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Mathematical Model for a paper winding machine
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Winding machine Mathematical Model
Firstly Motor Drive
Motor Dynamics is separated into 3 Stages:
1. Electrical Dynamics equation.
Representing the dynamics of the motor Electrical
Circuit
2. Electromechanical Linkage equation.
Representing the Electromagnetic Torque Developed
from the electric circuit.
3. Mechanical Dynamics equations.
Representing the Dynamics of the motor mechanical
Drive (Mechanical System coupled to motor ).
Bipolar Stepper Motor Mathematical Model
Bipolar Stepper motor Construction:
1. A multi pole permanent magnet Rotor.
2. Multiple Stator Winding creating Stator phases.
Theory of operation:
When energizing a certain stator phase a magnetic field in direction of the stator
phase is induced, this field produces a torque over the rotor causing the rotor to
rotate until is aligns with the field.
So when energizing the stator phases in sequence a rotating magnetic field is
produced and the rotor rotates trying to align with the rotating magnetic field.
Mathematical Model
Electrical Equations:
Assume a 2 phase (a and b) Stepper motor
Each phase can be represented by this equation
๐๐ = ๐ ๐๐๐ + ๐ฟ๐
๐๐๐
๐๐ก+ ๐๐
๐๐ = โ๐พ๐๏ฟฝฬ๏ฟฝ sin(๐๐ ๐)
Where
๐๐: Phase a applied Voltage [Volt].
๐ ๐: Phase a winding Resistance [Ohm].
๐๐: Phase a Current [ampere].
๐ฟ๐: Phase a winding inductance [H].
๐๐ : Back emf (electromagnetic force) induced in phase a [Volt].
๐พ๐: Electromotive Force Constant, (Motor Torque constant) [๐๐๐๐ก. ๐ ๐๐ ๐๐๐โ ]
Same equations represents phase b.
Electromechanical Torque Equation: In the Stepper Motor case the Torque developed over the rotor is the sum of the torque induced from each phase.
The Torque developed by each stator phase is dependent on the position of the
rotor in reference to that phase (as mentioned before) maximum torque when the phase induced magnetic field is perpendicular on the rotor (rotor field line
which connects the rotor poles) and minimum torque is when the rotor is aligned with the phase magnetic field.
this relation is represented by a sinusoidal wave (sine for first phase and cosine
for next phase as it varies with 90 mechanical degree )
So:
๐๐ = โ๐พ๐ (๐๐ โ๐๐
๐ ๐) sin(๐๐๐) + ๐พ๐ (๐๐ โ
๐๐
๐ ๐) cos(๐๐๐)
Where:
๐: Rotor Position
๐พ๐: Motor Torque Constant [๐. ๐ ๐ด๐๐]โ
๐๐ : phase a current [๐ด๐๐ ]
๐๐ : phase b current [๐ด๐๐ ]
๐๐ : Back emf (electromagnetic force) induced in phase a [volt]
๐๐ : Back emf (electromagnetic force) induced in phase b [volt].
๐๐: Is the number of teeth on each of the two rotor poles. The Full step
size parameter is (ฯ/2)/Nr.
๐ ๐: Magnetizing Resistance in case of neglecting iron losses itโs assumed to
be infinite which causes the term ( ๐๐
๐ ๐= 0 ).
As Shown the system equations is nonlinear.
Dc Motor Model
Dc Motors Control Techniques:
1. Armature Control.
2. Field Control.
Armature Controlled Dc Motor Mathematical Model:
Fig 1 Armature Controlled Dc Motor Schematic
Electrical Equations:
๐๐ = ๐ ๐ ๐๐ + ๐ฟ๐
๐๐๐
๐๐ก+ ๐๐๐๐๐
๐๐๐๐๐ = ๐พ๐๐๐๐ ๏ฟฝฬ๏ฟฝ
Where:
๐๐: Voltage applied over Motor Armature [Volt].
๐ ๐: Armature Resistance [Ohm].
๐๐: Armature Current [ampere].
๐ฟ๐: Armature Inductance [H].
๐๐๐๐๐ : Back volt induced from rotor into armature [Volt].
๐พ๐๐๐๐:Electromotive Force Constant [๐๐๐๐ก. ๐ ๐๐ ๐๐๐โ ]
Taking Laplace Transform
๐๐(๐ ) = ๐๐(๐ )(๐ ๐ + ๐ ๐ฟ๐) + ๐ ๐พ๐๐๐๐ ๐
Current volt Transfer Function ๐๐(๐ )
๐๐(๐ )โ๐พ๐๐๐๐ ๏ฟฝฬ๏ฟฝ(๐ )=
1
๐ ๐+๐ ๐ฟ๐
Electromechanical Torque Equation: In general, the torque generated by a DC motor is proportional to the armature current and the strength of the magnetic field.
