1. P16601: Guide Rollers
Electrical Systems

2. Table of Contents → Overview of Subsystem → Motor Selection
→ Drive Selection
→ PLC Selection
→ Sensor Selection
→ Drawing/Documentation

3. Subsystem Overview

4. Network Design
Kinetix 5500
CompactLogix 1768
Servo Motors:
RDB-B21529

5. Motor Selection

6. Torque and Speed Requirements
From the numbers given for torque, the starting torque needs to be approx. 40Nm while running torque is near 20Nm. The speed to move the wire at 12m/s would be about 900RPM for 320mm diameter roller. Using these two numbers a motor can be selected.
Initially the need for precision was felt to not be strong enough for a servo motor to be selected. However, the drives and motors for 5-20Hp 900RPM 3phase synchronous motors do NOT come with encoders for monitoring position. This can be accomplished with servo motors. Making servo motors the correct choice.

7. dB=0.16 m r=0.08 m M=65 kg M=16 kg DS 264 rollers L=840 mm 2x320 mm
N=4100 loops
N=265 loops
dB=0.32 m
dB=0.24 m
dB=0.16 m
r=0.16 m
r=0.12 m
r=0.08 m
M=130 kg
M=65 kg
M=36.5 kg
M=16 kg
ri= m
ri= m
ri= m
α=12.5 rad/sec2
α=12.5 rad/sec
α=16.7 rad/sec2
α=25 rad/sec
900 RPM
1200 RPM
1800 RPM
Results:
TB=49.5 Nm
TB=3.49 Nm
TB=3.3 Nm
TB=2.4 Nm
TB=1.6 Nm
Trf=229.6 Nm
Trf=14.8 Nm
Trf=11.1 Nm
Trf=7.4 Nm
Tg=196.8 Nm
Tg=12.7 Nm
Tg=9.5 Nm
Tg=6.4 Nm
TI=20.8 Nm
TI=10.4 Nm
TI=4.4 Nm
TI=1.3 Nm
TA=496.7 Nm
TA=51.8 Nm
TA=41.3 Nm
TA=27.5 Nm
TA=16.7 Nm
hp=125.6
hp=6.6
hp=5.2
hp=4.6
hp=4.2
total hp=170.4
total hp=13.2
total hp=10..4
total hp=9.2
total hp=12.6
Constants: μb=.0015, μr=.007, μg=0.4, T=25 N, Fg=0.75 N
During the 7.5 second acceleration cycle, the inertia is about 25% of the load at 265 cuts. However, this analysis scaled down the nominal torque of the DS264 motor (500 Nm) so to be safe, 7.5 Nm would be required.

8. Servo Motor Selection
The B21529 has the the closest parameters that meet our specifications.

9. Drive Selection

10. Synchronization Requirements
The two guide rollers must be synchronized with each other in order to prevent wire breaks. Rough estimates suggest the torque differences in each motor should not exceed 0.1 Nm per loop (one loop is about rotations of the motor shaft). The detailed analysis is still a work in progress.

11. PLC Selection

12. I/O Requirements of the entire system
The CompactLogix 5370 L3 Controller comes with 256 I/) points. This is more than meets the needs of the system.

13. Regentive Energy Analysis

14. Regenerative Analysis for DS264 (Friction Ignored)
Ir=2(Iroller+Iroller motor)=2( )=3.79 kgm2
Is=2(Ispool+Ispool motor)=2( )=1.21 kgm2
Tr=Irαr=3.79*12.5=47.38 Nm
Ts=Isαs=1.21*25=30.25 Nm
ωr,avg=152(0.16)=46.88 rad/sec
ωs,avg=152(0.08)=93.75 rad/sec
Pr,avg=47.38*46.88=2221 W
Psavg=30.25*93.75=2836 W
Pavg=Pr,avg+Ps,avg=5057 W
E=Pavg*t=5057*7.5=37.9 kJ
2550*365*37.9kJ=35.28 GJ
866.3 GJ*(0.06$)/36MJ=588 $ at 100% uptime and 100% efficiency

15. Sensor Selection

16. Temperature Sensors
Need to Monitor Motor temperatures (will that be on the motor or does that need to be monitored separately?)
Need to monitor bearing temperature (no feedback control necessary just overtemp alarm).

17. Power Supply Options

18. DC power supply option
For the 24V DC bus supply the P1606-XLP could be used.
Advantages of this system are:
• Applications are not interrupted due to voltage dips and drops or inrush spikes
• Clear status indication by status LED and signaling terminals
• Provides additional power for short and heavy peak loads
• Any number of units can be installed in parallel to increase power buffer or back-up time