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 application, 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, Film | 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.
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 |
| IEC61131-3 Programming Environment | Global standard environment provides programming familiarity and consistent performance expectations |
| Ethernet/IP and Ethernet Modbus TCP protocols | Most widely used protocols in the industry enhance communication with plant-wide systems |
| Distributed network connections to servo axes | Easy quick-connect cable reduces system wiring and improves reliability |
| 4,8,16 axis control versions with electronic gearing | Best combination of price vs control capabilities |
Sigma-5 Servopacks and Servo Motors | Autotuning | Out-of-the-box, automatic adaptive tuning requires no intervention or specific knowledge by the installer and speeds installation |
| High resolution serial encoder | 20-bit resolution translates into excellent speed and torque ripple characteristics. High noise immunity is afforded by serial encoder technology utilizing error-checking algorithms. |
| EN954-1 Category3 StopO input | Built-in safety circuit for regulatory compliance |
| High torque to inertia ratio | Dynamic performance in a small space saving design |
| High IP ratings available | IP67 on some models permits both solid debris and liquid containments easing machine design requirements |
| Auto ID Encoder | Machine commissioning requires no loading of motor data into the amplifier – plug and play operation |
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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.