Hardware in the loop model for irregular conditions in tension leveler applications

One of the main parts of the production line in a metal web processing applications is tension leveler. It contains unwinder, tension bridles and winder. Parameters setting of regulators which control the production line and their testing of control system are needed. The paper presents a simulation and 3D visualization model of tension leveler developed for purpose of testing the control strategy. Complete hardware installed on the production line (drives, motors, etc.) is emulated by Simulation Unit hardware and is connected with detailed mathematical model of the tension leveler. Control software developed for the application is tested on hardware-in-the-loop real time simulation. Main goal of the work presented in the paper is to design and test control strategy for regular and irregular conditions in the simulated process of web tension leveling, and to represent it as a 3D animation.