texite

Subject to change without prior notice Order No.: E20001-Y360-P620-X-7600 Dispostelle 06372 SCHÖ/28126 GD.MC.20.TEXT.59.0.01 MP 09101.0 Printed in Germany © Siemens AG 2010

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

www.siemens.com/textile

Integrated and modular solutions for textile machines provide highest productivity across the entire production process.

Answers for industry.

How do you achieve highest reliability and cost effectiveness, even in the smallest fiber?

Solutions for textile machines – for highest reliability and cost effectiveness

Whether textile machines for natural or man-made fibers are concerned,

or for their refining: The industry is facing new challenges every day. Short-lived

trends, fierce competition and enormous cost pressure are all making demands.

The integrated and modular automation and drives solutions from Siemens can

help you stay ahead. For we provide the flexibility you need in times of short-

lived trends.

Our innovative products and systems, along with plant-wide applications and

solutions for the entire textile production process, ensure high productivity and

efficiency right down to the smallest fiber.

siemens.com/textile

Perfect textile finishing solutions in record timeFinishing Toolbox: Solutions for finishing continuous material webs

Solutions for Textiles

2

Tailor-made solutions for textile finishing – with minimum effort: the Finishing Toolbox

The textile industry is increasingly facing the challenges posed by rising production rates,

maximum availability, high flexibility, optimum product quality and minimum lifecycle costs.

In parallel industry specific technologies are placing ever increasing demands on the automa-

tion. Therefore, concepts with which you as a machine builder in the textile industry can con-

tinuously optimize the productivity of your solutions are in demand.

3

Totally convincing: the comprehensive portfolio from Siemens.

As a system supplier, we address the complete range of machines for finishing continuous material webs, with our portfolio for automation and drives technology. As a machine builder, you can depend on the latest state-of-the-art technology, customized functions and outstanding quality with our products, systems and services. For instance, our mechatronically optimized machine con-cepts ensure a high degree of flexibility, increase the cycle rates, shorten changeover times and reduce maintenance costs. Advantages that pay-off – day in, day out.

Typical applications for our solutions:

•Classic textile finishing: washing, bleaching, merceriz-ing, dyeing, drying

•Textile printing•Calendering•Heat-setting•Thermo bonding•Coating and laminating of non-woven materials and

technical textiles•Adhesive application•Powder coating•Impregnating viscose, glass and carbon fibres•and many more

Outstanding: the SINAMICS DCC Finishing Toolbox

The Finishing Toolbox – a standard library of SINAMICS DCC application blocks that can run on the SINAMICS S120 motion control drive system and that have been spe-cially created for you. This means that you can profit from fully functional solutions and tested know-how – perfectly documented and tested in advance.

The Finishing Toolbox significantly simplifies material web finishing applications - allowing for more margins when it comes to pricing and deadlines. It includes open, parameterizable blocks, which optionally can be combined with the SINAMICS S120 Safety Integrated functions.

With these pre-configured functions and applications you can realize perfectly tailor-made solutions in the shortest time.

SINAMICS DCC Finishing Toolbox

4

Getting there faster – with the Finishing Toolbox applications

SINAMICS DCC Electronic Gearbox

The SINAMICS DCC Electronic Gearbox application is used to realize angular syn-chronous gearing with freely selectable ratio between several axes. It can be used universally for continuous material webs.

With the SINAMICS DCC Electronic Gear-box application, two or more axes can be operated with precise angular synchro-nism without requiring a mechanical coupling.

SINAMICS DCC Separate Chain

The SINAMICS DCC Separate Chain appli-cation was specifically created for the control of transport chain drives in stenter frames. In this application two chains guide the material web in angular synchronism through the machine to achieve precise alignment of the material web at thread level.

This application is suitable for continuous material fabric and non-woven material webs as well as for fibres and yarn.

General properties:

•A real or virtual master can be used•Gear ratio can be input as a rational

number•Integrated runtime correction

This application is based on the SINAMICS DCC Electronic Gearbox, and enables angular synchronous gearing between two endlessly rotating rotary axes with a fixed ratio of 1. During synchronous operation a relative offset between the synchronous axes can be set.

Graphic programming with SINAMICS Drive Control

Chart (SINAMICS DCC) in the SINAMICS S120 drive

system allows the drive functionality to be adapted to

specific machine configurations and technology-specific

features to be added. With its Finishing Toolbox,

Siemens offers a library with tried-and-tested blocks –

specifically for applications in the textile industry – with

which individual automation solutions can be quickly

and reliably created.

SINAMICS DCC and the Finishing Toolbox offer you the following advantages:

•Quick and reliable implementation of automation and drive solutions using pre-configured and tested parameterizable blocks

•Adaptation to individual requirements as blocks can be freely combined to supplement or modify your own application-specific blocks

• Blocks with machine builder specific know-how can be protected

5

SINAMICS DCC Line Tension Control

The SINAMICS DCC Line Tension Control application was developed to create a flexible, parameterizable solution for tension or dancer roll based control tasks with SINAMICS S120 as a higher-level controller. It is suitable for web-type materials in the textile industry.

