We reserve the right to make technical changes to this product.
Copyright
Reproduction, transmission or use of this document or its contents is not
permitted without express written authority. Offenders will be liable for
damages. All rights, including rights created by patent grant or registration
or a utility model or design, are reserved.
The standard applications are not binding and do not claim to be
complete regarding the circuits shown, equipping and any eventuality.
The standard applications do not represent customer-specific solutions.
They are only intended to pro-vide support for typical applications. You
are responsible in ensuring that the de-scribed products are correctly
used. These standard applications do not relieve you of the responsibility
in safely and professionally using, installing, operating and servicing
equipment. When using these application examples, you recognize that
Siemens cannot be made liable for any damage/claims beyond the
liability clause described. We reserve the right to make changes to these
standard applications at any time without prior notice. If there are any
deviations between the recommendations provided in these standard
applications and other Siemens publications - e.g. Catalogs - then the
contents of the other documents have priority.
Warranty, liability and support
We do not accept any liability for the information contained in this
document.
Any claims against us - based on whatever legal reason - resulting from the
use of the examples, information, programs, engineering and performance
data etc., described in this standard application shall be excluded. Such an
exclusion shall not apply in the case of mandatory liability, e.g. under the
German Product Liability Act (“Produkthaftungsgesetz”), in case of intent,
gross negligence, or injury of life, body or health, guarantee for the quality
of a product, fraudulent concealment of a deficiency or breach of a
condition which goes to the root of the contract (“wesentliche
Vertragspflichten”). However, claims arising from a breach of a condition
which goes to the root of the contract shall be limited to the foreseeable
damage which is intrinsic to the contract, unless caused by intent or gross
negligence or based on mandatory liability for injury of life, body or health
The above provisions does not imply a change in the burden of proof to
your detriment.
For questions regarding this application please contact us at the following
e-mail address:
mailto:applications.erlf@siemens.com
V 1.4 Release 06/06/08 3/107
General Notes
SIMOTION Flying Saw A4027118-A0414
Qualified personnel
In the sense of this documentation qualified personnel are those who are
knowledgeable and qualified to mount/install, commission, operate and
service/maintain the products which are to be used. He or she must have
the appropriate qualifications to carry-out these activities
e.g.:
• Trained and authorized to energize and de-energize, ground and tag
circuits and equipment according to applicable safety standards.
• Trained or instructed according to the latest safety standards in the care
and use of the appropriate safety equipment.
• Trained in rendering first aid.
There is no explicit warning information in this documentation. However,
reference is made to warning information and instructions in the Operating
Instructions for the particular product.
A standard SIMOTION application comprises the following components:
• One or several software objects or code blocks with defined interfaces
that can be simply integrated into other software projects – without
requiring any significant programming – in order to fulfill a precisely
defined technology task there. (Core functions)
• A software project based on a demonstration case to show the
functionality and possible uses of the standard application - including
the associated WinCCflex screen for demonstration. (Demonstration project)
• A document to describe the functionality, background information and
handling of the standard application. Further, its use as demonstration
model is explained. (Description)
you require to obtain an overview of this
standard application. This Section explains the
prerequisites and the objective when using this
application.
Some of the uses of this standard application are
explained as well as situations where this
application cannot be used.
Section B is interesting if you wish to use this
B
standard application for demonstration purposes.
Here, you are provided with information about
how you can download this application from your
PC/PG to the demonstration case step-by-step
and how it then used.
Section C provides you with all of the necessary
C
steps to integrate the core functions of the
standard application into your user project.
Preparations and parameterizing operations are
also explained. Further, you are also told how to
integrate the core functions into your application
step-by-step.
In addition, tips are provided on how to use the
core functions.
Section D is interesting if you wish to
D
expand/adapt the functionality of the core
functions provided for your particular application.
Section E “Appendix” provides you with detailed
E
information including a detailed fault/error
description, a description of a test program for
the core standard application functions as well as
references. A feedback sheet is also provided
which you can use to give us your comments
and suggestions on this document.
14 Please help us to become even better...................................................... 107
V 1.4 Release 06/06/08 9/107
Flying Saw with SIMOTION A4027118-A0414
Basic information
Section A: Prerequisites and objectives
Content
Section A will provide you with everything that you require to obtain an
overview of this standard application. The prerequisites and the objective
for using this standard application are presented.
The applications shown will give you a good understanding for what this
standard application can be used for. Further, some applications will be
listed for which this standard application cannot be used. In addition, the
performance limits of this standard application will be shown.
Objective
Section A of this document should provide the user with the following
information:
• The objective and purpose of this standard application
• Indicate the performance limits of this standard application.
