Overview

The adjustable measurement roller simulator is designed to replicate realistic mechanical and electrical conditions for testing, calibration, and validation of force measurement and tension control systems. It enables flexible adjustment of rotational parameters and signal generation characteristics, ensuring accurate and repeatable simulation of operating environments.

Key Features

Variable rotational speed:
Supports continuously adjustable rotation speeds ranging from 10 rpm to 3000 rpm, with smooth acceleration and deceleration transitions for precise simulation of real motion dynamics.

Bidirectional rotation:
Allows operation in both rotational directions with seamless and vibration-free direction switching.

Adjustable package and slot angles:

Package angle: Continuously adjustable between 4° and 70°, enabling adaptation to different material wrap configurations.

Slot angle: Configurable within 90° – φw, depending on the roller geometry and application requirements.

Adjustable applied force:
Each integrated sensor can withstand a maximum load of 12.5 kN, with variable force settings for dynamic load simulation.

Sensor offset control:
Supports configurable synchronization pulse-to-force pulse offset for sensors positioned in slot A, ensuring flexible timing alignment in test setups.

Regional activation:
Allows selective activation or deactivation of specific force signal regions, supporting targeted measurement or partial system testing.

Power and Signal Generation

Unmodulated force signal simulation:
Generates accurate force signal representations based on defined mechanical and control parameters, closely approximating actual system behavior.

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

Amplitude modulation:
Implements precise amplitude modulation using the carrier signal to emulate real-time force dynamics.

Pulse signal output:
Generates speed- and direction-dependent pulse signals compatible with BMS pulse signal input requirements.

System clock synchronization:
Outputs a synchronized system clock to align the PFSA103D DA converter with the BMS AD converter, ensuring coherent data acquisition timing.

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

Performance and Integration

Dynamic adjustment:
All roller parameters—including speed, direction, and force—can be modified during operation with smooth transition control to prevent signal distortion.

Communication interface:
Provides a clear and flexible communication interface, compatible with FPGA-based architectures, including PowerPC and MicroBlaze microprocessors. Integration protocols ensure straightforward connectivity and control.

Diagnostic signaling:
Equipped with LED indicators providing real-time diagnostic feedback, including:

Simulator roller operational status

System reset status

Rotational speed indication