To set the required material tension and/or to ensure correct material trans-port through the machine, the standard SINAMICS DCC Line Tension Control application includes various closed and open-loop control modes:

•Tension control using torque limiting•Tension control using speed adaptation•Dancer roll position control using speed

adaptation

SINAMICS DCC Setpoint Cascade

The SINAMICS DCC Setpoint Cascade application allows a velocity cascade to be calculated in the drive. This is designed for larger production lines invol-ving a minimum of eight drives.

The setpoint cascade application com-prises of system ramp-function generator and setpoint cascade function blocks. The system ramp-function generator operates as a central ramp-function generator for the complete production line and is cou-pled to the higher-level controller.

Open-loop control mode:

•Indirect tension control (tension pre-control) using a torque limit

•Draw control (ratio between speeds)

Additional functions:

•Torque pre-control (tension, friction, acceleration)

•Line operation, without closed-loop control

Typically the components involved in the closed-loop control are part of a larger system/machine, which may include several tension zones and also winders.

Communication to the PLC can be realized via PROFIBUS or PROFINET. To control the overall cascade a separate setpoint cascade is used for each drive.

Function overview:

•Group setpoint•Supplementary setpoint for catching up

or closed-loop dancer roll control•Individual operation

SINAMICS DCC Harmonic Wave Compensation

The SINAMICS DCC Harmonic Wave Compensation application can be used to counteract harmonics. The advantages: relieves the speed controller and reduces speed ripple.

Application features:

•Can be flexibly adapted for a particular machine

•Independent compensation of up to three sinusoidal, periodic torque harmonics

6

SINAMICS DCC Winder: Solution for winder applications

The SINAMICS DCC Winder application is directly implemented in the drive and addresses a wide range of winder appli-cations with one single application soft-ware package. As a result of its openness, the application can be configured or if necessary modified as required. The application allows a winder or unwinder to be implemented for the widest range of applications – also in textile machines. Machine builders can optimally incorpo-rate their existing know-how – and profit from the fact that the look & feel is simi-lar to that of a function chart.

SINAMICS DCC Load Sharing Control

Coupled axes are used in a large number of machines. The coupling can either be rigid (direct) or flexible (through the material web itself). In such cases the load must be distributed between the coupled drives.

The SINAMICS DCC Load Sharing appli-cation offers the following features:

The following winder functions are available:

•Closed-loop control mode: closed-loop dancer roll position control with speed correction, closed-loop tension control with torque limiting, closed-loop ten-sion control with speed correction and open-loop torque control (indirect closed-loop tension control)

•Integrated diameter calculation using the ratio between the material web velocity and winder speed

•Optional: tension reduction for winders (winding hardness characteristic)

•Torque pre-control (tension, moment of inertia compensation, friction)

•Torque de-coupling•Overcontrol and torque limiting•Droop and compensation

Advantages of a correctly adjusted load distribution:

•Energy efficiency•Less heat is generated

7

Complete portfolio from a single source

As your partner, we can offer you all of the components that you need to realize first-class solutions for finishing continuous material webs:

SIMATIC S7-300: This modular controller is the optimum solution for applications in central and distributed topologies. In addi-tion to standard automation functions, safety technology and motion control can also be integrated.

SIMATIC HMI: The globally-leading, complete and seamless range of products and systems for all tasks involving opera-tor control and monitoring.

SINAMICS S120: This modular drive system is the first choice for high-perfor-mance motion control applications in industrial machine building and plant construction.

Value-added for machine and plant

Powerful and high-performance motors for motion control applications:

From our extensive motor portfolio, you can select the optimum motor that is pre-cisely matched to the SINAMICS S120 drive system for your application. Especially our 1LE1 induction motors, MOTOX geared motors and 1FK7 servomotors have admi-rably proven themselves in textile machine applications.

In addition to their outstanding properties and their perfect interaction, our compo-nents set themselves apart through the consequential use of well-proven commu-nication standards such as PROFIBUS and PROFINET.

Whether talking about productivity, flexibility, costs, safety or shorter times to

market: our comprehensive portfolio can play a decisive role for you in setting new

standards with your solutions – and so helping you to sustainably improve your

competitiveness. Our portfolio precisely addresses the issues that allow you

to fulfill the continuously increasing challenges in your industry.