Subjects discussed
Chap. Title Contents
1 Basic information
2 Uses
3
4
Structure and
function
Program
environment and
interfaces
The necessary prerequisites to use the standard “flying saw”
application.
The use of this application.
Software components and code blocks of the standard
“flying saw” application.
Tasks and properties of the core functions of the standard
“flying saw” application
Exclusions and restrictions
Hardware components required
Type of design and physical quantities for which the “flying
saw” core function can be used.
Type of cams that the “flying saw” core functions calculate
and used.
Operating states at the FlyingSaw FB.
Call environment of the FlyingSaw FB
Description of the interfaces and the parameters of the
FB_BGD_TEMPLATE_FlyingSaw()
V 1.4 Release 06/06/08 10/107
Flying Saw with SIMOTION A4027118-A0414
Basic information
1 Basic information
1.1 Prerequisites
1.1.1 Target group
The standard application is conceived for all programmers and users who
wish to quickly and simply implement a flying saw using SIMOTION.
1.1.2 Knowledge base
In order to use this technology template, you should be able to use SCOUT
and technology objects and technology function calls in SIMOTION.
This document does not provide an introduction into these subjects and is
solely restricted to providing information and data on how to use this
standard application.
This standard application can only be used, without having to make any
changes, in conjunction with SIMOTION D and the SINAMICS
demonstration case.
1.2 Objective and purpose of this standard application
1.2.1 Task description
Using SIMOTION, a material web, fed using the material feed mechanism
is to be cut into identical parts and sections. As a result of the
characteristics of the material, the material cannot be cut at once across
the whole width of the web with just one cut. In order that the motion of the
material web does not have an impact on the cut, either the material web
must be stopped during the cut, or the cutting device must be moved in
synchronism with the material web – i.e. the material web is cut "on the fly".
Why flying processing/machining?
"Flying" processing/machining is required, if
• If the flow of products were to be stopped due to a sub-process
(generally a thermal process) this would result in a reduction in quality
or even waste.
• Stopping the product flow cannot be justified as a result of the energy
demand when decelerating and accelerating.
• The individual processing/machining steps are too different so that a
standard delay time cannot be justified from a cost-effective
perspective.
V 1.4 Release 06/06/08 11/107
Flying Saw with SIMOTION A4027118-A0414
Basic information
Principle design of a "flying saw"
The material is fed-in as an endless web (e.g. plastic, sheet steel or fiber
board) using a conveyor belt that runs with a constant velocity.
The position of the cut on the material web is either sensed using a print
mark using a sensor or is specified by the control after a cut length has
been passed that can be adjusted. The synchronous position is
simultaneously defined. From this point onwards, the shears slide of the
flying saw synchronously follows the material at the position to be cut and
the cut can be started. After the cut has been completed, the shears slide is
returned to its starting position where it waits for the next cut position.
Fig. 1-1: Principle of operation of the “flying saw”
1.2.2 Solution using the standard “flying saw” application
The standard “flying saw” application discussed here can be used to
implement such applications, and to develop a functioning "flying saw" as
quickly as possible.
The standard application already includes, as core function, a preconfigured motion control of the flying saw axis. This can be adapted to the
particular application using the appropriate parameters. The core function is
responsible for completely controlling the flying saw axis.
V 1.4 Release 06/06/08 12/107
Flying Saw with SIMOTION A4027118-A0414
Basic information
The user program only has to control the material feed and to supply the
core function with the correct parameters.
Additional function of the standard application
Further, using this standard application, after the material has been cut with
the cutting device, a gap can be created between the individual cut pieces.
This function can also be set at the core function and commissioned by
simply entering the appropriate parameters.
1.2.3 Advantages of the standard "flying saw" application
When the standard “flying saw” application is used, it offers users the
following advantages:
When the standard “flying saw” application is used, it is simple to quickly
implement a "flying saw" functionality when programming with SIMOTION.
The core functions provided in the standard application can be transferred
into the application to be generated quickly and simply by copying. The
description of this standard application explains the additional configuring
steps that are necessary.
Automatic motion control
The core functions of the standard “flying saw” application can be used to
realize all of the flying saw axis motion control using SIMOTION technology
functions. The user only programs a execution sequence that corresponds
to the actual behavior of the machine function to be implemented.
Possibility of adaptation
The standard “flying saw” application includes all of the source codes in a
commented form. This means that the existing core functions can be
quickly and simply expanded by the user's own particular functions.
This description also provides you with an explanation of the background
required to expand the core functions.
