Siemens A4027118-A0414 User Manual

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User Manual Flying Saw

SIMOTION Flying Saw V1.4

Application number: A4027118 -A0414

General Notes

SIMOTION Flying Saw A4027118-A0414

Manual_SIMOTION Flying Saw_V1.4.doc

We reserve the right to make technical changes to this product.

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.

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General Notes

SIMOTION Flying Saw A4027118-A0414

General Notes

Manual_SIMOTION Flying Saw_V1.4.doc

Note

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

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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.

Manual_SIMOTION Flying Saw_V1.4.doc

Reference regarding export codes

AL: N ECCN: N

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Foreword

SIMOTION Flying Saw A4027118-A0414

Foreword

Standard SIMOTION application

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)

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Foreword

SIMOTION Flying Saw A4027118-A0414

Document structure

The documentation of this application is sub-divided into the following main section:

Manual_SIMOTION Flying Saw_V1.4.doc

Sec-

Description Note

tion

Section A will provide you with everything that

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

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

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

expand/adapt the functionality of the core functions provided for your particular application.

Section E “Appendix” provides you with detailed

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.

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List of contents

SIMOTION Flying Saw A4027118-A0414

List of contents

Section A: Prerequisites and objectives..................................................................10

1 Basic information ......................................................................................... 11

1.1 Prerequisites................................................................................................... 11

1.1.1 Target group................................................................................................... 11

1.1.2 Knowledge base............................................................................................. 11

1.1.3 Technical environment.................................................................................... 11

1.2 Objective and purpose of this standard application........................................ 11

1.2.1 Task description.............................................................................................. 11

1.2.2 Solution using the standard “flying saw” application....................................... 12

1.2.3 Advantages of the standard "flying saw" application ...................................... 13

1.3 Components included in the standard application.......................................... 13

2 Uses............................................................................................................... 15

2.1 Applications ....................................................................................................15

2.1.1 Controls that are permitted............................................................................. 15

2.1.2 Tasks that can be implemented using the core functions............................... 15

2.1.3 Properties and features of the core “flying saw” functions.............................. 16

2.2 Application environment ................................................................................. 17

3 Structure and function ................................................................................. 18

3.1 Design of the "flying saw" ............................................................................... 18

3.1.1 General design ...............................................................................................18

3.1.2 Physical quantities that can be parameterized............................................... 18

3.2 Operating states of the "FlyingSaw-FB".......................................................... 20

Section B: The application example as demonstration system............................22

4 Installing the hardware and software ......................................................... 23

4.1 Regarding your safety..................................................................................... 23

4.1.1 Safety information and instructions................................................................. 23

4.1.2 Responsibilities of the operator ...................................................................... 24

4.2 Hardware structure and mounting/installation ................................................ 25

4.3 Installing the standard SIEMENS software..................................................... 28

4.4 Downloading the user program and parameterizing the drive in the SIMOTION

D demonstration case................................................................................ 28

4.4.1 De-archiving the SIMOTION project...............................................................28

4.4.2 Resetting SIMOTION D435 to the factory settings.........................................28

4.4.3 Re-configuring the double-axis motor module from 3A/3A to 5A/5A .............. 30

4.4.4 Setting the Ethernet interface of the PG/PC...................................................32

4.4.5 Downloading the hardware configuration after a factory setting..................... 37

4.4.6 Downloading the SIMOTION project of the standard application................... 38

5 Operator control of the application example ............................................. 41

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List of contents

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5.1 Brief instructions to demonstrate.................................................................... 41

5.1.1 Structure overview..........................................................................................42

5.1.2 Brief instructions............................................................................................. 43

5.2 Detailed operating instructions .......................................................................47

5.2.1 Structure overview..........................................................................................48

5.2.2 Start................................................................................................................ 48

5.2.3 Machine parameter settings ........................................................................... 51

5.2.4 Operator control functions in the setting-mode............................................... 53

5.2.5 Operator functions of the process in the automatic mode.............................. 54

5.2.6 Technology view.............................................................................................59

5.2.7 Operator control functions in the status display.............................................. 60

Section C: Integrating the core “flying saw” functions .........................................61

6 Program environment and interfaces.........................................................62

6.1.1 Function and identification of the program groups.......................................... 62

6.1.2 Program structure........................................................................................... 63

6.2 Call environment............................................................................................. 65

6.3 Interfaces........................................................................................................ 65

6.3.1 Classifying the interfaces................................................................................ 65

6.3.2 Block interface of the FB_BGD_TEMPLATE_FlyingSaw()............................. 66

6.3.3 Structure of the global data area of the data unit FS_Var .............................. 68

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7 Integrating the core “flying saw” functions...............................................72

7.1 This is how you integrate core functions into your project..............................72

7.2 Prerequisites................................................................................................... 72

7.2.1 SIMOTION SCOUT with SIMATIC STEP 7.................................................... 72

7.2.2 SIMOTION control.......................................................................................... 73

7.2.3 Technology objects required and synchronous relationships......................... 74

7.3 Preparations ...................................................................................................75

7.3.1 De-archiving the standard "flying saw" application.........................................75

7.3.2 Downloading the core functions into your SCOUT project..............................75

7.4 Setting-up the required technology objects ....................................................76

7.4.1 Flying saw axis ............................................................................................... 76

7.4.2 Axis, material web........................................................................................... 77

7.5 Assigning the synchronous relationships........................................................ 78

7.5.1 FlyingSawAxis_SYNCHRONOUS_OPERATION........................................... 78

7.6 Integrating into your application...................................................................... 79

7.6.1 Calling the “FlyingSaw FB” in the user program.............................................79

7.6.2 Integrating the template block in the processing sequence............................80

8 Using the "FB_BGD_TEMPLATE_FlyingSaw()"......................................... 81

8.1 General information and instructions.............................................................. 81

8.2 Initial state of the "FB_BGD_TEMPLATE_FlyingSaw()".................................81

8.3 Mode changeover sequence .......................................................................... 81

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8.4 Using the restart bit......................................................................................... 83

8.5 Error messages .............................................................................................. 83

8.6 Help functions within the core “flying saw” functions...................................... 85

Section D: Program description...............................................................................86

9 Information and instructions to adapt the core “flying saw” functions.. 87

9.1 Information and warnings ............................................................................... 87

10 Description of important program elements.............................................. 88

10.1 Program structure........................................................................................... 88

10.2 Declaration part FS_Var ................................................................................. 88

10.3 Functions of the FB_BGD_Template_FlyingSaw() ("FlyingSaw-FB")............. 89

10.3.1 Declarations.................................................................................................... 89

10.3.2 Start identification, axis monitoring and automatic state change chains ........ 90

10.3.3 Checking the input parameters and parameterization of the technology

settings that are absolutely necessary....................................................... 91

10.3.4 State machine of the “FlyingSaw FB” ............................................................. 91

10.4 Properties/features of startup_SAP................................................................ 98

10.5 Help routines................................................................................................... 98

10.5.1 Features and characteristics of the MT_FS1_PrintmarkDetection (print mark

sensing)...................................................................................................... 98

10.5.2 Properties/features of the IPO_FS1_IPO_Routine.........................................98

10.5.3 SyncPos buffer ............................................................................................... 98

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Section E: Appendix................................................................................................100

11 General information on the application.................................................... 100

11.1 Scope of supply............................................................................................ 100

11.2 Revisions/Author........................................................................................... 100

12 Error messages........................................................................................... 101

12.1 Signaling error events at the “FlyingSaw FB” of the core “flying saw” functions101

12.2 Possible error messages at the error code output ErrorID of the

„FB_BGD_TEMPLATE_FlyingSaw()“ ...................................................... 101

13 Contact partner...........................................................................................106

14 Please help us to become even better...................................................... 107

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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

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

• List several applications

• Indicate the performance limits of this standard application.

Subjects discussed

Chap. Title Contents

1 Basic information

2 Uses

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()

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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.

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

1.1.3 Technical environment

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.

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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”

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

Sensor

Web drive or measuring system

Starting position

Drive of 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.

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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:

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

Programs can be quickly generated

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.

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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.

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

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Uses

2 Uses

2.1 Applications

2.1.1 Controls that are permitted

The standard “flying saw” application has only been tested for use in the following control system:

• SIMOTION D 435

However, it can also be used – without any significant additional costs – also in the SIMOTION P or SIMOTION C controls.

2.1.2 Tasks that can be implemented using the core functions

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

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”.

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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.

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

• "Cutting" at a print mark

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.

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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

PG / PC

SIMOTION D

Encoder

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

Motor

Sensor

Material web

Motor Encoder

SIMOTION D used to control the material feed of the material web and to control the "flying" axis.

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Structure and function

3 Structure and function

3.1 Design of the "flying saw"

3.1.1 General design

The "flying saw", which is based on the "flying saw" core function comprises a spindle axis that is mounted on the cutting unit.