MOTOX geared motors

SIMATIC HMI

SIMATIC S7-300

SINAMICS S120

1FK7 servomotors

1LE1 induction motors

SINAMICS S120 with Safety Integrated functions

SIMATIC HMISIMATIC S7-300

SINAMICS DCC Finishing Toolbox

Servomotors

PROFIBUS/PROFINET with PROFIsafe

Induction motors

Additional information: www.siemens.com/textile

Siemens AG Industry Sector Motion Control Systems P.O. Box 3180 91050 ERLANGEN GERMANY

Subject to change without prior notice 09/11 Order No.: E20001-A1500-P620-X-7600 Dispo 06372 SCHÖ/34634 B2TX.52.1.04 WS 09112.0 Printed in Germany © Siemens AG 2011

The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

siemens.com/textile

Reference, Marzoli S.p.A.

Automation for the leader in innovationStrategic partnership for developing textile machines in-line with the market

Everything but hand-knitted: Marzoli – the textile machine specialist securing its power of innovation

by entering a long-term partnership with Siemens automation technology.

Marzoli – based in Brescia, Italy – has been manufactur-ing textile machines since 1851. Its strength lies in its portfolio of machines and systems that covers the complete spinning production process. The company‘s port folio extends from machines for processing cotton, man-made and composite fibers – from bale breakers to carding lines, drawframes, flyers and the manufacturing of yarn using a ring-spinning process.

Strategic partnership creates security

Its many years of experience, in-depth industry know-how, high level of technological competence and flexible manufacturing system allow Marzoli to respond to market demands with a high degree of innovation. To secure this position Marzoli has been working closely with Siemens for many years in the field of automation and drive tech-nology. Their complete portfolio of machines has been equipped with SIMOTION and SINAMICS to achieve the highest degree of homogeneity in the different machine series.

Efficient drive technology

The modular, scalable structure of the SINAMICS S120 family of drives and the enormous flexibility of SIMOTION controllers significantly simplify and rationalize the

development of various machine types. For instance, machines can essentially “inherit“ the hardware and soft-ware engineering that has been implemented in other machines. The multi-axis technology of the SINAMICS S120 family allows the control cabinet design to be optimized: the space required is minimized, cabling and electro-mechanical components are reduced.

Rugged and durable

The configuration of motor modules connected to a common DC bus and fed by an Active Line Module guarantees a high degree of reliability and ruggedness, even if the quality of the line supply is poor. This feature is of special significance for flyers and spinning frames. Until now voltage dips or power failures could cause all of the yarns to break resulting in significant production downtimes. The SINAMICS drive modules with Cold Plate technology dissipate the power loss using an external heat sink via the thermal interface at the rear of the unit. This technology avoids the risk of the power unit overheating, which can occur in environments heavily laden with fluff.


Subject to change without prior notice Order No.: E20001-A1510-P620-X-7600 DISPO 06372 SCHÖ/36072 B2TX.52.1.06 SB 09111.0 Printed in Germany © Siemens AG 2011

Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY

Recipe for success: Flexibility through standardization

Integration makes the difference

The principle of integration employed by the multi-axis system SINAMICS S120 allows all of the drive param eters to be saved on one compct flash card, therefore signifi-cantly simplifying the commissioning of serial machines. The system also proves itself in operation: The Control Unit recognizes if a module is defective and the spare part is automatically integrated – without having to recommission the drive. Using the standard STARTER software tool, it is also possible to engineer all of the converters and servo drives of the SINAMICS family. The diagnostic tools available in STARTER allow the dynamic behavior of the drive components to be analyzed in detail.

As a result of the extensive options for setting the control parameters in the drive the Marzoli application engineers can implement in creased levels of machine performance without overstressing the mechanical system. The mechanical transmission elements are specially protected as the torques of the individual motors in the coupled drive train can be flexibly distributed. The fact that the components are fully integrated via a fieldbus allows a whole series of internal drive parameters to be displayed at the operator interface where they can be easily moni-tored. Consequentially, maintenance technicians can simply call up useful information for monitoring the condition of the machine. Using the operator interface (MP 277) and communication with the Marzoli supervisory system via Ethernet, operators can simply adapt the process parame-ters to the particular yarn.

Energy-saving is a must

A large family of reliable motors power the Marzoli machines, starting with 1FK7 servomotors for dynamic axes up to 1LG and 1LE induction motors for higher power ranges.

Marzoli has made a fundamental decision to use IE2 motors with increased efficiency according to the latest European energy-saving standard for all of their machines. The use of induction motors with increased efficiency in conjunction with the SINAMICS Active Line Module infeed units (with active front-end technology) clearly demonstrates that Marzoli is convinced that energy- saving and innovation go hand in hand. According to the company‘s philosophy of standardization, SINAMICS S120 Motor Modules are used for all of the machine types. With a few components and a minimum stock of spare parts it is possible to cover the complete range of drives installed in the system. In conjunction with the global presence of Siemens, it is ensured that maintenance costs

and system down times can be reduced across the board.

More than just a supplier relationship

In its partnership with Siemens, Marzoli has found a sin-gle supplier for the complete automation of its machines and systems – one single partner for the quality, the inte-gration and the after sales support provided through the global Siemens service centers.

