Multifunction Winder Controller
MWC
The MWC is a microprocessor-based control system for yarn take-up
winders such as the Leesona 968 series (and others). It provides
precise, programmable and intelligent control of all winding parameters
to enhance the winder’s performance and provide the winding engineer
with a tool that enables an infinite number of possible combinations of
the factors that determine package formation and winder operation.
Control of the multiple functions of the winder provides the
flexibility to optimize the winding process for a variety of yarn
deniers and styles, process speeds and package dimensions while
remaining within the electrical and mechanical limitations of the
winder.
Significant quantifiable benefits may be realized by implementation of the MWC system such as:
Greatly improved package appearance, conformity and consistency
Greater process and winding speed capability for increased production rate
Greater package density gives more yarn per package of same diameter
Greater package stability, less shifting or deformation during shipping and handling
Improved winder repeatability per position and reduced position-to-position variations
Improved thread-up due to extremely accurate "preset" speed control
Metered-length yielding consistent package measure
Improved yield through reduced winding waste, deformed tails, poor first-wraps, etc.
Reduced influence of environmental climate on winding performance
Improved and consistent unspooling performance
Faster package unspooling capability
Improved winder efficiency, less power consumption and fewer winder-caused breakouts
Improved operator efficiency by tighter control over winder operation at doff and string-up
Reduction in winder component wear translating to less maintenance
These are some of the benefits that have been realized by
customers using the MWC since 1992. To accomplish full control over
winding the MWC monitors and optimizes these factors:
1. PRESET SPEED Precise programmable spindle preset speed
regulation assures consistent string-up performance and eliminates the
need for constant re-calibration due to drift. The preset speed for all
positions is slaved to the to the process speed by the auto-preset that
"sync-locks" to the delivery roll drive motor. Thus the preset
automatically follows changes with no reprogramming necessary for
product change. Or instead, a master control may be used to manually
set the preset speed for all positions simultaneously.
2. TENSION CONSISTENCY The patented Selectronics RSC
(Regulated Set-point Convergence) provides precise spindle speed and
torque regulation in response to compensator arm position. This
minimizes the normal traverse-induced tension spikes to provide uniform
tension, which contributes greatly to the proper formation of each
package.
3. TENSION CONTROL The yarn winding tension may be programmed to follow
a tapering profile as the package builds to improve package stability
and density. The MWC controls the analog electrical command reference
to a proportional air pressure regulator, which feeds a pneumatic
linear actuator that applies pull-down force on the compensator arm.
4. COMPACTION CONTROL The spindle-to-roller bail pressure may
be programmed to follow a tapering profile as the package builds to
improve package stability and density. The MWC controls the analog
electrical command reference to a proportional air pressure regulator,
which feeds a pneumatic linear actuator that applies frame-in force to
the winder carriage.
5. RATIO CONTROL The traverse-to-spindle wind ratio is
normally fixed by the belt linkage between the spindle and the traverse
cam. The MWC system utilizes a separate motor to drive the cam and then
controls its angular position precisely in step with the spindle, as if
it were belt-driven, but now with the flexibility to continuously
control the helix angle of the yarn as it is applied to the spindle.
Thus, the wind ratio may be changed at will to a fixed value or
step-changed as the package builds to allow optimization of the package
geometry for improved density and stability.
6. METERED LENGTH The MWC provides control of automatic cut, aspirate
and stop actions after the package reaches the programmed linear
measure to assure consistent yarn measure for each package.
7. ARM HOLD-DOWN During thread-up the compensator arm is held against
the bottom rail with high force to prevent the yarn string-up process
from the lifting arm prematurely. This aids in string-up performance.
8. PRESET ALERT An attention-getting light may be mounted at
each position to indicate when spindle has reached preset speed for
operator cueing to prevent unsuccessful thread-up due to premature yarn
presentation.
9. TAIL TRANSFER Automatic transfer from tail-wind to
traverse-wind (if used) assures precise, consistent tail lengths. The
MWC provides control of the tail transfer action.
10. OPERATOR ALERT The operator alert light mounted at each
position indicates: "almost-ready-to-doff", "full-package-stop",
"incomplete package stop" and "fault-stop" (break-out, etc.).
11. MEASURE MONITOR The total measure wound on the package is
stored in memory and may be read by the host or displayed by the Keypad
Display Unit to verify contents of full or partial packages.
12. SEQUENCING The MWC’s timing and control logic for
automatic thread-up (if used) and automatic doffing (if used) provides
the sequencing of any ancillary devices to effect such functions as
tube grip and release, cut, waste, aspirate, spindle braking, full
package push-out, etc.
13. HOST COMMUNICATION RS-422/RS-485 data may be exchanged between each
MWC board and any "host" PLC, computer, SCADA or Distributive Control
System. This allows parameter "recipe" programming for quick style
changes, monitoring of winding process. It also allows the
interrogation of the board for the stored historical data such as
package length, the number of complete packages, the number of
incomplete packages, winder "downtime" (time between doffs), etc.
14. PORTABLE COMMUNICATOR A port is provided on each plug-in
board for temporary connection of a Keypad Display Unit which can be
used to monitor winder operation, check and modify program parameters,
and provide for easy testing and set-up of individual units in place of
or in the absence of host control.