1.3 Components included in the standard application
The standard “flying saw” application is implemented as SIMOTION project.
It is a program that can be executed for a (demonstration) machine for the
SIMOTION D and PC demonstration case with WinCCflex for visualization.
V 1.4 Release 06/06/08 13/107
Flying Saw with SIMOTION A4027118-A0414
Basic information
The program fulfills the following tasks:
• Operating mode manager for the complete (demonstration) machine
• The control of the (demonstration) machine
• The core functions of the "flying saw" functionality with absolute gearing
• All of the machine functions that are relevant for the demonstration case
environment are simulated
• The (demonstration) machine is displayed on the WinCCflex screen
This means that the user immediately sees which program modules are
required to implement his particular flying saw application; these program
modules are sub-divided into program groups and are appropriately
designated.
This means that the core functions of the standard “flying saw” application
can be quickly and simply integrated into user projects.
These core functions are used to control flying equipment and mechanisms
to
• Cut
• Perforate
• Emboss
• Seal
• Saw
• Drill
• Paint
• etc.
The core “flying saw” function completely handles the motion control of the
flying axis used for cutting/sawing. The functionality associated with the
material feed is implemented outside the core functions in the user
program.
Definition
In the following text, the “flying saw” term is used to represent all of the
other conceivable machine versions.
The term “saw” is used for all parts of the machine where direct contact
is made to the material when “cutting”.
V 1.4 Release 06/06/08 15/107
Flying Saw with SIMOTION A4027118-A0414
Uses
2.1.3 Properties and features of the core “flying saw” functions
The following properties and features were taken into account when
implementing the core functions, and can also be used in a user program
that you generate yourself:
•Precisely synchronizing at a specific position
The "flying" axis is accelerated to the velocity of the material web so
that this reaches this velocity above a position on the material that can
be specified.
•Flying axis
The "flying" axis and the material move at the same velocity while
sawing/cutting.
•The starting position of the "flying" axis can be set
The starting position of the "flying" axis between two cuts can be set
using a parameter at the core function.
The synchronous position is detected using a measuring probe and
print mark.
•"Cutting" to length
The synchronous position is calculated from the distance that the
material has moved through.
•Immediate cut
A cut is initiated by an operator function independently of the distance
that the material has moved. (This function is only possible for "cut" to
length!)
•Creating a gap
After a cut has been made, the cutting unit additionally moves the cut
material in the direction in which the material is moving until a certain
distance is reached to the rest of the material. This distance can be
specified. The cutting unit only returns to its starting position after this
operation has been completed.
•Asymptotic synchronizing
The “flying” axis is accelerated to the velocity of the material web
without overshoot in velocity.
•Gearing Ratio
Ratio between measured and effective velocity of the material web.
V 1.4 Release 06/06/08 16/107
Flying Saw with SIMOTION A4027118-A0414
Uses
2.2 Application environment
The standard “flying saw” application can be used in the following hardware
environment:
Fig. 2-1 Application environment of the standard “flying saw” application
Distance (clearance) between the axis zero of the "flying saw"
and the sensor to sense the material and print mark
StartPos
[mm]
SyncPos
[mm]
Starting position of the cutting unit referred to the axis zero
point of the "flying saw".
Position where the cutting unit reaches the specified material
position and material velocity. Starting point of the
synchronous range
EndSyncPos
[mm]
End point of the synchronous range. If, at this particular
position, sawing/cutting has still not been completed, then it is
now interrupted.
EndPos
[mm]
End point (end position) of the traversing range of the "flying
saw"
(software limit switch)
ToStartposVelocity
[mm/s]
ToBackposVelocity
[mm/s]
GapLength
[mm]
Velocity for travel to the starting position
Velocity with which the flying saw returns to its starting position
Length of the gap after the cutting unit has made a cut. This
gap is to be additionally created between the cut material and
the material web.
GapVelocity
[mm/s]
GearingRatio
Superimposed velocity with which the gap is to be created
Ratio between measured and effective velocity of the material
web.
AccelerationCut
Acceleration value for synchronization motion
[mm/s²]
AccelerationBack
[mm/s²]
AccelerationGap
[mm/s²]
Acceleration value for positioning motion back to the starting
position
Acceleration value for the higher-level positioning to create the
"gap"
Synchronous range
The synchronous range is located between SyncPos and the
EndSyncPos. The material is cut within this range.
V 1.4 Release 06/06/08 19/107
Flying Saw with SIMOTION A4027118-A0414
Section A: Prerequisites and objectives
Structure and function
3.2 Operating states of the "FlyingSaw-FB"
The “FlyingSaw FB” automatically controls the “flying saw” axis to
implement the required level of functionality.