In close cooperation, the common objectives are pursued in an open spirit of partnership – which in turn gu ar antees a continuous improvement process. Starting with the technical optimization of the solutions, which are used for the complete range of machines, up to the joint logis-tical control of supplied machines, both partners work hand in hand to create optimum solutions to address the current challenges of the spinning frame industry.

A trusting partnership bonds Marzoli and Siemens. In their cooperation, their individual core competen-cies are optimally applied, which in turn secures the ongoing technological development of Marzoli machines and systems.

siemens.com/textile

RWTH Aachen University, Institute for Textile Technology

Flexible harness control on a loom

Development of a test stand to optimize the heddle/harness system

The Institute for Textile Technology of the renowned RWTH Aachen is a recognized partner to the textile machinery construction sector. At RWTH, a harness test stand was developed in order to analyze and optimize the interaction of the heddle/ harness system for the weav-ing process. The special challenge: Harness motion was to be able to be flexibly varied. For the electrical equip-ment to move the harnesses, RWTH Aachen completely used Siemens components. Siemens not only supplied the automation, but also supported RWTH when designing the drives, commissioning the test stand and the mechatronic optimization.

Technological task

The heddle/harness system is used to form the shed in the weaving process. A vertical play between the heddles and the carrier rail of the harness is absolutely necessary and is used among other things to thread the yarn, rectify yarn breaks – and compensate for tolerances in the high-speed weaving process. However, this play must be pre-cisely dimensioned. Otherwise, this will result in rougher yarn, diminished weaving quality, negative effects on machine operation and increased energy usage. In order to improve the heddle/harness system, the interaction of the heddle play had to be analyzed. To achieve this, the Institute for Textile Technology of RWTH developed a measuring system, which acquires the relative motion of the heddles in the harness frame during high-speed operation. In parallel to this, a test stand was designed which allows the influencing parameters to be varied and simultaneously utilized in actual operation. This test stand was developed in close cooperation with Siemens.

Test stand to vary parameters

To start, a requirement profile for the test stand was developed and sub-divided into mandatory, reference and can crite-ria. The must criteria included the follow-ing: the static and dynamic relationships at the machine were to be emulated as close as possible to those in practice at realistic machine speeds of up to 1000 rpm and different motion profiles had to be emulated (with/without rest phase). After evaluating different methods, the components for the measuring system shown in Fig. 1 were selected. In addi-tion, the noise was determined according to the envelope technique. The complete sensor system can be used in industrial weaving machines and can therefore be used in weaving mills. The team then drafted various test stand concepts and mirrored the requirements that had been drawn-up against these. The concept in-volving an industrial weaving machine with modified shedding formation device was finally selected, which guaranteed the best possible reference to practice. The weaving machine – equipped with single-motor drives to move the harness – is shown in Fig. 2. This design allowed the harness motion profile to be widely varied: e.g. a sinusoidal motion and mo-tion with a rest phase (see Fig. 3).

Using this test stand and the measuring system, it was possible to analyze how the various parameters, e.g. machine speed, motion profile, warp tension level and harness type affect the relative mo-tion of the heddles in the harness frame, the noise generated as well as the wear and the weave quality.

Drive equipment to move the harnesses

The automation configuration for the test stand is shown in Fig. 4. It comprises four servo motors and the drive system to control the motors. The test stand is op-erated using the SIMOTION Scout© engi-neering system. An operator panel is not required. All of the drive components are connected through DRIVE-CLiQ©, the uni-form, digital interface system.

Highest dynamic performance required

In order to achieve the specified machine speeds of 1000 rpm, the harnesses must be accelerated at an extremely high rate. This is the reason that RWTH used 1FK7 HD (High-Dynamic) permanent-magnet synchronous motors to move the har-nesses. These motors set themselves apart as they have a very low intrinsic moment of inertia and 300% overload ca-pability. Further, two motors are coupled to one shaft for each harness (see Fig. 2). With the same total torque, the motors have a lower moment of inertia than a correspondingly larger single motor for each harness. A motor follows the torque of the coupled motor. The torques can

be generated in absolute time synchro-nism as a result of the connection through the digital DRIVE-CLiQ interface system.The test stand requires a total of four mo-tors. These are controlled from two dou-ble motor modules from the SINAMICS S120 drive system. These motors are con-nected to a common DC link fed from a Base Line Module. The motors can ex-change energy through the DC bus. As a consequence, the energy that is released when a motor brakes can be used by an-other motor to accelerate.

Motion control using cams connected in series

SIMOTION D from Siemens is used to con-trol the drive to implement the motion profile that is required. The module is di-rectly integrated into the drive line-up. SIMOTION also executes the PLC func-tions, which means that a separate, pro-grammable logic controller is not re-quired. What is especially worth mentioning is the fact that SIMOTION provides a wide range of motion control and technology functions, including a cam function. For the test stand, the mo-tion of the harnesses is derived from a virtual master axis - and implemented in a user-friendly fashion using two elec-tronic cams connected in series (see Fig. 5).