๐๐ = ๐พ๐๐๐๐
The Strength of the magnetic field is constant as its armature controlled so:
๐๐ = ๐พ๐๐๐
Where:
๐พ๐: Motor Torque Constant [๐. ๐ ๐ด๐๐]โ
๐๐ : Armature current [๐ด๐๐ ]
Current to Torque Transfer function
๐๐ (๐ )
๐๐ (๐ )= ๐พ๐
So Volt Torque Transfer Function: ๐๐(๐ )
๐๐(๐ )โ๐พ๐๐๐๐๏ฟฝฬ๏ฟฝ(๐ )=
๐๐(๐ )
๐๐(๐ )โ๐พ๐๐๐๐๏ฟฝฬ๏ฟฝ(๐ ) .
๐๐(๐ )
๐๐(๐ )=
๐พ๐
๐ ๐+๐ ๐ฟ๐
Field Controlled Dc Motor Model:
In Field Controlled Dc motor the armature current is kept constant, the torque is
controlled by modulating the magnetic flux.
The magnetic field is controlled by controlling the voltage applied on the field
winding (๐๐) so in this case the manipulated variable is field winding Voltage
(๐๐).
Electrical equation:
๐๐ = ๐ ๐ ๐๐ + ๐ฟ๐
๐๐๐
๐๐ก
๐๐: Voltage applied over Motor field winding [Volt].
๐ ๐: Field winding Resistance [Ohm].
๐๐: Field winding Current [ampere].
๐ฟ๐: Field winding Inductance [H].
Taking Laplace Transform
๐๐ (๐ ) = ๐ ๐ ๐๐(๐ ) + ๐ ๐ฟ๐ ๐๐(๐ )
๐๐(๐ )
๐๐(๐ )=
1
๐ ๐ + ๐ ๐ฟ๐
Electromechanical Torque:
As armature current is constant
๐๐ = ๐พ๐๐๐
๐พ๐: Motor Torque Constant [๐. ๐ ๐ด๐๐]โ
๐๐ : Field winding current [๐ด๐๐ ]
Current to Torque Transfer function:
๐๐ (๐ )
๐๐(๐ )= ๐พ๐
So Volt Torque Transfer Function: ๐๐(๐ )
๐๐(๐ )=
๐๐(๐ )
๐๐(๐ ).
๐๐(๐ )
๐๐(๐ )=
๐พ๐
๐ ๐+๐ ๐ฟ๐
๐๐ = ๐น๐ก1๐๐ค๐๐๐๐๐
๐๐ :Load Torque over the winder Driver
๐น๐ก1: Web Tension force at Winder Region (Control Variable).
๐น๐ก0: Web Tension force at unWinder Region (assumed constant).
๐๐ : Winder Tangential Velocity.
๐1 : unwinder Tangential Velocity.
๐๐๐๐๐๐๐ : Displacement of Dancer.
๐๐ค๐๐๐๐๐ :Raduis of winder cylinder.
๐๐ : Dancer Velocity๐๐ =๐๐๐๐๐๐๐๐
๐๐ก.
๐๐ค๐๐๐๐๐
๐๐๐๐๐๐๐
๐น๐ก1
๐น๐ก1 ๐น๐ก๐
Model Assumptions:
1. The paper velocity from the unwinder is constant
2. The cross section area of the web is uniform
3. The definition of strain is normal and only small deformation is
expected.
4. The deformation of the web material is elastic this assumption is used
because plastic deformation is unwanted during the winding process and
quite difficult to model.
5. The density of the web is unchanged
6. The dancer movement is negligible compared to the length of the web between the unwinder and the winder.
7. The speed of the dancer is negligible compared to the speed of the web
๐๐<<๐1
8. The web material is very stiff, hence ๐๐โ๐1
If assumption 6 is correct and the material is stiff the unwinder paper
speed and the winder paper speed is approximately the same.
9. The tension in the unwinder section is constant.
10. The change of roll radius does not change the web length between the
winders:
as one radius is increasing the other is decreasing therefore the changing
radius is estimated to only having little influence on the web length and
is therefore neglected.
Mechanical Equations:
In our case we have two torques opposing the torque from the motor:
1. The tension in the web is acting as the load on the winder motor
๐๐ = ๐น๐ก1๐๐ค๐๐๐๐๐
2. Friction Torque Consisting of :
a. Coulomb Friction (Static Friction) throughout the Drive
system (as in bearing , Gears โฆetc.)
