviourallowed to achieve important goals byacquiring jobs for national big groupswith world wide subsidiaries and plants- Asian countries mainly -.However the domestic market SAELrepresents the majority of theinstallations: Marchi, Burgo, Milltex,Reno de Medici, Favini group, Cordenons

etc.. Also important are all the othercustomers/transformers who boughtautomations.To be competitive vs. the most famousautomation brands, the constant R&Dinvestments have been the key. Thisallowed to use a mix of components:standard PLC with own “IntelligentDrive”.A simple architecture without ownHardware use - drives apart, where thecontinuous research developed specificAC and DC controls with own high-tech.

T e c n o l o g i aT e c n o l o g i aT e c n o l o g i aT e c n o l o g i aT e c n o l o g i a

press line and ed cupling

Rebuilding of Teleset, Telebok ed LDS in a VariRoll winder

The “Intelligent Drive” control offers avariety of options fit for any specificpaper mill application. Within thesoftware there are specific configurablemathematic blocks allowing any motor/motion control.There are many communication ports -As standard: 2 x Can; 1 x RS232. AsOption: all the Field Buses - Those portsallows a fast connectivity the existingDCS systems in the plant.The powerful software “AZWORKER” isthe best friendly user Drive tool. Itconnects all the mathematic blocksgetting the desired settings and all theDigital / Analogical on board Driveconfigurations.

Time after time, application afterapplication, every SAEL AC or DC drivegot the historical know-how inside.Today an inverter can drive a simplepump up to the most sophisticated Reelwith automatic diameter calculation,inertia compensation with feedback by

Within this PLC series - 200 up to 400 -there is a direct Can Bus dialog througha specific Bridge. Without added costsall our AC or DC drives can be linked tothe most common PLC. Any regulationsettable via PLC can be done by Write/Read words - Ser vo-diameters;Cascade Refs; Filtering; Multipliers; CellsRegulators; Speed adjusters;Positioners and so on -. The standardoutput are: 2 x Encoder in; 4 xAnalogical out; 4 x Analogical in; 8 xDigital out; 8 x Digital in). They can beconfigured as a PLC S7 I/O extension.The Drive does the positioning. It is alsopossible to send out the computing tothe PLC using this data to stop the motorat the right position. Every singleproduct was developed to meet anycustomer needs with less elements inthe equipment possible.Every engineered equipment with thosedrives uses a standard PLC. Thanks tothe common platform developed everydrive - whatever AC or DC - has thesame regulation board for every size,and it is possible to replace Thyristor

load cell. Atough andrough, reliableproduct fit forthe Paper Millenvironmentwho well jointsthe SiemensS7 PLC.

Jagemberg Syncro 1600 Rebuilding, Burgo

Rebuilding of N°2 sheters Jagemberg, IB Italcart.

or IGBT. A SAEL spare part means oneboard, a branch of thyrostor or IGBT.The DC installations possible are above1 MW and the AC above 800 kW.

The SAEL “CUT SYSTEM”:The SAEL “CUT SYSTEM”:The SAEL “CUT SYSTEM”:The SAEL “CUT SYSTEM”:The SAEL “CUT SYSTEM”:

Our paper shearers cut system todayis the evolution of more than 30 yearsexperience. From the very beginningbased on solid state electronic board -cmos, dac and counters - up to thelatest microprocessors of today - 64bit RISC based -.Over the years many cut systems havebeen developed across the paper andsteel industry achieving the bestsolution possible for any customerneeds today.The algorithms have a double regulationloop, one vir tual loop and one closingloop. To any Brushless motor-drive,Inverter or DC drive, this solution is thebest flexible and suitable ever.This is why we can apply our cut cam tothe old equipments using the existingdrives and motors without dismantlingthe cabinets. The blade regulation isdriven by the own DCS - Digital CutSystem -, a microprocessor whocomputes the stand alone algorithm inthe presence of non SAEL drives only.In case of SAEL “Intelligent Drive”, thealgorithm is embedded within the

Inverter or the DC drive who processesand manages the motor speed andcurrent loop.There are many regulation options: fromthe basic blade up to the sophisticated“scissor” mainly used for steelapplications - over the cutting and alongthe blade angling, the system maintainsa constant periphery speed suitable toany variation caused by the blades itselves -.The recovering profile is generated ontime or space base. To simplify pleaseget the “Time” or the “Space” as the“Recovering Profile”. This profile couldbe trapezoidal or triangular as afunction of the acceleration or axesspeed step increase. The picture 1 isthe Recovering Profile in case ofelectrical axes. The Recovering Profilegets over in case of positive masterspeed meeting with the settled timeonly. In case the master keeps invertedthe Profile automatically compensatesby consequence. It is given that theProfile restarts to exceed the recoveringstarting quote when the master backsto the original direction.It is possible to enable the RecoveringProfile generation by a “sin2 fnc” ramp:this gets a smooth recover with theaverage acceleration made on a linearmode, but with 20% exceeding peakover the mid point of the ramp.