This functionality is sub-divided into five operating states so that the
sequences at the “flying saw” are implemented as a result of the states or
also as a result of the transitions between the states.
This means the user only influences the “flying saw” by specifying the
required operating mode with the required parameters.
A differentiation is made between the following operating modes:
•Error (0)
The “FlyingSaw FB” has detected an error and brought the flying saw
axis into a safe state. The fault is still available and the user can
evaluate it.
The flying saw axis is stopped and is in the “disable” state.
•Disable (1)
The “FlyingSaw FB” is already being used but is in the safety operating
state. All of the faults/errors present have been successfully
acknowledged.
After a reset, the flying saw axis is in the disabled and stopped state.
2
2
Startposi-
Startposi-
tion
tion
3
3
Auto-
Auto-
matic
matic
0
0
Error
Error
•Starting position (2)
The flying saw axis moves to the starting position or is located at the
V 1.4 Release 06/06/08 20/107
Flying Saw with SIMOTION A4027118-A0414
Structure and function
starting position and is ready to synchronize to the material web.
The flying saw axis waits in the “enable” state.
•Automatic (3)
The flying saw axis has been synchronized to the material web and cuts
the material as specified.
•Manual (4)
The flying saw axis is in the manual mode and the user can manually
move the shaft.
The flying saw axis waits in the “enable” state.
These operating modes are available to users to implement their "flying
saw" functionality in a user program and can be signaled to the "FlyingSaw
FB“ using input parameters.
The “FlyingSaw FB” indicates the currently reached status using an output
parameter.
Section B: The application example as demonstration
system
Contents
All of the necessary steps to commission the standard “flying saw”
application as demonstration system are explained in Section B.
Preparations and parameterizing operations are also explained. Further,
you are told how you can use the WinCCflex Pro man-machine interface
(screen) of the application example step-by-step.
Objective
Section B of this document provides the reader with the following
• The prerequisites to use this standard SIMOTION application as
demonstration system
Section B: The application example as demonstration
• Preparations and parameterizing operations are explained
• Describes the steps necessary when presenting this standard
application.
• Provides tips for using this standard application.
Subjects discussed
Chap. Title Contents
5
6
Installing the
hardware and
software
Operator control of
the application
example
Safety information and instructions
Components and their interconnections required for the
presentation
Installation of standard SIEMENS software
Downloading the user program in SIMOTION D435
Downloading drive parameters in SINAMICS
Brief instructions on how to use the demonstration system
Detailed operating instructions
V 1.4 Release 06/06/08 22/107
Flying Saw with SIMOTION A4027118-A0414
Section B: The application example as demonstration
system
4 Installing the hardware and software
4.1 Regarding your safety
4.1.1 Safety information and instructions
Pictograms, signal words and text
Every piece of safety information/instruction in this document is designated
by text graphics – comprising pictogram and signal word, and
supplemented by explanatory text. A clear classification according to the
degree of the potential hazard is provided as a result of the combination of
pictogram and signal word. Safety information/instructions are provided in
front of the information regarding activities to be executed.
Classification
There are three different stages regarding safety information/instructions.
These are designated by the same pictogram. They differ by the signal
word.
This safety information/instruction indicates an immediate hazard. If
the information/instruction is not carefully followed, this results in
severe bodily injury or even death.
!
Warning
This safety information/instruction indicates a potential hazard. If
the information/instruction is not carefully followed, this can result
in severe bodily injury or even death.
!
Caution
This safety information/instruction indicates a potentially hazardous
situation, which can result in slight to average bodily injury. This
pictogram/text word can also warn about potential material damage.
V 1.4 Release 06/06/08 23/107
Flying Saw with SIMOTION A4027118-A0414
system
4.1.2 Responsibilities of the operator
Correct use
The correct use of the application components exclusively relates to the
open-loop and closed-loop control of test set-ups that were adapted to the
power/performance of the application components. In order that the
application functions perfectly, the required standard SIMATIC components
as well as also the necessary hardware and software components must be
installed.
The company/person operating the system may only make changes to the
application components after having received written authorization from the
suppliers.
Misuse
The following are considered to be misuse:
Section B: The application example as demonstration
• Inadmissible loads applied to the application components.
• Any application deviating from the use specified above, or applications
that go beyond the specified use.
• Non-observance of the safety information and instructions.
• If faults that could have a negative impact on the safety are not
immediately resolved/removed.
• Any changes/modifications to equipment/devices that are used to
ensure perfect function and operation, unrestricted use as well as active
or passive safety.
