`WDR_FeedbackConverter` (FB)

FUNCTION_BLOCK WDR_FeedbackConverter

Description:

This function block is designed to scale and convert raw analog sensor signals such as those from a load cell, dancer position sensor, diameter sensor, and line encoder into usable engineering values. These outputs are critical for downstream speed and tension control loops in winding applications.

Key Features :

Scales raw analog input signals into engineering units.

Supports calibration using minimum and maximum signal values for each sensor type.

Sensor input types can include analog voltage, encoder values, or fieldbus feedback.

Supports structured data exchange via the WinderLink (WDR_WinderRef) interface.

If parameters SignalMin-Maximum and EngMin-Maximum are set to zero, then corresponding scaling block is considered unused and excluded from error checks.

Converts:

Load cell signal to actual web tension, Unit: N. (ActTension)

Dancer position signal to actual roll position, Unit: mm. (ActDancerPosition)

Diameter sensor signal to actual roll diameter, Unit: mm or Deg. (ActDiameterFromSensor)

Line roller rotary encoder into actual line encoder speed, Unit: MPM. (ActLineSpeedFromEnc)

Supports direct RPM (Mode 1), RMP from Counts (Mode 2) and direct MPM (Mode 3).

Supports averaging of line speed values over configurable samples (LineSpeedAverageSamples).

Example : A load cell provides signal values (LoadCellSignalInput). These are to be converted to load values in Newton (engineering units). The input signal range is defined by the limits LoadCellSignalMin and LoadCellSignalMax. The output (load in Newton) value range is defined by the limits LoadCellTensionMin and LoadCellTensionMax.

Note

FeedbackFilterPara: This enables the optional low-pass filter selection for the input signals. If signals have high-frequency noise, users can enable and set the filtering time.

Load Cell: LoadCellLPSEnable, LoadCellLPSTime [ms]
Dancer: DancerPosLPSEnable, DancerPosLPSTime [ms]
Diameter: DiameterLPSEnable, DiameterLPSTime [ms]
Line Encoder:
1. RPM/MPM mode uses LineEncoderLPSEnable, LineEncoderLPSTime [ms]
2. COUNT mode uses EncoderAvgSampleSize instead.

Higher time = smoother signal but slower response.

Note

Example of sensor configuration :

LOAD CELL SENSOR

The Load Cell sensor is used to measure and scale the actual tension (ActTension) in the web.

Raw analog signal from the load cell is mapped to LoadCellSignalInput.
LoadCellSignalMin represents the minimum signal value, Example : 4 mA.
LoadCellSignalMax represents the maximum signal value, Example : 20 mA.
LoadCellTensionMin represents the tension value at minimum signal, Example : 0 Nm.
LoadCellTensionMax represents the tension value at maximum signal, Example : 20Nm.
The scaled tension value is available at ActTension output parameter.

DANCER SENSOR

The Dancer sensor is used to measure and scale the actual dancer position (ActDancerPosition) to indirectly control web tension.

Raw analog signal from the dancer position sensor is mapped to DancerSignalInput.
DancerSignalAtLowTension represents the signal value when tension is lower, Example : 4 mA or 20 mA.
DancerSignalAtHighTension represents the signal value when tension is higher, Example : 20 mA or 0 mA.
DancerLowTensionPosition represents the physical position of the dancer arm when tension is lower, Example : 0 mm or 100 mm.
DancerHighTensionPosition represents the physical position of the dancer arm when tension is higher, Example : 100 mm or 1 mm.
Note DancerHighTensionPosition value will be always considered as the higher tension direction of dancer.
The scaled dancer position value is available at ActDancerPosition output parameter.

DIAMETER SENSOR

The Diameter sensor is used to measure and scale the actual roll diameter (ActRollDiameter) for dynamic torque control and speed compensation.

Raw analog signal from the diameter sensor is mapped to DiameterSignalInput.
DiameterSignalMin represents the minimum signal value , Example : 4 mA corresponding to minimum roll diameter.
DiameterSignalMax represents the maximum signal value , Example : 20 mA corresponding to maximum roll diameter.
DiameterMin represents the minimum roll diameter value , Example : 0 mm.
DiameterMax represents the maximum roll diameter value , Example : 100 mm.
The scaled diameter value is available at ActRollDiameter output parameter.

LINE ENCODER SENSOR

The Line Encoder sensor is used to measure and scale the web line speed for open loop speed control and material tracking.

