MpTension Diameter Estimation Not Updating from Preset Value (Velocity Based)

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1

Environment:

  • Automation Runtime: Q4.93

  • mapp Control: 5.24.3

Setup: I have MpAxisTension configured with an Unwinder and Winder. The Winder diameter is known and used to calculate line velocity, which I feed into the Unwinder’s ActLineVelocity input for velocity-based diameter estimation.

Problem: The estimated diameter never updates from the preset value despite:

  • DiameterEstimation.Active = TRUE

  • Consistent mismatch between SetLineVelocity and ActLineVelocity

  • Over 1800m of processed material

Configuration:

  • Utilization: Unwinder (Center)

  • Diameter estimation: Velocity based

  • Estimation window: 360.0

  • Filter time: 0 (initially default of 0.1)

  • Min diameter: 1mm / Max diameter: 10000mm (initially 115mm - 160mm)

  • Material: Wire (0.25mm diameter)

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Runtime Values:

  • SetLineVelocity: 60 m/min

  • ActLineVelocity: 59.8 m/min and decreasing as unwinder diameter decreases

  • ActAxisVelocity: ~130 rpm

  • PresetDiameter: 140.0 mm

  • EstimatedDiameter: 140.0 mm ← Never changes

  • DiameterEstimation.Active: TRUE

What I’ve verified:

  • Units are correct (m/min for line velocity, rpm for axis velocity)

  • ActLineVelocity is updating

  • Velocity ratio suggests diameter should be calculated differently than preset

  • Reproduced in simulation with direct variable linking (SetLineVelocity + offset → ActLineVelocity)

Screenshot of simulation run with 10 m/min setpoint and -.5 m/min actual velocity offset:

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image578×726 104 KB

Has anyone encountered this behavior? Any insight into what conditions are required for the estimated diameter to actually update would be appreciated.

2

I was not able to figure out why velocity-based diameter estimation did not work, but I was able to get position-based diameter estimation functioning with the same configuration.

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