The adjustable measurement roller simulator is designed to reproduce realistic mechanical and electrical conditions for system testing and calibration. It provides precise control of rotational and force parameters, along with advanced signal generation and synchronization functions, making it ideal for validating measurement systems such as tension control and force feedback modules.

Adjustable Measurement Roller Properties

Rotational speed:
Continuously adjustable from 10 rpm to 3000 rpm, with smooth and stable speed transitions to simulate varying operating conditions.

Rotation direction:
Supports bidirectional rotation, allowing seamless and vibration-free transition between clockwise and counterclockwise directions.

Package angle:
Adjustable within a range of 4° to 70°, enabling flexible simulation of different wrap configurations.

Slot angle:
Configurable within 90° – φw, adaptable to various roller geometries.

Applied force:
Each sensor supports a maximum load of 12.5 kN, with continuously variable force control for realistic dynamic simulation.

Sensor A offset:
For sensors located in slot A, the offset between the synchronization pulse and the force pulse can be freely adjusted to match test conditions.

Regional activation:
Enables activation or deactivation of specific signal regions corresponding to force measurements for selective testing and data analysis.

Power and Data Generation

Unmodulated force signal:
Accurately reproduces actual force waveforms based on defined mechanical and control parameters.

Carrier generation:
Generates a 1953.125 Hz sine wave as the carrier for amplitude modulation of the force signal.

Amplitude modulation:
Uses carrier-based amplitude modulation to simulate dynamic force variations.

Pulse signal generation:
Outputs speed- and direction-dependent pulse signals compliant with BMS pulse signal input electrical requirements.

System clock synchronization:
Transmits a system clock synchronized with force data to align the PFSA103E DA converter with the BMS AD converter, ensuring timing consistency.

Force DA control:
Converts amplitude-modulated force signals into analog signals using high-precision DA converters operating at a 31.25 kHz sampling rate.

Performance and Integration

Dynamic parameter adjustment:
Allows real-time modification of roller parameters—including speed, direction, and force—during operation, ensuring smooth transitions without disrupting signal integrity.

Communication interface:
Provides a well-defined communication interface compatible with FPGA-based architectures, including PowerPC and MicroBlaze microprocessors, simplifying system integration and data exchange.

Diagnostic signaling:
Equipped with LED indicators that display key diagnostic information such as:

Simulator roller operational status

System reset condition

Rotational speed status