๐๐๐๐ข๐
b. Viscous Friction (Dynamic Friction) throughout the Drive
system
๐๐๐ = ๐๏ฟฝฬ๏ฟฝ
So Mechanical Differential Equation:
โ ๐ = ๐ฝ๏ฟฝฬ๏ฟฝ
๐๐ โ ๐๐ โ ๐๐๐๐ข โ ๐๏ฟฝฬ๏ฟฝ = ๐ฝ๏ฟฝฬ๏ฟฝ
Taking Laplace Transform:
๐๐(๐ ) โ ๐๐ โ ๐๐๐๐ข โ ๐๐ ๐(๐ ) = ๐ฝ๐ 2๐(๐ )
Angular Position Transfer Function:
๐
๐๐ โ ๐๐๐๐ข โ ๐น๐ก1๐๐ค๐๐๐๐๐
=1
๐ฝ๐ 2 + ๐๐
๐ฝ: is variable as winding Cylinder mass increases as winding goes on
its calculations is at the end of paper
Web Material Model
The purpose in modelling the web material is to find an expression for the tension force
development in the web material located between the winders. This requires a physical
interpretation on how stress arises in the web material and how the stress is related to the
winders tangential velocities ๐๐ and ๐1 .
In the following the Voigt model is used to explain arising stress and with the before
mentioned assumptions, control volume analysis and continuum mechanics it is shown how
the stresses are related to ๐๐ and ๐1 .
Voigt Model:
The Voigt model consists of a viscous damper and an elastic spring in parallel as shown
With this model the Stress on the material ๐ =๐น๐ก
๐ด is expressed as follows
๐ =๐น๐ก
๐ด= ๐ธ๐ + ๐ถ๐ฬ
Where
๐:Stress on web material
๐ธ: material youngโs modulus of elasticity
๐ด:Material Cross Section area A=material width *material thickness
๐:Strain Due to Tension force ๐ =โ๐ฟ
๐ฟ (Deformed length over normal length)
๐น๐ก:Tension Force over material
Taking Laplace Transform we get ๐ =๐น๐ก
๐ด๐ธ+๐ด๐ถ๐ (1)
Mass Continuity Definition:
Mass of material doesnโt change as the material is Stretched
๐๐ด๐ฟ = ๐๐ด๐ ๐ฟ๐
Where
A: Normal Area of material
L: Normal length of material
๐ฟ๐ :Stretched Length of material
๐ด๐ :Stretched Cross sectional area
As Density is assumed constant โด ๐ด๐ฟ = ๐ด๐ ๐ฟ๐ (2)
From Strain Definition ๐ =โ๐ฟ
๐ฟ=
๐ฟ๐ โ๐ฟ
๐ฟ=
๐ฟ๐
๐ฟโ 1 (3)
From (2) and (1) ๐ด๐ =๐ด
(๐+1) (3)
Since ๐ โช 1 equation (3) can be expressed as
๐ด๐ = ๐ด(1 โ ๐) (4)
Mass Conservation Law:
The definition of mass conservation states that the change in mass of the control
volume equals the difference between the mass entering and exiting the control
volume.
๐
๐๐ก๐๐ด๐ฟ = ๐๐ด๐๐๐ โ ๐๐ด1๐1
In our case and since density constant ๐
๐๐ก๐ด๐ฟ = ๐ด๐ ๐๐๐ โ ๐ด๐ 1๐1
From equation (4) we get
๐
๐๐ก๐ด(1 โ ๐1)๐ฟ = ๐ด๐(1 โ ๐๐)๐๐ โ ๐ด1(1 โ ๐1)๐1
As area is assumed uniform over all machine
โด๐
๐๐ก(1 โ ๐1)๐ฟ = (1 โ ๐๐)๐๐ โ (1 โ ๐1)๐1 (5)
Since the Length of web is influenced only by the Dancer
Displacement (assumption 10)
Dancer Displacement affects web length from both sides
โด ๐ฟ = ๐ฟ๐ โ 2๐
Where: ๐ฟ๐:Constant Length of web.
๐ : Dancer Displacement.