Fig. 1: Measuring components at the heddle play test stand Fig. 2: Motors mounted on the test stand

High-speed camera

LightingHarness stroke sensor

Warptension sensor

Soundmeasurement

To start, the relationship between the machine angle of the loom and the har-ness position (height in millimeter) is de-fined. The associated angular position of the eccentric (in degrees) is then mapped at the gear unit output. Contrary to their mechanical peers, electronic cams can be quickly replaced and their cam shape can be configured as required. As a conse-quence, harness motion can be specified intuitively in a user-friendly fashion and the motion function of the harnesses can be varied over wide ranges. This is abso-lutely necessary in order to investigate the influencing parameters; however, this is either not possible or only possible with some restrictions at a conventional series loom.

Test support using user-friendly diagnostic options

The SIMOTION Scout engineering system combines the functions to parameterize, program, diagnose and document the au-tomation under one user interface. As a consequence, Scout is not only used to dimension the drives, for commissioning and to enter different motion profiles, but is also used to operate the test stand. During the various investigations, the trace function turned out to be especially useful. Using this trace function, internal and external parameters – for example setpoint and actual speed and torque val-ues - can be recorded in real time, ar-chived and exported to other programs.

Interaction between technology and automation know-how

As a partner to the textile machine sector, Siemens also gets deeply involved when it comes to innovative topics at an early stage. Within the scope of this project, drive and automation solutions from Siemens were convincing from many perspectives:• It was clearly shown: The product port-

folio from Siemens fulfills the require-ments of the textile sector - in a com-prehensive and efficient fashion.

• The automation task was able to be completely realized using standard components. When compared to cus-tomized solutions, they offer advantag-es due to the fact that spare parts are available worldwide and cost efficiency as existing platforms can be used..

Fig. 5: Electronic cams connected in series to implement harness motion

Fig. 4: Automation configuration for harness motion

Fig. 3: Examples of possible motion functions of the harnesses at the test stand

Machineangle

Harness position Eccentricposition

Cam 1 Cam 2

DRIVE-CLiQSIMOTION SCOUT Engineering

HMI• Configuring

Control• Parameterization• Programming• Commissioning,

diagnostics

Communication• Configuration

Drive• Commissioning

Harness 2Harness 1

SINAMICS S120

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-20.00

-30.00

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Har

ness

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(mm

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Machine angle (°)

Sinusoidal motion profileMotion profile with rest phase

0 90 180 270 360 450 540 630 720

Subject to change without prior notice Order No.: E20001-A1150-P620-X-7600 Dispo 06372 Schö/34628 GD.MC.PM.B2TX.52.1.05 SB 08111.0 Printed in Germany © Siemens AG 2011


The information provided in this brochure contains merely general descriptions or performance characteristics which in case of actual use do not always apply as described or which may change as a result of further development of the prod-ucts. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations could be trademarks or product names of Siemens AG or other companies, which, if used by third parties, could infringe the rights of their owners.

Drive generation change

Textile


Totally Integrated Automation in impregnation systems for technical fibers with SINAMICS

For years now, Benninger Zell has been depending on Totally Integrated Auto- mation for its impregnation systems for tire cord and other technical fibers. The global market leader has now complet-ed the change to the latest generation of drives – the SINAMICS S120. The machine manufacturer as well as the end-users both profit to the same extent. At the beginning, various manufacturers of transport belts became involved with the mining industry in the US and China as well as with the manufacturer of cord fibersfor the tire industry. The conveyor belts used in mining are used to transport earth, ores and coal – often along stretches of several hundred kilome-ters. The width of new transport belt conveying systems has been increased from 1.6 up to 3.2 m; this places high demands on the drive system and the design of the belts. The “core” of the textile fiber must bear the majority of the forces that occur.

The advantage of textile-based conveyor belts:if they break, they can be more simply spliced than steel-armored versions. This has led to a certain end-user preference – and in turn, to a whole series of orders that Benninger Zell has in-house.

Stability to the power of three

An absolute must for the consistently high quality of the impregnation – and the success recipe for this company belonging to the Swiss Benninger AG – is the absolute constant tensions, temperatures and times during impreg-nation. This secures the optimum ad- hesion of the rubber or plastic coatings that are subsequently applied to the material – even under extreme loads and continuous bending cycles. For years, Benninger Zell achieved this demanded stability – especially in the continuously running center section of its systems – using control and drive technology from Siemens.A redundant PC system enters the set-points, which communicates with the SIMATIC S7-400 system control via Ethernet. Several tension units with driven roll pairs are connected to the SIMATIC PLC control via Profibus. These roll pairs are precisely coordinated with one another, therefore guaranteeing that the continuous material web is precisely stretched – or that is to say constant tensions and bumpless changeover between stretching and tension. According to Benninger Zell, the speed of the drives must be con-trolled with an extremely high precision and a synchronous operation tolerance of 0.1% continuously main-tained. As a consequence, the company critically views any potential change to a proven, running system.