3.1.2 Physical quantities that can be parameterized

The following physical quantities of the “flying saw” (designations in white) are used in the “flying saw” core function:

Fig 3-1 Physical quantities for the standard “flying saw”

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

Starting position

Sync position EndSync-

position

Sensor

Synchronous range

DistanceToSensor

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Structure and function

Table 3-1: Explanation of the parameterizable physical quantities

Physical quantity Description

Section A: Prerequisites and objectives

Manual_SIMOTION Flying Saw_V1.4.doc

DistanceToSensor [mm]

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.

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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.

Fig. 3-2 Operating modes

Manual

Manual_SIMOTION Flying Saw_V1.4.doc

Disable

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.

Startposi-

tion

Auto-

matic

Error

• Starting position (2)

The flying saw axis moves to the starting position or is located at the

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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 A: Prerequisites and objectives

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system

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

Manual_SIMOTION Flying Saw_V1.4.doc

• 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

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

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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.

Manual_SIMOTION Flying Saw_V1.4.doc

Danger

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.

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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

Manual_SIMOTION Flying Saw_V1.4.doc

• 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.

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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

MPI/DP

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Table 4-1 Hardware components

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.

Manual_SIMOTION Flying Saw_V1.4.doc

Communications

PROFIBUS connector up to 12 Mbit/s

PROFIBUS cable

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:

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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

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.

Connect the SIMOTION D training case to

the power supply.

3 Power-up all of the equipment/devices.

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4.3 Installing the standard SIEMENS software

Minimum required releases

Table 4-3 Versions

Component Version.

STEP 7 V5.4 + SP2 SIMOTON SCOUT V4.1.1.6 WinCCflex Advanced 2007 Hotfix 4

Installation

Please install the following

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

• Step 7 V5.4 incl. SP2

• SIMOTION SCOUT V4.1.1.6

• WinCCflex 2007 Hotfix 4 Advanced

(with the option: Integration in Step 7)

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

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• 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

Fig. 4-2 Mode selector switch, SIMOTION D435

Manual_SIMOTION Flying Saw_V1.4.doc

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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

Manual_SIMOTION Flying Saw_V1.4.doc

• Select the power unit being used from the list – refer to the serial

number on the front of the double motor module, e.g. 6SL3120-2TE150AA0 (5A/5A)

• Press “Continue” and acknowledge the alarm messages

• Press the “Continue” button – without making any additional changes –

until the “Complete” button appears; also press this

• Close the Device Configurator

• In the Expert list of the red and blue drives (select the particular drive ->

righthand mouse key -> Expert -> Expert list), reduce parameter p210 from 600V to 345V

• Compile and save the project, go online and load the project into the

target system

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Fig. 4-3: Re-configuring the motor module

Section B: The application example as demonstration

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4.4.4 Setting the Ethernet interface of the PG/PC

Setting the PG/PC interface

Table 3-5: Setting the PG/PC interface

No. Action Comment

In SIMOTION SCOUT open the interface

Section B: The application example as demonstration

configuration using O PG/PC INTERFACE...

In the “Interface Parameter Assignment

Used” area, select your Ethernet card/interface of the PG/PC using the

interface setting “TCP/IP Æ ......”.

(e.g. "TCP/IP Æ VIA PCI 10/100 Fast Ethernet Adapter“)

PTIONS Æ SET

Manual_SIMOTION Flying Saw_V1.4.doc

Acknowledge (possible) warning with

Yes.

Acknowledge your change with OK

Now return to SIMOTION SCOUT and

open the network configuration

NETPRO using the button or the menu P

ROJECT Æ OPEN NETPRO .

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Open Properties by double-clicking on

the PG/PC(1).

Under the “Assignment” tab (this is

already automatically selected), the ETHERNET interface used must be listed under “Assigned”. If this is already the case, then select this and set the checkmark for S7ONLINE acce ss active.

In this case, you skip steps 8 and 9!

Acknowledge your entry with OK.

Section B: The application example as demonstration

Under certain circumstances, the Ethernet line of the PG/PC will have a ”yellow border”.

If the ETHERNET interface used is still not listed under “Assigned” then execute steps 8 and 9 (but only then!).

The ETHERNET interface is still not

“assigned”: The configured interface of the control is

listed under “Configured Interfaces” and all of the available interfaces of the PG/PC are under “Interface Parameter Assignments in the PG/PC”.

Select the ETHERNET interface to be used under “Interface Parameter Assignments in the PG/PC” (just the same as set in “Set PG/PC interface”) and press the Assign button.

If a warning is displayed, then acknowledge this with OK.

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The interface of the control is now

assigned the interface of the PG/PC. Select this and if it has still not been set, then set the checkmark for S7ONLINE access Active.

Acknowledge your entry with OK.

Under certain circumstances, the Ethernet line of the PG/PC will have a ”yellow border”.

Please select “Compile and check

everything” (button ) and acknowledge with OK

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

If any references are made to alarms,

then please close.

Before you load the project, please close

NETPRO and set the Ethernet address of your PG/PC.

Refer to the next Section

Setting the Ethernet address of the PG/PC

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Table 3-6: Ethernet address

No. Action Comment

Open the window Network and Dial-up

Connections of your PG/PC and select the network connection to SIMOTION D435 and open its properties.

(righthand mouse click Æ Properties – or

Section B: The application example as demonstration

select the symbol and then F PROPERTIES).

In the window “This connection uses the

following items” select “Internet Protocol (TCP/IP)” and open its properties.

ILE Æ

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The Ethernet interface IE2 (X130) of

SIMOTION D435 has, as standard, the IP address 169.254.11.22.

Select “Use the following IP address” and enter the IP address 169.254.11.23.

Enter 255.255.0.0 as “Subnet mask”.

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

The address set above must be identical

to the address for the PG/PC. Check this address by selecting the PG/PC interface in Netpro and, if required, modify this.

Acknowledge your changes by pressing

twice on OK.

4.4.5 Downloading the hardware configuration after a factory setting

To download the hardware configuration, please proceed as follows

Table 4-4: Downloading the hardware configuration after a factory setting

No. Action Comment

Now go into the hardware configuration

and press the Download to target module button

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2 Acknowledge with OK

3 Acknowledge with OK

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

4 Press No and do not restart

Close the hardware configuration and

change to Scout

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4.4.6 Downloading the SIMOTION project of the standard application

Table 4-5: Downloading the SIMOTION project

No. Action Comment

Before you download the project, in the offline

Section B: The application example as demonstration

mode, please check under Target system/Select target devices

Whether both SIMOTION D435 as well as

also SINAMICS_Integrated are selected.

Please acknowledge changes with OK.

Manual_SIMOTION Flying Saw_V1.4.doc

After establishing the ONLINE connection,

the operating states of the devices accessed are displayed in the diagnostics overview.

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After starting the download, you will be

prompted as to whether you wish to “copy RAM to ROM“ after the download. Always answer this question with Yes as otherwise your program must be again downloaded after power ON/OFF.

This copy operation only refers to the SIMOTION part of the project

Once the download has been completed,

please acknowledge with OK

Also acknowledge the data that has been

successfully copied from the RAM to ROM with OK

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

The system now prompts you whether you

wish to also copy the parameters of SINAMICS_Integrated from the RAM to the ROM.

Also answer this with Yes

Also acknowledge the data that has been

successfully copied from the RAM to ROM with OK

After the download has been completed, you

will see the adjacent diagnostics overview.

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Now switch the SIMOTION D435 into the

Section B: The application example as demonstration

RUN state.

To do this, click on the SIMOTION-CPU and with the righthand mouse key and target device/operating state, go to the operating state display.

13 Here, click on the RUN button

The SIMOTION D435 is then in RUN and the demonstration case is now ready to be used for the presentation!

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5 Operator control of the application example

The application can be used to present SIMOTION D with SINAMICS and get to know and test the functions of the CPU D435.

You will find brief instructions on how to demonstrate and present the

Section B: The application example as demonstration

application in the following

demonstrate.

You will find a detailed description of all of the operator screens in Chapter

5.2 Detailed operating instruction

5.1 Brief instructions to demonstrate

Here, in these instructions you will only be shown and explained the steps necessary to demonstrate the application. Not all of the operator screens are discussed.. A detailed description of all operator screens is provided in

Chapter 5.2 Detailed operating instruction.

Chapter 5.1 Brief instructions to

Manual_SIMOTION Flying Saw_V1.4.doc

Prerequisites

The following prerequisites must be fulfilled to use the application example:

• The SIMOTION project is provided online in SIMOTION D435.

• The parameterization for the applications has been downloaded into

SINAMICS. (also included in the SIMOTION project!)

• All of the devices are powered-up.

• The SIMOTION D435 has been switched into the “Run” state using the

online function of SIMOTION SCOUT.

• At least WinCCflex Advanced 2007 Hotfix 4 is installed on the PC/PG.

Note

WinCCflex requires the appropriate authorization. Authorization for at least 256 power tags is required.

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5.1.1 Structure overview

Please refer to the following diagram for the basic operator control structure with all of the operator areas of the application.