As mentioned above the RecoveringProfile could be trapezoidal ortriangular as a function of theacceleration or axes speed stepincrease control option. According tothe own logic there are fourcombinations available. Having thissystem many applications are possible:cut, press, hot press, embossing.Somehow it is possible to reach thedouble of the original production.Example of paper print or polyethylenefilm:After printing cycle on, there are fivephases as following:

1. Print starting phase - the slaveand the master speed are thesame at the touch point.

2. Intermediate printing phase -the slave and the masterspeed are the same at thetouch point.

3. Ending of the printing phase -the slave and the masterspeed are the same at thetouch point.

4. Slave recovering position phase- - the slave and the masterspeed are different

5. Next printing phase - - the slaveand the master speed are thesame at the touch point.

Scusa Paolo: Nel testo in italiano, nellefasi 1-2-3 e 5, dici che “la velocità delloslave nel punto di contatto è uguale aquella del master”. E’ giusto che siacosì per tutte e 5 le fasi?Se è giusto, allora non ti preoccuparepoiché ho tradotto pedissequamente.

Calander in Burgo Papermill, Toscolano

In caso contrario dammi la nuovaversione che te la traduco.

In case of phase nr. 4 the electrical axesrecovery must be applied. It is therecovering space needed to meet thesynchronization of the following print,equal to “P” - (3/2 P - 1/2 P where 1/2P is the space of the electrical axes).Moreover to a perfect synchronizationthe recovery must be done “on Space”with a saving period equal to P/2: therecovering start must be triggered overthe master axes P/2 exceeding. Thismeans that the recovering can be doneon phase 2 and 3 as well. Important isto set the trigger quote of therecovering start before.

The SAEL “REWINDING SYSTEM”:The SAEL “REWINDING SYSTEM”:The SAEL “REWINDING SYSTEM”:The SAEL “REWINDING SYSTEM”:The SAEL “REWINDING SYSTEM”:

Through a SAEL Supervisor based on aPC - suitable for trend measurement,hardness curves, etc. - in combinationwith a S7 PLC, it is possible to managethe hardness curves and Rewinder theoperational. The S7 PLC is mainlyfocused on the sequencesmanagement.

The communication between the PLCand the drives is Profibus based asmuch as CAN BUS for the drives. Theinteraction of the two communicationnets allows a safe and fast dataexchange for the motor loadmanagement. This is a distinctive keyfor SAEL application:

The drives set the coil hardness by anown curve without PLC calculationoverloading. So the system computesall the motor speed and current refsthrough the interaction of the PLC andthe “Intelligent Drive Sael”. Two DCmotors are used to set the hardnessof the main cylinders over the rewindingphase. The entering cylinder motor drive(rear) is the Master and gives themachine speed. The out cylinder motordrive (front) is the Slave and it iscontrolled by a torque loop. The coilhardness is given by the two motortorque dif ference. By a positiontransducer - existing potentiometer onthe rider roll - the coil diameter isdetected. Through interpolation pointsand computing in the Drive, the coil

Tissue Winder A.Celli in Georgia Pacific Papermills

Rebuilding of SDW winder in Villorba papermill, Burgo Group

hardness is given for the starting andthe ending phase.The two motors cur rent controlautomatically gives the use within theoperating range. The ride roll - everyVari-Dur is equipped by - has and ownlightning curve managed by the PLCand settled by a video-keyboard. Thesystem encloses: “Rewinding DimaterStop” with a programmable metercounter by video-keyboard; “SpeedDecreasing” for the ending coil; “Meterod Diameter Stop selection” by video-keyboard; “Machine Alarm” by video-keyboard; “Unwinder Breaking” for theunwinder with inertias and diametercalculation; “Cell or Dandy Roll”management by 0-10 V analogicalsignal; “Reel” release potentiometerfrom 0 to 100%.The Rewinder Drum Motors releasesare: Speed ref with ramp for the Reelmanagement without external feelers;Rewinder Motor Torque for coilhardness and diameter fnc; Ride Rollpressure computing and servo-valveactuation.

The coil hardness and the Ride Rollcurves regulations are settled viasupervisor or video-keyboard andadjustable at any time for the flexiblesystem ever.

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All the Reel electronic computing andthe regulations are a specific topic

within the SAEL “Intelligent Drive”architecture. By the Drive electronicboard is possible to set all thealgorithms for the Reel managementas much as the speed ref and drivingsettings.All the Drives have a software releasewho reaches +/- 3% accuracy also incase of dramatic line speed variationwithout any load cell use. The Softwarehas the following features:

· Diameter computing· 2nd derived computing for

inertia compensations· Machine inertia computing· Coil inertia computing· Grazing Friction computing· Speed Refs generation· Video-keyboard and visualizer

communication and set-upparameters.

Within the last software release a newmacro routine has been upgraded. Thisallows the indirect reel calculation maindata auto-tuning.The system operator has a hugeadvantage of that, because any specificskills are required.