Then equation (5)
๐
๐๐ก(1 โ ๐1)(๐ฟ๐ โ 2๐) = (1 โ ๐๐)๐๐ โ (1 โ ๐1)๐1
By differentiating and simplifying we get
(๐ฟ๐ โ 2๐). ๐1ฬ = ๐1โ๐๐ โ 2๐๐ + ๐๐๐๐ โ (๐1 โ 2๐๐)๐1
By taking Laplace Transform
(๐ฟ๐ โ 2๐). ๐ ๐1 = ๐1โ๐๐ โ 2๐๐ + ๐๐๐๐ โ (๐1 โ 2๐๐)๐1 (6)
From transfer function (1) into (6) we get equation (7)
๐น๐ก1 (๐ +๐1 โ 2๐๐
๐ฟ๐ + 2๐) =
๐ด1 ๐ธ + ๐ด1 ๐ถ๐
๐ฟ๐ โ 2๐(โ๐๐ + ๐1 โ 2๐๐ ) +
๐1๐น๐ก๐
๐ฟ๐ โ 2๐.๐ด1
๐ด2
From assumption 6, 7 and 8
Dancer displacement is negligible to total web length between winder and
unwinder
Dancer speed is negligible relative to winder and unwinder relative velocities
Material is stiff therefore ๐๐โ๐1
Therefor ๐ฟ๐โ๐ฟ๐ โ 2๐ and ๐๐โ๐1 โ 2๐๐ (8)
๐ฟ๐: Approximate web length between winder and unwinder
Substituting in equation (7)
๐น๐ก1 (๐ +๐๐
๐ฟ๐
) =๐ด1 ๐ธ + ๐ด1 ๐ถ๐
๐ฟ๐
(โ๐๐ + ๐1 โ 2๐๐ ) +๐1 ๐น๐ก๐
๐ฟ๐
.๐ด1
๐ด2
The Term ๐1๐น๐ก๐
๐ฟ๐.
๐ด1
๐ด2 is constant due to assumptions 1, 2 and 9 and it
represents the initial Tension force.
Finally we get the transfer function of tension force from inputs (paper Linear
velocities and dancer velocity)
๐น๐ก1
๐1 โ ๐๐ โ 2๐๐=
๐ด๐ฟ๐
(๐ถ๐ + ๐ธ)
๐ +๐๐๐ฟ๐
Dancer Mathematical Model
From Newtonโs Second law of motion
โ ๐น๐๐ฅ๐ก๐๐๐๐๐ = ๐๐
By deriving equation and taking Laplace Transform
๐น๐ก๐ + ๐น๐ก1 โ ๐๐ . ๐ = (๐๐๐ 2 + ๐ถ๐๐ + ๐พ๐)๐
Where
๐๐: Dancer mass
๐ถ๐: Dancer damping coefficient
๐พ๐:Spring Stiffness
๐:Dancer Dsiplacment
Dancer position Transfer function ๐
๐น๐ก1+๐น๐ก๐โ๐๐ .๐=
1
๐๐ ๐ 2+๐ถ๐๐ +๐พ๐
๐น๐ก1 ๐น๐ก๐
๐๐ . ๐
Complete model Summary:
Stepper Motor:
๐๐ = ๐ ๐๐๐ + ๐ฟ๐
๐๐๐
๐๐ก+ ๐๐
๐๐ = โ๐พ๐๏ฟฝฬ๏ฟฝ sin(๐๐ ๐)
๐๐ = โ๐พ๐ (๐๐ โ๐๐
๐ ๐) sin(๐๐๐) + ๐พ๐ (๐๐ โ
๐๐
๐ ๐) cos(๐๐๐)
Dc motor armature controlled:
๐๐(๐ )
๐๐(๐ ) โ ๐พ๐๐๐๐๏ฟฝฬ๏ฟฝ(๐ )=
๐พ๐
๐ ๐ + ๐ ๐ฟ๐
Dc motor Field controlled:
๐๐(๐ )
๐๐ (๐ )=
๐พ๐
๐ ๐ + ๐ ๐ฟ๐
Mechanical Transfer Function: ๐
๐๐โ๐๐๐๐ขโ๐น๐ก1๐๐ค๐๐๐๐๐=
1
๐ฝ๐ 2+๐๐
Material Transfer Function: ๐น๐ก1
๐1โ๐๐โ2๐๐=
๐ด
๐ฟ๐(๐ถ๐ +๐ธ)
๐ +๐๐๐ฟ๐
Dancer Transfer function:๐
๐น๐ก1+๐น๐ก๐โ๐๐.๐=
1
๐๐ ๐ 2+๐ถ๐ ๐ +๐พ๐
Calculation of varying moment of inertia:
Length of winded material:
๐ฟ๐ค๐๐๐๐๐ = โซ ๐1๐๐ก
Radius of Winder Cylinder:
๐๐ค๐๐๐๐๐ = โ๐ฟ๐ค๐๐๐๐๐ . ๐ก
๐+ ๐๐๐๐๐
2
Material Mass:
๐ = ๐๐ฃ. ๐. ๐ค(๐๐ค๐๐๐๐๐2 โ ๐๐๐๐๐
2)
๐๐ฃ: Material mass per unit volume
๐๐๐๐๐: Winder Cylinder Core radius
Variable material Moment of inertia:
๐ฝ๐ค =1
2๐(๐๐ค๐๐๐๐๐
2 + ๐๐๐๐๐2)
Total Drive moment of inertia:
๐ฝ = ๐ฝ๐ค + ๐ฝ๐
๐ฝ๐ : Winder Cylinder Core Moment of inertia