Section B: The application example as demonstration

SETTINGS, STATUS and MANUAL displays are not required when

The presenting the application and are therefore not described in the detailed Operating Instructions.

Fig. 5-1 Structure overview to demonstrate the application

Manual_SIMOTION Flying Saw_V1.4.doc

HOME

Manual-Mode

MANUAL

Automatic-Mode

AUTO

SETTINGS

STATUS

TECHNOLOGY

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5.1.2 Brief instructions

Execute the following steps in the sequence as listed in the following table to demonstrate the application example:

Table 5-1: Brief instructions to demonstrate/present the “flying saw” application example

No. Action Comment

Call the following file

"C:\Siemens\Step7\S7Proj\SAP_FlyingSaw\TDOP\

Section B: The application example as demonstration

PRO__00.fwd"

As an alternative, you can also select the operator panel using Step 7. In the SIMATIC Manager, open the

SAP_FlyingSaw project. You will find the HMI object OP1 at the project level. Start the runtime from the

context menu (righthand mouse key). If the connection to the CPU was able to be established,

the screen form appears at the top left - mode: Idle At the bottom left, please click on AUTO

button from the left!)

Check that your PG/PC is set to PROFIBUS with 12 Mbit/s.

Manual_SIMOTION Flying Saw_V1.4.doc

First activate the print mark simulation by pressing the

Print Mark Simulation ON / OFF

button.

Next, activate the travel to the starting position using the

button Flying Saw STARTPOS

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Once the “flying saw” has reached its starting position,

the Flying Saw START button is displayed to activate the “flying saw”

Before you activate the “flying saw”, the required cut length should be selected using the Cutlength slider.

7 Now you can start the material feed!

Select the Material Velocity using the Material Velocity slider

You can start the material feed by pressing the Material START button

After the material web starts, the material enters the unit

and the print mark simulation generates, after the length, set using the Cutlength slider switch, a print mark. The flying saw then makes a cut.

You can immediately generate a print mark using the on- the-spot CUT button – which is also then cut by the flying

Section B: The application example as demonstration

saw.

The red bar

indicates how far the flying saw must travel with the material web with the current setting for one cut.

Activate the technology screen by pressing the TECHNOLOGY button

10 The following are displayed in the technology screen:

• The actual material velocity

• The actual velocity of the "flying saw"

• The actual position of the "flying saw"

• The position of the material referred to the actual cut

•

You can return to the automatic screen by pressing the AUTO button

The material can be removed

by pressing the Material END button

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After the last cut, the “flying saw” automatically moves to

its starting position and waits for new material.

Once the material has been completely removed

from the screen area, then you can either allow new material to enter by pressing the Material START button and continue with Step 8, or end the “flying saw” by pressing the Flying Saw END button.

After the “flying saw” has been ended, you can

return to the welcome screen by pressing the HOME button

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

Process screen

The process screen is the main screen in the automatic mode of the application example to control (operator control) the “flying saw”.

Fig. 5-2 Process screen in the automatic mode of the “flying saw”

Mode of the

"FlyingSaw FB“

Position and velocity of the

material and "Flying Saw“

Operating state (OMAG)

application example

Flying Saw

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Random print

mark offset

system

Material

Start flying

Move flying saw

to the starting

position

Terminate flying saw

Manual_SIMOTION Flying Saw_V1.4.doc

saw

(end)

Basic

settings

Manual

mode

Automatic

mode

Calls-up the

technology

screen

To the

status

display

The material and the “flying saw” can be started, terminated (exited) and monitored in the process screen.

The material (material web) is started, stopped (held) and terminated (exited) on the righthand side; the “flying saw” is started and exited on the lefthand side.

Start

Material

Stop

Material

Allow

material to

run-out

To the

start

screen

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5.2 Detailed operating instructions

A detailed description of the application is provided in these instructions. This is necessary so that you can get to know and test the CPU functions.

Prerequisites

The following prerequisites must be fulfilled to use the application example:

• The STEP7 project is available online in the S7-CPU.

• The parameterization for the application has been downloaded into

SIMODRIVE.

• All of the devices are powered-up.

• At least WinCCflex Advanced 2007 Hotfix 4 is installed on the PC/PG.

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

Note

WinCCflex requires the appropriate authorization. Authorization for at least 256 power tags is required.

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5.2.1 Structure overview

Please refer to the following diagram for the basic operator control structure with all of the operator areas of the application.

Section B: The application example as demonstration

Fig. 5-3 Structure overview

Manual_SIMOTION Flying Saw_V1.4.doc

HOME

Manual-Mode

MANUAL

Automatic-Mode

AUTO

SETTINGS

STATUS

TECHNOLOGY

5.2.2 Start

In the SIMATIC Manager, open the SAP_FlyingSaw project. You will find the HMI object

OP1 at the project level. Start the runtime from the context

menu (righthand mouse key). or Call the following file

C:\Siemens\Step7\S7Proj\SAP_FlyingSaw\TDOP\PRO__00.fwd".

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The welcome screen is displayed

Fig. 5-4 Welcome screen

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

General screen areas

The screen forms of the application are handled using buttons at the lower edge of each of the screen forms.

Refer to

The name of the actual operator screen form and the presently valid mode are displayed in the upper righthand corner of the screen forms.

Refer to

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The following functions can be selected using the individual buttons:

Table 5-2 General buttons to control/handle the screen forms

Button Function

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

You can access the pre-setting screen from every operator screen using the SETTINGS button.

You can access the setting-up screen from every operator screen using the MANUAL button.

If the application is in the IDLE or AUTOMATIC-STOPPED modes, the MANUAL mode is selected

You can access the automatic screen from every operator screen using the AUTO button.

If the application is in the IDLE or MANUAL modes, the AUTOMATIC-STOPPED mode is selected

You can access the technology screen from every operator screen using the TECHNOLOGY button.

You can access the status screen from every operator screen using the STATUS button.

You can access the welcome screen (home) from every operator screen using the HOME button.

If the application is in the MANUAL or AUTOMATICSTOPPED modes, the IDLE mode is selected

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5.2.3 Machine parameter settings

The standard application allows the following parameters to be adapted:

Machine geometry

Section B: The application example as demonstration

Distance to sensor

•

Distance between the flying saw axis and the sensor of the material and print mark detection

• StartPosition

Position from which the flying saw starts motion to achieve synchronism (with the material web)

• StartSyncPosition

Position at which the flying saw is synchronized, start of the synchronous traversing range

• EndSyncPosition

End of the synchronous traversing range

Manual_SIMOTION Flying Saw_V1.4.doc

• EndPosition

Maximum traversing range of the flying saw

Flying Saw Axis Accelerations

•

Cut

Acceleration value for synchronization

• Back

Acceleration value for return motion

• Gap

Acceleration value for creating a "gap".

Creating a "gap"

•

GapVelocity

Additional velocity in order to create a gap between the material and the cut piece

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Fig. 5-5 SETTINGS operator screen for machine geometry settings

Section B: The application example as demonstration

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5.2.4 Operator control functions in the setting-mode

In the manual mode, the material web and flying saw can be manually moved.

This standard application does not require any functions that may only be executed in the setting-up mode. This is the reason that we are only providing users with an empty screen form that can be adapted, when required - to the specifications and requirements of the user’s application.

Fig. 5-6 MANUAL operator control screen form for the operator functions in the setting-up mode

Section B: The application example as demonstration

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5.2.5 Operator functions of the process in the automatic mode

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

Note

The automatic mode is only available, if

• There is no fault,

• Both axes are enabled, and

• For both of these axes, no manual operator control functions are

active.

Fig. 5-7 AUTOMATIC operator screen form for operator functions in the automatic mode

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Standard operator control

Table 5-3: Standard operator control in the automatic mode

No. Action Comment

Section B: The application example as demonstration

Manual_SIMOTION Flying Saw_V1.4.doc

1 Initial situation:

The “flying saw” is in the AUTOMATIC-STOPPED mode

Using the Sync Position slider switch, enter the position

at which the flying saw reaches the position where the material web is to be cut.

The flying saw starts to move to the starting position by

pressing the Flying Saw STARTPOS button

After the starting position has been reached, the flying

saw is in the AUTOMATIC-READY mode

The flying saw is enabled for operation using the Flying

Saw START button.

The flying saw is in the AUTOMATIC-STANDBY mode

and waits for material.

Select the required material web velocity using the

Material Velocity slider.

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Depending on the material velocity and the cutting

duration, an actual maximum position of the flying saw is obtained, which is identified by a red bar.

You can start to thread the material web or continue

Section B: The application example as demonstration

motion after the material web was stopped by pressing the Material START button.

If the flying saw has synchronized itself to the motion of

the material web, the flying saw is in the AUTOMATICPRODUCING mode.

Here, you can select whether a cutting position is to be

generated at each print mark (sensor signal) or only after n print marks.

Manual_SIMOTION Flying Saw_V1.4.doc

You can stop the material web using the Material BREAK

button.

When the material web has been stopped, the flying saw

is in the AUTOMATIC-HELD mode

You can start to remove the material web from the system

by pressing the Material END button.

