⊙ PORTFOLIO — SIMULATION
Winding Line Unwinder / Dancer / Traverse / Winder
Complete winding line simulation from unwinder to winder. Material unwinds from supply spool, tension is balanced via dancer arm, and traverse guide distributes layers onto the winding spool. Winder RPM automatically decreases as diameter grows while tension remains constant.
Unwinder Winder Dancer Arm Traverse Tension CODESYS Lenze i950 PID
WINDER LINE v2.0 | Winding Line Simulation
● RUNNING
▸ ROLL
WIND36mm
UNWIND110mm
LAYERS0
▸ SPEED
LINE100m/min
RPM0rpm
▸ DANCER
POS0°
STOK
▸ TENSION
ACT50kg
TGT50kg
▸ AXES
WINDER OK
UNWINDER OK
TRAVERSE OK
MODE
TENSION 50 kg
SPEED 1.0 ×
What Does It Do?
- ▸ Provides continuous material flow from unwinder to winder
- ▸ Balances tension via dancer arm to maintain constant kg
- ▸ Winder RPM automatically decreases as diameter grows
- ▸ Traverse guide ensures even layer-by-layer winding
How Does It Work?
- ▸ Unwinder and winder diameters calculated via encoder in real-time
- ▸ RPM = line speed / (π × dia) — RPM drops as diameter grows
- ▸ Dancer arm deviation feeds PID, tension adjustable via slider
- ▸ CODESYS v3.5 + Lenze i950 — 3 axes (winder, unwinder, traverse)
Industrial Use Cases
- ⚙ Paper & cardboard roll machines
- ⚙ Plastic film & foil winding
- ⚙ Wire & cable winding systems
- ⚙ Textile yarn & fabric rolls
- ⚙ Aluminum & steel strip winding
// Traditional vs. Smart Winding Control
| Criterion | ❌ Traditional | ✅ Smart Winding |
|---|---|---|
| Tension accuracy | ±10% | ±1% |
| Speed adaptation | Manual | Diameter-based auto |
| Unwinder / Winder sync | Independent control | Line speed synchronized |
| Traverse control | Fixed step | Sinusoidal, layer-based |
| Break protection | None | Instant response |
| Dancer response time | >500 ms | <50 ms |
// Typical Application Parameters
| Parameter | Value | Unit / Note |
|---|---|---|
| Max winder diameter | 800 | mm |
| Min diameter (core) | 76 | mm |
| Max unwinder diameter | 1000 | mm |
| Target tension | 1–50 | kg |
| Line speed | up to 600 | m/min |
| Dancer arm angle | 55–105 | ° |
| Traverse stroke | ±200 | mm |
| Servo drive | Lenze i950 | 3-axis |
| Software | CODESYS v3.5 | PID+Calc |
| PLC Task Cycle | 1 | ms |
// Cycle Phases
UNWIND
Material unwinds from supply spool, diameter shrinks
DANCER
Dancer arm balances tension, kg kept constant
TRAVERSE
Traverse guide distributes material layers
WIND
Winder diameter grows, RPM auto-decreases
NEW ROLL
Roll full: continue with new core