Benninger Zell GmbH, Germany

The drive concept of the Benninger Zell system with SINAMICS converters


New drive generation with advantages:Having said that, Benninger Zell wants to sustainably secure its leading position in the market – and of course innovation represents the best way of achieving this.This is the reason that the company has now brought its drive solutions up to the latest state-of-the-art technology. It is called SINAMICS S120 and still has the high closed-loop control quality of MASTERDRIVES – its predecessor. The SINAMICS family is seamlessly integrated into the well-proven SIMATIC STEP 7 system platform; this means the maximum degree of seamless integration in the configuring/programming as well as the communication and data management between the control, HMI and drive levels. And as a consequence, significantly simplifies a lot of work – from engineering up to (remote) diagnostics. Benninger Zell has consequentially used the modul- arity and scalability of the new SINAMICS system and has developed a drive con-cept that is also applicable for future sys-tems as it is simple to transfer and adapt. In this case, a SINAMICS CU320 Control Unit is used for the motors for the unwinder, process section and winder plant areas respectively. The digital system in-terface DRIVE-CLiQ connects the associat-ed components with one another and eliminates all of the signal transmission problems that used to sporadically occur for cable lengths of over 100 m. The machine manufacturer also sees an additional advantage in the fact that the interaction between the SINAMICS converter and the standard Siemens induction motors is intensively checked to ensure that it functions perfectly in the field. This is an additional detail that shortens the time to market as well as the commissioning of a system. The drive line-up of a typical impregnation system for transport conveyor belts includes nine single-motor drives (DC/AC) with power-ratings of up to 30 kW for the material web transport, six auxiliary drives (DC/AC) as well as six fan drives (AC/AC). Also part of the system are 18 smaller MICROMASTER 440 units to power the motors for the lateral guides controlled via the SIMATIC ET 200.

Subject to change without prior noticeOrder No.: E20001-A1130-P620-X-7600Dispo 06372SCHÖ/10809304 B2TX.52.1.03 SB 04111.0Printed in Germany© Siemens AG 2011

Siemens AGIndustry SectorMotion Control SystemsP.O. Box 318091050 ERLANGENGERMANY

Saves space, costs and effort

The modular system design with its autonomous control modules (Control Units) and power units (Motor Modules) in a compact booksize format saves space in the control cabinet so that in the future, smaller standard control cabinets can be used – which of course, are more favorably priced. The common DC busbar also means that disconnectors, fuses and copper busbars can be eliminated, therefore significantly reducing the installation and wiring costs. The parameter assign-ment of the motor modules used in the system (available for one or two motors) is saved on the compact flash memory card in the Control Unit. This means that it is immediately available when service is required. This keeps downtimes short and the productivity

of these systems – which basically run around the clock – at the highest level. Not only this, but with the changeover to the new generation, Benninger Zell has again secured the long-term availability of spare parts, which for system lifetimes of up to 30 years is an advantage for future customers that should certainly not be underestimated. As a well known brand, many users prefer Siemens as they know they can offer spare parts and support around the globe. The change-over to the new drive standard in the impregnation systems of Benninger Zell went smoothly during their day-to-day business without any problems of note. Siemens drive specialists supported Benninger‘s inhouse team for two days during the hot phase while the system was being commissioned.



Textile

The machine experts from Klagenfurt, Austria, achieve perfectly harmonized motor speeds for their coating machines using SINAMICS.

SINAMICSJ. Zimmer Maschinenbau GmbH with Siemens on the winner’s side

For 134 years, the name Zimmer stands for high-tech textile machines. Today, this company has approximately 340 employees in its two factories: 140 of these employees develop and produce digital printing machines in the Kufstein factory – the other 200 are mainly engaged in rotary screen printing and coating machines in the Klagenfurt facility. The personnel in Klagenfurt have specialized on magnoroll machines that are based on a magnet-roll system used in screen printing and coating technology that the company has developed. Product Manager Gert Scheriau reported that recently, customers have been increasingly demanding that complete plants and systems are supplied: “As a consequence, for three or four years now, we have been more actively engaged in plant and system construction. This meant a transi - tion for us at the beginning, be - cause as a machine construction facility, we produce as many parts as possible in our own company – on one hand, to keep delivery times short, and on the other hand, to be able to guarantee quality through our own production. We purchase parts and components where it doesn’t make sense for us to manu - facture them ourselves. This is the

reason that for our coating machines and dryers, we can assume a vertical range of manufacture of 70%.” In doing so, the modular design is a main issue. Modules for four different widths – from 500 mm up to about 6,000 mm – form the grid basis for all the systems that we can supply.