The flying saw then waits in the AUTOMATIC-STANDBY

mode for the next material web.

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system

Expanded operator control

Table 5-4: Expanded operator control in the automatic mode

No. Action Comment

If the flying saw is in the AUTOMATIC-STOPPED,

Section B: The application example as demonstration

operating mode, you can select one of two possibilities:

1. Print Mark Simulation OFF i.e. the demonstration case itself generates print marks using sensors. The cut length can only be changed in steps of complete revolutions.

2. Print MARK simulation ON this means that the print marks – and therefore also the cut length – can be freely selected .

Manual_SIMOTION Flying Saw_V1.4.doc

If the print mark simulation has been activated, this

character is displayed at the top left edge of the screen.

You can change the cut length with the Cutlength slider.

The system automatically calculates the minimum cut length from the data specified for the material velocity, cut duration, velocity for return positioning and the actual acceleration values. The maximum cut length is obtained from the minimum plus 1000!

You can enter the cutting time using sel

For act the remaining cutting time is displayed during the cut itself.

You can activate/deactivate the "gap" function using the

Gap ON / OFF button

You can define the size of the gap by entering Gap Length

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Section B: The application example as demonstration

Here, you can set the velocities for the return to the

starting position and also when returning to the starting position in the automatic mode

Display areas

Fig. 5-8: Flying saw mode

This area informs you about the selected and presently active operating mode of the FlyingSaw FB.

Manual_SIMOTION Flying Saw_V1.4.doc

Fig. 5-9: Actual velocity / position

In this area, the actual velocity [mm/s] and the actual position [mm] are displayed for the material and flying saw axis.

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5.2.6 Technology view

Fig. 5-10 Technology view of the flying saw

Velocity of the flying saw

system

The technology view of the application can be selected from every operator

Section B: The application example as demonstration

screen using the

TECHNOLOGY button.

Velocity of the material web

Actual position of the flying saw

Manual_SIMOTION Flying Saw_V1.4.doc

Quiescent position of the flying saw

Using the trace-

record function

Using the trace function on the HMI screen, the actual position and velocity of the flying saw, the starting position, its velocities and position of the material web referred to the particular cut can be monitored and traced in the technology view.

It can also be easily seen how the position of the flying saw precisely corresponds to that of the material web during the cut itself.

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5.2.7 Operator control functions in the status display

The status display of the application can be selected from every operator

Section B: The application example as demonstration

screen using the

STATUS button.

Fig. 5-11: Status

Manual_SIMOTION Flying Saw_V1.4.doc

You can see the actual state of the FlyingSaw FB in the status display. The error numbers that are displayed under ErrorID can be viewed under

Chapter 12.2 Possible error messages at the error output ErrorID of the

„FB_BGD_TEMPLATE_FlyingSaw()“. Errors can be acknowledged using the If the FlyingSaw-FB is in the

“error” state, then the Quitt button should be

pressed until the FlyingSaw-FB is in the

QUITT button.

“disable” state.

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Operator control of the application example

Section C: Integrating the core “flying saw” functions

Content

All of the steps necessary to integrate the core “flying saw” functions into your application are explained in Section C.

Preparations and parameterizing operations are also explained. Further, you are also told how to integrate the “FlyingSaw FB” into your application step-by-step.

Objective

Section C of this document is intended to provide the user with

• The prerequisites to use this standard SIMOTION application

• Preparations and parameterizing operations are explained

• The necessary steps to integrate this standard application into their

application.

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

• Information and references to possible error messages and tips on how

to use this standard application.

Subjects discussed

Chap. Title Contents

Program environment and interfaces

Integrating the core “flying saw” functions

Using the „FB_BGD_TEMPLA TE_FlyingSaw()“

Structure of the standard application Function and identification of the program groups Call environment of the FlyingSaw FB Description of the interfaces and the parameters of the

FB_BGD_TEMPLATE_FlyingSaw() Prerequisites that are absolutely necessary to use the core

“flying saw” functions Preparations to use the core functions in your application Technology objects required and their parameterization Synchronous objects required and their parameterization Integrating core functions into your application

General information and instructions Basic state of the function block

“FB_BGD_TEMPLATE_FlyingSaw()” and when this state occurs. Mode changeover at the "FB_BGD_TEMPLATE_FlyingSaw()". Using the restart bit of the block. Function of the "immediate cut" of

FB_BGD_TEMPLATE_FlyingSaw()“. Function of the "create gap" of the

FB_BGD_TEMPLATE_FlyingSaw()“. Display of block errors Function of the synchronizing mechanism of the

FB_BGD_TEMPLATE_FlyingSaw ()

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Program environment and interfaces

6 Program environment and interfaces

6.1.1 Function and identification of the program groups

The standard “flying saw” application is sub-divided into the following program groups:

• OMAC

• SAP

•

SIM

•

HMI

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

OMAC

In the OMAC program group, the operating mode manager is used according to the OMAC standard of the standard SIMOTION Easy Basics (SEB) application.

SAP

Program group to solve automation tasks (demo) machine with the application example of the standard “flying saw” application. Based on the SIMOTION D demonstration case, the mode of operation and core functions of the standard application are presented/demonstrated in conjunction with a WinCCflex-base visualization system.

Program group with the core functions of the standard “flying saw” application. This program group includes the "flying saw" TEMPLATE and supplementary functions to manage the synchronous position.

SIM

Program group to simulate system signals in the demonstration case environment

HMI

Program group to display system sequences on the WinCCflex operator interface (screen)

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Program environment and interfaces

6.1.2 Program structure

All of the functions, implemented in the standard “flying saw” application are listed in the following table according to their assignment to a particular program group and program unit.

Table 6-1: Program structure of the standard “flying saw” application

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

Pro-

gram

Program

unit

Program

module

Data

unit

Section

OMAC

OmacMain OmacMain()

OmacVar

OmacStUp OmacStUp()

SAP

SAP_FS

BGD_SAP_FlyingSaw() Startup_SAP()

SAP_Var

SAP

SAPState FC_SAP_FlyingSaw_AutomaticAborted()

FC_SAP_FlyingSaw_AutomaticAborting() FC_SAP_FlyingSaw_AutomaticHeld() FC_SAP_FlyingSaw_AutomaticHolding() FC_SAP_FlyingSaw_AutomaticProducing() FC_SAP_FlyingSaw_AutomaticStandby() FC_SAP_FlyingSaw_AutomaticReady() FC_SAP_FlyingSaw_AutomaticStarting() FC_SAP_FlyingSaw_AutomaticStopping() FC_SAP_FlyingSaw_AutomaticStopped() FC_SAP_FlyingSaw_AutomaticManual() FC_SAP_FlyingSaw_AutomaticIdle() FC_SAP_FlyingSaw_AutomaticEStop()

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Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

Pro-

gram

Section

SIM

HMI

Program

unit

FS_TEMPL

FS_PMIPO

FS_SPB FB_BGD_FS_SPB_in()

SIM_PM IPO_SIM_Printmarks()

HMI_SAP BGD_HMI_FlyingSaw()

FB_BGD_TEMPLATE_FlyingSaw()

MT_FS1_PrintmarkDetection() IPO_FS1_IPO_routine()

FB_BGD_FS_SPB_reset() FB_BGD_FS_SPB_read() FB_BGD_FS_SPB_out()

Startup_SIM()

Startup_HMI() FB_BGD_HMI_Printmarks() FB_BGD_HMI_Cuts() FB_BGD_HMI_Material()

Program

module

Data

unit

FS_Var

SIM_Var

HMI_Var

The meanings are as follows: FB: The program module is programmed as function block FC: The program module is programmed as function MT: The program must be called in the motion task BGD: Programming function or function block is used to make a call in

the background task. IPO: Program is used to make a call in the IPO task. Startup Program is used to make a call in the start-up task. Core functions, which the user can use, unchanged in his

application.

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Program environment and interfaces

6.2 Call environment

The function block FB_BGD_TEMPLATE_FlyingSaw() of the “flying saw” core function must be cyclically called in the user program. This is the reason that the call can only be made from a program that is incorporated in the background task.

Fig. 6-1 Call environment of the FB_BGD_TEMPLATE_FlyingSaw()

SIMOTION

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

TO specific

B a

g r o u n d

T a s k

r o g

r a m

Unit „FS_Var“

„FB_BGD_ TEMPLATE_ FlyingSaw()“

commands

TO specific

commands

Central Function Flying Saw

in mode (4)

Manual only

other Axes

Flying Saw Axis

The technology object “FlyingSawAxis”, influenced by the function block FB_BGD_TEMPLATE_FlyingSaw(), may only be addressed by the user program if, beforehand, the user switched the core “flying saw” function into

Mode 4 “Manual”. In all of the other modes, it is not permissible that the

user program influences the technology object “FlyingSawAxis”.