LineEncoderModeSelect is the mode selection for feeder line encoder, example Mode 0 = None, Mode 1 = Speed in RPM, Mode 2 = Encoder Count, Mode 3 = Line Speed in MPM.
LineEncoderInput is the current value from the encoder input interpreted based on the selected encoder mode. Mode 1 example value 1500 RPM. Mode 2 example value 256000 Counts. Mode 3 example value 20 MPM.
LineEncoderPPR is the encoder resolution in Pulses Per Revolution, Example : 1024 PPR, 2048 PPR, or 3600 PPR. Range greater than 0.
LineEncoderMaxCount is the maximum encoder counter value before rollover, Example : 65535 or 4294967295. Range greater than 0.
EncoderAvgSampleSize is the number of averaging samples of encoder counts where each sample equals one task cycle. Example : 0 for no averaging, 5 for light smoothing, 10 for medium smoothing, 20 for heavy smoothing. 0 means no averaging and values greater than 0 provide smoother but slower response with higher values providing more smoothing.
LineRollerDiameter is the line roller diameter in millimeter unit, Example : 50 mm, 100 mm, or 200 mm. Range greater than 0. This value is used for calculating line speed from LineEncoderInput.
The scaled line speed and encoder information is available at ActLineSpeed output parameter.

InOut:

Scope	Name	Type	Comment
Input	`Enable`	`BOOL`	[TRUE] Enables the feedback converter.
	`LoadCellSignalInput`	`LREAL`	Input signal from the load cell (e.g., tension sensor).
	`LoadCellSignalMin`	`LREAL`	Minimum calibration value of the signal.Range: < 0 or > 0
	`LoadCellSignalMax`	`LREAL`	Maximum calibration value of the signal. Range: < 0 or > 0.
	`LoadCellTensionMin`	`LREAL`	[N] Minimum tension value.Range: < 0 or > 0.
	`LoadCellTensionMax`	`LREAL`	[N] Maximum tension value.Range: < 0 or > 0.
	`DancerSignalInput`	`LREAL`	Input signal from the dancer position sensor (e.g., potentiometer or encoder).
	`DancerSignalAtLowTension`	`LREAL`	Low tension position calibration value of the signal.Range: < 0 or > 0.
	`DancerSignalAtHighTension`	`LREAL`	High tension position calibration value of the signal.Range: < 0 or > 0.
	`DancerLowTensionPosition`	`LREAL`	Low tension position value. Unit : [mm] for linear or [deg] for rotary encoder.Range: < 0 or > 0.
	`DancerHighTensionPosition`	`LREAL`	High tension position value. Unit : [mm] for linear or [deg] for rotary encoder.Range: < 0 or > 0.
	`DiameterSignalInput`	`LREAL`	Input signal from the diameter sensor (e.g., analog voltage or encoder pulse).
	`DiameterSignalMin`	`LREAL`	Minimum calibrated signal value. Range: < 0 or > 0.
	`DiameterSignalMax`	`LREAL`	Maximum calibrated signal value. Range: < 0 or > 0.
	`DiameterMin`	`LREAL`	[mm] Minimum engineering value. Range: > 0.
	`DiameterMax`	`LREAL`	[mm] Maximum engineering value. Range: > 0.
	`LineEncoderModeSelect`	WDR_LINE_ENCR_MODE	Mode selection for feeder line encoder :
	`LineEncoderInput`	`LREAL`	Current value from the encoder input. Value Interpreted based on line encoder mode selected, Mode 1 = Speed in RPM, Mode 2 = Encoder Counts, Mode 3 = Line Speed in MPM
	`LineEncoderPPR`	`DINT`	Encoder resolution (PPR). Range: > 0.
	`LineEncoderMaxCount`	`DINT`	Maximum encoder counter value before rollover. Range: > 0.
	`EncoderAvgSampleSize`	`UINT`	Averaging samples of encoder counts. Each sample = one task cycle, 0 = no averaging and >0(Higher value) = smoother but slower.
	`LineRollerDiameter`	`REAL`	[mm] Line roller diameter, Cosidered in Unit: Millimeter. Range: > 0.
	`FeedbackFilterPara`	WDR_FeedBackFilterParameter	Low pass filter parameters for feedback converter signals.
Output	`Busy`	`BOOL`	[TRUE] Indicates the function block is currently running.
	`Error`	`BOOL`	[TRUE] Indicates an error occurred in the function block. The error flag resets after the error condition is resolved and when the Enable input transitions from TRUE to FALSE.
	`AppErrorID`	WDR_APP_ERROR_ID	Application-specific error code.
	`ActTension`	`LREAL`	[N] Actual web tension.
	`ActDancerPosition`	`LREAL`	Actual dancer roll position. Unit : [mm] for linear or [deg] for rotary encoder.
	`ActDiameterFromSensor`	`LREAL`	[mm] Actual roll diameter.
	`ActLineSpeedFromEnc`	`LREAL`	[MPM] Actual line speed calculated from the line encoder.
Inout	`WinderLink`	WDR_WinderLink	Structured data to share common variables between mandatory function blocks.

WDR_FeedbackConverter (FB)

`WDR_FeedbackConverter` (FB)