Rotary printing machine for non-woven materials

A rotary printing machine for non- woven materials was recently shipped from our Klagenfurt plant to the Freudenberg Company based in the US, a daughter company of the large German company having the same name. The machine with a working width of 2,200 mm pro- duces non-woven materials at a rate of up to 50 meters per minute. After the unwinding equipment, the non-woven material passes through the following stations: a splice table to automatically establish a thermal connection with the next roll, a viewing table for the first optical check, a metal detector to track needles that may have remained in the material after production on the needle loom and a subsequent buffer zone. This is then followed by a cleaning machine before the material passes through a material

the other hand, in plant construction worldwide, it can be clearly seen that if you work with Siemens, then you are certainly on the winner‘s side. It is all about service, availability, and subsequent support.“ In the case of the large coating system for Freudenberg, the partnership with Siemens went far beyond the nor- mal customer support on a partnership basis: “Siemens gave us a level of on-site support that was quite exceptional. Our electrical technicians and Siemens experts met at least once or twice a week. The next project phase was discussed, every participant was allocated his specific tasks – and then the next week, the results were combined and incorporated in the program. This also meant that we could use this contract to simultaneously train our personnel.”

Intelligent SINAMICS drive technology

Martin Hafner, Drive Technology Consult - ant and Siemens expert on site, provided the technical details: “The drive system itself is a SINAMICS S120 multi-axis system that controls 14 drives. The connection is realized through PROFIBUS. The multi-axis system uses four coordi - nat ed CU320 control units that control several drives.” These units are logically structured: The first unit handles the unwinder, the closed-loop dancer control and the material buffer. The next unit controls the four drives of the magnoroll. What is especially important in this case is that the rotary screens must move in angular synchronism to the magnet roll. The third unit controls the feeding system, fan and upper or lower belt of the mechanisms in the dryer – and the fourth is responsible for the two drives in the J-Box and the winder. The intelligent drive system controls the angular synchronism, which ensures that the angle of the rolls with respect to one another and the peripheral velocities of the rolls, which are in contact with the material web, always remain the same. Further, the drive controls the complete winding

and unwinding functions as well as the closed-loop dancer roll control.These types of functions can be easily pro gramm ed in the drive using DCC (Drive Control Chart). The PLC, a SIMATIC S7/317 F, only outputs the setpoint, the drives orientate themselves to the magnet roll. All of the drives are equipped with safety functions. In the case of an emergency stop, the system must come to a standstill within two seconds. This emergency stop can either be manually initiated or using integrated repeater rolls and pressure sensors. This sophisticated safety system was especially important for the US client. When as- ked about installing the system in the US, Scheriau, the Product Manager, respond- ed by saying that commissioning will be performed together with the personnel who will later be the machine operators. And added: “If things do get a little diffi- cult, then we can also contact Siemens locally – perfect support and cooperation will certainly be available from there.”

The information provided in this brochure contains merely general descriptions or characteristics of performance which in actual case of use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.

guide device, which optimally positions the material before the actual printing process. “The main machine in this plant is our magnoroll printing machine”, explained Product Manager Scheriau. “There are two magnet systems inside the printing cylinder that are used to operate two rotary screens. This means that two-color coatings can be realized in just one operation – this is a unique feature that other manufacturers do not have. The material then passes through our drying system, which is at a temper - ature between 160 and 180 degrees, and in this particular case is over 36 meters long. This is where the printing ink is dried and fixed.“

From unwind to wind

Just like other non-woven products, this type of felt is extremely sensitive to expansion when it is warm. This is the reason that after drying, it is cooled down in a controlled fashion in a cold-air cooling duct. It then reaches the so-called “J-Box”. If a bale is changed while the finished product is being rolled, then the material is first buffered in this box until a new product has been fed and rolling can continue with the edges correctly aligned. “Our scope of supply extends from the unwind operation up to the wind operation and therefore naturally includes all control cabinets as well as washing equipment for the printing screens. From what has already been stated, it is clear that all of the various roll mechanisms of the plant must be precisely controlled so that they perfectly interact with one another”, explained Scheriau about the essential features of the process.

Successful cooperation with Siemens

“When all is said and done, customers also have their say when selecting suppliers. We are more than willing to accept this as long as customers don’t start to specify “no-name products”. On

Subject to change without prior noticeOrder No.: E20001-A970-P620-X-7600Dispo 06372SCHÖ/10809304 GD.MC.20.TEXT.52.0.06 SB 10101.0Printed in Germany© Siemens AG 2010

Siemens AGIndustry SectorMotion Control SystemsP.O. Box 31 8091050 ErlangenGERMANY


The advantages for Cordenka

• Increased production capacity through a higher degree of flexibility and plant availability

• Simplified maintenance

Integrated solution from Siemens

The control and drive technology were designed in close cooperation with Cor denka in the Summer of 2004. The innovated machines had to fulfill four criteria: Single-motor drives, line failure buffering, simple operator control and preparation for a central machine visualization. The machine was mechanically overhauled and the drive technology modernized using single-motor drives. The objective was to increase the production capacity through a higher degree of flexibility and plant availability, improve the quality and create a basis for future technological developments in the form of single-motor drives and automated production operations.