6.3 Interfaces

6.3.1 Classifying the interfaces

The function block FB_BGD_TEMPLATE_FlyingSaw() can be influenced using several parameters and interfaces that are classified/sub-divided into the following areas:

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Program environment and interfaces

• Block interfaces

• User interface in the global data area (data unit FS_Var)

The function block is signaled changing tasks and modes using the block interface. The function block signals the actual status and possibly occurring faults back to the user program also via this interface.

The function block is mainly signaled the physical quantities of the “flying saw” to be controlled via the user interface in the global data area. In normal “flying saw” operation, these quantities are not changed.

6.3.2 Block interface of the FB_BGD_TEMPLATE_FlyingSaw()

The following interfaces are provided at the block to control the flying saw using the function block FB_BGD_TEMPLATE_FlyingSaw():

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

IN OUT

Execute Mode StopCutting KnifeOut Gap OnTheSpotCut PMGenerationMode TypeOfSynchronization

IN / OUT

UsersInterface ErrorInterface InternalData SyncPosManagement TimeCalc

FB_BGD_TEMPLATE_FlyingSaw()

Done Busy Error Cut EndSyncPosReached OnTheSpotCutPossible OnTheSpotCutDone ErrorID State

Table 6-2 Interfaces of the FB_BGD_TEMPLATE_FlyingSaw()

Parameter Data type Initial value Description

Input parameter (IN)

Execute BOOL False

A queued mode changeover is activated using this input.

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Program environment and interfaces

Parameter Data type Initial value Description

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

Mode INT 0

Using Mode, the mode is preselected that is activated with the next positive signal edge at the execute input.

StopCutting BOOL False

When this bit is set, the module is informed that cutting has been completed and a gap can be created or the cutting device can be withdrawn from the material.

KnifeOut BOOL False

When this bit is set, the module is signaled that the cutting device is no longer in contact with the material and the cutting device can be returned to its starting position.

Gap BOOL False

If this bit is set, after a cut, the flying saw generates a gap between the cut piece of material web and the material web using a superimposed motion of the cutting device.

OnTheSpotCut BOOL False

When this bit is set, a synchronous position is immediately generated on the material web for the next cut.

PMGenerationMod e

INT

PM_CALCULA TED

PM_CALCULATED: The next cut position is defined automatically after running one cutlength.

PM_MEASURED: The next cut position is defined by printmark detection.

TypeOfSynchronis ation

INT BY_TIME

BY_TIME: The synchronizing is done according to dynamic values entered.

BY_LEADING_AXIS_VALUE: The synchronizing is done according to leading axis values. The master synclength is set to a value as twice as slave synclength automatically. This causes an asymptotic synchronization.

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Section C: Integrating the core “flying saw” functions

Parameter Data type Initial value Description

Input/output parameter (IN/OUT)

UsersInterface STRUCT User interface ErrorInterface STRUCT

InternalData STRUCT

SyncPos Management

TimeCalc STRUCT Time calculation data

Output parameter (OUT)

Done BOOL False

Busy BOOL False Mode changeover is active. Error BOOL False

Cut BOOL False

EndSyncPos Reached

OnTheSpotCut Possible

OnTheSpotCut Done

SyncNotPossible BOOL False

ErrorID WORD 0 Fault code State INT 0 Actual operating mode

STRUCT

BOOL False

ErrorID of the technology functions

Internal data of the sequence control

Data of the synchronous position management

Selected mode has been activated.

Indicates faults/errors within the FBs and at the cross-cutter axes.

The flying saw moves in synchronism with the material web – cutting can start.

Alarm, if the flying saw passes/exceeds the upper limit value of the synchronous range when in the automatic mode

The flying saw is in its starting position and an immediate cut is possible

The immediate cut was carriedout

The last synchronization operation could not be executed with the secondary conditions/constraints present.

6.3.3 Structure of the global data area of the data unit FS_Var

The interconnection and links with the technology objects required and the physical reference quantities and control information are saved in the user interface of the instance data area.

The parameters saved here are generally not changed during fault-free operation of the “flying saw”.

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Program environment and interfaces

Fig. 6-2 Structure of the global data area of the core “flying saw” function

Unit FS_Var

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

User rinterface

ErrorID of the technology

functions

Internal data of the

sequence control

Data of the synchronous

position management

Data of the time calculation

TOs used

Physical quantities

Control information

User must adapt val u es User may not change values

DW24

DW34

DW58

DW60

Table 6-3 User interface in the global data area of the unit FS_Var

Parameter Data type Initial

value

Description

User interface Matrix of the TOs used

FS_AxesTOs StructAxesTOs

Matrix to reference the technology objects relevant for the “flying saw”.

Physical quantities

DistanceToSensor [mm] LREAL 200.0

Clearance between the sensor and zero position of the FlyingSawAxis

StartPos [mm] LREAL 0.0

Circumference of the cross-cutter / number of knives

SyncPos [mm] LREAL 100.0

Position from where the flying saw moves in synchronism with the material web.

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Section C: Integrating the core “flying saw” functions

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Parameter Data type Initial

Description

value

EndSyncPos [mm] LREAL 20.0

End position of the synchronous range

EndPos [mm] LREAL 125.0

Starting position of the cross-cutter

ToStartposVelocity [mm/s] LREAL 100.0

Velocity of the travel back to the starting position

ToBackposVelocity [mm/s] LREAL 150.0

Velocity of the travel back to the starting position

AccelerationCut [mm/s²] LREAL 100.0

Acceleration value for synchronization motion

AccelerationBack [mm/s²] LREAL 100.0

Acceleration value for return motion to the starting position

AccelerationGap [mm/s²] LREAL 100.0

Acceleration value for motion to create a "gap".

GearingRatio LREAL 1.0

Ratio between measured and effective velocity of the material web.

CutEverySensorSignal DINT 1

Specifies after how many sensor signals a synchronous position is to be generated.

GapLength LREAL 10.0

Length of the gap that should be located between the cut pieces

GapVelocity LREAL 50.0

Higher-level velocity with which the gap is to be created

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Program environment and interfaces

Section C: Integrating the core “flying saw” functions

Parameter Data type Initial

Description

value

Control information

Restart BOOL false

If the bit is set (e.g. in the StartUp task), then the template executes a re-initialization and resets the bit.

This bit must

be set

for each new start!

MaterialIn BOOL false

If the bit is set, the material web is in the flying saw area.

MaterialInMotion BOOL false

If the bit is set, the material web in the flying saw area.is moving.

Fig. 6-3 Matrix of the relevant technology objects (TOs)

Axis_FlyingSawAxis_Material

Pos_Axis

X--

Manual_SIMOTION Flying Saw_V1.4.doc

Following_Axis

External_Encoder

Following_Objekt

Printmark

-- X

(X) --

-- X

X--

(X) In realen Anwendungen kann auch auf einen

externen Geber zugegriffen werden

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Integrating the core “flying saw” functions

7 Integrating the core “flying saw” functions

7.1 This is how you integrate core functions into your project

Please proceed as follows to integrated core functions into your project:

• Check whether your equipment fulfills the software and hardware

Section C: Integrating the core “flying saw” functions

prerequisites listed in

De-archive and load the relevant project sections as described in

•

Chapter 7.3 Preparations.

•

Set-up the required technology objects as described in Chapter 7.4

Setting-up the required technology objects.

•

Assign the synchronous relationships as described in Chapter 7.5

Assigning the synchronous relationships.

•

Call-up the core functions as listed in Chapter 7.6 Integrating into

your application.

Chapter 7.2 Prerequisites.

Manual_SIMOTION Flying Saw_V1.4.doc

•

Information and instructions on how you must integrate core functions

into the sequence of your user program are provided in

Chapter 8

Using the "FB_BGD_TEMPLATE_FlyingSaw()".

7.2 Prerequisites

7.2.1 SIMOTION SCOUT with SIMATIC STEP 7

In order to use this standard SIMOTION application, the SIMOTION SCOUT programming interface must be correctly installed on your computer.

You have two possibilities to do this:

• You can install SIMOTION SCOUT in its standalone version - the STEP

7 functions required will be automatically installed.

Table 7-1 Software components

Software Diagram Order No./MLFB and functions Version used

SIMOTION SCOUT standalone

6AU1810-0CA40-0XA0 SCOUT standalone is the engineering

tool to program all SIMOTION controls without STEP 7

V4.0.0

• You install STEP 7 followed by SIMOTION SCOUT.

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Table 7-2 Software components

Software Diagram Order No./MLFB and functions Version used

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

STEP 7

SIMOTION SCOUT

6ES7810-4CC07-0YA5 Step7 is the basis package for all

optional software packages and is used to program the SIMATIC S7.

6AU1810-0BA40-0XA0 SCOUT is the engineering tool to

program all SIMOTION controls

V5.3 SP3 HF1

V4.0.0

This form of the installation has been used when generating the standard “flying saw” application and should therefore be the preferred one for users.

7.2.2 SIMOTION control

A SIMOTION control is required to operate the core “flying saw” functions. All SIMOTION D, SIMOTION P and SIMOTION C controls can be used.