15. AUTONOMY Once the "recipe" of parameters for a style is
programmed into a MWC board it then will function completely
independently of the host PC, PLC or SCADA system. Communication
between the MWC and the host is only necessary for style change. In
fact, the Keypad Display Unit can download parameters so a host
connection is not necessary at all.
16. RELIABILITY Non-contact compensator arm position sensing
and solid-state logic circuitry insures dependable long life for all
elements. Plug-in circuit boards allow quick change for minimum
downtime should a board replacement be necessary. The MWC system has
been used widely since 1992 with less than one percent of units ever
requiring service. The MWC board is GUARANTEED free from defects in
materials and workmanship for FIVE-YEARS!
System Elements
MWC board The Multifunction Winder Controller main circuit
board is the heart of the system. It contains the input signal
processors, microcomputer, logic circuitry, output and switching
circuitry for performing all of the start, wind and doff functions.
Each board controls one winder position. Its functions include:
1. Receive the parameter programming data from the host and store it in non-volatile E2 PROM memory for:
the tension start, stop and ramp values
the compaction start, stop and ramp values
the warning measure value
the full package measure value
the tail transfer measure (if used)
and, up to 24 ratio-step-changes-per cycle
2. Receive the closure signal from the start switch and
sequence the starting functions by relay contact switching to effect:
brake release, package grip, both motors start, frame-in and arm
hold-down.
3. Receive the preset pilot frequency and sync-lock the spindle while in preset mode.
4. Detect thread-up and wind the proper length tail then effect yarn transfer to traverse winding by relay contact switching.
5. Process the arm position reference input by applying PID and RSCR to
produce a reference for the spindle's DC motor drive to accurately
control the spindle torque to minimize tension spikes.
6. Convert the compaction control value stored in memory to a 4-20 mA reference for the compaction air pressure regulator.
7. Convert the tension control value stored in memory to a 4-20 mA reference for the tension air pressure regulator.
8. Taper the pressure and tension references as the package builds according to the stored profile.
9. Process the pulses from the spindle motor's tachometer pickup and by
using the ratio value stored in memory to produce a pilot reference
pulse train for the traverse control.
10.Process the pulses from the traverse motor's encoder and
provide a speed reference to the traverse drive to sync-lock the two
motors and accomplish perfect numerical ratio precision between the
two.
11. Totalize the accumulated linear measure on the package and when
each stored step-change value is reached effect a ratio change.
12. At the appropriate times provide a contact closure output to illuminate the alert light for status indications.
13. When the total measure for full package is reached or the
stop circuit opens then sequence the doffing functions by relay contact
switching to provide: exhaust, cut, aspirate, braking, frame-out,
release and package push-out.
CARD CAGE A metal frame with printed-circuit card edge guides
and plug-in connectors is used to secure multiple MWC boards in a
convenient and protected area, usually remote from the winder location.
This facilitates a quick board change to minimize down time should
servicing be necessary.
KDU The Keypad Display Unit plugs directly onto any MWC board
to access all parameters and memory functions for viewing or altering.
This is helpful in ratio, tension and compaction development and
testing of selected positions that may be temporarily removed from host
control. It also may be used in case of failure of the host or its
communications ability.
SOFTWARE Programming software for the MWC is provided in a non-volatile
E2 PROM that resides on the MWC board. The system is supplied with the
software that provides the functions stated here in.
FRC The Frequency Reference Converter samples the motor voltage that
drives the delivery roll and determines its frequency. It then
processes this frequency with programmed multiplication and division
constants and derives an output frequency that serves as a pilot preset
reference for all the winder positions fed by that delivery drive. This
pilot is then used by each position to sync-lock the preset for
ultra-accurate regulation that automatically responds to delivery roll
speed changes.
IPS The inductive proximity sensor serves as a tachometer pickup to
measure the spindle speed and angular position. It is used with an
existing or customer-provided gear or wheel mounted on the spindle
drive train. Information from this sensor is used in control of Preset
speed and in the syncing of the traverse cam to the spindle.
MAS The Magnetic Angle Sensor replaces the old-style
transducer. It offers extremely high reliability because it makes no
contact with any moving parts thus any wear or mechanical problems are
not possible. The MAS is mounted stationary and senses the position of
the compensator arm by measuring the relative angle of the magnetic
field produced by a small magnet mounted on the arm shaft. The arm
position is then converted to a voltage reference signal that is
transmitted to the MWC main board where it is processed and used to
control the spindle torque.
DMA The Dancer Magnet Assembly is an aluminum collar that fits
over the bell crank on the compensator arm shaft. On the end of the
collar a small bar magnet is attached. The collar is positioned on the
bell crank and secured with a setscrew so that the magnet is
perpendicular to the end of the MAS case when the arm is in the desired
running position. This is a one-time alignment and requires no further
adjustment throughout the life of the system.
OTHER REQUIRED ELEMENTS
The additional devices required to implement the system and
functions stated above that are not provided with the MWC system are:
spindle motor
spindle motor drive
traverse motor
traverse motor drive
pneumatic valves
pneumatic regulators
pneumatic actuators
power supplies for any of these elements
operator's start/stop station
alert light
interconnecting wiring and tubing
Warranty – FIVE YEARS
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