Course Overview

   Drives for Web Handling and Converting (Europe)


Clarence Klassen

Use the date links below to see details on specific course dates, hotels, etc.

Web Handling including Winders are among the most complex of drive applications. In this new course learn about the importance of tension control to winding quality rolls. There are a number of options available for tension control. Learn about:

  • Selecting a drive for web handling applications
  • Ac and dc drives
  • Load cell vs. dancer vs. open loop control of tension
  • Power requirements (actual vs. motor rating)
  • Tension Loop Control Block Diagrams
  • Drive functions for Turret Winders
  • Tuning your drives and tension loops
  • Troubleshoot tension issues

  • Drive safety (guard interlocks and E-Stop)
  • Knowing if your project is in trouble

The course will be general and applicable to any brand of drive. Limited high school mathematics will be presented, but emphasis will be on description of the controls. We will not touch on university level control theory (Bode, Nyquist, etc.) in this course..


Click here to read Dr. David Roisum's thoughts on Clarence Klassen's Drives in Web Handling class.


Course Outline
Day 1: 8AM - 5PM
Day 2: 8:30AM - 4PM


Web Handling Tension Sections

  • Introduction to Web Handling - What is Web Handling?
  • Web Handling View of Tension
  • Drive Control Strategies
  • Drive Control Considerations - Feed Forward, Inertia Compensation, Friction, no-web load torques, backlash
  • DC, AC, AC Vector, Servo
  • Hmi's - What should be displayed and how?
  • Drive Tuning - With On Screen Simulation

Web Handling Control Block Diagram Sections

  • Why Use Control Block Diagrams
  • Diameter Calculator
  • Load Cells into the Torque Regulator
  • Load Cells into the Speed Regulator
  • Dancer Position Regulator
  • Starting Conditions - Payout and Takeup, Thread, Stall Tension


Bonus Materials Sections


  • Rollers, Bowed Spreader Rolls, Nips, Coating
  •  Mechanical Brakes, Clutches
  • Automation - Turret Winders
  • Safety - Electrical
  • Safety - Guard Interlocks
  • Safety - Emergency Stop
  • Knowing if your Winder Project is in Trouble

    This Class is Suitable for
    This course is intended for electrical/instrumentation maintenance, drive startup personnel, and junior to intermediate drive systems engineers. Emphasis will be on the practical aspects of drives for winding. A prerequisite is electrical aptitude and enough troubleshooting experience to be familiar with the names for the: parts of your machines, and electrical terms like volts, amps, 3 phase, parameters.

    Some Detailed Section Abstracts:


Drive Control Strategies
The drive control strategy is generally restricted by the winder mechanical design, often without consulting the drive expert. The mechanical design restricts whether a center wind or surface wind is possible or whether nip is available. The web characteristics determine the sensitivity to tension variations during winding. High performance tension regulation carries a higher initial cost and future maintenance costs. We will consider using open loop, load cells and dancer regulators for adequate tension control. We will also discuss the means of measuring or calculating the diameter of the winding roll. The selected drive must be capable of controlling tension adequately.

If the winder does not perform, responsibility for mechanical and electrical troubleshooting most likely falls on the drive tech. If the problem escalates, independent and vendor consultants may be required. The knowledgeable drive tech must use authority to contribute to mechanical, as well as control design, and the earlier the better.

Why Use Control Block Diagrams

Block diagrams are very useful for design, commissioning and troubleshooting for drive control systems. Block diagrams allow people to discuss the design or a troubleshooting problem over the phone or in meetings. Present control system methodology recommends the block diagram be completed during the early stages of the design. New controllers are programmed in function block diagram (FBD - IEC 61131-3) which closely matches a block diagram.

A good block diagram will show

  • signal names that can be searched for in the software.
  • Units
  • Scaling (such as 4095@1 per unit current)
  • Indication if the signal is analog, in the PLC or in the drive


FEES: Course Registration Fee, Hotel and Room Rate information for each date are available using the date links below.


Dates for this course:
| October 7 - 8, Brussels, Belgium |