Note

The application example has been developed and tested for use in conjunction with the SIMOTION D training case with CPU D435. Modifications and changes may have to be made when used in another hardware environment

In order to correctly use the program elements in this document, you should be knowledgeable about handling, and programming the control being used as well as its functions.

Table 7-3 Hardware components of the core “flying saw” functions

Hardware element Diagram Order No./MLFB and functions

SIMOTION CPU D435

SIMOTION D435 32MB CF-Card

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6AU1435-0AA00-0AA0 Version C The CPU D435 processes the user

program, the technology and checks the drives.

6AU1400-2JA00-0AA0 The SIMOTION program and the

SINAMICS configuring are saved on the CF card.

Flying Saw with SIMOTION A4027118-A0414

Integrating the core “flying saw” functions

7.2.3 Technology objects required and synchronous relationships

The following technology objects must be set-up and interconnected with one another in the following fashion in order to use the core “flying saw” functions:

Technology objects

The required technology objects are listed according to their function within the core “flying saw” functions in the following:

• Generating the master (leading) value from the motion of the material

web:

– TO Achse “MaterialAxis” as real positioning or synchronous axis

(maximum configuration) To determine the position and velocity of the material web as

master (leading) value of the core “flying saw” functions and to coordinate the motion of the axis – material web from the same control.

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

– TO axis “FlyingSawAxis” as real synchronous axis

Synchronous relationships

The "flying saw" core functions require the following synchronous relationships:

Fig. 7-1 Synchronous relationship required for the “FlyingSaw FB”

• Coordinating the flying saw axis

Material

Axis

External encoder

or positioning

axis

1:1

Gearing

Flying

Saw

Axis

Synchronous

axis

The MaterialAxis is the reference quantity for the “flying saw”. For this purpose, it must be made available to the “flying saw FB” as “positioning axis”.

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The FlyingSawAxis is connected, for the cut, as “synchronous axis” with the MaterialAxis in a 1:1 (gearing) synchronous relationship.

The technology objects and synchronous relationships listed above must be set-up and configured/engineered by the user in SIMOTION SCOUT.

7.3 Preparations

7.3.1 De-archiving the standard "flying saw" application

The standard “flying saw” application is supplied as STEP 7/SCOUT project. In order to use the template, this project must be de-archived either using STEP 7 or SCOUT.

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

7.3.2 Downloading the core functions into your SCOUT project

In order to quickly and simply transfer the core “flying saw” functions into your SCOUT project, you should proceed as shown in the following steps.

Table 7-4 This is how you download the core functions into your project

No Action Comment

1 Open the standard “flying saw” application using SCOUT 2 Open your user project with SCOUT

3 Copy the program units

4 Close SCOUT using the standard application Ready!

SCOUT is opened a second time!

By dragging and dropping

FS_SPB FS_PMIPO FS_TEMPL FS_VAR

from the standard application into your user project

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7.4 Setting-up the required technology objects

Prerequisite

SIMOTION SCOUT has been started. The user knows how to apply the SIMOTION SCOUT program.

7.4.1 Flying saw axis

Configuration

Insert a new axis with the name FlyingSawAxis

•

• Parameterize the axis as synchronous axis

• Set the axis type as linear

• Parameterize as modulo axis with a modulo length greater than the

maximum traversing distance (this is monitored from the FlyingSaw-FB

Æ “parameterizing error”)

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

• All of the additional parameters should be set corresponding to the drive

and encoder data.

Mechanical system

•

For the parameter “distance for each spindle revolution” enter the

distance that the knife tip of the “flying saw” moves through for one motor revolution.

• Appropriately supplement the other parameters as well as geometry

and design.

Pre-assignment

Please enter this parameter corresponding to the drive dynamic

•

performance.

Limits

Please enter these parameters corresponding to the system layout and

•

configuration.

Referencing (homing)

Please enter these parameters corresponding to the encoder

•

(the template assumes a referenced/homed axis). If an incremental encoder is used, it is necessary to reference/home the axis in

“Manual”

before additional operating modes are selected. )

mode 4

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Integrating the core “flying saw” functions

Monitoring functions – closed-loop control

Section C: Integrating the core “flying saw” functions

Please set these parameters corresponding to the system layout and

•

configuration.

7.4.2 Axis, material web Configuration

Insert a new axis with the name MaterialAxis

•

• Parameterize the axis as positioning axis

• Set the axis type as linear

• Parameterize as modulo axis with a modulo length greater than the

maximum product length

• All of the additional parameters should be set corresponding to the drive

and encoder data.

Manual_SIMOTION Flying Saw_V1.4.doc

Mechanical system

For the parameter “distance for each spindle revolution”, the distance

•

that the material web moves through for one revolution of the drive roll should be entered.

• Appropriately supplement the other parameters as well as geometry

and design.

Pre-assignment - limits

Please enter these parameters corresponding to the system / drive

•

relationships.

Referencing (homing)

Parameterize “not required”

•

Monitoring functions – closed-loop control

Please set these parameters corresponding to the system layout and

•

configuration.

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7.5 Assigning the synchronous relationships

7.5.1 FlyingSawAxis_SYNCHRONOUS_OPERATION Configuration

Select the MaterialAxis as master (leading) axis

•

• Select setpoint coupling as coupling type.

Pre-assignment (gear synchronization)

Synchronizing:

•

Enter the synchronizing position of the master (leading) axis and slave (following) axis

(this is checked and corrected by the FlyingSaw FB)

• Position reference:

Synchronize before the synchronizing position

(this is checked and corrected by the FlyingSaw FB)

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

• SyncPos master (leading) value:

0.0

(the FlyingSaw FB enters the actual value)

• SyncPos slave (following) axis:

0.0

(the FlyingSaw FB enters the actual value)

• The other values are no longer relevant.

Pre-assignment (dynamic)

Profile input: Time-related synchronizing profile

•

(this is checked and corrected by the FlyingSaw FB)

• Please select the dynamic parameters of the time-related

synchronization so that the FlyingSawAxis does not reach the dynamic limits when synchronizing and de-synchronizing.

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7.6 Integrating into your application

7.6.1 Calling the “FlyingSaw FB” in the user program

The function block of the core “flying saw” functions can also be simply called in the program after integration into your SIMOTION project.

Calling the “FB_BGD_TEMPLATE_FlyingSaw()” in ST and FBD

As an example, the calls of the function block

FB_BGD_TEMPLATE_FlyingSaw()” of the core “flying saw” functions in

“ the ST and FBD programming languages are shown here:

Table 7-5 Calling the function block “_BGD_TEMPLATE_FlyingSaw()“

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

FUP

FB_BGD_TEMPLATE_FlyingSaw()

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Assigning the instance

In the calling user program, the function block “FB_BGD_TEMPLATE_FlyingSaw()” must be assigned an instance. The following table includes examples in ST and FBD.

Table 7-6 Generating an instance of the “FB_BGD_TEMPLATE_FlyingSaw()”

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

FUP

Instance

7.6.2 Integrating the template block in the processing sequence

The core “flying saw” function is integrated in the processing sequence using a simple function block call and transferring the required parameters.

This call strategy corresponds to that of PLC-Open standard function blocks.

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8 Using the "FB_BGD_TEMPLATE_FlyingSaw()"

8.1 General information and instructions

The most important element of the technology template is the function block “FB_BGD_TEMPLATE_FlyingSaw()”. The connected “flying saw” is parameterized and controlled using this block.

In the user program, the block must therefore be parameterized and the block mode changed-over in order to initiate that the “FB_BGD_TEMPLATE_FlyingSaw()” executes the required functions.

The "FB_BGD_TEMPLATE_FlyingSaw()“ is parameterized as described in

Chapter 6.3 Interfaces. When parameterizing (assigning parameter

values), basic values of the “flying saw” are defined that normally do not change; for example, the name of the flying saw axis, the starting position, the synchronous position etc. These values may only be changed when the system is at a standstill and changes require a re-initialization (restart) of the "FB_BGD_TEMPLATE_FlyingSaw()“!

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

The individual modes of the"FB_BGD_TEMPLATE_FlyingSaw()“ are described in

Chapter 3.2 Operating states of the "FlyingSaw-FB". The

procedure to change over the mode is described in more detail in the following Chapters.

8.2 Initial state of the "FB_BGD_TEMPLATE_FlyingSaw()"

After a “restart”, the “FB_BGD_TEMPLATE_FlyingSaw()” is in the “disable” state.

Each time that the control is started, “restart” must be run by setting the restart bit in the startup task. (this is realized automatically when using the program startup_SAP() in the UNIT SAP_FS)

This means that the template is transitioned into its initial state and important technology parameters are checked regarding plausibility, if possible adapted, and if not possible, parameterizing errors are flagged to the user at the fault output.

8.3 Mode changeover sequence

The functions of the function block “FB_BGD_TEMPLATE_FlyingSaw()” and therefore the functions of the connected “flying saw” are controlled using the various state modes of the block.

