Unwind/Rewind Tension Loss during Auto Run

#3381 - Unwind/Rewind Tension Loss during Auto Run


PROBLEM
  1. Customer operating RDC in Auto Run, suddenly having tension loss from U1 Upper Rewind

INVESTIGATION
  1. Customer running U1 in Tension Mode, Rewind, CW
  2. Customer would start machine at low speed, increasing slowly to 40 m/min setpoint
  3. U1 observed to be losing tension suddenly and jam material in die set
  4. U1 tension loss occurred at no particular speed, but only when increasing speed.
  5. SYSCO team confirm that FAT testing start machine at 40 m/min, and press "Auto Run"
  6. DCS team confirm that SAT testing start machine at low speed, then manually increase to 40 m/min
ROOT CAUSE
  1. New Yaskawa servo require MP-3000 PLC to control overspeed during speed increases
  2. SYSCO confirm that MP-3000 overspeed control was stopping Rewind servo motor during manual speed increase (see Video 2_SYSCO Test)

SOLUTION
  1. Modify MP-3000 driver (MP Updata) to reduce over-speed control

IMPLEMENTATION
  1. SYSCO create new "MP Updata" file for MP-3000 PLC
  2. DCS team take new "MP Updata" file on flashdrive
  3. Updated MP-3000 using "Update MP3200 program with USB Device" instructions (see attached)
  4. Tested 5000m of product, varying speed manually, stopping 200-300m, no issue occured!

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