• If recommended hardware and software components are not used.
• If the application components are not in a perfect technical condition are
not operated conscious of safety and hazards, and not taking into
account all of the instructions provided in the documentation.
The manufacturer assumes no liability for incorrect use (misuse).
Responsible for monitoring
The company or person operating the system is responsible in continually
monitoring the overall technical status of the application components
(defects and damage that can be externally identified as well as changes in
the operating behavior).
The company/person operating the system is responsible in ensuring that
the application is only operated in a perfect state. He must check the state
of the application components before they are used and must ensure that
any defect is removed before commissioning.
V 1.4 Release 06/06/08 24/107
Flying Saw with SIMOTION A4027118-A0414
system
Qualification of personnel
The operating company/person may only deploy trained, authorized and
reliable personnel. In so doing, all safety regulations must be carefully
observed.
Personnel must receive special instructions regarding the hazards/dangers
that can occur.
4.2 Hardware structure and mounting/installation
Overview
Fig. 4-1 Hardware components (without power cable!)
Section B: The application example as demonstration
Hardware element Diagram Order No./MLFB and functions
Training case, SIMOTION D435 with SINAMICS S120
Section B: The application example as demonstration
SIMOTION D
demonstration and
training case
6ZB2 470-0AE00
The SIMOTION D training case comprises
standard components (SIMOTION D435,
two SINAMICS axes with motors) and has
two axes. These are used to demonstrate
the application.
The case is already pre-configured and
connected-up. It only has to be connected
to the HMI system via PROFIBUS.
6ES7972-0BA41-0XA0
The connector is used to establish a
connection between the HMI system and
the SIMOTION D435 training case
6XV1830-0EH10 (sold by the meter, from
20m)
The cable is used to establish a connection
between the HMI system and the
SIMOTION D435 training case
HMI system
PG/PC with MPI
interface
-
The PG/ PC is used as the HMI display
screen.
Procedure
Please proceed as follows to configure and install the hardware
components for the application example:
V 1.4 Release 06/06/08 26/107
Flying Saw with SIMOTION A4027118-A0414
system
Table 4-2 Hardware configuration and mounting
No. Action Comment
Section B: The application example as demonstration
Connect the MPI/DP interface of your PG/PC
1
to the righthand MPI/DP interface (contact
X136) of the SIMOTION D435 using a
PROFIBUS cable and switch the terminating
resistors in the two terminating connectors of
the cable to “On”.
Do not
use the standard MPI cable,
supplied with the PG/PC to connect the
PG/PC to the SIMOTION D435!
The connection should be operated with a
12Mbit/s baud rate. Under all
circumstances, a PROFIBUS cable must
be used between the PG/PC and
SIMOTION D435 with the terminating
resistors switched-in. If this is not do ne,
communication problems can occur
between the PG/PC and the SIMOTION
D435.
Please follow the instructions of the installation programs.
4.4 Downloading the user program and parameterizing the drive in
the SIMOTION D demonstration case
4.4.1 De-archiving the SIMOTION project
• Open SIMOTION SCOUT
• De-archive the SIMOTION project and open it using SIMOTION
SCOUT
4.4.2 Resetting SIMOTION D435 to the factory settings
In order to obtain a fixed starting point for the description on how to
download the user program into the demonstration case, restore the factory
setting at the demonstration case as described below:
• Power-down the demonstration case
• Set the mode switch SIMOTION D435 to setting 3 (MRES)
• Power-up the demonstration case
V 1.4 Release 06/06/08 28/107
Flying Saw with SIMOTION A4027118-A0414
system
• When RDY lights green and STOP lights orange, set the SIMOTION
D435 mode switch to the 0 position (RUN)
• RDY and RUN are green
Once the factory setting has been restored, the SIMOTION D435 has
PROFIBUS address 2 and the baud rate is 1.5 Mbit/s.
Section B: The application example as demonstration
4.4.3 Re-configuring the double-axis motor module from 3A/3A to 5A/5A
This application example is configured as standard using a 3A/3A motor
module. However, there are demonstration cases in the field, which are still
equipped with a 5A/5A motor module. The hardware should be carefully
checked before the project is downloaded! If a 3A/3A motor module is not
used in the demonstration case, then the project can be re-configured by
following the subsequent instructions:
• Go offline
• In the project tree, open the “Drive Navigator”
• A selection window opens when the “Device configuration” button is
pressed
• Open the Configurator by pressing the “Execute drive configuration"
button
• Scroll in the selection menu of the power unit by pressing the
“Continue” button
Section B: The application example as demonstration