The following state modes and status transitions can be called at the block:

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Fig. 8-1 Possible state transitions at the "FB_BGD_TEMPLATE_FlyingSaw()"

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

RESTART

Disable

Manual

Startposi-

tion

Automa-

tic

Error

Standard Zustandsü bergang Fehlerzustandsübergang Automatische Zustandswechselkette

The actual block state is displayed at the

state output.

Fig. 8-2 Inputs and outputs of the mode changeover

IN OUT

Execute

Mode

StopCutting KnifeOut Gap OnTheSpotCut

FB_BGD_TEMPLATE_FlyingSaw()

Done Busy

Error Cut OnTheSpotCutPossible OnTheSpotCutDone

ErrorID

State

Changing-over the mode

In order to transition the block into a new state, the number of the required target state must be specified at the activated using a high signal at changeover into the new state using a high signal at the

mode input. The changeover is

Execute input. The block signals the active

Busy output. If all

of the actions associated with the changeover have been successfully

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carried-out and the new state has been reached, this is flagged by a high

Section C: Integrating the core “flying saw” functions

signal at the off at the

done block output. The number of the new state can be read-

state output.

The sequences and actions that are executed during the changeover are described in detail in Chapter 10.3.4 of this document.

8.4 Using the restart bit

Restart after a new start

The restart bit must be set at each new start of the SIMOTION D435 or when changing the parameterization. This is the reason that an initialization routine is run in the “FB_BGD_TEMPLATE_FlyingSaw()” and a parameter check is made and the block is brought into a defined state.

Manual_SIMOTION Flying Saw_V1.4.doc

Note

In the startup task, we recommend that the program startup_SAP() of the unit SAP_FS is used in order to initialize the "FB_BGD_TEMPLATE_FlyingSaw()" block.

The restart bit should also be set there in order to bring the block into a defined state!

Note

At restart, the block checks essential technology parameters as well as the existence of saved technology objects

After the block has been successfully initialized, the restart bit is automatically reset.

8.5 Error messages

If faults occur in the block itself or in technology objects and technology functions involved while FB_BGD_TEMPLATE_FlyingSaw() is operational, then these are signaled using the block outputs

error and ErrorID.

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Fig. 8-3 Block outputs for fault messages

IN OUT

Section C: Integrating the core “flying saw” functions

Execute Mode StopCutting KnifeOut Gap OnTheSpotCut

FB_BGD_TEMPLATE_FlyingSaw()

Done Busy

Error

Cut OnTheSpotCutPossible OnTheSpotCutDone

ErrorID

State

The

error bit signals an error while an error code is output at output

ErrorID; this can be analyzed using the error analysis function.

A list of the possible error codes with a description of the error causes is provided in the Appendix of this document, Chapter 12.2.

Note

The error output is only set if the execute input is set. The ErrorID and

state 0 are still output even after execute has been reset!

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8.6 Help functions within the core “flying saw” functions

As part of the core functions, there are also help functions that make it easier for you to implement your “flying saw” application.

It provides you with solutions for the following functions:

• The synchronous position is sensed using sensors/measuring probes

• Buffer to save the measured synchronous positions for sequential

execution of several cuts by the "flying saw".

Section C: Integrating the core “flying saw” functions

Manual_SIMOTION Flying Saw_V1.4.doc

The names and description of these functions are listed in

Help routines.

Chapter 10.5

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Section D: Program description

Content

Section D is interesting if you wish to expand/adapt your application based on the technology templates available.

Objectives

This part of the documentation should

• Explain to readers the special features/issues when generating a

program

• Describe in detail the program structure of the FlyingSaw FB

• Illustrate and describe important program elements

Provide information and instructions on how this template can be adapted.

Section D: Program description

Manual_SIMOTION Flying Saw_V1.4.doc

Prerequisite

Before possibly expanding this template it is helpful to have read the chapters in Section A and B in order to get to know the basic functions and applications of the template.

Subjects discussed

Chap. Title Contents

10 Description of important program elements

Information and instructions to adapt the core “flying saw” functions

Note

Before you make changes to the template, please observe the information and warnings listed in the following Chapter as well as the associated restrictions regarding support!

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9 Information and instructions to adapt the core “flying

saw” functions

9.1 Information and warnings

Before carrying-out changes

Before you carry-out changes to the components included in the core functions, you should get to know how the components function by referring to and reading the ST/MMC documentation.

Uncontrolled, incorrect changes and modifications to core functions can result in death and severe bodily injury!

Restrictions regarding support when changing components of the core functions

The Application Center can only provide support for core functions that have not been changed

Section D: Program description

Manual_SIMOTION Flying Saw_V1.4.doc

If changes have been made to the code, then support can no longer be provided for core functions.

This also applies for the revision and adaptation recommendations listed in this Chapter.

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10 Description of important program elements

10.1 Program structure

The core functions of the standard “flying saw” application are sub-divided into two sections

• Declaration section

•

Instruction section

All of the interfaces, constants, instance data and multi-instance of the

Section D: Program description

function blocks called from the block are described in the

section

. Er besteht aus der Unit FS_Var.

All program instructions of the code that can be run are provided in the

Instruction section. This Section is sub-divided into four units.

• FS_TEMPL with the "FlyingSaw FB“.

Declaration

Manual_SIMOTION Flying Saw_V1.4.doc

• FS_PMIPO with the print mark sensing and the ipo-synchronous

functions.

• FS_SPB with the FBs to manage the synchronous positions in the

SyncPo buffer

10.2 Declaration part FS_Var

The structure of all of the data required for the FlyingSaw FB is saved in the unit FS_Var. Instances will be the data in the user unit SAP_Var. When required, in this unit, this data area can also be instantiated several times so that the FlySaw FB can also be called for several flying saws within one project.

Constants

Axis numbers

•

• Operating states of the flying saw

• Sequence phases of the parameter check

• Sequence phases of the automatic parameterization

• Sequence phases when changing from the “error” to “disable”

• Sequence phases when changing from the “error” to “disable” state

• Sequence phases when changing from the “disable” to “error”

• Sequence phases when changing from the “disable” to “starting

position”

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• Sequence phases when changing from the “disable” to “manual”

• Sequence phases when changing from the “starting position” to

“disable”

• Sequence phases when changing from the “starting position” to “error”

• Sequence phases when changing from the “starting position” to

“automatic”

• Sequence phases when changing from the “automatic” to “disable”

• Sequence phases when changing from the “automatic” to “starting

position”

• Sequence phases when changing from the “manual” to “disable”

• Sequence phases in "automatic" operation.

• Maximum length of the SyncPos buffer

Static variables

Section D: Program description

Manual_SIMOTION Flying Saw_V1.4.doc

Description of the data structure of the TO parameters

•

• Description of the data structure of the user interface with the geometry,

machine data and control bits

• Description of the data structure of the error interface with the error IDs

of the state change and the RetDINT and FR values of the system commands.

• Description of the data structure of the internal data area of the

FlyingSaw FBs. Under no circumstances may users change these values.

• Description of the data structure to manage synchronous positions.

• Description of the data structure for time calculations within the

FlyingSaw FBs

• Description of the data structure of the synchronous position detection

using measuring function.

10.3 Functions of the FB_BGD_Template_FlyingSaw() ("FlyingSaw-FB")

10.3.1 Declarations

•

Input interface

• Input/output interface

• Output interface

• Internal program data

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10.3.2 Start identification, axis monitoring and automatic state change chains

Start identification

Identify whether a restart is present. If yes, then

• Activate the monitoring of the parameterization of the technology

objects as well as auto-parameterization.

• Control the state machines in the “manual” state via the state sequence

– Error

(if activated, the monitoring and auto-parameterization are realized in the error state)

– Disable

Section D: Program description

Manual_SIMOTION Flying Saw_V1.4.doc

– Manual

From any state.

If no, then

• Transfer the selected operating state with a positive edge at the

execute input

• Reset all block outputs with a negative signal edge at the execute input

Axis monitoring functions

The flying saw axis has an error, the "FlyingSaw FB“ is forced into the error state.

However, the monitoring function is only active after the technology objects have been successfully completed.

Automatic state change sequences

The following automatic state change sequences have been implemented:

• From the “error” state into the “starting position” state.

“Error“

Æ “Disable” Æ “Starting position”

• From the “error” state into the “automatic” state.

“Error“

Æ “Disable” Æ “Starting position” Æ “Automatic”

• From the “error” state into the “manual” state.

“Error“

Æ “Disable” Æ “Manual”

• From the “starting position” state into the “manual” state.

“Starting position”

Æ “Disable” Æ “Manual”

• From the “automatic” state into the “manual” state.

“Automatic”

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Description of important program elements

• From the “manual” state into the “starting position” state.

Section D: Program description

“Manual”

Æ “Disable” Æ “Starting position”

10.3.3 Checking the input parameters and parameterization of the technology settings that are absolutely necessary

This program function is only active in the error state if it was activated by the user using the restart bit.

The following are monitored:

• The existence of specified TOs.

• The function (positioning axis, synchronous axis, …)

• Special properties/features required for the template, such as: Modulo

axis and modulo value.