Rayon® is a material that is obtained from cellulose and is used to reinforce high-performance tires. As a result of its advantageous characteristics, it is the preferred reinforcing material for tires that have emergency running properties. Cordenka in Obernburg, one of the leading manufacturers of high strength textile fibers, wanted to further expand its production capacity and mod-ernize its machines to reflect the latest state-of-the-art technology. To retrofit its spinning machines, which up until now used products from various manufacturers, Cordenka used a complete electrical solution from Siemens.

Textile


Retrofit for a higher production capacityCordenka GmbH, Germany

Using a complete solution from Siemens, spinning machines for tire cord were brought up to speed to reflect the latest state-of-the-art technology

Reliable in a tough environment

The machine spins tire cord-viscose fibers from cellulose dissolved in a sulfuric acid spinning bath and winds them for further processing. The aggressive ambient air has a high concentration of hydrogen sulfide that places high demands on the electrical equipment. Special protective mea-sures were applied to the converters, contacts and metals to secure their reliability and to increase their resis-tance to corrosive gases.

Innovative technology cocktail

In the first four machines, our experts replaced the central gearbox with line shaft using a controlled MASTERDRIVES VC Compact Plus and Active Front End (AFE) infeed. The SIMATIC S7-300 control, the distributed ET200M I/O and PROFIBUS completed the retrofit.


Subject to change without prior notice Order No.: E20001-A1140-P620-X-7600 Dispostelle 06372 SCHÖ/29061 GD.MC.20.TEXT.52.0.03 SB 10101.0 Printed in Germany © Siemens AG 2010


The information in this brochure only provides a general description and performance features. For a specific application, this information will not always be applicable in the form described here. This information can also change due to ongoing product development. The required performance features are only binding if they had been expressly agreed upon in the form of a written contract. All product designations could be trademarks or product names of Siemens AG or other companies, which, if used by third parties, could infringe the rights of their owners.

For the fifth machine, the new drive and automation solution is an interaction between the following components: the SIMATIC S7-300 control with the OP17 operator stations and PROFIBUS DP as well as the latest family of SINAMICS S120 converters with coldplate technol-ogy and Active Line Modules, which - op-erating as infeed/regenerative feedback units - ensure a higher degree of security against failure. The SINAMICS coldplate technology directly dissipates the power loss and therefore removes heat sources from the control cabinet. Cordenka benefits from a low temperature inside the cabinet - and as a consequence from a longer service life of the equipment in it. Also included in the retrofit: Maintenance-free SIEMOSYN synchro-nous motors without encoder including gearbox for the spinning pumps, godet rolls, winding and traversing roll as well as standard 1LA motors.

Future already integrated

A possible expansion to include a central service station was also taken into account in the concept. Siemens config-ured the automation so that a central machine visualization using an HMI station - that will only be implemented in a subsequent modernization step - is already prepared.

Satisfied customer

Siemens received an order for the complete management of the electrical project - including the engineering, commissioning and building the control cabinet. Working very closely with Cordenka, a complete solution was drawn-up that was implemented by the Siemens Application Center (APC) in Erlangen. The complete modernization project, including the development and implementation of the integrated drive and automation solution, was completed on schedule.

Higher capacity, homogeneous quality

Extensive and careful planning facilitated a straightforward changeover from MASTERDRIVES VC to SINAMICS S120 Booksize drive units. The coldplate technology proved itself to be a practical supplement to the Siemens product range. An additional advantage of the retrofit: By using individual drives for the various

functions, the number of mechanical components - which are prone to wear - was reduced, therefore increasing the plant availability and simplifying mainte-nance. The powerful drives increased the production capacity by more than 10%, improved the quality and increased the overall flexibility of machine.

The new drives maintain the velocity setpoints - generated using a setpoint cascade - very precisely and reliably. As a consequence, the quality of the end product is more uniform and consistent. In order to avoid material faults, the Active Line Module infeed/regenerative feedback units and kinetic buffering (KIP) buffer brief line failures. Not only this, they minimize line harmonics and EMC load for the existing low-voltage supply.

As a result of the many advantages, Cordenka is planning additional machines based on innovative drive and automa-tion technology from Siemens.

New: Equipment with motors for single drives and operator station. The control cabinet with converters is located centrally on a platform.

Old: Equipment with central gearbox and motor (cannot be seen) as well as power distribution and operator station.

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