Deviations with respect to the template are displayed as fault messages.

Manual_SIMOTION Flying Saw_V1.4.doc

Parameterization of the technology objects absolutely required is carriedout in another program part.

The parameters that are therefore changed are described in

Setting-up the required technology objects the synchronous relationships

and Chapter 7.5 Assigning

Chapter 7.4

10.3.4 State machine of the “FlyingSaw FB”

The state machines of the “FlyingSaw FB” are described in the following diagram. It includes possible operating states that can be activated and clearly shows the possible state transitions that may be initiated by the user.

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Fig. 10-1 State model of the "FlyingSaw FB"

Section D: Program description

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RESTART

Disable

Manual

Startposi-

tion

Automa-

tic

Error

Standard Zustandsü bergang Fehlerzustandsübergang Automatische Zustandswechselkette

The functional sequences that are hidden behind the states and state changes (transitions) are listed in the following table.

Table 10-1 Description of the sequences at the state change (state transition) in the “FlyingSaw FB”

Step Function Comment

Mode Error (0)

Error Æ Disable

All ErrorID memories are reset

Calls the _resetAxisError() for the flying saw axis

Calls the _resetFollowingObject() for the flying saw axis If the axis and the synchronous object have no error

condition, then the "disable“ mode is activated.

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Error

Disable

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Description of important program elements

Section D: Program description

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Step

Function Comment

Mode Disable (1)

Disable

Disable Æ Disable

Disable

0 The stop command is prepared

_stop() is called for the flying saw axis

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated.

Disable Æ Error

Disable

Error

0 Preparation

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the “error” mode is activated

Disable Æ Starting position

Disable

Startpo-

sition

0 The enable command is prepared

_enableAxis() is called for the flying saw axis

If the axis is enabled, then advance to step 2

_resetAxisError() is called for the flying saw axis

If the axis is OK, advance to step 3

_pos() is called for the flying saw axis with the direction of

rotation for the shortest path If the starting position is reached, then the “starting

position” mode is activated.

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Section D: Program description

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Step

Function Comment

Disable Æ Manual

The enable command is prepared.

Disable

Manual

_enableAxis() is called for the flying saw axis

If the axis is enabled, then the “manual” mode is activated

Startpo-

sition

Startpo-

sition

Error

Mode, starting position (2)

Starting position Æ Error

0 Preparation

_disableAxis() is called for the flying saw axis

If the axes are disabled, then the “error” mode is activated

Starting position Æ Disable

The stop command is prepared.

Startpo-

sition

Disable

_stop() is called for the flying saw axis

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated

Starting position Æ Automatic

Startpo-

sition

Automa-

tic

0 The SyncPosBuffer is reset

Wait until a valid synchronous position is available

If yes, then advance to step 2 _enableGearing() is called to synchronize the flying saw

axis to the material web at the master and slave positions If successfully synchronized, then advance with step 4, if not, then advance with step 3

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Section D: Program description

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Step

Function Comment

_disableGearing() is called to delete (clear) the command

from the command queue. If required, then continue with step 1

The "cut" output bit is set

The actual synchronous position is deleted (cleared) from the SyncPosBuffer

Wait until "StopCutting" signal appears

If the "Gap" signal is present, then continue with step 6 If not, then continue with step 7

_pos() is called for the flying saw axis with the

"superimposed" merge mode in order to create a gap with the superimposed motion.

When completed, then continue with step 7.

If the "KnifeOut" signal appears, then _pos() is called for

the flying saw axis to position back to the starting position. When completed, then continue with step 1.

Starting position Æ Manual

This state change is achieved using an automatic state

Startpo-

sition

Manual

change sequence that reaches the manual state through the disable state.

Mode, automatic (3)

Automa-

tic

Automatic cycle

Wait until a valid synchronous position is available

If yes, then advance to step 1

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Section D: Program description

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Step

Function Comment

_enableGearing() is called to synchronize the flying saw

axis to the material web at the master and slave positions If synchronization was successful, then continue with step

3, if not, then continue with step 2

_disableGearing() is called to delete (clear) the command

from the command queue. If this is successful, then continue with step 0

The "cut" output bit is set

The actual synchronous position is deleted (cleared) from the SyncPosBuffer

Wait until "StopCutting" signal appears

If the "Gap" signal is present, then continue with step 5 If not, then continue with step 6

_pos() is called for the flying saw axis using the merge

mode "SUPERIMPOSED_MOTION_MERGE" in order to create a gap with the superimposed motion.

When completed, then continue with step 6.

If the "KnifeOut" signal appears, then _pos() is called for

the flying saw axis to return to the starting position. When completed, then continue with step 1.

Automatic Æ Error

_disableAxis() is called for the flying saw axis

Automa-

tic

Error

If the axis is disabled, then the “error” mode is activated

Automatic Æ Disable

Automa-

tic

Error

0 The stop command is prepared

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Section D: Program description

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Step

Function Comment

_stop() is called for the flying saw axis

If the axis is disabled, then advance to step 2

_disableAxis() is called for the flying saw axis

If the axis is disabled, then the “disable” mode is activated

Automatic Æ Starting position

Resets the "cut" output bit

Automa-

tic

Startposi-

tion

If the "KnifeOut" signal is present, then prepare the position command and advance to step 1

_pos() is called to return the flying saw axis back to its

starting position.

Mode, manual (4)

Manual Æ Error

_disableAxis() is called for the auxiliary axis and the flying

saw axis If the axes are disabled, then the “error” mode is activated.

Manual

Error

Manual Æ Disable

Manual

Disable

0 The stop command is prepared

_stop() is called for the flying saw axis

_disableAxis() is called for the flying saw axis

If the axes are disabled, then the “disable” mode is activated

Manual Æ Starting position

This state change is achieved using an automatic state

Manual

Startposi-

tion

change sequence where the starting position state is reached via the disable state.

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Description of important program elements

10.4 Properties/features of startup_SAP

Section D: Program description

The startup_SAP program is located in the unit SAP_FS

• Assigns the actual TO instances

• Assigns the machine-specific parameters

• Resets the restart bit.

• Deletes the SyncPos buffer.

• Resets all internal program flags.

10.5 Help routines

Manual_SIMOTION Flying Saw_V1.4.doc

10.5.1 Features and characteristics of the MT_FS1_PrintmarkDetection (print mark sensing)

The program MT_FS1_PrintmarkDetection is in the unit RK_PMIPO and must be called from a motion task.

The following functions are executed:

• Waits for a valid measured value

• Determines the synchronous position for the actual print mark

• Enters the synchronous position into the SyncPos buffer

10.5.2 Properties/features of the IPO_FS1_IPO_Routine

The program IPO_FS1_IPO_Routine is located in the RK_PMIPO unit and must be called from the IPO task.

• Calculates the position of the MaterialAxis referred to the flying saw

• Edge detection.

10.5.3 SyncPos buffer

Using the following FBs of the FS_SPB unit, the SyncPos buffer is managed

• FB_BGD_FS_SPB_reset()

• FB_BGD_FS_SPB_in()

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• FB_BGD_FS_SPB_out()

• FB_BGD_FS_SPB_read()

FB_BGD_FS_SPB_reset()

The SyncPos buffer is deleted (cleared) using this FB.

FB_BGD_FS_SPB_in()

Using this FB, when the print mark is sensed, a new synchronous position is entered into the buffer.

FB_BGD_FS_SPB_out()

Using this FB, after every cut, a synchronous position is deleted (cleared) from the buffer (FIFO)

FB_BGD_FS_SPB_read()

This FB is used to check as to whether a new synchronous position is available for the next cut and the flying saw must be synchronized.

Section D: Program description

Manual_SIMOTION Flying Saw_V1.4.doc

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General information on the application

Section E: Appendix

11 General information on the application

11.1 Scope of supply

The "flying saw" package comprises:

• Program

S7/Scout project as ZIP file:

FlyingSaw_for_SIMOTION_V4.1.1_V1.4.zip

• Documentation

Implementation/Operating Instructions as PDF file

FlyingSaw_with_SIMOTION_V4.1.1_V1.4.pdf

11.2 Revisions/Author

Section E: Appendix

Manual_SIMOTION Flying Saw_V1.4.doc

Table 11-1: Revisions/Author

Version Date/Revision Author

V 1.0 Generation H.-E. Böhm V 1.1 Change-over Ethernet H.-E. Böhm V 1.2 Protool templates trilingual

V 1.2 Changes General Notes A. Hagelauer V 1.3 13.04.06 Scout V4.0 H.-E. Böhm V 1.3

(V 2.0!)

V 1.4

04.04.07 Functional Changes:

- synchronization according to leading axis values. (asymptotic synchronization)

- Ratio between measured and effective velocity of material web

06.06.08 Replacing ProTool by WinCflex / SCOUT V4.1.1.6

Ch. Pabst H.-E. Böhm

H.-E. Böhm

P. Tabori H.-E. Böhm

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Specifications and Main Features

Frequently Asked Questions

User Manual